Komatsu SAA6D114E-3, 114E-3 Series SEN00169-02 (Preview)
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00 INDEX AND FORWORD
INDEX
ORGANIZATION LIST OF THE SHOP MANUAL
TABLE OF CONTENTS
FOREWORD AND GENERAL INFORMATION
SAFETY NOTICE
HOW TO READ THE SHOP MANUAL
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD
HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENT
HOW TO READ ELECTRIC WIRE CODE
METHOD OF DISASSEMBLING AND CONNECTING PUSH-PULL TYPE COUPLER
STANDARD TIGHTENING TORQUE TABLE
CONVERSION TABLE
01 SPECIFICATION
SPECIFICATION AND TECHNICAL DATA
GENERAL
SPECIFICATIONS
GENERAL VIEW
DIMENSIONS TABLE
ENGINE PERFORMANCE CURVES
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
STRUCTURE ,FUNCTION AND MAINTENANCE STANDARD
INTAKE, EXHAUST SYSTEM
INTAKE SYSTEM
EXHAUST SYSTEM
TURBOCHARGER
LUBRICATION OIL SYSTEM
COOLING SYSTEM
FUEL SYSTEM (COMMON RAIL)
MAINTENANCE STANDARD
TURBOCHARGER
CYLINDER HEAD
CYLINDER BLOCK
CYLINDER LINER
CRANKSHAFT
PISTON, PISTON RING AND PISTON PIN
CONNECTING ROD
VIBRATION DAMPER
TIMING GEAR
CAMSHAFT
VALVE AND VALVE GUIDE
ROCKER ARM, SHAFT AND TAPPET
FLYWHEEL AND FLYWHEEL HOUSING
OIL PUMP
20 STANDARD VALUE TABLE
STANDARD SERVICE VALUE TABLE
STANDARD VALUE TABLE FOR TESTING, ADJUSTING AND TROUBLESHOOTING
RUN-IN STANDARD AND PERFORMANCE TEST CRITERIA
30 TESTING AND ADJUSTING
TESTING AND ADJUSTING
TESTING AND ADJUSTING
TESTING AIR BOOST PRESSURE
ADJUSTING VALVE CLEARANCE
TESTING COMPRESSION PRESSURE
TESTING BLOW-BY PRESSURE
TESTING OIL PRESSURE
HANDLING FUEL SYSTEM PARTS
RELEASING RESIDUAL PRESSURE IN FUEL SYSTEM
TESTING FUEL PRESSURE
REDUCED CYLINDER MODE OPERATION
NO-INJECTION CRANKING
TESTING LEAKAGE FROM PRESSURE LIMITER AND RETURE RATE FROM INJECTOR
BLEEDING AIR FROM FUEL CIRCUIT
TESTING FUEL SYSTEM FOR LEAKAGE
HANDLING CONTROLLER HIGH-VOLTAGE CIRCUIT
40 TROUBLESHOOTING
GENERAL INFORMATION ON TROUBLESHOOTING
POINTS ON TROUBLESHOOTING
ERROR AND FAILURE CODE TABLE
TROUBLESHOOTING OF MECHANICAL SYSTEM (S-MODE)
METHOD OF USING TROUBLESHOOTING CHARTS
S-1 STARTING PERFORMANCE IS POOR
S-2 ENGINE DOES NOT START
S-3 ENGINE DOSE NOT PICK UP SMOOTHLY
S-4 ENGINE STOPS DURING OPERATIONS
S-5 ENGINE DOES NOT ROTATE SMOOTHLY
S-6 ENGINE LACK OUTPUT (OR LACKS POWER)
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)
S-9 OIL BECOMES CONTAMINATED QUICKLY
S-10 FUEL CONSUMPTION IS EXCESSIVE
S-11 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN)
S-12 OIL PRESSURE DROPS
S-13 OIL LEVEL RISES (ENTRY OF COOLANT OR FUEL)
S-14 COOLANT TEMPERATURE BECOMES TOO HIGH (OVERHEATING)
S-15 ABNORMAL NOISE IS MADE
S-16 VIBRATION IS EXCESSIVE
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE), PART 1
INFORMATION IN TROUBLESHOOTING TABLE
E-1 CODE [111/CA111] ENGINE CONTROLLER INTERNAL FAILURE
E-2 CODE [115/CA115] ENG. NE AND BLUP SPEED SENSOR ERROR
E-3 CODE [122/CA122] CHARGE AIR PRESS SENSOR HIGH ERROR
E-4 CODE [123/CA123] CHARGE AIR PRESS SENSOR LOW ERROR
E-5 CODE [131/CA131] THROTTLE SENSOR HIGH ERROR
E-6 CODE [132/CA132] THROTTLE SENSOR LOW ERROR
E-7 CODE [144/CA144] COOLANT TEMP. SENSOR HIGH ERROR
E-8 CODE [145/CA145] COOLANT TEMP. SENSOR LOW ERROR
E-9 CODE [153/CA153] CHARGE AIR TEMP. SENSOR HIGH ERROR
E-10 CODE [154/CA154] CHARGE AIR TEMP. SENSOR LOW ERROR
E-11 CODE [155/CA155] CHARGE AIR PRESS. HIGH SPEED DERATE
E-12 CODE [187/CA187] SENSOE SUP.2 VOLT. LOW ERROR
E-13 CODE [221/CA221] AMBIENT AIR PRESS. SENSOR HIGH ERROR
E-14 CODE [222/CA222] AMBIENT AIR PRESS. SENSOR LOW ERROR
E-15 CODE [227/CA227] ABNORMALLY HIGH LEVEL IN SENSOR POWER SUPPLY
E-16 CODE [234/CA234] ENG. OVERSPEED
E-17 CODE [238/CA238] NE SPEED SENSOR SUP. VOLT. ERROR
E-18 CODE [271/CA271] PCV1 SHORT ERROR
E-19 CODE [272/CA272] PCV1 OPEN ERROR
E-20 CODE [281/CA281] HIGH PRESSURE PUMP ERROR
E-20 CODE [322/CA322] INJECTOR #1 (L/B #1) SYSTEM OPEN/SHORT ERROR
E-21 CODE [323/CA323] INJECTOR #5 (L/B #5) SYSTEM OPEN/SHORT ERROR
E-22 CODE [324/CA324] INJECTOR #3 (L/B #3) SYSTEM OPEN/SHORT ERROR
E-23 CODE [325/CA325] INJECTOR #6 (L/B #6) SYSTEM OPEN/SHORT ERROR
E-24 CODE [331/CA331] INJECTOR #2 (L/B #2) SYSTEM OPEN/SHORT ERROR
E-25 CODE [332/CA332] INJECTOR #4 (L/B #4) SYSTEM OPEN/SHORT ERROR
E-26 CODE [342/CA342] ENGINE CONTROLLER DATA MATCHING ERROR
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE), PART 2
E-27 CODE [351/CA351] INJ. DRIVE CIRCUIT ERROR
E-28 CODE [352/CA352] SENSOR SUP.1 VOLT. LOW ERROR
E-29 CODE [386/CA386] SENSOR SUP.1 VOLT. HIGH ERROR
E-30 CODE [428/CA428] WATER SENSOR HIGH LEVEL ERROR
E-31 CODE [429/CA429] WATER SENSOR LOW LEVEL ERROR
E-32 CODE [431/CA431] IDLE VALIDATION SWITCH ERROR
E-33 CODE [432/CA432] IDLE VALIDATION PROCESS ERROR
E-34 CODE [435/CA435] ENG. OIL SWITCH ERROR
E-35 CODE [441/CA441] SUPPLY VOLTAGE LOW ERROR
E-36 CODE [442/CA442] SUPPLY VOLTAGE HIGH ERROR
E-37 CODE [449/CA449] RAIL PRESS. HIGH ERROR 2
E-38 CODE [451/CA451] RAIL PRESS. SENSOR HIGH ERROR
E-39 CODE [452/CA452] RAIL PRESS. SENSOR LOW ERROR
E-40 CODE [488/CA488] CHARGE AIR TEMP. HIGH TORQUE DERATE
E-41 CODE [553/CA553] RAIL PRESS. HIGH ERROR 1
E-42 CODE [559/CA559] RAIL PRESS LOW ERROR
E-43 CODE [689/CA689] ENG. NE SPEED SENSOR ERROR
E-44 CODE [731/CA731] ENG. BKUP SPEED SENSOR PHASE ERROR
E-45 CODE [757/CA757] ALL ENGINE CONTROLLER DATA LOST ERROR
E-46 CODE [778/CA778] ENG. BKUP SPEED SENSOR ERROR.
E-47 CODE [1633/CA1633] KOMNET ERROR
E-48 CODE [2185/CA2185]THROTTLE SENS. SUP. VOLT. HIGH ERROR
E-49 CODE [2186/CA2186]THROTTLE SENS. SUP. VOLT. LOW ERROR
E-50 CODE [2249/CA2249] RAIL PRESS VERY LOW ERROR
E-51 CODE [2265/CA2265] ABNORMALLY HIGH LEVEL IN ELECTRIC LIFT PUMP
E-52 CODE [2266/CA2266] ABNORMALLY LOW LEVEL IN ELECTRIC LIFT PUMP
E-53 CODE [2311/CA2311] IMV SOLENOID ERROR
E-54 CODE [2555/CA2555] INTALE AIR HEATER RELAY SUPPLY VOLTAGE LOW ERROR
E-55 CODE [2556/CA2556] INTALE AIR HEATER RELAY SUPPLY VOLTAGE HIHE ERROR
E-56 CODE [—/B@BAZG] ENG. OIL PRESS. LOW SPEED DERATE
E-57 CODE [—/B@BAZG] ENG. OIL PRESS. LOW SPEED DERATE
E-58 CODE [—/B@BCNS] ENG. OVERHEAT
50 DISASSEMBLY AND ASSEMBLY
GENERAL INFORMATION ON DISASSEMBLY AND ASSEMBLY
HOW TO READ THIS MANUAL
COATING MATERIALS LIST
SPECIAL TOOLS LIST
DISASSEMBLY AND ASSEMBLY, PART 1
GENERAL DISASSEMBLY OF ENGINE
DISASSEMBLY AND ASSEMBLY, PART 2
GENERAL ASSEMBLY OF ENGINE
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