Komatsu 114E-3 Series - 00 Index and Foreword

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114E-3 Series 1

SEN00171-05

Engine

1SHOP MANUAL

114E-3 Series

00 Index and foreword 1

Index

Composition of shop manual................................................................................................................ 2

Table of contents .................................................................................................................................. 3

Main Page

Table of Contents5
Safety Notice12
How to Read the Shop Manual17
Explanation of Terms for Maintenance Standard19
Handling of Electric Equipment and Hydraulic Component21
Handling of Connectors Newly Used for Engines30
How to Read Electric Wire Code33
Precautions When Carrying out Operation36
Method of Disassembling and Connecting Push-Pull Type Coupler39
Standard Tightening Torque Table42
Conversion Table46
Specification53
General54
Specification and Technical Data54
Specifications55
General View60
Dimensions Table64
Engine Performance Curves65
Intake, Exhaust System72
Intake System72
Exhaust System73
Turbocharger74
Lubricating Oil System77
Cooling System79
Fuel System (Common Rail)80
Maintenance Standard85
Turbocharger85
Cylinder Head86
Cylinder Block88
Cylinder Liner90
Crankshaft92
Piston, Piston Ring and Piston Pin93
Connecting Rod94
Vibration Damper96
Timing Gear97
Camshaft98
Valve and Valve Guide100
Rocker Arm, Shaft and Tappet102
Flywheel and Flywheel Housing104
Oil Pump106
Standard Value Table109
Standard Service Value Table SEN00261-02109
Series109
Standard Value Table for Testing, Adjusting and Troubleshooting110
Run-In Standard and Performance Test Criteria114
Testing and Adjusting119
Testing and Adjusting Tools List121
Testing and Adjusting121
Testing Air Boost Pressure122
Adjusting Valve Clearance123
Testing Compression Pressure125
Testing Blow-By Pressure128
Testing Oil Pressure129
Handling Fuel System Parts130
Releasing Residual Pressure in Fuel System130
Testing Fuel Pressure131
Reduced Cylinder Mode Operation136
Injection Cranking136
Testing Leakage from Pressure Limiter and Return Rate from Injector137
Bleeding Air from Fuel Circuit139
Testing Fuel System for Leakage140
Handling Controller High-Voltage Circuit141
Replacing Alternator Belt141
General Information on Troubleshooting143
Points on Troubleshooting144
Troubleshooting144
General Information on Troubleshooting144
Error and Failure Code Table145
Information in Troubleshooting Table148
Troubleshooting of Electrical System (E-Mode), Part 1151
Code [111/CA111] Engine Controller Internal Failure153
Code [115/CA115] Eng. Ne and Bkup Speed Sensor Error153
Code [122/CA122] Charge Air Press Sensor High Error154
Code [123/CA123] Charge Air Press Sensor Low Error156
Code [131/CA131] Throttle Sensor High Error158
Code [132/CA132] Throttle Sensor Low Error160
Code [144/CA144] Coolant Temp. Sensor High Error162
Code [145/CA145] Coolant Temp. Sensor Low Error164
Code [153/CA153] Charge Air Temp. Sensor High Error166
Code [154/CA154] Charge Air Temp. Sensor Low Error168
Code [155/CA155] Charge Air Press. High Speed Derate170
Code [187/CA187] Sensor Sup. 2 Volt. Low Error172
Code [221/CA221] Ambient Air Press. Sensor High Error174
Code [222/CA222] Ambient Air Press. Sensor Low Error176
Code [227/CA227] Abnormally High Level in Sensor Power Supply 2 Circuit178
Code [234/CA234] Eng. Overspeed179
Code [238/CA238] Ne Speed Sensor Sup. Volt. Error180
Code [271/CA271] IMV (IMA) Short Error181
Code [272/CA272] IMV (IMA) Open Error182
Code [281/CA281] High Pressure Pump Error184
Code [322/CA322] Injector No. 1 System Open/Short Error186
Code [323/CA323] Injector No. 5 System Open/Short Error188
Code [324/CA324] Injector No. 3 System Open/Short Error190
Code [325/CA325] Injector No. 6 System Open/Short Error192
Code [331/CA331] Injector No. 2 System Open/Short Error194
Code [332/CA332] Injector No. 4 System Open/Short Error196
Code [342/CA342] Engine Controller Data Matching Error198
Code [351/CA351] INJ. Drive Circuit Error203
Troubleshooting203
Troubleshooting of Electrical System (E-Mode), Part 2203
Code [352/CA352] Sensor Sup. 1 Volt. Low Error205
Code [386/CA386] Sensor Sup. 1 Volt. High Error207
Code [428/CA428] Water Sensor High Level Error208
Code [429/CA429] Water Sensor Low Level Error210
Code [431/CA431] Idle Validation Switch Error212
Code [432/CA432] Idle Validation Process Error214
Code [435/CA435] Eng. Oil Switch Error216
Code [441/CA441] Supply Voltage Low Error218
Code [442/CA442] Supply Voltage High Error220
Code [449/CA449] Rail Press. High Error 2222
Code [451/CA451] Rail Press. Sensor High Error224
Code [452/CA452] Rail Press. Sensor Low Error226
Code [488/CA488] Charge Air Temp. High Torque Derate228
Code [553/CA553] Rail Press. High Error 1229
Code [559/CA559] Rail Press Low Error230
Code [689/CA689] Eng. Ne Speed Sensor Error232
Code [731/CA731] Eng. Bkup Speed Sensor Phase Error234
Code [757/CA757] All Engine Controller Data Lost Error236
Code [778/CA778] Eng. Bkup Speed Sensor Error238
Code [1633/CA1633] KOMNET Error240
Code [2185/CA2185] Throttle Sens. Sup. Volt. High Error242
Code [2186/CA2186] Throttle Sens. Sup. Volt. Low Error243
Code [2249/CA2249] Rail Press very Low Error244
Code [2265/CA2265] Abnormally High Level in Electric Lift Pump246
Code [2266/CA2266] Abnormally Low Level in Electric Lift Pump248
Code [2311/CA2311] IMV (IMA) Solenoid Error250
Code [2555/CA2555] Intake Air Heater Relay Supply Voltage Low Error252
Code [2556/CA2556] Intake Air Heater Relay Supply Voltage High Error254
Code256
Code257
Troubleshooting of Mechanical System (S-Mode)261
Method of Using Troubleshooting Charts261
Starting Performance Is Poor264
Engine Does Not Start265
Engine Does Not Pick up Smoothly268
Engine Stops During Operations269
Engine Does Not Rotate Smoothly270
Engine Lacks Output (or Lacks Power)271
Exhaust Smoke Is Black (Incomplete Combustion)272
Oil Consumption Is Excessive (or Exhaust Smoke Is Blue)273
Oil Becomes Contaminated Quickly274
Fuel Consumption Is Excessive275
Oil Is in Coolant (or Coolant Spurts Back or Coolant Level Goes Down)276
Oil Pressure Drops277
Oil Level Rises (Entry of Coolant or Fuel)278
Coolant Temperature Becomes too High (Overheating)279
Abnormal Noise Is Made280
Vibration Is Excessive281
General Information on Disassembly and Assembly283
How to Read this Manual284
Coating Materials List285
Special Tools List288
Disassembly and Assembly, Part 1291
Disassembly and Assembly291
General Disassembly of Engine292
Disassembly and Assembly, Part 2309
Disassembly and Assembly310
General Assembly of Engine310

Komatsu 114E-3 Series - 00 Index and Foreword; Index

Table of Contents

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