Komatsu SAA6D114E-3 Engine Workshop Repair Service Manual
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ENGINE
SEN00169-15
114E
-3
SERIES
114E-3 Series 1
SEN00171-15
ENGINE
1SHOP MANUAL
114E-3 Series
00 Index and foreword 1
Index
Composition of shop manual .......................................................................................................................... 2
Table of contents ............................................................................................................................................. 3
SEN00171-15 00 Index and foreword
2 114E-3 Series
Composition of shop manual 1
The contents of this shop manual are shown together with Form No. in a list.
Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly.
The marks shown to the right of Form No. denote the following:
Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.)
Note 2: This shop manual can be supplied for each Form No.
Note 3: To file this shop manual in the special binder for management, handle it as follows:
• Place a divider on the top of each section in the file after matching the Tub No. with No. indicated
next to each Section Name shown in the table below:
• File overview and other materials in sections in the order shown below and utilize them accord-
ingly.
Section Title Form Number
Shop Manual, contents binder, binder label and tabs SEN00169-15
00 Index and foreword SEN00170-15
Index SEN00171-15 q
Foreword and general information SEN00172-04
01 Specification SEN00173-06
Specification and technical data SEN00174-06 q
10 Structure, function and maintenance standard SEN00175-06
Structure and function, maintenance standard SEN00176-06 q
20 Standard value table SEN00260-06
Standard service value table SEN00261-06 q
30 Testing and adjusting SEN00454-02
Testing and adjusting SEN00455-02
40 Troubleshooting SEN00456-04
General Information on troubleshooting SEN00457-03
Troubleshooting of electrical system (E-mode), Part 1 SEN00459-02
Troubleshooting of electrical system (E-mode), Part 2 SEN00460-03
Troubleshooting of mechanical system (S-mode) SEN00458-02
50 Disassembly and assembly SEN00461-04
General information on disassembly and assembly SEN00462-04
Disassembly and assembly, Part 1 SEN00463-01
Disassembly and assembly, Part 2 SEN00464-02
Disassembly and assembly, Part 3 SEN03962-00
90 Repair and Replacement of parts SEN05217-00
Information related repair and replacement SEN05218-00
Parts related to cylinder head SEN05219-00
Parts related to cylinder block SEN05220-00
00 Index and foreword SEN00171-15
114E-3 Series 3
Table of contents 1
00 Index and foreword
Index SEN00171-15
Composition of shop manual ................................................................................................... 2
Table of contents ..................................................................................................................... 3
Foreword and general information SEN00172-04
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 ...................................................................... 20
How to read electric wire code ................................................................................................ 23
Precautions when carrying out operation ................................................................................ 26
Method of disassembling and connecting push-pull type coupler ........................................... 29
Standard tightening torque table .............................................................................................. 32
Conversion table...................................................................................................................... 36
01 Specification
Specification and technical data SEN00174-06
General .................................................................................................................................... 2
Specifications........................................................................................................................... 3
General view............................................................................................................................ 12
Dimensions table ..................................................................................................................... 36
Engine performance curves..................................................................................................... 37
10 Structure, function and maintenance standard
Structure, function and maintenance standard SEN00176-06
Intake, exhaust system ............................................................................................................... 3
Intake system .......................................................................................................................... 3
Exhaust system ....................................................................................................................... 4
Turbocharger ........................................................................................................................... 5
Lubricating oil system.................................................................................................................. 8
Cooling system............................................................................................................................ 10
Fuel system (common rail) .......................................................................................................... 12
Maintenance standard................................................................................................................. 17
Turbocharger ........................................................................................................................... 17
Cylinder head .......................................................................................................................... 18
Cylinder block .......................................................................................................................... 20
Cylinder liner............................................................................................................................ 22
Crankshaft ............................................................................................................................... 24
Piston, piston ring and piston pin............................................................................................. 25
Connecting rod ........................................................................................................................ 26
Vibration damper ..................................................................................................................... 28
Timing gear .............................................................................................................................. 29
Camshaft ................................................................................................................................. 30
Valve and valve guide.............................................................................................................. 32
Rocker arm, shaft and tappet .................................................................................................. 34
Flywheel and flywheel housing ................................................................................................ 36
Oil pump .................................................................................................................................. 38
Water pump drive .................................................................................................................... 40
Water pump ............................................................................................................................. 41
Thermostat .............................................................................................................................. 42
Fan drive.................................................................................................................................. 43
Alternator ................................................................................................................................. 44
SEN00171-15 00 Index and foreword
4 114E-3 Series
Starting motor .......................................................................................................................... 46
20 Standard value table
Standard service value table SEN00261-06
Standard value table for testing, adjusting and troubleshooting .............................................. 2
Run-in standard and performance test criteria ........................................................................ 8
30 Testing and adjusting
Testing and adjusting SEN00455-02
Testing and adjusting tools list .................................................................................................... 3
Sketches of special tools ............................................................................................................. 5
Testing air boost pressure ........................................................................................................... 6
Adjusting valve clearance............................................................................................................ 7
Testing compression pressure .................................................................................................... 9
Testing blowby pressure ............................................................................................................. 12
Testing oil pressure ..................................................................................................................... 13
Handling fuel system parts .......................................................................................................... 14
Releasing residual pressure in fuel system................................................................................. 14
Testing fuel pressure ................................................................................................................... 15
Reduced cylinder mode operation............................................................................................... 20
No-injection cranking ................................................................................................................... 20
Testing leakage from pressure limiter and return rate from injector ............................................ 21
Bleeding air from fuel circuit ........................................................................................................ 23
Testing fuel system for leakage................................................................................................... 24
Handling controller high-voltage circuit ....................................................................................... 25
Replacing alternator belt ............................................................................................................. 25
40 Troubleshooting
General information on troubleshooting SEN00457-03
Points on troubleshooting ............................................................................................................ 2
Error and failure code table ......................................................................................................... 3
Information in troubleshooting table ............................................................................................ 6
T-branch box and T-branch adapter table ................................................................................... 8
Connection table for connector pin numbers............................................................................... 44
Troubleshooting of electrical system (E-mode), Part 1 SEN00459-02
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 .................................................. 4
E-4 Code [123/CA123] Charge Air Press Sensor Low Error ................................................... 6
E-5 Code [131/CA131] Throttle Sensor High Error.................................................................. 8
E-6 Code [132/CA132] Throttle Sensor Low Error .................................................................. 10
E-7 Code [144/CA144] Coolant Temp. Sensor High Error....................................................... 12
E-8 Code [145/CA145] Coolant Temp. Sensor Low Error ....................................................... 14
E-9 Code [153/CA153] Charge Air Temp. Sensor High Error .................................................. 16
E-10 Code [154/CA154] Charge Air Temp. Sensor Low Error................................................. 18
E-11 Code [155/CA155] Charge Air Press. High Speed Derate .............................................. 20
E-12 Code [187/CA187] Sensor Sup. 2 Volt. Low Error .......................................................... 22
E-13 Code [221/CA221] Ambient Air Press. Sensor High Error .............................................. 24
E-14 Code [222/CA222] Ambient Air Press. Sensor Low Error ............................................... 26
E-15 Code [227/CA227] Abnormally high level in sensor power supply 2 circuit .................... 28
E-16 Code [234/CA234] Eng. Overspeed................................................................................ 29
E-17 Code [238/CA238] Ne Speed Sensor Sup. Volt. Error .................................................... 30
E-18 Code [271/CA271] IMV (IMA) Short Error ....................................................................... 31
00 Index and foreword SEN00171-15
114E-3 Series 5
E-19 Code [272/CA272] IMV (IMA) Open Error ...................................................................... 32
E-20 Code [281/CA281] High pressure pump error ................................................................ 34
E-21 Code [322/CA322] Injector No. 1 System Open/Short Error ........................................... 36
E-22 Code [323/CA323] Injector No. 5 System Open/Short Error ........................................... 38
E-23 Code [324/CA324] Injector No. 3 System Open/Short Error ........................................... 40
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
Troubleshooting of electrical system (E-mode), Part 2 SEN00460-03
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. 1 Volt. High Error ......................................................... 7
E-31 Code [428/CA428] Water Sensor High Level Error......................................................... 8
E-32 Code [429/CA429] Water Sensor Low Level Error ......................................................... 10
E-33 Code [431/CA431] Idle Validation Switch Error .............................................................. 12
E-34 Code [432/CA432] Idle Validation Process Error ............................................................ 14
E-35 Code [435/CA435] Eng. Oil Switch Error ........................................................................ 16
E-36 Code [441/CA441] Supply Voltage Low Error ................................................................. 18
E-37 Code [442/CA442] Supply Voltage High Error ................................................................ 20
E-38 Code [449/CA449] Rail Press. High Error 2.................................................................... 22
E-39 Code [451/CA451] Rail Press. Sensor High Error .......................................................... 24
E-40 Code [452/CA452] Rail Press. Sensor Low Error ........................................................... 26
E-41 Code [488/CA488] Charge Air Temp. High Torque Derate ............................................. 28
E-42 Code [553/CA553] Rail Press. High Error 1.................................................................... 29
E-43 Code [559/CA559] Rail Press Low Error ........................................................................ 30
E-44 Code [689/CA689] Eng. Ne Speed Sensor Error ............................................................ 32
E-45 Code [731/CA731] Eng. Bkup Speed Sensor Phase Error ............................................. 34
E-46 Code [757/CA757] All Engine Controller Data Lost Error ............................................... 36
E-47 Code [778/CA778] Eng. Bkup Speed Sensor Error ........................................................ 38
E-48 Code [1633/CA1633] KOMNET Error ............................................................................. 40
E-49 Code [2185/CA2185] Throttle Sens. Sup. Volt. High Error ............................................. 42
E-50 Code [2186/CA2186] Throttle Sens. Sup. Volt. Low Error .............................................. 43
E-51 Code [2249/CA2249] Rail Press very Low Error ............................................................. 44
E-52 Code [2265/CA2265] Abnormally high level in electric lift pump .................................... 46
E-53 Code [2266/CA2266] Abnormally low level in electric lift pump ...................................... 48
E-54 Code [2311/CA2311] IMV (IMA) Solenoid Error .............................................................. 50
E-55 Code [2555/CA2555] Intake Air Heater Relay Supply Voltage Low Error ....................... 52
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
Troubleshooting of mechanical system (S-mode) SEN00458-02
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
S-5 Engine does not rotate smoothly ...................................................................................... 12
S-6 Engine lacks output (or lacks power) ................................................................................ 13
S-7 Exhaust smoke is black (incomplete combustion) ............................................................ 14
S-8 Oil consumption is excessive (or exhaust smoke is blue) ................................................. 15
S-9 Oil becomes contaminated quickly ................................................................................... 16
S-10 Fuel consumption is excessive ....................................................................................... 17
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) .............................. 18
S-12 Oil pressure drops ........................................................................................................... 19
SEN00171-15 00 Index and foreword
6 114E-3 Series
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
50 Disassembly and assembly
General information on disassembly and assembly SEN00462-04
How to read this manual.............................................................................................................. 2
Coating materials list ................................................................................................................... 4
Special tools list ........................................................................................................................... 8
Disassembly and assembly, Part 1 SEN00463-01
Disassembly and assembly ......................................................................................................... 2
General disassembly of engine ................................................................................................... 2
Disassembly and assembly, Part 2 SEN00464-02
Disassembly and assembly ......................................................................................................... 2
General assembly of engine........................................................................................................ 2
Disassembly and assembly, Part 3 SEN03962-00
Disassembly and assembly ......................................................................................................... 2
Disassembly and assembly of supply pump ............................................................................... 2
90 Repair and Replacement of parts
Information related repair and replacement SEN05218-00
Special tool table ......................................................................................................................... 2
Parts related to cylinder head SEN05219-00
Dimensions of cylinder heads ..................................................................................................... 2
Checking of valves ...................................................................................................................... 3
Pressure test ............................................................................................................................... 7
Vacuum test of valve seat insert ................................................................................................. 9
Cleaning and checking of cylinder head bolts ............................................................................. 10
Parts related to cylinder block SEN05220-00
Replacement of camshaft bushings ............................................................................................ 2
Cleaning and checking of cylinder liners before reuse ................................................................ 4
Cleaning and checking of pistons before reuse .......................................................................... 16
Cleaning and checking of crankshafts before reuse ................................................................... 18
Replacement of crankshaft gears................................................................................................ 20
Cleaning and checking of main bearings before reuse ............................................................... 23
Cleaning and checking of main bearing metal caps and mounting bolts before reuse ............... 24
Cleaning and checking of connecting rod bearings before reuse ............................................... 24
Cleaning and checking of connecting rods before reuse ............................................................ 26
Checking of connecting rods for bending and twisting ................................................................ 28
Replacement of connecting rod bushings ................................................................................... 31
00 Index and foreword SEN00171-15
114E-3 Series 7
8
SEN00171-15
KOMATSU 114E-3 Series Diesel engine
Form No. SEN00171-15
© 2013 KOMATSU
All Rights Reserved
Printed in Japan 10-13 (01)
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This workshop service manual for the Komatsu SAA6D114E-3 Engine is designed for mechanical technicians familiar with service procedures for BRP products. It covers repair and overhaul procedures, assuming the technician's familiarity with general automobile practices. The manual includes instructions on components manufactured for the engine, as well as repairs of proprietary components. It provides reliable information and emphasizes particular information denoted by the wording and symbols: WARNING, CAUTION, NOTE.
The manual offers diagnostic and repair procedures, making it useful for both professional mechanics and DIY enthusiasts. It also emphasizes the importance of safety equipment and precautions when working on the engine, including the use of a torque wrench and special tools for adjustments or repairs.
Owners will find that owning and referring to this manual will make it possible to be better informed and to more knowledgeably perform repairs like a professional automotive technician. It contains specifications and procedures available in an authorized Komatsu SAA6D114E-3 Engine dealer service department.
This is a .PDF manual and contains information such as tune-ups, maintenance, removal & install procedures, assemblies & disassemblies, fuel system, ignition, lubrication system, exhaust, electrical system, and more extensive repair involving engine and transmission disassembly. It also includes general maintenance tags for various components and systems of the engine.
The content of the service manual depicts parts and/or procedures applicable to the particular product at the time of writing. It is available for fast and free electronic delivery via email and is printable. The language used in the manual is English.
