Page 1 SEN00169-05 ENGINE 114E SERIES...
Page 3 SEN00171-05 Engine 1SHOP MANUAL 114E-3 Series 00 Index and foreword Index Composition of shop manual........................ 2 Table of contents ..........................3 114E-3 Series...
Page 4 Troubleshooting of electrical system (E-mode), Part 2 SEN00458-01 q Troubleshooting of mechanical system (S-mode) 50 Disassembly and assembly SEN00461-01 SEN00462-01 q General information on disassembly and assembly SEN00463-01 q Disassembly and assembly, Part 1 SEN00464-01 q Disassembly and assembly, Part 2 114E-3 Series...
Page 5: Table Of Contents
Rocker arm, shaft and tappet ....................32 Flywheel and flywheel housing....................34 Oil pump ..........................36 20 Standard value table Standard service value table SEN00261-02 Standard value table for testing, adjusting and troubleshooting ..........Run-in standard and performance test criteria ................ 114E-3 Series...
Page 6 E-24 Code [325/CA325] Injector No. 6 System Open/Short Error........... 42 E-25 Code [331/CA331] Injector No. 2 System Open/Short Error........... 44 E-26 Code [332/CA332] Injector No. 4 System Open/Short Error........... 46 E-27 Code [342/CA342] Engine Controller Data Matching Error..........48 114E-3 Series...
Page 7 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)......18 S-12 Oil pressure drops......................19 S-13 Oil level rises (Entry of coolant or fuel) ................20 S-14 Coolant temperature becomes too high (overheating)............ 21 S-15 Abnormal noise is made ....................22 S-16 Vibration is excessive ..................... 23 114E-3 Series...
Page 8 How to read this manual ......................Coating materials list ....................... Special tools list ........................Disassembly and assembly, Part 1 SEN00463-01 Disassembly and assembly......................General disassembly of engine ....................Disassembly and assembly, Part 2 SEN00464-01 Disassembly and assembly......................General assembly of engine ....................114E-3 Series...
Page 9 00 Index and foreword SEN00171-05 114E-3 Series...
Page 11 SEN00172-03 Engine 1SHOP MANUAL 114E-3 Series 00 Index and foreword Foreword and general information Safety notice ..............................2 How to read the shop manual ......................... 7 Explanation of terms for maintenance standard ..................... 9 Handling of electric equipment and hydraulic component ................11 Handling of connectors newly used for engines ...................
Page 12: Safety Notice
Proper service and repair are extremely important for safe machine operation. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe. Some of these techniques require the use of tools specially designed by Komatsu for the specific purpose.
Page 13 2 bolts in diagonal positions. Loosen those bolts gradually and alternately to release the pressure, and then remove the cover. When removing components, be careful not to break or damage the electrical wir- ing. Damaged wiring may cause electrical fires. 114E-3 Series...
Page 14 If you grasp them, your fingers as large as 39.2 kN {4,000 kg}. may be caught. After the wire ropes are stretched, stop the crane and check the condi- tion of the slung load, wire ropes, and pads. 114E-3 Series...
Page 15 11) After operating the hoist, do not swing the control switch. 12) Remember the position of the main switch so that you can turn off the power immedi- ately in an emergency. 114E-3 Series...
Page 16 (R134a) (DENSO: ND-OIL8, ZEXEL: ZXL100PG (equivalent to PAG46)) to its O-rings. a Example of O-ring (Fitted to every joint of hoses and tubes) a For tightening torque, see the precautions for installation in each section of "Disassembly and assembly". 114E-3 Series...
Page 17: How To Read The Shop Manual
This section explains the method of reproducing, repairing, and replacing parts. Revision and distribution Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most up-to-date information before you start any work. 114E-3 Series...
Page 18 Places where oil, etc. must be drained, and quantity to be drained. Units In this shop manual, the units are indicated with International System of units (SI). For reference, con- ventionally used Gravitational System of units is indicated in parentheses { }. 114E-3 Series...
Page 19: Explanation Of Terms For Maintenance Standard
The tightness of fit is decided by the toler- ance. Indication of size of rotating shaft and hole and relationship drawing of them Example: Tolerance Standard size Shaft Hole –0.030 +0.046 –0.076 114E-3 Series...
Page 20 If a product is worn to the allowable value, it must be checked or repaired. Since the permissible value is estimated from vari- ous tests or experiences in most cases, however, it must be judged after consider- ing the operating condition and customer's requirement. 114E-3 Series...
Page 21: Handling Of Electric Equipment And Hydraulic Component
The pins of the male and female connec- tors are in contact at the crimped terminal or soldered portion, but if there is exces- sive force brought to bear on the wiring, the plating at the joint will peel and cause improper connection or breakage. 114E-3 Series...
Page 22 If there is oil or water in the com- pressed air, the contacts will become even dirtier, so remove the oil and water from the compressed air com- pletely before cleaning with com- pressed air. 114E-3 Series...
Page 23 If the machine is left disassem- bled for a long time, it is particu- larly easy for improper contact to occur, so always cover the con- nector. 114E-3 Series...
Page 24 If the connector cannot be cor- rected easily, remove the clamp and adjust the position. If the connector clamp has been removed, be sure to return it to its original position. Check also that there are no loose clamps. 114E-3 Series...
Page 25 (2) while moving it up and down until the locks are set normally. Arrow: 1), 2), 3) a Right of figure: Lock (a) is pulled down (not set completely) and lock (b) is set completely. (1): Male connector (2): Female connector (a), (b): Locks 114E-3 Series...
Page 26 After completely drying the con- n e c t o r, b l o w i t w i t h c o n ta c t restorer and reassemble. 114E-3 Series...
Page 27 If there is any change, there is proba- bly defective contact in that circuit. 114E-3 Series...
Page 28 If an oil clean- ing device is used, it is possible to filter out the dirt that has collected during storage, so this is an even more effective method. 114E-3 Series...
Page 29 The oil cleaning equipment is used to remove the ultra fine (about 3 ) particles that the filter built in the hydraulic equipment can- not remove, so it is an extremely effective device. 114E-3 Series...
Page 30: Handling Of Connectors Newly Used For Engines
Even if lock (L2) is pressed, connec- tor (1) cannot be pulled out toward you, if part A does not float. In this case, float part A with a small screw- driver while press lock (L2), and then pull out connector (1) toward you. 114E-3 Series...
Page 31 If the lock is on the underside, use flat-head screwdriver [1] since you cannot insert your fingers. While pressing up lock (C) of the connec- tor with flat-head screwdriver [1], pull out connector (3) in the direction of the arrow. 114E-3 Series...
Page 32 Insert the connector to the end, while setting its groove. Turn housing (H1) in the direction of the arrow until it “clicks”. Example) Speed sensor of fuel supply pump: G (SUMITOMO-3) a Pull the connector straight up. 114E-3 Series...
Page 33: How To Read Electric Wire Code
(Nominal No. 3 and below) Insulator Soft polyvinyl chloride automobile Conduc- Annealed copper for elec- Heat-resis- General wiring in extremely tric appliance tant low-volt- –50 to +110 cold district, wiring at high-tem- age wire for Heat-resistant crosslinked perature place Insulator automobile polyethylene 114E-3 Series...
Page 34 (approx.) 10.4 12.0 13.6 Standard – – – – – – – – – Cov- Standard 10.8 11.4 13.0 13.6 16.0 17.6 er D Standard 10.8 11.4 13.0 13.6 16.0 17.6 “f” of nominal No. denotes flexible”. 114E-3 Series...
Page 35 – – Others – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – 114E-3 Series...
Page 36: Precautions When Carrying Out Operation
07371-30400 07379-00500 07378-10500 07371-30500 If the part is not under hydraulic pressure, the following corks can be used. Dimensions Nominal Part Number number 07049-00608 07049-00811 07049-01012 07049-01215 07049-01418 11.5 07049-01620 13.5 07049-01822 07049-02025 07049-02228 18.5 07049-02430 07049-02734 22.5 114E-3 Series...
Page 37 If any part is loosened or damaged, retighten or repair it. Fuel system Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel leakage. If any part is loosened or damaged, retighten or repair it. 114E-3 Series...
Page 38 If any bolt or nut is loosened, retighten it. Checking muffler function Check the muffler for abnormal sound and sound different from that of a new muffler. If any abnormal sound is heard, repair the muffler, referring to “Troubleshooting” and “Disassembly and assembly”. 114E-3 Series...
Page 39: Method Of Disassembling And Connecting Push-Pull Type Coupler
After inserting the hose in the mating adapter perfectly, pull it back to check its connecting condition. (Fig. 5) a When the hose is pulled back, the rubber cap portion moves toward the hose about 3.5 mm. This does not indicate abnormality, however. 114E-3 Series...
Page 40 2), pull out whole body (7) to discon- nect it. (Fig. 8) Connection Hold the tightening portion and push body (7) straight until sliding prevention ring (6) contacts contact surface (a) of the hexag- onal portion at the male end. (Fig. 9) 114E-3 Series...
Page 41 2), pull out whole body (9) to discon- nect it. (Fig. 12) Connection Hold the tightening portion and push body (9) straight until the sliding prevention ring contacts contact surface (b) of the hexag- onal portion at the male end. (Fig. 13) 114E-3 Series...
Page 42: Standard Tightening Torque Table
The following table corresponds to the bolts in Fig. B. Thread diameter of bolt Width across flats Tightening torque 5.9 – 9.8 0.6 – 1.0 13.7 – 23.5 1.4 – 2.4 34.3 – 46.1 3.5 – 4.7 74.5 – 90.2 7.6 – 9.2 Fig. A Fig. B 114E-3 Series...
Page 43 93.1 – 122.5 { 9.5 – 12.5} 107.8 {11.0} – 107.8 – 147.0 {11.0 – 15.0} 127.4 {13.0} 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5} – 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5} – 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0} 114E-3 Series...
Page 44 Thread size Tightening torque 8 ± 2 0.81 ± 0.20 10 ± 2 1.02 ± 0.20 12 ± 2 1.22 ± 0.20 24 ± 4 2.45 ± 0.41 36 ± 5 3.67 ± 0.51 114E-3 Series...
Page 45 0.31 ± 0.10 8 ± 2 0.81 ± 0.20 12 ± 2 1.22 ± 0.20 15 ± 2 1.53 ± 0.20 24 ± 4 2.45 ± 0.41 36 ± 5 3.67 ± 0.51 60 ± 9 6.12 ± 0.92 114E-3 Series...
Page 46: Conversion Table
2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898 114E-3 Series...
Page 47 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153 114E-3 Series...
Page 48 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4 114E-3 Series...
Page 49 3,015 3,030 3,044 3,058 3,072 3,086 3,101 3,115 3,129 3,143 3,158 3,172 3,186 3,200 3,214 3,229 3,243 3,257 3,271 3,286 3,300 3,314 3,328 3,343 3,357 3,371 3,385 3,399 3,414 3,428 3,442 3,456 3,470 3,485 3,499 3,513 3,527 3,542 114E-3 Series...
Page 50 167.0 65.6 302.0 –14.4 42.8 105.8 24.4 168.8 68.3 311.0 –13.9 44.6 107.6 25.0 170.6 71.1 320.0 –13.3 46.4 109.4 25.6 172.4 73.9 329.0 –12.8 48.2 111.2 26.1 174.2 76.7 338.0 –12.2 50.0 113.0 26.7 176.0 79.4 347.0 114E-3 Series...
Page 51 00 Index and foreword SEN00172-03 114E-3 Series...
Page 53: Specification
SEN00174-02 Engine 1SHOP MANUAL 114E-3 Series 01 Specification Specification and technical data Specification and technical data........................2 General ..............................2 Specifications ............................3 General view ............................8 Dimensions table..........................12 Engine performance curves ....................... 13 114E-3 Series...
Page 54: General
Specification and technical data General 1. Applicable machine Engine Serial No. Applicable machine PC300-7E0, PC300LC-7E0 Hydraulic excavator PC350-7E0, PC350LC-7E0 Hydraulic excavator PC300-8, PC300LC-8 Hydraulic excavator SAA6D114E-3 PC350-8, PC350LC-8 Hydraulic excavator WA430-6 Wheel loader D65EX-15E0, D65PX-15E0, D65WX-15E0 Bulldozer GD655-3E0, GD675-3E0 Motor grader 114E-3 Series...
Page 55: Specifications
Lubricating oil amount (refill capacity) 40 (35) Coolant amount 10.4 Alternator — 24V, 35A, 60A (if equipped) Starting motor — 24V, 7.5kW, 11kW (if equipped) Battery — 12V, 120Ah/140Ah × 2 Turbocharger — HOLSET HX40W Air compressor — — Others — — 114E-3 Series...
Page 56 Lubricating oil amount (refill capacity) 40 (35) Coolant amount 10.4 Alternator — 24V, 60A Starting motor — 24V, 7.5kW, 11kW (if equipped) Battery — 12V, 120Ah/140Ah × 2 Turbocharger — HOLSET HX40W Air compressor — — Others — — 114E-3 Series...
Page 57 Lubricating oil amount (refill capacity) 37 (32) Coolant amount 10.4 Alternator — 24V, 60A, 90A (if equipped) Starting motor — 24V, 7.5kW, 11kW (if equipped) Battery — 12V, 136Ah/140Ah × 2 Turbocharger — HOLSET HX40W Air compressor — Equipped Others — — 114E-3 Series...
Page 58 Lubricating oil amount (refill capacity) 33 (28) Coolant amount 10.4 Alternator — 24V, 60A, 90A (if equipped) Starting motor — 24V, 7.5kW, 11kW (if equipped) Battery — 12V, 112Ah/140Ah × 2 Turbocharger — HOLSET HX40W Air compressor — — Others — — 114E-3 Series...
Page 59 Lubricating oil amount (refill capacity) 30 (25) Coolant amount 10.4 Alternator — 24V, 60A, 90A (if equipped) Starting motor — 24V, 7.5kW, 11kW (if equipped) Battery — 12V, 112Ah × 2 Turbocharger — HOLSET HX40W Air compressor — — Others — — 114E-3 Series...
Page 60: General View
SEN00174-02 01 Specification General view SAA6D114E-3 (Left side view of engine) Machine model: PC300-7E0, PC300LC-7E0, PC350-7E0, PC350LC-7E0 a The shape may differ according to the machine model. Crankshaft center Flywheel housing rear surface 114E-3 Series...
Page 61 01 Specification SEN00174-02 SAA6D114E-3 (Right side view of engine) Machine model: PC300-7E0, PC300LC-7E0, PC350-7E0, PC350LC-7E0 a The shape may differ according to the machine model. Crankshaft center Flywheel housing rear surface 114E-3 Series...
Page 62 SEN00174-02 01 Specification SAA6D114E-3 (Front view of engine) Machine model: PC300-7E0, PC300LC-7E0, PC350-7E0, PC350LC-7E0 a The shape may differ according to the machine model. Crankshaft center Cylinder center 114E-3 Series...
Page 63 01 Specification SEN00174-02 SAA6D114E-3 (Rear view of engine) Machine model: PC300-7E0, PC300LC-7E0, PC350-7E0, PC350LC-7E0 a The shape may differ according to the machine model. Crankshaft center Cylinder center 114E-3 Series...
Page 64: Dimensions Table
PC350-7E0, PC350LC-7E0 1,625 1,601 1,004 PC300-8, PC300LC-8 PC350-8, PC350LC-8 SAA6D114E-3 WA430-6 1,135 1,605 D65EX-15E0, D65PX-15E0, D65WX-15E0 1,189 1,532 GD655-3E0, GD675-3E0 1,128 1,455 a These dimensions are given for reference when the engine is set on a test bench. 114E-3 Series...
Page 65: Engine Performance Curves
01 Specification SEN00174-02 Engine performance curves Engine Engine serial No. Machine model Page PC300-7E0, PC300LC-7E0 PC350-7E0, PC350LC-7E0 PC300-8, PC300LC-8 PC350-8, PC350LC-8 SAA6D114E-3 WA430-6 D65EX-15E0, D65PX-15E0, D65WX-15E0 GD655-3E0, GD675-3E0 114E-3 Series...
Page 66 SEN00174-02 01 Specification SAA6D114E-3 (Machine model: PC300-7E0, PC300LC-7E0, PC350-7E0, PC350LC-7E0, PC300-8, PC300LC-8, PC350-8, PC350LC-8) Rated output: 194 kW {260 HP}/1,950 rpm (Gross) Max. torque: 1,129 Nm {115 kgm}/1,450 rpm (Gross) 114E-3 Series...
Page 67 01 Specification SEN00174-02 SAA6D114E-3 (Machine model: WA430-6) Rated output: 173 kW {232 HP}/2,100 rpm (Gross) Max. torque: 1,020 Nm {104 kgm}/1,450 rpm (Gross) 114E-3 Series...
Page 68 SEN00174-02 01 Specification SAA6D114E-3 (Machine model: D65EX-15E0, D65PX-15E0, D65WX-15E0) Rated output: 154 kW {206 HP}/1,950 rpm (Gross) Max. torque: 1,010 Nm {103 kgm}/1,450 rpm (Gross) 114E-3 Series...
Page 69 01 Specification SEN00174-02 SAA6D114E-3 (Machine model: GD655-3E0, GD675-3E0) Rated output: 154 kW {206 HP}/1,900 rpm (Gross) Max. torque: 990 Nm {101 kgm}/1,450 rpm (Gross) 114E-3 Series...
Page 71 SEN00176-02 Engine 1SHOP MANUAL 114E-3 Series 10 Structure, function and maintenance standard Intake, exhaust system ........................... 2 Intake system............................2 Exhaust system ............................ 3 Turbocharger ............................4 Lubricating oil system ............................. 7 Cooling system ............................... 9 Fuel system (common rail)..........................10 Maintenance standard ..........................
Page 72: Intake, Exhaust System
CAC piping (2), to the CAC (3), the intake air heater (if applicable), and into the intake manifold (4). From the intake manifold, air is forced into the cylinders (5) and used for combus- tion. 114E-3 Series...
Page 73: Exhaust System
10 Structure, function and maintenance standard SEN00176-02 Exhaust system General Information Exhaust valve Exhaust manifold (pulse type) Dual-entry turbocharger Turbocharger exhaust outlet 114E-3 Series...
Page 74: Turbocharger
An adequate supply of good, filtered oil is very important to the life of the turbocharger. Make sure that a high-quality oil is used and that it and the oil filter are changed according to maintenance recommendations. 114E-3 Series...
Page 75 Since the exhaust gas is gated around the turbine wheel, less energy is absorbed through the turbine and transferred to the compressor, reducing the intake manifold pressures and turbine speeds. 114E-3 Series...
Page 76 The wastegate valve is mounted inside the turbo- charger in the turbine housing. As the valve opens, exhaust gas is allowed to bypass the turbine wheel, lowering turbine speed to adjust the intake manifold pressure. 114E-3 Series...
Page 77: Lubricating Oil System
From lubricating oil filter To lubricating oil pan Full flow lubricating oil filter Lubrication for power components From lubricating oil cooler From main lubricating oil rifle Main lubricating oil rifle To connecting rod bearing To camshaft To piston cooling nozzle 114E-3 Series...
Page 78 10 Structure, function and maintenance standard Lubrication for turbocharger Lubricating oil supply from filter Turbocharger lubricating oil supply Turbocharger lubricating oil drain Lubrication for the overhead From cam bushings Transfer slot Rocker lever support Rocker lever shaft Rocker lever bore Rocker lever 114E-3 Series...
Page 79: Cooling System
A torque converter cooling system with a remote bypass allows the torque converter to receive cool- ant flow when the thermostat is closed (engine cold). 114E-3 Series...
Page 80: Fuel System (Common Rail)
Fuel gear pump 19. Fuel pressure relief valve Fuel from gear pump to fuel filter 20. Fuel injector drain flow line 10. Primary fuel filter 21. Fuel return to supply tanks 11. Fuel inlet to fuel pump actuator 114E-3 Series...
Page 81 Some fuel continuously returns to drain through the air-bleed orifice fitting. Fuel that is metered through the fuel pump actuator enters the high-pressure fuel pump head where it is pumped to fuel rail pres- sure and exits at the high-pressure outlet fitting. 114E-3 Series...
Page 82 An air-bleed orifice fitting in the fuel pump actuator housing aids in purging air from the fuel supply. Because of the air-bleed orifice fitting, some fuel that is supplied by the gear pump will return to drain at all times. 114E-3 Series...
Page 83 Once the engine is started, additional fuel is drawn through the lift pump head via the gear pump. A valve in the head opens when the gear pump requires more flow than the lift pump can provide or when the lift pump is shut off. 114E-3 Series...
Page 84 The edge filters are not a substitute for clean- ing and covering all fuel system connections during repair. a Be sure to cap or cover all fuel fittings and ports. 114E-3 Series...
Page 85: Maintenance Standard
Criteria Remedy Replace bearing Radial play (Play in radial direction) 0.330 – 0.508 parts Replace thrust End play (Play in axial direction) 0.025 – 0.127 parts Target (Nm {kgm}) Tightening torque of turbine housing Tighten bolt 26 {2.6} 114E-3 Series...
Page 86: Cylinder Head
SEN00176-02 10 Structure, function and maintenance standard Cylinder head 114E-3 Series...
Page 87 110 {11.2} 5th stage Retighten 120° Replace nozzle Projection of nozzle 2.25 – 2.80 or gasket Target (Nm {kgm}) Tightening torque for injector holder mounting bolt 10 {1.0} Tighten Tightening torque for head cover mount- 24 {2.4} ing bolt 114E-3 Series...
Page 88: Cylinder Block
SEN00176-02 10 Structure, function and maintenance standard Cylinder block 114E-3 Series...
Page 89 3rd stage 30.4 {3.1} (Apply engine oil to threads) 4th stage 50 {5.1} 5th stage Retighten 120° Target (Nm {kgm}) Tightening torque for oil pan mounting bolt 28 {2.8} Tighten Tightening torque for crankshaft pulley 200 {20.4} mounting bolt 114E-3 Series...
Page 90: Cylinder Liner
SEN00176-02 10 Structure, function and maintenance standard Cylinder liner 114E-3 Series...
Page 91 Replace cylinder Outside diameter of cylinder liner 130.938 – 13.0958 liner Inside diameter of cylinder liner bore in 130.900 – 13.0950 Replace cylinder cylinder block liner or cylinder Clearance between cylinder liner and block Min. 0.229 cylinder block 114E-3 Series...
Page 92: Crankshaft
Taper of main journal Max. 0.013 Replace main Clearance of main journal 0.038 – 0.116 bearing metal Outside diameter of crankshaft gear 75.987 – 76.006 Use undersize journal crankshaft or Inside diameter of crankshaft gear jour- replace 75.898 – 75.923 114E-3 Series...
Page 93: Piston, Piston Ring And Piston Pin
Clearance at piston ring end gap 2nd ring 0.85 – 1.15 ring or piston Oil ring 0.30 – 0.73 Outside diameter of piston pin 44.997 – 45.003 Peplace piston or piston pin Inside diameter of piston pin bore 45.006 – 45.012 114E-3 Series...
Page 94: Connecting Rod
SEN00176-02 10 Structure, function and maintenance standard Connecting rod 114E-3 Series...
Page 95 Tightening torque for connecting rod Tighten and cap mounting bolt 2nd stage Loosen retighten (Coat thread of bolt nut with engine oil) 3rd stage 70 {7.1} 4th stage Retighten 60° Replace connect- Side clearance of connecting rod 0.100 – 0.300 ing rod 114E-3 Series...
Page 96: Vibration Damper
SEN00176-02 10 Structure, function and maintenance standard Vibration damper Unit: mm Check item Criteria Remedy Target (Nm {kgm}) Tighten and Tightening torque of vibration damper retighten 200 {20.4} 114E-3 Series...
Page 97: Timing Gear
Timing gear Unit: mm Check item Criteria Remedy Backlash of oil pump 0.08 – 0.33 gear Backlash of camshaft – Backlash of each gear 0.08 – 0.33 Replace gear Backlash of oil pump idler 0.08 – 0.33 gear 114E-3 Series...
Page 98: Camshaft
0.12 – 0.50 plate Outside diameter of camshaft bearing 59.962 – 60.013 Correct or replace journal Thickness of camshaft thrust plate 9.40 – 9.60 Replace Target (Nm {kgm}) Tightening torque of camshaft thrust Tighten plate mounting bolt 24 {2.4} 114E-3 Series...
Page 99 10 Structure, function and maintenance standard SEN00176-02 114E-3 Series...
Page 100: Valve And Valve Guide
SEN00176-02 10 Structure, function and maintenance standard Valve and valve guide 114E-3 Series...
Page 101 Judge condition of contact valve, valve seat surface with vacuum test Exhaust 45° Outside diameter of valve stem 7.96 – 7.98 Replace Diameter of valve guide bore 8.019 – 8.071 Clearance between valve guide and 13.15 – 13.65 Correct valve stem 114E-3 Series...
Page 102: Rocker Arm, Shaft And Tappet
SEN00176-02 10 Structure, function and maintenance standard Rocker arm, shaft and tappet 114E-3 Series...
Page 103 24 {2.5} Valve Repair limit Valve clearance (cold) Intake 0.305 Adjust Exhaust 0.559 Outside diameter of tappet 15.936 – 15.977 Replace tappet Target (Nm {kgm}) Tightening torque of rocker arm Tighten mounting bolt 65 {6.6} 114E-3 Series...
Page 104: Flywheel And Flywheel Housing
SEN00176-02 10 Structure, function and maintenance standard Flywheel and flywheel housing 114E-3 Series...
Page 105 Face runout of flywheel Reassemble, For torque correct Diameter (actual measurement) × 0.0005 converter Radial runout of flywheel Repair limit: 0.13 Tightening torque of flywheel mounting Target (Nm {kgm}) Tigthen and bolt retighten 137 {14.0} (Coat bolt thread with engine oil) 114E-3 Series...
Page 106: Oil Pump
0.025 – 0.127 Clearance between outer rotor and 0.178 – 0.381 body Replace oil pump Clearance between outer rotor and 0.025 – 0.178 inner rotor Target (Nm {kgm}) Tightening torque of oil pump mounting Tigthen and bolt retighten 24 {2.4} 114E-3 Series...
Page 107 10 Structure, function and maintenance standard SEN00176-02 114E-3 Series...
Page 109: Standard Value Table
SEN00261-02 Engine 1SHOP MANUAL 114E-3 Series 20 Standard value table Standard service value table Standard service value table ........................... 2 Standard value table for testing, adjusting and troubleshooting ............2 Run-in standard and performance test criteria ..................6 114E-3 Series...
Page 110: Standard Value Table For Testing, Adjusting And Troubleshooting
(Ratio to fuel consumption) Radiator pressure Opening pressure — — valve (Differential pressure) {kg/cm Fan speed At rated engine speed 1,346 — Fan and alternator belt Deflects when pushed with a Auto-tensioner — tension force of 98 N {10 kg} 114E-3 Series...
Page 111 Radiator pressure Opening pressure — — valve (Differential pressure) {kg/cm — Fan speed At rated engine speed — (Chassis side) Fan and alternator belt Deflects when pushed with a Auto-tensioner — tension force of 98 N {10 kg} 114E-3 Series...
Page 112 Radiator pressure Opening pressure — — valve (Differential pressure) {kg/cm — Fan speed At rated engine speed — (Chassis side) Fan and alternator belt Deflects when pushed with a Auto-tensioner — tension force of 98 N {10 kg} 114E-3 Series...
Page 113 Radiator pressure Opening pressure — — valve (Differential pressure) {kg/cm — Fan speed At rated engine speed — (Chassis side) Fan and alternator belt Deflects when pushed with a Auto-tensioner — tension force of 98 N {10 kg} 114E-3 Series...
Page 114: Run-In Standard And Performance Test Criteria
This table shows the standard values with an air cleaner installed, muffler installed, alternator under no load. a The dynamometer load shows the value for an arm length of 716 mm. a Use ASTM D975 diesel oil as the fuel. a Use SAE15W-40 as the lubricating oil. 114E-3 Series...
Page 115 This table shows the standard values with an air cleaner installed, muffler installed, alternator under no load. a The dynamometer load shows the value for an arm length of 716 mm. a Use ASTM D975 diesel oil as the fuel. a Use SAE15W-40 as the lubricating oil. 114E-3 Series...
Page 116 This table shows the standard values with an air cleaner installed, muffler installed, alternator under no load. a The dynamometer load shows the value for an arm length of 716 mm. a Use ASTM D975 diesel oil as the fuel. a Use SAE15W-40 as the lubricating oil. 114E-3 Series...
Page 117 This table shows the standard values with an air cleaner installed, muffler installed, alternator under no load. a The dynamometer load shows the value for an arm length of 716 mm. a Use ASTM D975 diesel oil as the fuel. a Use SAE15W-40 as the lubricating oil. 114E-3 Series...
Page 119: Testing And Adjusting
SEN00455-01 ENGINE 1SHOP MANUAL 114E-3 Series 30 Testing and adjusting Testing and adjusting Testing and adjusting ............................3 Testing and adjusting tools list ......................3 Testing air boost pressure ........................4 Adjusting valve clearance ........................5 Testing compression pressure ......................7 Testing blow-by pressure ........................
Page 120 SEN00455-01 30 Testing and adjusting Replacing alternator belt ........................23 114E-3 Series...
Page 121: Testing And Adjusting Tools List
1 Controller (50 poles) 799-601-4220 • T-adapter 1 Controller (60 poles) 799-601-4140 • T-adapter 1 Atmospheric pressure sensor 799-601-4340 • T-adapter 1 Pump actuator 799-601-4260 • T-adapter 1 Controller (4 poles) 799-601-4190 • T-adapter 1 Common rail pressure sensor 114E-3 Series...
Page 122: Testing Air Boost Pressure
Remove air boost pressure pickup plug (1) between the turbocharger and aftercooler. After finishing testing, remove the measuring tools and return the removed parts. Install nipple [1] and hose [2] of boost gauge kit A and connect it to gauge [3]. 114E-3 Series...
Page 123: Adjusting Valve Clearance
Remove cap (5), insert gear C1, and rotate it forward. After placing the No. 1 cylinder at the compres- sion top dead center, place a counter mark on the damper, and install a pointer to gear cover (7) using wire. 114E-3 Series...
Page 124 Fix adjustment screw (11) and tighten Head cover assembly mounting bolt: locknut (10). 11.8 ± 1.96 Nm {1.2 ± 0.2 kgm} Locknut: 24 ± 4 Nm {2.45 ± 0.41 kgm} a After tightening the locknut, check the valve clearance again. 114E-3 Series...
Page 125: Testing Compression Pressure
Remove the injector using puller D1 and the impact of slide hammer. a Do not unclench the upper part of the injector. Disconnect fuel high-pressure tube (5). Loosen injector terminal nut (6) and remove the terminal from the injector. 114E-3 Series...
Page 126 Tighten bolt (12) by three or four threads with hands. Coat the O-ring of inlet connector (11) and the mounting hole on the head with engine oil (EO15W-40). Install inlet connector (11) temporarily with retainer (10). Retainer: 15 ± 5.0 Nm {1.5 ± 0.5 kgm} 114E-3 Series...
Page 127 After installing the rocker arm assembly, adjust the valve clearance, referring to “Adjusting valve clearance”. a Install the injector wiring harness terminal (5) in a direction where it will not interfere with the rocker arm (6) which moves up and down. 114E-3 Series...
Page 128: Testing Blow-By Pressure
, t e s t o n t h e c o n d i t i o n described in the shop manual for the machine. After finishing testing, remove the measuring tools and return the removed parts. 114E-3 Series...
Page 129: Testing Oil Pressure
After finishing testing, remove the measuring tools and return the removed parts. Install adapter F3 and nipple [1] of hydraulic tester F1 to the plug mount. Connect the hose of hydraulic tester F1 to nip- ple [1] and gauge F2. 114E-3 Series...
Page 130: Handling Fuel System Parts
The pressure in both low-pressure circuit and a Precautions for replacing fuel filter cartridge high-pressure circuit lowers to a safety level Be sure to use the Komatsu genuine fuel filter automatically 30 seconds after the engine is cartridge. stopped.
Page 131: Testing Fuel Pressure
Remove fuel pressure pickup plug (1) 20 – 22 Nm {2.0 – 2.2 kgm} from the fuel supply connector. Testing fuel negative pressure circuit pres- sure (supply pump) Remove fuel pressure pickup plug (2) from the supply pump. 114E-3 Series...
Page 132 (fuel filter inlet side) Remove fuel pressure pickup plug (3) from the fuel main filter inlet side. After finishing testing, remove the testing tools and return the removed parts. Fuel pressure pickup plug: 20 – 22 Nm {2.0 – 2.2 kgm} 114E-3 Series...
Page 133 Fuel filter inlet pressure – Fuel filter outlet pressure a If the drop of fuel low-pressure circuit pressure is in the following range, it is normal. Standard value of drop of fuel low- pressure circuit pressure: Max. 0.14 MPa {Max. 1.4 kg/cm 114E-3 Series...
Page 134 3 – 4 times with the starting switch to bleed air from the fuel circuit and fill the pump with fuel and then measure the outlet pressure again. Connect M10 computer check fitting G4 to gauge G3. 114E-3 Series...
Page 135 (8) of engine controller cooling plate (7) and check to see if the valve is seized. After finishing measurement, remove the measuring instruments and return the removed parts. Fuel pressure pickup plug: 20 – 22 Nm {2.0 – 2.2 kgm} 114E-3 Series...
Page 136: Reduced Cylinder Mode Operation
Perform the reduced cylinder mode opera- tion with the engine mounted on the machine or connected to INSITE (trouble- shooting kit). Before performing, see Testing method in the shop manual for the machine or INSITE (troubleshooting kit). 114E-3 Series...
Page 137: Testing Leakage From Pressure Limiter And Return Rate From Injector
If the return rate from the supply the fuel from leaking. pump is in the following range, it is normal. Cranking Max. 200 cc/30 sec. Low idle Max. 300 cc/30 sec. 114E-3 Series...
Page 138 24 ± 4 Nm {2.45 ± 0.41 kgm} Connect hose kit H1 to the cylinder head side, and insert its tip into measuring cylin- der H3. Connect adapter H2 to the return tube joint connecting part at the cylinder block side to block fuel leakage. 114E-3 Series...
Page 139: Bleeding Air From Fuel Circuit
(a). a If clean fuel is not available, do not remove the fuel pre-filter but fill it with the fuel by operating priming pump. a Do not add fuel to fuel main filter (1) from outside. 114E-3 Series...
Page 140: Testing Fuel System For Leakage
2. Run the engine at high idle and load it. a When checking while the components to be checked are mounted on the machine, stall the torque converter or relieve the hydraulic pump. 114E-3 Series...
Page 141: Handling Controller High-Voltage Circuit
If a T-adapter is inserted in or connected to a connector related to the high-voltage circuit for troubleshooting, do not start the engine. a You may turn the starting switch to the OFF or ON position but must not turn it to the START position. 114E-3 Series...
Page 143: General Information On Troubleshooting
SEN00457-01 ENGINE 1SHOP MANUAL 114E-3 Series 40 Troubleshooting General information on troubleshooting General information on troubleshooting......................2 Points on troubleshooting........................2 Error and failure code table ........................3 Information in troubleshooting table ..................... 6 114E-3 Series...
Page 144: Points On Troubleshooting
Radical countermeasures against failure cause Even if the immediate problem is removed, a similar failure will reoccur unless its root cause is removed. To prevent reoccurrence, examine the reason of the failure cause occurrence and remove the root cause. 114E-3 Series...
Page 145: Error And Failure Code Table
Supply Voltage Low Error SEN00460-01 CA442 Supply Voltage High Error CA449 Rail Press. High Error 2 CA451 Rail Press. Sensor High Error CA452 Rail Press. Sensor Low Error CA488 Charge Air Temp. High Torque Derate CA553 Rail Press. High Error 1 114E-3 Series...
Page 146 3- or 4-digit error code displayed on INSITE when a failure occurrence condition is confirmed using INSITE. a Machine failure code: An error code of 5 or 6 digits displayed on the machine monitor when the occurrence condition of the failure is confirmed with the machine monitor, etc. on the machine side. 114E-3 Series...
Page 147 40 Troubleshooting SEN00457-01 114E-3 Series...
Page 148: Information In Troubleshooting Table
Connect positive (+) lead and negative (–) lead of tester as explained below for troubleshooting, unless otherwise specified. • Connect positive (+) lead to pin No. or wiring harness entered on front side. • Connect negative (–) lead to pin No. or wiring harness entered on rear side. 114E-3 Series...
Page 149 40 Troubleshooting SEN00457-01 Related circuit diagram This drawing is a part of the electric circuit diagram related to troubleshooting. • Connector No.: Indicates (Model – Number of pins) and (Color). 114E-3 Series...
Page 151: Troubleshooting Of Electrical System (E-Mode), Part 1
SEN00459-01 ENGINE 1SHOP MANUAL 114E-3 Series 40 Troubleshooting Troubleshooting of electrical system (E-mode), Part 1 Troubleshooting of electrical system (E-mode), Part 1 ................... 3 E-1 Code [111/CA111] Engine Controller Internal Failure ..............3 E-2 Code [115/CA115] Eng. Ne and Bkup Speed Sensor Error............3 E-3 Code [122/CA122] Charge Air Press Sensor High Error ...............
Page 152 E-24 Code [325/CA325] Injector No. 6 System Open/Short Error ............. 42 E-25 Code [331/CA331] Injector No. 2 System Open/Short Error ............. 44 E-26 Code [332/CA332] Injector No. 4 System Open/Short Error ............. 46 E-27 Code [342/CA342] Engine Controller Data Matching Error ............48 114E-3 Series...
Page 153: Code [111/Ca111] Engine Controller Internal Failure
Possible causes Causes Standard value in normal state/Remarks on troubleshooting and standard Defective connection of sen- Check Ne speed sensor and Bkup speed sensor directory for defec- value in normal sor connector tive connection (wrong connection). state 114E-3 Series...
Page 154: Code [122/Ca122] Charge Air Press Sensor High Error
• Humidity in connector, entry of dirt or dust, poor insulation a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 6 Defective engine controller Voltage Between (37) – (47) Power supply 4.75 – 5.25 V 114E-3 Series...
Page 155 40 Troubleshooting SEN00459-01 Circuit diagram related to boost pressure, temperature sensor (combination sensor) 114E-3 Series...
Page 156: Code [123/Ca123] Charge Air Press Sensor Low Error
• Humidity in connector, entry of dirt or dust, poor insulation a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 6 Defective engine controller Voltage Between (37) – (47) Power supply 4.75 – 5.25 V 114E-3 Series...
Page 157 40 Troubleshooting SEN00459-01 Circuit diagram related to boost pressure, temperature sensor (combination sensor) 114E-3 Series...
Page 158: Code [131/Ca131] Throttle Sensor High Error
• Humidity in connector, entry of dirt or dust, poor insulation a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 6 Defective engine controller Voltage Between (22) – (23) Power supply 4.75 – 5.25 V 114E-3 Series...
Page 159 40 Troubleshooting SEN00459-01 Circuit diagram related to fuel control dial 114E-3 Series...
Page 160: Code [132/Ca132] Throttle Sensor Low Error
• Humidity in connector, entry of dirt or dust, poor insulation a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 6 Defective engine controller Voltage Between (22) – (23) Power supply 4.75 – 5.25 V 114E-3 Series...
Page 161 40 Troubleshooting SEN00459-01 Circuit diagram related to fuel control dial 114E-3 Series...
Page 162: Code [144/Ca144] Coolant Temp. Sensor High Error
J1 (female) Coolant temperature Resistance 0°C 30 – 37 kz 5 Defective engine controller 25°C 9.3 – 10.7 kz Between (15) – (38) 50°C 3.2 – 3.8 kz 80°C 1.0 – 1.3 kz 700 – 800 z 95°C 114E-3 Series...
Page 163 40 Troubleshooting SEN00459-01 Circuit diagram related to coolant temperature sensor 114E-3 Series...
Page 164: Code [145/Ca145] Coolant Temp. Sensor Low Error
25°C 9.3 – 10.7 kz 5 Defective engine controller Between (15) – (38) 50°C 3.2 – 3.8 kz 80°C 1.0 – 1.3 kz 700 – 800 z 95°C Between (15) – All range Min. 100 kz chassis ground 114E-3 Series...
Page 165 40 Troubleshooting SEN00459-01 Circuit diagram related to coolant temperature sensor 114E-3 Series...
Page 166: Code [153/Ca153] Charge Air Temp. Sensor High Error
ON. J1 (female) Charge temperature Resistance 0°C 29 – 36 kz 5 Defective engine controller 25°C 9 – 11 kz Between (23) – (47) 40°C 4.9 – 5.8 kz 600 – 700 z 100°C 114E-3 Series...
Page 167 40 Troubleshooting SEN00459-01 Circuit diagram related to boost pressure, temperature sensor (combination sensor) 114E-3 Series...
Page 168: Code [154/Ca154] Charge Air Temp. Sensor Low Error
0°C 29 – 36 kz 5 Defective engine controller 25°C 9 – 11 kz Between (23) – (47) 40°C 4.9 – 5.8 kz 600 – 700 z 100°C Between (23) – All range Min. 100 kz chassis ground 114E-3 Series...
Page 169 40 Troubleshooting SEN00459-01 Circuit diagram related to boost pressure, temperature sensor (combination sensor) 114E-3 Series...
Page 170: Code [155/Ca155] Charge Air Press. High Speed Derate
Abnormally high tempera- Inspect related parts directly. state ture at turbocharger outlet If causes 1 and 2 are not detected, engine controller may be defec- 3 Defective engine controller tive. (Since trouble is in system, troubleshooting cannot be carried out.) 114E-3 Series...
Page 171 40 Troubleshooting SEN00459-01 114E-3 Series...
Page 172: Code [187/Ca187] Sensor Sup. 2 Volt. Low Error
• Humidity in connector, entry of dirt or dust, poor insulation If causes 1 and 2 are not detected, engine controller may be defec- 3 Defective engine controller tive. (Since trouble is in system, troubleshooting cannot be carried out.) 114E-3 Series...
Page 173 40 Troubleshooting SEN00459-01 Circuit diagram related to sensor power supply 2 114E-3 Series...
Page 174: Code [221/Ca221] Ambient Air Press. Sensor High Error
• Humidity in connector, entry of dirt or dust, poor insulation a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 6 Defective engine controller Voltage Between (33) – (38) Power supply 4.75 – 5.25 V 114E-3 Series...
Page 175 40 Troubleshooting SEN00459-01 Circuit diagram related to atmospheric pressure sensor 114E-3 Series...
Page 176: Code [222/Ca222] Ambient Air Press. Sensor Low Error
• Humidity in connector, entry of dirt or dust, poor insulation a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 6 Defective engine controller Voltage Between (33) – (38) Power supply 4.75 – 5.25 V 114E-3 Series...
Page 177 40 Troubleshooting SEN00459-01 Circuit diagram related to atmospheric pressure sensor 114E-3 Series...
Page 178: Code [227/Ca227] Abnormally High Level In Sensor Power Supply 2 Circuit
• Humidity in connector, entry of dirt or dust, poor insulation If cause 1 is not detected, engine controller may be defective. 2 Defective engine controller (Since trouble is in system, troubleshooting cannot be carried out.) Circuit diagram related to sensor power supply 2 114E-3 Series...
Page 179: Code [234/Ca234] Eng. Overspeed
Way of use may be improper. Teach proper way of use to operator. value in normal If causes 1 and 2 is not detected, engine controller may be defec- state 3 Defective engine controller tive. (Since trouble is in system, troubleshooting cannot be carried out.) 114E-3 Series...
Page 180: Code [238/Ca238] Ne Speed Sensor Sup. Volt. Error
Defective wiring harness • Loose connector, broken lock, broken seal connector • Corrosive, bent, broken, forced-in, or extended pin • Humidity in connector, entry of dirt or dust, poor insulation Circuit diagram related to engine Ne speed sensor 114E-3 Series...
Page 181: Code [271/Ca271] Imv (Ima) Short Error
Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 5 Defective engine controller J1 (Female) Resistance Between (2) – chassis ground Min. 100 kz Circuit diagram related to supply pump actuator (metering unit) 114E-3 Series...
Page 182: Code [272/Ca272] Imv (Ima) Open Error
• Humidity in connector, entry of dirt or dust, poor insulation a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 6 Defective engine controller J1 (Female) Resistance Max. 5 z Between (2) – (32) 114E-3 Series...
Page 183 40 Troubleshooting SEN00459-01 Circuit diagram related to supply pump actuator (metering unit) 114E-3 Series...
Page 184: Code [281/Ca281] High Pressure Pump Error
• Humidity in connector, entry of dirt or dust, poor insulation If causes 1 and 2 are not detected, engine controller may be defec- 3 Defective engine controller tive. (Since trouble is in system, troubleshooting cannot be carried out.) 114E-3 Series...
Page 185 40 Troubleshooting SEN00459-01 114E-3 Series...
Page 186: Code [322/Ca322] Injector No. 1 System Open/Short Error
Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. J1 (female) Resistance 7 Defective engine controller Max. 2 z Between (45) – (53) Between (45) – chassis ground Min. 100 kz 114E-3 Series...
Page 187 40 Troubleshooting SEN00459-01 Circuit diagram related to injector No. 1 114E-3 Series...
Page 188: Code [323/Ca323] Injector No. 5 System Open/Short Error
Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. J1 (female) Resistance 7 Defective engine controller Max. 2 z Between (46) – (60) Between (46) – chassis ground Min. 100 kz 114E-3 Series...
Page 189 40 Troubleshooting SEN00459-01 Circuit diagram related to injector No. 5 114E-3 Series...
Page 190: Code [324/Ca324] Injector No. 3 System Open/Short Error
Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. J1 (female) Resistance 7 Defective engine controller Max. 2 z Between (55) – (52) Between (55) – chassis ground Min. 100 kz 114E-3 Series...
Page 191 40 Troubleshooting SEN00459-01 Circuit diagram related to injector No. 3 114E-3 Series...
Page 192: Code [325/Ca325] Injector No. 6 System Open/Short Error
Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. J1 (female) Resistance 7 Defective engine controller Max. 2 z Between (57) – (59) Between (57) – chassis ground Min. 100 kz 114E-3 Series...
Page 193 40 Troubleshooting SEN00459-01 Circuit diagram related to injector No. 6 114E-3 Series...
Page 194: Code [331/Ca331] Injector No. 2 System Open/Short Error
Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. J1 (female) Resistance 7 Defective engine controller Max. 2 z Between (54) – (51) Between (54) – chassis ground Min. 100 kz 114E-3 Series...
Page 195 40 Troubleshooting SEN00459-01 Circuit diagram related to injector No. 2 114E-3 Series...
Page 196: Code [332/Ca332] Injector No. 4 System Open/Short Error
Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. J1 (female) Resistance 7 Defective engine controller Max. 2 z Between (56) – (58) Between (56) – chassis ground Min. 100 kz 114E-3 Series...
Page 197 40 Troubleshooting SEN00459-01 Circuit diagram related to injector No. 4 114E-3 Series...
Page 198: Code [342/Ca342] Engine Controller Data Matching Error
Standard value in normal state/Remarks on troubleshooting causes and 1 Defective related system If another failure code is indicated, carry out troubleshooting for it. standard value 2 Defective engine controller Carry out troubleshooting for failure code [CA757] in normal state 114E-3 Series...
Page 199 40 Troubleshooting SEN00459-01 114E-3 Series...
Page 201 SEN00460-01 ENGINE 1SHOP MANUAL 114E-3 Series 40 Troubleshooting Troubleshooting of electrical system (E-mode), Part 2 Troubleshooting of electrical system (E-mode), Part 2 ................... 3 E-28 Code [351/CA351] INJ. Drive Circuit Error .................. 3 E-29 Code [352/CA352] Sensor Sup. 1 Volt. Low Error............... 5 E-30 Code [386/CA386] Sensor Sup.
Page 202 E-56 Code [2556/CA2556] Intake Air Heater Relay Supply Voltage High Error......... 54 E-57 Code [---/B@BAZG] Eng. Oil Press. Low Speed Derate ............56 E-58 Code [---/B@BAZG] Eng. Oil Press Low Torque Derate ............56 E-59 Code [---/B@BCNS] Eng. Overheat ..................57 114E-3 Series...
Page 203: Code [351/Ca351] Inj. Drive Circuit Error
Wiring harness between J3 (female) (1) – Resis- Max. 10 z chassis ground (T12) tance If causes 1 – 4 are not detected, engine controller may be defective. 5 Defective engine controller (Since trouble is in system, troubleshooting cannot be carried out.) 114E-3 Series...
Page 204 SEN00460-01 40 Troubleshooting Circuit diagram related to engine controller power supply 114E-3 Series...
Page 205: Code [352/Ca352] Sensor Sup. 1 Volt. Low Error
• Humidity in connector, entry of dirt or dust, poor insulation If causes 1 and 2 are not detected, engine controller may be defec- 3 Defective engine controller tive. (Since trouble is in system, troubleshooting cannot be carried out.) 114E-3 Series...
Page 206 SEN00460-01 40 Troubleshooting Circuit diagram related to sensor power supply 1 114E-3 Series...
Page 207: Code [386/Ca386] Sensor Sup. 1 Volt. High Error
• Humidity in connector, entry of dirt or dust, poor insulation If cause 1 is not detected, engine controller may be defective. 2 Defective engine controller (Since trouble is in system, troubleshooting cannot be carried out.) Circuit diagram related to sensor power supply 1 114E-3 Series...
Page 208: Code [428/Ca428] Water Sensor High Level Error
• Humidity in connector, entry of dirt or dust, poor insulation a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 5 Defective engine controller J1 (female) Resistance Max. 10 z Between (14) – (47) 114E-3 Series...
Page 209 40 Troubleshooting SEN00460-01 Circuit diagram related to water-in-fuel sensor 114E-3 Series...
Page 210: Code [429/Ca429] Water Sensor Low Level Error
• Humidity in connector, entry of dirt or dust, poor insulation a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. J1 (female) Resistance 5 Defective engine controller Max. 10 z Between (14) – (47) Between (14) – chassis ground Min. 100 kz 114E-3 Series...
Page 211 40 Troubleshooting SEN00460-01 Circuit diagram related to water-in-fuel sensor 114E-3 Series...
Page 212: Code [431/Ca431] Idle Validation Switch Error
Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. J2 (Female) Accelerator pedal Resistance Max. 1 z Release Defective engine controller Between (11) – (32) Press Min. 1 Mz Release Min. 1 Mz Between (1) – (32) Max. 1 z Press 114E-3 Series...
Page 213 40 Troubleshooting SEN00460-01 Circuit diagram related to accelerator pedal 114E-3 Series...
Page 214: Code [432/Ca432] Idle Validation Process Error
Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. J2 (Female) Accelerator pedal Resistance 5 Defective engine controller Release 1.5 – 3.0 kz Between (22) – (9) Press 0.25 – 1.5 kz 114E-3 Series...
Page 215 40 Troubleshooting SEN00460-01 Circuit diagram related to accelerator pedal 114E-3 Series...
Page 216: Code [435/Ca435] Eng. Oil Switch Error
Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 5 Defective engine controller OIL PRESSURE SWITCH (male) Resistance Max. 10 z Between (1) – body Circuit diagram related to engine oil pressure switch 114E-3 Series...
Page 217 40 Troubleshooting SEN00460-01 114E-3 Series...
Page 218: Code [441/Ca441] Supply Voltage Low Error
Inspect them directly. Defective wiring harness con- • Loose connector, broken lock, broken seal nector • Corrosive, bent, broken, forced-in, or extended pin • Humidity in connector, entry of dirt or dust, poor insulation 114E-3 Series...
Page 219 START and carry out troubleshooting. causes and standard value J3 (Female) Starting switch Voltage 9 Defective engine controller in normal state Min. 24 V Between (3) – (1) START Min. 12 V Circuit diagram related to engine controller power supply 114E-3 Series...
Page 220: Code [442/Ca442] Supply Voltage High Error
Min. medium speed 27.5 – 29.5 V chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 3 Defective engine controller J3 (Female) Voltage Between (3) – (1) Max. 32 V 114E-3 Series...
Page 221 40 Troubleshooting SEN00460-01 Circuit diagram related to engine controller power supply 114E-3 Series...
Page 222: Code [449/Ca449] Rail Press. High Error 2
Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective common rail pres- Monitoring on INSITE Monitoring information sure sensor 0 ± 0.39 MPa Condition when Common rail pressure engine stopped {0 ± 4 kg/cm 114E-3 Series...
Page 223 Max. 10 z Between (1) (2) – chassis ground 10 Defective supply pump If causes 1 – 9 are not detected, supply pump may be defective. Circuit diagram related to common rail pressure sensor and engine controller GND line 114E-3 Series...
Page 224: Code [451/Ca451] Rail Press. Sensor High Error
• Humidity in connector, entry of dirt or dust, poor insulation a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 6 Defective engine controller Voltage Between (37) – (47) Power supply 4.75 – 5.25 V 114E-3 Series...
Page 225 40 Troubleshooting SEN00460-01 Circuit diagram related to common rail pressure sensor 114E-3 Series...
Page 226: Code [452/Ca452] Rail Press. Sensor Low Error
• Humidity in connector, entry of dirt or dust, poor insulation a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 6 Defective engine controller Voltage Between (37) – (47) Power supply 4.75 – 5.25 V 114E-3 Series...
Page 227 40 Troubleshooting SEN00460-01 Circuit diagram related to common rail pressure sensor 114E-3 Series...
Page 228: Code [488/Ca488] Charge Air Temp. High Torque Derate
Abnormally high tempera- Inspect related parts directly. state ture at turbocharger outlet If causes 1 and 2 are not detected, engine controller may be defec- 3 Defective engine controller tive. (Since trouble is in system, troubleshooting cannot be carried out.) 114E-3 Series...
Page 229: Code [553/Ca553] Rail Press. High Error 1
Defective connection of • Ground terminal of engine value in normal ground terminal • Ground terminal of engine controller state • Ground terminal of starting motor Broken O-ring of supply Inspect O-ring directly for breakage. pump actuator 114E-3 Series...
Page 230: Code [559/Ca559] Rail Press Low Error
“Testing leakage from pressure limiter and return rate from injec- tor.” Cranking (When Defective injector (High-pres- Max. 100 cc/ engine cannot be sure piping in head included) 30 sec. started) Return rate from injector At low idle (When Max. 300 cc/ engine can be 45 sec. started) 114E-3 Series...
Page 231 • If this error occurs during bleeding air after replacement of the fuel filter, air left in the fuel circuit is suspected. Continue engine oper- ation at low idle approximately 3 minutes. When air is bled from the fuel circuit, engine speed becomes stable and the error indi- cation disappears. 114E-3 Series...
Page 232: Code [689/Ca689] Eng. Ne Speed Sensor Error
Inspect them directly. Defective wiring harness con- • Loose connector, broken lock, broken seal nector • Corrosive, bent, broken, forced-in, or extended pin • Humidity in connector, entry of dirt or dust, poor insulation 114E-3 Series...
Page 233 Prepare with starting switch OFF, then turn starting switch ON and causes and carry out troubleshooting. standard value 10 Defective engine controller Voltage in normal state Between (16) – (48) Power supply 4.75 – 5.25 V Circuit diagram related to engine Ne speed sensor 114E-3 Series...
Page 234: Code [731/Ca731] Eng. Bkup Speed Sensor Phase Error
Inspect following directly for connection of ground terminal. • Ground terminal (battery (–)) of machine main unit. Defective connection of • Ground terminal of engine ground terminal • Ground terminal of engine controller • Ground terminal of starting motor 114E-3 Series...
Page 235 40 Troubleshooting SEN00460-01 114E-3 Series...
Page 236: Code [757/Ca757] All Engine Controller Data Lost Error
• Humidity in connector, entry of dirt or dust, poor insulation a Prepare with starting switch OFF, then turn starting switch ON and START and carry out troubleshooting. J3 (female) Starting switch Voltage 8 Defective engine controller Min. 24 V Between (3) – (1) START Min. 12 V 114E-3 Series...
Page 237 40 Troubleshooting SEN00460-01 Circuit diagram related to engine controller power supply 114E-3 Series...
Page 238: Code [778/Ca778] Eng. Bkup Speed Sensor Error
Inspect them directly. Defective wiring harness • Loose connector, broken lock, broken seal connector • Corrosive, bent, broken, forced-in, or extended pin • Humidity in connector, entry of dirt or dust, poor insulation 114E-3 Series...
Page 239 Prepare with starting switch OFF, then turn starting switch ON and and standard carry out troubleshooting. value in normal 10 Defective engine controller Voltage state Between (37) – (47) Power supply 4.75 – 5.25 V Circuit diagram related to engine Bkup speed sensor 114E-3 Series...
Page 240: Code [1633/Ca1633] Komnet Error
Resistance cuit, disconnection) 47 – 67 z Between (A) – (B) If causes 1 – 4 are not detected, engine controller may be defective. 5 Defective pump controller (Since trouble is in system, troubleshooting cannot be carried out.) 114E-3 Series...
Page 241 40 Troubleshooting SEN00460-01 Circuit diagram related to CAN communication 114E-3 Series...
Page 242: Code [2185/Ca2185] Throttle Sens. Sup. Volt. High Error
• Humidity in connector, entry of dirt or dust, poor insulation If causes 1 and 2 are not detected, engine controller may be defec- 3 Defective engine controller tive. (Since trouble is in system, troubleshooting cannot be carried out.) Circuit diagram related to fuel control dial 114E-3 Series...
Page 243: Code [2186/Ca2186] Throttle Sens. Sup. Volt. Low Error
• Humidity in connector, entry of dirt or dust, poor insulation If causes 1 – 3 are not detected, engine controller may be defective. 4 Defective engine controller (Since trouble is in system, troubleshooting cannot be carried out.) Circuit diagram related to fuel control dial 114E-3 Series...
Page 244: Code [2249/Ca2249] Rail Press Very Low Error
• Output drops. Related infor- • Method of reproducing failure code: Start engine. mation Possible causes Causes Standard value in normal state/Remarks on troubleshooting and standard value in normal Carry out troubleshooting for failure code [CA559]. state 114E-3 Series...
Page 245 40 Troubleshooting SEN00460-01 114E-3 Series...
Page 246: Code [2265/Ca2265] Abnormally High Level In Electric Lift Pump
• Humidity in connector, entry of dirt or dust, poor insulation a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 6 Defective engine controller J1 (female) Resistance Max. 20 z Between (1) – (11) 114E-3 Series...
Page 247 40 Troubleshooting SEN00460-01 Circuit diagram related to electric lift pump actuator 114E-3 Series...
Page 248: Code [2266/Ca2266] Abnormally Low Level In Electric Lift Pump
• Humidity in connector, entry of dirt or dust, poor insulation a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. J1 (female) Resistance 6 Defective engine controller Max. 20 z Between (1) – (11) Between (1) – chassis ground Min. 100 kz 114E-3 Series...
Page 249 40 Troubleshooting SEN00460-01 Circuit diagram related to electric lift pump actuator 114E-3 Series...
Page 250: Code [2311/Ca2311] Imv (Ima) Solenoid Error
• Humidity in connector, entry of dirt or dust, poor insulation a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. J1 (Female) Resistance 6 Defective engine controller Max. 5 z Between (2) – (32) Between (2) – chassis ground Min. 100 kz 114E-3 Series...
Page 251 40 Troubleshooting SEN00460-01 Circuit diagram related to supply pump actuator (metering unit) 114E-3 Series...
Page 252: Code [2555/Ca2555] Intake Air Heater Relay Supply Voltage Low Error
• Humidity in connector, entry of dirt or dust, poor insulation a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 5 Defective engine controller J2 (female) Resistance 300 – 600 z Between (40) – (42) 114E-3 Series...
Page 253 40 Troubleshooting SEN00460-01 Circuit diagram related to preheating, starting and charging engine 114E-3 Series...
Page 254: Code [2556/Ca2556] Intake Air Heater Relay Supply Voltage High Error
• Humidity in connector, entry of dirt or dust, poor insulation a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 5 Defective engine controller J2 (female) Resistance 300 – 600 z Between (40) – (42) 114E-3 Series...
Page 255 40 Troubleshooting SEN00460-01 Circuit diagram related to preheating, starting and charging engine 114E-3 Series...
Page 256: Code
Standard value in normal state/Remarks on troubleshooting Possible causes and This fault is indicated on only machine side when detected. Carry out troubleshooting on standard value Accordingly, contents of troubleshooting depend on machine model. machine side in normal state See Shop manual for machine. 114E-3 Series...
Page 257: Code
Standard value in normal state/Remarks on troubleshooting Possible causes and This fault is indicated on only machine side when detected. Carry out troubleshooting on standard value Accordingly, contents of troubleshooting depend on machine model. machine side in normal state See Shop manual for machine. 114E-3 Series...
Page 259 SEN00458-01 ENGINE 1SHOP MANUAL 114E-3 Series 40 Troubleshooting Troubleshooting of mechanical system (S-mode) Troubleshooting of mechanical system (S-mode)................... 3 Method of using troubleshooting charts ....................3 S-1 Starting performance is poor ......................6 S-2 Engine does not start........................7 S-3 Engine does not pick up smoothly....................10 S-4 Engine stops during operations ....................11...
Page 260 SEN00458-01 40 Troubleshooting S-13 Oil level rises (Entry of coolant or fuel) ..................20 S-14 Coolant temperature becomes too high (overheating) .............. 21 S-15 Abnormal noise is made ......................22 S-16 Vibration is excessive ........................ 23 114E-3 Series...
Page 261: Troubleshooting Of Mechanical System (S-Mode)
When narrowing the “causes”, apply the items marked with w before those marked with Q. When narrowing the causes, do not apply the items marked with E. (If no items have other marks and the causes cannot be narrowed, however, you may apply them.) 114E-3 Series...
Page 262 Let us assume that [Clogged air cleaner] is taken to be the cause of black exhaust gas. 3 symptoms have causal relationship with this problem: [Color of exhaust gas gradually became black], [Power was lost gradu- ally], and [Air cleaner clogging caution lamp is flashing]. 114E-3 Series...
Page 263 If we look from these 3 symptoms to find the causes, we find that there is a relationship with 5 causes. Let us explain here the method of using this causal relationship to pinpoint the most probable cause. 114E-3 Series...
Page 264: Starting Performance Is Poor
Is voltage 20 – 30 V between alternator terminal B and terminal E with engine at low idle? When specific gravity of electrolyte and voltage of battery are measured, they are Remedy *1: Code [559/CA559] and code [2249/CA2249] in E-mode *2: Code [2265/CA2265] and code [2266/CA2266] in E-mode 114E-3 Series...
Page 265: Engine Does Not Start
ON Even if terminal B and terminal C at safety relay outlet are connected, engine does not start When terminal at safety switch and terminal B at starting motor are connected, engine starts Remedy 114E-3 Series...
Page 266 Engine can be started in reduced cylinder mode Fuel flows out when pressure limiter return piping is disconnected Remedy *1: Code [559/CA559] and code [2249/CA2249] in E-mode *2: Code [271/CA271] and code [272/CA272] in E-mode *3: Code [2265/CA2265] and code [2266/CA2266] in E-mode 114E-3 Series...
Page 267 Coolant temperature gauge does not indicate normally (if coolant tempera- ture gauge is installed) When starting switch is turned to HEAT, intake air heater mount does not become warm Remedy *1: Code [559/CA559] and code [2249/CA2249] in E-mode *2: Code [2265/CA2265] and code [2266/CA2266] in E-mode 114E-3 Series...
Page 268: Engine Does Not Pick Up Smoothly
Carry out troubleshooting according to “No-pressure feed by supply pump (*1)” in E- mode When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change Remedy *1: Code [559/CA559] and code [2249/CA2249] in E-mode 114E-3 Series...
Page 269: Engine Stops During Operations
Inspect fuel filter, strainer directly Inspect feed pump directly Carry out troubleshooting according to “No-pressure feed by supply pump (*1)” in E-mode Engine rotates when pump auxiliary equipment (pump, compressor, etc.) is removed Remedy *1: Code [559/CA559] and code [2249/CA2249] in E-mode 114E-3 Series...
Page 270: Engine Does Not Rotate Smoothly
Carry out troubleshooting according to “Abnormality in Ne speed sensor (*1)” in E-mode Carry out troubleshooting according to “Abnormality in Bkup speed sensor (*2)” in E-mode Remedy *1: Code [689/CA689] in E-mode *2: Code [778/CA778] in E-mode 114E-3 Series...
Page 271: Engine Lacks Output (Or Lacks Power)
Inspect boost pressure sensor mount directly Carry out troubleshooting according to “Abnormality in boost pressure sensor (*2)” in E- mode Remedy *1: Code [559/CA559] and code [2249/CA2249] in E-mode *2: Code [122/CA122] and code [123/CA123] in E-mode 114E-3 Series...
Page 272: Exhaust Smoke Is Black (Incomplete Combustion)
Carry out troubleshooting according to “Abnormality in coolant temperature sensor (*2)” in E-mode Confirm with INSITE or with monitoring function on applicable machine side Remedy *1: Code [559/CA559] and code [2249/CA2249] in E-mode *2: Code [144/CA144] and code [145/CA145] in E-mode 114E-3 Series...
Page 273: Oil Consumption Is Excessive (Or Exhaust Smoke Is Blue)
When compression pressure is measured, it is found to be low Inspect rear oil seal directly Pressure-tightness test of oil cooler shows there is leakage q q q q There is external leakage of oil from engine Remedy 114E-3 Series...
Page 274: Oil Becomes Contaminated Quickly
When compression pressure is measured, it is found to be low Inspect breather and breather hose directly Inspect oil cooler directly Inspect oil filter directly Spring of oil filter safety valve is hitched or broken Inspect turbocharger lubrication drain tube directly Remedy 114E-3 Series...
Page 275: Fuel Consumption Is Excessive
Carry out troubleshooting according to “Abnormality in coolant temperature sensor (*2)” in E-mode Confirm with INSITE or with monitoring function on applicable machine side Remedy *1: Code [559/CA559] and code [2249/CA2249] in E-mode *2: Code [144/CA144] and code [145/CA145] in E-mode 114E-3 Series...
Page 276: Oil Is In Coolant (Or Coolant Spurts Back Or Coolant Level Goes Down)
Hydraulic oil or power train oil on applicable machine side is milky When hydraulic oil or power train oil is drained, water is found Pressure-tightness test of cylinder head shows there is leakage Inspect cylinder block, liner directly Pressure-tightness test of oil cooler shows there is leakage Remedy 114E-3 Series...
Page 277: Oil Pressure Drops
Inspect oil pan strainer, pipe directly Oil pump rotation is heavy, there is play in oil pump Valve and spring of regulator valve are fatigued, damaged Inspect oil filter directly If oil level sensor is replaced, oil level monitor indicates normally Remedy 114E-3 Series...
Page 278: Oil Level Rises (Entry Of Coolant Or Fuel)
When compression pressure is measured, it is found to be low Remove injector and inspect O-ring. Inspect cylinder block, liner directly Inspect rear oil seal directly Pressure-tightness test of oil cooler shows there is leakage Remove and inspect supply pump directly Inspect seal of auxiliary equipment directly Remedy 114E-3 Series...
Page 279: Coolant Temperature Becomes Too High (Overheating)
Temperature difference between upper and lower tanks of radiator is slight Inspect radiator core directly When operation of radiator cap is carried out, its cracking pressure is low Inspect fan belt, pulley directly When coolant temperature is measured, it is found to be normal Remedy 114E-3 Series...
Page 280: Abnormal Noise Is Made
Inspect fan and fan belt directly When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change Abnormal noise is heard only when engine is started Confirm with INSITE or with monitoring function on applicable machine side Remedy 114E-3 Series...
Page 281: Vibration Is Excessive
Confirm with INSITE or with monitoring function on applicable machine side Inspect engine mounting bolts and cushions directly When alignment is checked, radial runout or facial runout is detected Inspect output shaft or inside of damper directly Remedy 114E-3 Series...
Page 283: General Information On Disassembly And Assembly
SEN00462-01 ENGINE 1SHOP MANUAL 114E-3 Series 50 Disassembly and assembly1 General information on disassembly and assembly General information on disassembly and assembly ..................2 How to read this manual ........................2 Coating materials list..........................3 Special tools list............................ 6 114E-3 Series...
Page 284: How To Read This Manual
: Precautions related to safety in execution of work. a : Know-how or precautions for work. : Type of coating materials. : Tightening torque. : Quantity of oil or coolant to be added. 114E-3 Series...
Page 285: Coating Materials List
• Used to seal flywheel housing, intake mani- fold, oil pan, thermostat housing, etc. • Features: Silicon-based, heat and cold-resis- LG-8 tant, vibration-resistant, impact-resistant seal- ThreeBond 419-15-18131 100 g Tube ant. 1207B • Used to seal transfer case, etc. 114E-3 Series...
Page 286 • Feature: Silicone grease with wide using tem- G2-S perature range, high resistance to thermal-oxi- ThreeBond — 200 g Tube dative degradation and performance to prevent 1855 deterioration of rubber and plastic parts. • Used for oil seals of the transmission, etc. 114E-3 Series...
Page 287 (Using limit: 6 months after date of manu- container SEALANT facture) • Used to seal joint of glasses. GE TOSHIBA Translucent white seal. SILICONES 22M-54-27220 333 ml Cartridge (Using limit: 12 months after date of manu- TOSSEAL 381 facture) 114E-3 Series...
Page 288: Special Tools List
Tools marked with Q in the sketch column are tools introduced in the sketches of the special tools (See Sketches of special tools) a Nos. in the upper line of the Part No. column are KOMATSU part Nos. and those in the lower line are CUMMINS part Nos.
Page 289 Removal and installation of 795-799-2270 Remover and installer q 1 main bearing Rotating crankshaft 795-799-1131 Barring tool Tightening injector wiring 795-799-7110 Torque wrench harness nut Measuring cylinder head 795-790-2210 Gauge bolt length Installation of cylinder liner 795-799-2190 Clamp set 114E-3 Series...
Page 291: Disassembly And Assembly, Part 1
SEN00463-01 ENGINE 1SHOP MANUAL 114E-3 Series 50 Disassembly and assembly1 Disassembly and assembly, Part 1 Disassembly and assembly ..........................2 General disassembly of engine......................2 114E-3 Series...
Page 292: General Disassembly Of Engine
Size of bolt bolt torque Remove the fuel filter. 24 ± 4 Nm {2.5 ± 0.4 kgm} 43 ± 6 Nm b, c {4.4 ± 0.6 kgm} Drain the engine coolant and engine oil. Engine oil: Approx. 24 114E-3 Series...
Page 293 After removing the alternator belt (1), return the tensioner assembly (2) slowly with care. 114E-3 Series...
Page 294 (1) – (6) and then remove high-pres- Remove coolant inlet connector (2). sure pipes. 10. Thermostat Removal of high-pressure pipes (1), (3), Remove thermostat (1). and (5) Remove head cover assembly (9). Disconnect clamp (11) of injector wir- ing harness (10). 114E-3 Series...
Page 295 13. Common rail Remove the joint bolt of fuel drain tube (1). Remove mounting bolt (3) and common rail (2). 15. Fuel filter bracket Remove fuel filter bracket assembly (1). 114E-3 Series...
Page 296 Remove nut (3) and washer (4). 18. Fuel lift pump and main controller cooling plate Remove fuel lift pump (3) on the back side of Install tool P with bolt [1] (M8 × 1.25). main controller cooling plate (2). 114E-3 Series...
Page 297 No. 6 cylinder, remove rear engine rocker arm is installed. hanging plate (3). Remove crosshead (3). a Record the position of each cross- head and the shapes of holes (a) and (b). 114E-3 Series...
Page 298 (1). Remove bolt (5) and holder (6). 24. Turbocharger and exhaust manifold Remove tube (1). Remove bracket (2). Remove turbocharger assembly (3). Using tool F, pull up injector (7). a Do not pry up the injector top. 114E-3 Series...
Page 299 (2). Raise the cylinder head assembly and pull Cylinder head assembly: 85 kg out valve (6). a Make a mark on valve (6) so that it will be returned to the correct position of the cylinder head. 114E-3 Series...
Page 300 Air intake valve: Blue valve seal (7-2) Use tool Q to remove the valve seals. Remove vibration damper (4). 27. Front cover Remove engine front hanging plate (1). Remove 23 mounting bolts (6) and front cover (5). Remove water pump (2). 114E-3 Series...
Page 301 Remove 4 bolts (1) and oil pump assembly (2). Remove front seal (8). 30. Oil pan Remove 32 bolts (1) and oil pan (2). 28. Supply pump drive gear Remove supply pump drive gear (1). Remove suction tube (3) and bed plate (4). 114E-3 Series...
Page 302 Remove bolts (3) and thrust plate (4). Remove bolts (1) and 6 piston cooling nozzles (2). Before removing the cooling nozzle of the No. 6 cylinder, remove speed sensor ring (3). While turning the camshaft gear assembly (1), remove the camshaft. 114E-3 Series...
Page 303 (4) on the cylinder head side. a Take care not to damage the inside of the cylinder with a corner of the con- necting rod. a Make a cylinder No. mark on the pis- ton. 114E-3 Series...
Page 304 Remove 12 bolts (1) and flywheel housing (2). a Keep the piston, connecting rod, 37. Rear seal housing bearing, piston rings, and piston pin Remove seal housing (1). by the cylinders. 35. Flywheel Install lock plate [1] and remove mounting bolt (1). 114E-3 Series...
Page 305 Remove mounting bolts (2) of main cap (1). Mark the position No. on main cap (1). a Check that the embossed letters of “BACK” on side (A) of the main cap are directed toward the rear of the cylinder block. 114E-3 Series...
Page 306 Make the position marks on the main caps, upper bearings, and upper thrust bearings (in the claws of the bearings), and then keep them by the main caps so that they will not be damaged. 114E-3 Series...
Page 307 (2), and then remove cylinder liner (1) with both hands. a Mark the position No. on the removed cylinder liner. 41. Cylinder block Remove cylinder block (1) from repair stand A. Cylinder block: 245 kg Remove tool B. 114E-3 Series...
Page 309: Disassembly And Assembly, Part 2
SEN00464-01 ENGINE 1SHOP MANUAL 114E-3 Series 50 Disassembly and assembly1 Disassembly and assembly, Part 2 Disassembly and assembly ..........................2 General assembly of engine ........................ 2 114E-3 Series...
Page 310: Disassembly And Assembly
Fit O-ring (3) to cylinder liner (1). polish those faces until the machined sur- a When fitting the O-ring, check that it faces appear. (Take care not to scrub too is not twisted. much.) Apply clean engine oil (EO15W-40) to faces (A) and (B). 114E-3 Series...
Page 311 Projection of liner: 0.026 – 0.122 mm a Do not turn the cylinder block more than 90°. If it is turned more than 90°, the tappets will be off the mounting holes. 114E-3 Series...
Page 312 Apply engine oil (EO15W-40) to the inside of the bearings. Do not apply it to the back side, however. a When reusing the bearings, check the marks made on them when removed and install them to their original posi- tions. 114E-3 Series...
Page 313 Tighten main cap mounting bolts (2). a Apply engine oil (EO15W-40) to the bolts. a Tighten the mounting bolts in the order shown below: [1] → [14] After tightening the bolts, make sure that the crankshaft turns smoothly. 114E-3 Series...
Page 314 When fitting each ring, set the abutment joint off the thrust, anti-thrust, and piston axis directions. Using tool D, fit piston rings (7) to the pis- ton. Apply engine oil (EO15W-40) to the piston rings and piston skirt. 114E-3 Series...
Page 315 Using tool E, reduce the piston rings Insert piston pin (6) and install piston and push in the piston head with a (4) to connecting rod (2). wood bar, etc. Install snap rings (5) to both sides. 114E-3 Series...
Page 316 [1] → When not using tool J Make marks on the connecting rod cap and Mounting bolt: bolt with paint and then tighten the bolt by 60° 39.2 ± 2.0 Nm {4.0 ± 0.2 kgm} ± 5°. 114E-3 Series...
Page 317 Tightening order of bolts Tighten the mounting bolts in the numeri- cal order shown below: [1] → Mounting bolt: 1st time: 5 ± 1 Nm {0.5 ± 0.1 kgm} 2nd time: 24 ± 4 Nm {2.4 ± 0.4 kgm} 114E-3 Series...
Page 318 Set timing mark “00” of supply pump drive gear groove of the camshaft. (2) to timing mark “0” of camshaft gear assem- End play: Max. 0.5 mm bly (1). Measure the backlash of camshaft gear assembly (1) with tool L. Backlash: 0.2 ± 0.125 mm 114E-3 Series...
Page 319 Insert oil seal (8) from the front cover numerical order shown below: [1] → mounting side of carrier (7). Set the seal flush with the face on the Mounting nut: inserting side of the carrier. 9.8 ± 2.0 Nm {1.0 ± 0.2 kgm} 114E-3 Series...
Page 320 [10] [11] [13] [16] [17] (Stem length 50 mm) {2.9 ± 0.2 kgm} [19] [20] [22] [23] [3] [6] [9] [12] [14] 40 ± 2 Nm [15] [18] [21] [24] [25] (Stem length 16 mm) {3.9 ± 0.2 kgm} [26] 114E-3 Series...
Page 321 Install seal housing (1) and gasket (3) to guide pin [3]. Remove the guide pin and tighten the mounting bolts in the numerical order shown below: [1] → Mounting bolt: 12.7 ± 2.0 Nm {1.3 ± 0.2 kgm} 114E-3 Series...
Page 322 Apply strings of gasket sealant 1 mm in diameter to the range from the bolt hole center to the area of R7. Change the diameter of the gasket sealant smoothly from 1 mm to 3 mm for the other parts unless otherwise speci- fied. 114E-3 Series...
Page 323 Apply gasket sealant (strings) simi- 7) 1 – 3 mm in diameter to the hous- larly to step 2). ing mounting flange face and around each mounting bolt hole. Install oil pan (2) with mounting bolts (1). 114E-3 Series...
Page 324 Flywheel mounting face: a After the crankshaft is rotated by 1 Gasket sealant (LG-7) turn, check that the dial gauge indi- Flywheel assembly: 40 kg cates the value at the start of rotation. 114E-3 Series...
Page 325 2) Rotate the flywheel by 1 turn, and mea- sure the difference between the indi- cated lowest and highest values. 114E-3 Series...
Page 326 22. Cylinder head assembly Assemble the cylinder head assembly according to the following procedure: Install valve seals (7-1) and (7-2). a The valve seals are colored accord- ing to their locations. Exhaust valve: Black (7-1) Air intake valve: Blue (7-2) 114E-3 Series...
Page 327 Using tool C, compress valve spring (3) and install valve collet (4). a Hit the valve stem lightly with a plastic hammer to check that the valve collet is fitted to the groove of the valve stem. 114E-3 Series...
Page 328 150 ± 9.8 Nm {15.3 ± 1.0 kgm} Return all bolts 360° 115 ± 4.9 Nm {11.7 ± 0.5 kgm} Check tightening torque of 115 ± 4.9 Nm {11.7 ± 0.5 kgm} 120° ± 5° (Tighten with angle tightening tool) 114E-3 Series...
Page 329 Coat the O-ring of inlet connector (11) and the mounting hole on the head with engine oil (EO15W-40). Install inlet connector (11) temporarily with retainer (10). Retainer: 15 ± 5.0 Nm {1.5 ± 0.5 kgm} 114E-3 Series...
Page 330 The shapes of holes (a) and (b) of each crosshead are different. Accord- ingly, when reusing the crossheads, install each of them to the same intake and exhaust valve in the same direction as it has been installed. crosshead installed in either direction. 114E-3 Series...
Page 331 While the No. 6 cylinder is at the compres- sion top dead center, adjust the valve clearances marked with Q in the valve arrangement drawing. a Adjust the valve clearance according to steps 3) and 4) above. 114E-3 Series...
Page 332 Right side 2, 4, 6 Brown Left side a Take care that wiring harness (4) will not be pressed strongly against the inside wall of housing (1), will not come off guide (e), or will not be bent sharply. 114E-3 Series...
Page 333 Fit the O-ring and push in supply pump drive shaft (7) in supply pump drive gear (2), setting the pin of the former to the key way (b) of the latter, and tighten nut (3) and washer (4) temporarily. 114E-3 Series...
Page 334 (2). adapter but use new one when install- ing the hose again, as a rule. Install supply hose (2). Install low-pressure hose assembly (1). After connecting the hose, tighten the clamp bolt at the center. 114E-3 Series...
Page 335 Threaded part of adapter: Gear oil (#90) Adapter: 37 ± 4 Nm {3.8 ± 0.4 kgm} Start the engine and check that there is no leakage. For the testing procedure, see Testing and adjusting, “Testing fuel system for leakage”. 114E-3 Series...
Page 336 10) Fit the gasket and install head cover assembly (9). Head cover assembly mounting bolt: 11.8 ± 1.96 Nm {1.2 ± 0.2 kgm} 114E-3 Series...
Page 337 0.4 kgm} in the order of their numbers. Tighten all the bolts to 43 ± 6 Nm {4.4 ± 0.6 kgm}. Retighten only bolts [1] – [4] in the figure to 43 ± 6 Nm {4.4 ± 0.6 kgm} in the numerical order. 114E-3 Series...
Page 338 Install alternator (1) with mounting bolts (5) and (6). 39. Thermostat Mounting bolt (5): Fit the O-ring and install thermostat (1). 43 ± 6 Nm {4.4 ± 0.6 kgm} Mounting bolt (6): 24 ± 4 Nm {2.4 ± 0.4 kgm} 114E-3 Series...
Page 339 (1) during work. Install vibration damper (4). Install wiring harness (3). a Check that the clearance between Mounting bolt: 200 ± 10 Nm {20 ± 1.0 kgm} wiring harness (3) and fan belt (1) is 15 mm or wider. 114E-3 Series...
Page 340 Install ground wire (4) of the main control- ler to plate (3). Install muffler assembly (5). 48. Refilling with oil Check that the engine oil drain plug is tightened. Add oil through the oil filler to the specified level. Engine oil pan: Approx. 24 114E-3 Series...
Page 341 50 Disassembly and assembly SEN00464-01 114E-3 Series...

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