Komatsu 114E-3 Series Install guide

SEN00169-05
ENGINE 114E-3 SERIES

114E-3 Series 1
SEN00171-05
Engine
1SHOP MANUAL
114E-3 Series
00 Index and foreword 1
Index
Composition of shop manual................................................................................................................ 2
Table of contents .................................................................................................................................. 3

SEN00171-05 00 Index and foreword
2114E-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 SEN00169-05
00 Index and foreword SEN00170-05
Index SEN00171-05 q
Foreword and general information SEN00172-03
01 Specification SEN00173-02
Specification and technical data SEN00174-02
10 Structure, function and maintenance standard SEN00175-02
Structure and function, maintenance standard SEN00176-02
20 Standard value table SEN00260-02
Standard service value table SEN00261-02
30 Testing and adjusting SEN00454-01
Testing and adjusting SEN00455-01 q
40 Troubleshooting SEN00456-01
General information on troubleshooting SEN00457-01 q
Troubleshooting of electrical system (E-mode), Part 1 SEN00459-01 q
Troubleshooting of electrical system (E-mode), Part 2 SEN00460-01 q
Troubleshooting of mechanical system (S-mode) SEN00458-01 q
50 Disassembly and assembly SEN00461-01
General information on disassembly and assembly SEN00462-01 q
Disassembly and assembly, Part 1 SEN00463-01 q
Disassembly and assembly, Part 2 SEN00464-01 q

00 Index and foreword SEN00171-05
114E-3 Series 3
Table of contents 1
00 Index and foreword
Index SEN00171-05
Composition of shop manual ................................................................................................... 2
Table of contents ..................................................................................................................... 3
Foreword and general information SEN00172-03
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 SEN00174-02
General.................................................................................................................................... 2
Specifications........................................................................................................................... 3
General view............................................................................................................................ 8
Dimensions table ..................................................................................................................... 12
Engine performance curves..................................................................................................... 13
10 Structure, function and maintenance standard
Structure, function and maintenance standard SEN00176-02
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................................................................................................................. 15
Turbocharger ........................................................................................................................... 15
Cylinder head .......................................................................................................................... 16
Cylinder block .......................................................................................................................... 18
Cylinder liner............................................................................................................................ 20
Crankshaft ............................................................................................................................... 22
Piston, piston ring and piston pin............................................................................................. 23
Connecting rod ........................................................................................................................ 24
Vibration damper ..................................................................................................................... 26
Timing gear.............................................................................................................................. 27
Camshaft ................................................................................................................................. 28
Valve and valve guide.............................................................................................................. 30
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 .............................................. 2
Run-in standard and performance test criteria ........................................................................ 6

SEN00171-05 00 Index and foreword
4114E-3 Series
30 Testing and adjusting
Testing and adjusting SEN00455-01
Testing and adjusting................................................................................................................... 2
Testing and adjusting tools list ................................................................................................. 2
Testing air boost pressure........................................................................................................ 3
Adjusting valve clearance ........................................................................................................ 4
Testing compression pressure ................................................................................................. 6
Testing blow-by pressure ......................................................................................................... 9
Testing oil pressure.................................................................................................................. 10
Handling fuel system parts ......................................................................................................11
Releasing residual pressure in fuel system ............................................................................. 11
Testing fuel pressure................................................................................................................ 12
Reduced cylinder mode operation ........................................................................................... 17
No-injection cranking ............................................................................................................... 17
Testing leakage from pressure limiter and return rate from injector......................................... 18
Bleeding air from fuel circuit .................................................................................................... 20
Testing fuel system for leakage ............................................................................................... 21
Handling controller high-voltage circuit.................................................................................... 22
Replacing alternator belt.......................................................................................................... 23
General information on troubleshooting SEN00457-01
General information on troubleshooting ...................................................................................... 2
Points on troubleshooting ........................................................................................................ 2
Error and failure code table ..................................................................................................... 3
Information in troubleshooting table......................................................................................... 6
Troubleshooting of electrical system (E-mode), Part 1 SEN00459-01
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 .................................................. 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
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

00 Index and foreword SEN00171-05
114E-3 Series 5
Troubleshooting of electrical system (E-mode), Part 2 SEN00460-01
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. 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) SEN00458-01
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
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
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

SEN00171-05 00 Index and foreword
6114E-3 Series
50 Disassembly and assembly
General information on disassembly and assembly SEN00462-01
General information on disassembly and assembly.................................................................... 2
How to read this manual .......................................................................................................... 2
Coating materials list ............................................................................................................... 3
Special tools list ....................................................................................................................... 6
Disassembly and assembly, Part 1 SEN00463-01
Disassembly and assembly......................................................................................................... 2
General disassembly of engine ............................................................................................... 2
Disassembly and assembly, Part 2 SEN00464-01
Disassembly and assembly......................................................................................................... 2
General assembly of engine .................................................................................................... 2

00 Index and foreword SEN00171-05
114E-3 Series 7

8
SEN00171-05
KOMATSU 114E-3 Series Diesel engine
Form No. SEN00171-05
© 2007 KOMATSU
All Rights Reserved
Printed in Japan 05-07 (01)

114E-3 Series 1
SEN00172-03
Engine
1SHOP MANUAL
114E-3 Series
00 Index and foreword 1
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 ........................................................................................... 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

SEN00172-03 00 Index and foreword
2114E-3 Series
(Rev. 2007/03)
Safety notice 1
Important 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.
To prevent injury to workers, the symbol kis used to mark safety precautions in this manual. The
cautions accompanying these symbols should always be followed carefully. If any dangerous situa-
tion arises or may possibly arise, first consider safety, and take the necessary actions to deal with
the situation.
1. General precautions
kMistakes in operation are extremely
dangerous. Read the Operation and
Maintenance Manual carefully before
operating the machine.
1) Before carrying out any greasing or
repairs, read all the safety plates stuck to
the machine. For the locations of the
safety plates and detailed explanation of
precautions, see the Operation and Main-
tenance Manual.
2) Decide a place in the repair workshop to
keep tools and removed parts. Always
keep the tools and parts in their correct
places. Always keep the work area clean
and make sure that there is no dirt, water,
or oil on the floor. Smoke only in the areas
provided for smoking. Never smoke while
working.
3) When carrying out any operation, always
wear safety shoes and helmet. Do not
wear loose work clothes, or clothes with
buttons missing.
qAlways wear safety glasses when hit-
ting parts with a hammer.
qAlways wear safety glasses when
grinding parts with a grinder, etc.
4) When carrying out any operation with 2 or
more workers, always agree on the oper-
ating procedure before starting. Always
inform your fellow workers before starting
any step of the operation. Before starting
work, hang UNDER REPAIR warning
signs in the operator's compartment.
5) Only qualified workers must carry out work
and operation which require license or
qualification.
6) Keep all tools in good condition, learn the
correct way to use them, and use the
proper ones of them. Before starting work,
thoroughly check the tools, machine, fork-
lift, service car, etc.
7) If welding repairs are needed, always
have a trained and experienced welder
carry out the work. When carrying out
welding work, always wear welding
gloves, apron, shielding goggles, cap and
other clothes suited for welding work.
8) Before starting work, warm up your body
thoroughly to start work under good condi-
tion.
2. Preparations for work
1) Before adding oil or making any repairs,
park the machine on hard and level
ground, and apply the parking brake and
block the wheels or tracks to prevent the
machine from moving.
2) Before starting work, lower the work
equipment (blade, ripper, bucket, etc.) to
the ground. If this is not possible, insert
the lock pin or use blocks to prevent the
work equipment from falling. In addition,
be sure to lock all the control levers and
hang warning signs on them.
Safety points
1 Good arrangement
2 Correct work clothes
3 Following work standard
4 Making and checking signs
5Prohibition of operation and handling by
unlicensed workers
6 Safety check before starting work
7Wearing protective goggles
(for cleaning or grinding work)
8Wearing shielding goggles and protectors
(for welding work)
9 Good physical condition and preparation
10 Precautions against work which you are
not used to or you are used to too much

00 Index and foreword SEN00172-03
114E-3 Series 3
3) When disassembling or assembling, sup-
port the machine with blocks, jacks, or
stands before starting work.
4) Remove all mud and oil from the steps or
other places used to get on and off the
machine. Always use the handrails, lad-
ders or steps when getting on or off the
machine. Never jump on or off the
machine. If it is impossible to use the
handrails, ladders or steps, use a stand to
provide safe footing.
3. Precautions during work
1) Before disconnecting or removing compo-
nents of the oil, water, or air circuits, first
release the pressure completely from the
circuit. When removing the oil filler cap, a
drain plug, or an oil pressure pickup plug,
loosen it slowly to prevent the oil from
spurting out.
2) The coolant and oil in the circuits are hot
when the engine is stopped, so be careful
not to get scalded. Wait for the oil and
coolant to cool before carrying out any
work on the oil or water circuits.
3) Before starting work, stop the engine.
When working on or around a rotating
part, in particular, stop the engine. When
checking the machine without stopping
the engine (measuring oil pressure,
revolving speed, temperature, etc.), take
extreme care not to get rolled or caught in
rotating parts or moving parts.
4) Before starting work, remove the leads
from the battery. Always remove the lead
from the negative (–) terminal first.
5) When raising a heavy component (heavier
than 25 kg), use a hoist or crane. Before
starting work, check that the slings (wire
ropes, chains, and hooks) are free from
damage. Always use slings which have
ample capacity and install them to proper
places. Operate the hoist or crane slowly
to prevent the component from hitting any
other part. Do not work with any part still
raised by the hoist or crane.
6) When removing a cover which is under
internal pressure or under pressure from a
spring, always leave 2 bolts in diagonal
positions. Loosen those bolts gradually
and alternately to release the pressure,
and then remove the cover.
7) When removing components, be careful
not to break or damage the electrical wir-
ing. Damaged wiring may cause electrical
fires.
8) When removing piping, stop the fuel or oil
from spilling out. If any fuel or oil drips
onto the floor, wipe it up immediately. Fuel
or oil on the floor can cause you to slip
and can even start fires.
9) As a general rule, do not use gasoline to
wash parts. Do not use it to clean electri-
cal parts, in particular.
10) Be sure to assemble all parts again in their
original places. Replace any damaged
parts and parts which must not be reused
with new parts. When installing hoses and
wires, be sure that they will not be dam-
aged by contact with other parts when the
machine is operated.
11) When installing high pressure hoses,
make sure that they are not twisted. Dam-
aged tubes are dangerous, so be
extremely careful when installing tubes for
high pressure circuits. In addition, check
that connecting parts are correctly
installed.
12) When assembling or installing parts,
always tighten them to the specified
torques. When installing protective parts
such as guards, or parts which vibrate vio-
lently or rotate at high speed, be particu-
larly careful to check that they are
installed correctly.
13) When aligning 2 holes, never insert your
fingers or hand. Be careful not to get your
fingers caught in a hole.
14) When measuring hydraulic pressure,
check that the measuring tools are cor-
rectly assembled.
15) Take care when removing or installing the
tracks of track-type machines. When
removing the track, the track separates
suddenly, so never let anyone stand at
either end of the track.
16) If the engine is operated for a long time in
a place which is not ventilated well, you
may suffer from gas poisoning. Accord-
ingly, open the windows and doors to ven-
tilate well.

SEN00172-03 00 Index and foreword
4114E-3 Series
4. Precautions for sling work and making
signs
1) Only one appointed worker must make
signs and co-workers must communicate
with each other frequently. The appointed
sign maker must make specified signs
clearly at a place where he is seen well
from the operator's seat and where he can
see the working condition easily. The sign
maker must always stand in front of the
load and guide the operator safely.
qDo not stand under the load.
qDo not step on the load.
2) Check the slings before starting sling
work.
3) Keep putting on gloves during sling work.
(Put on leather gloves, if available.)
4) Measure the weight of the load by the eye
and check its center of gravity.
5) Use proper sling according to the weight
of the load and method of slinging. If too
thick wire ropes are used to sling a light
load, the load may slip and fall.
6) Do not sling a load with 1 wire rope alone.
If it is slung so, it may rotate and may slip
out of the rope. Install 2 or more wire
ropes symmetrically.
kSlinging with 1 rope may cause
turning of the load during hoisting,
untwisting of the rope, or slipping
of the rope from its original wind-
ing position on the load, which can
result in a dangerous accident.
7) Limit the hanging angle to 60°, as a rule.
Do not sling a heavy load with ropes form-
ing a wide hanging angle from the hook.
When hoisting a load with 2 or more
ropes, the force subjected to each rope
will increase with the hanging angle. The
table below shows the variation of allow-
able load in kN {kg} when hoisting is made
with 2 ropes, each of which is allowed to
sling up to 9.8 kN {1,000 kg} vertically, at
various hanging angles. When the 2 ropes
sling a load vertically, up to 19.6 kN {2,000
kg} of total weight can be suspended.
This weight is reduced to 9.8 kN {1,000
kg} when the 2 ropes make a hanging
angle of 120°. If the 2 ropes sling a 19.6
kN {2,000 kg} load at a lifting angle of
150°, each of them is subjected to a force
as large as 39.2 kN {4,000 kg}.
8) When installing wire ropes to an angular
load, apply pads to protect the wire ropes.
If the load is slippery, apply proper mate-
rial to prevent the wire rope from slipping.
9) Use the specified eyebolts and fix wire
ropes, chains, etc. to them with shackles,
etc.
10) Apply wire ropes to the middle portion of
the hook.
qSlinging near the tip of the hook may
cause the rope to slip off the hook
during hoisting. The hook has the
maximum strength at the middle por-
tion.
11) Do not use twisted or kinked wire ropes.
12) When lifting up a load, observe the follow-
ing.
qWind in the crane slowly until wire
ropes are stretched. When settling
the wire ropes with the hand, do not
grasp them but press them from
above. If you grasp them, your fingers
may be caught.
qAfter the wire ropes are stretched,
stop the crane and check the condi-
tion of the slung load, wire ropes, and
pads.

00 Index and foreword SEN00172-03
114E-3 Series 5
qIf the load is unstable or the wire rope
or chains are twisted, lower the load
and lift it up again.
qDo not lift up the load slantingly.
13) When lifting down a load, observe the fol-
lowing.
qWhen lifting down a load, stop it tem-
porarily at 30 cm above the floor, and
then lower it slowly.
qCheck that the load is stable, and
then remove the sling.
qRemove kinks and dirt from the wire
ropes and chains used for the sling
work, and put them in the specified
place.
5. Precautions for using mobile crane
aRead the Operation and Maintenance
Manual of the crane carefully in advance
and operate the crane safely.
6. Precautions for using overhead hoist crane
kWhen raising a heavy part (heavier
than 25 kg), use a hoist, etc. In Disas-
sembly and assembly, the weight of a
part heavier than 25 kg is indicated
after the mark of 4.
1) Before starting work, inspect the wire
ropes, brake, clutch, controller, rails, over
wind stop device, electric shock preven-
tion earth leakage breaker, crane collision
prevention device, and power application
warning lamp, and check safety.
2) Observe the signs for sling work.
3) Operate the hoist at a safe place.
4) Check the direction indicator plates (east,
west, south, and north) and the directions
of the control buttons without fail.
5) Do not sling a load slantingly. Do not move
the crane while the slung load is swinging.
6) Do not raise or lower a load while the
crane is moving longitudinally or laterally.
7) Do not drag a sling.
8) When lifting up a load, stop it just after it
leaves the ground and check safety, and
then lift it up.
9) Consider the travel route in advance and
lift up a load to a safe height.
10) Place the control switch on a position
where it will not be an obstacle to work
and passage.
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.
13) If the hoist stops because of a power fail-
ure, turn the power switch OFF. When
turning on a switch which was turned OFF
by the electric shock prevention earth
leakage breaker, check that the devices
related to that switch are not in operation
state.
14) If you find an obstacle around the hoist,
stop the operation.
15) After finishing the work, stop the hoist at
the specified position and raise the hook
to at least 2 m above the floor. Do not
leave the sling installed to the hook.
7. Selecting wire ropes
1) Select adequate ropes depending on the
weight of parts to be hoisted, referring to
the table below.
aThe allowable load is one-sixth of the
breaking strength of the rope used
(Safety coefficient: 6).
Wire ropes
(Standard “Z” twist ropes without galvanizing)
(JIS G3525, No. 6, Type 6X37-A)
Nominal
diameter of rope Allowable load
mm kN ton
10 8.8 0.9
12 12.7 1.3
14 17.3 1.7
16 22.6 2.3
18 28.6 2.9
20 35.3 3.6
25 55.3 5.6
30 79.6 8.1
40 141.6 14.4
50 221.6 22.6
60 318.3 32.4

SEN00172-03 00 Index and foreword
6114E-3 Series
8. Precautions for disconnecting and con-
necting hoses and tubes in air conditioner
circuit
1) Disconnection
kCollect the air conditioner refriger-
ant (R134a) from the air condi-
tioner circuit in advance.
aAsk professional traders for collecting
and filling operation of refrigerant
(R134a).
aNever release the refrigerant (R134a)
to the atmosphere.
kIf the refrigerant gas (R134a) gets
in your eyes, you may lose your
sight. Accordingly, when collect-
ing or filling it, you must be quali-
fied for handling the refrigerant
and put on protective goggles.
2) Connection
1] When installing the air conditioner cir-
cuit hoses and tubes, take care that
dirt, dust, water, etc. will not enter
them.
2] When connecting the air conditioner
hoses and tubes, check that O-rings
(1) are fitted to their joints.
3] Check that each O-ring is not dam-
aged or deteriorated.
4] When connecting the refrigerant pip-
ing, apply compressor oil for refriger-
ant (R134a) (DENSO: ND-OIL8,
ZEXEL: ZXL100PG (equivalent to
PAG46)) to its O-rings.
aExample of O-ring (Fitted to every joint of
hoses and tubes)
aFor tightening torque, see the precautions for
installation in each section of "Disassembly
and assembly".

00 Index and foreword SEN00172-03
114E-3 Series 7
How to read the shop manual 1
1. Composition of shop manual
This shop manual contains the necessary technical information for services performed in a workshop.
For ease of understanding, the manual is divided into the following sections.
00. Index and foreword
This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard
This section explains the structure, function, and maintenance standard values of each component.
The structure and function sub-section explains the structure and function of each component. It
serves not only to give an understanding of the structure, but also serves as reference material for
troubleshooting. The maintenance standard sub-section explains the criteria and remedies for dis-
assembly and service.
20. Standard value table
This section explains the standard values for new machine and judgement criteria for testing,
adjusting, and troubleshooting. This standard value table is used to check the standard values in
testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting
This section explains measuring instruments and measuring methods for testing and adjusting, and
method of adjusting each part. The standard values and judgement criteria for testing and adjusting
are explained in Testing and adjusting.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is
divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also
explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly
This section explains the special tools and procedures for removing, installing, disassembling, and
assembling each component, as well as precautions for them. In addition, tightening torque and
quantity and weight of coating material, oil, grease, and coolant necessary for the work are also
explained.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
qChassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
qEngine volume
This section explains the method of reproducing, repairing, and replacing parts.
2. 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.
qSome attachments and optional parts in this shop manual may not be delivered to certain areas. If one
of them is required, consult KOMATSU distributors.
qMaterials and specifications are subject to change without notice.
qShop manuals are divided into the “Chassis volume” and “Engine volume”. For the engine unit, see the
engine volume of the engine model mounted on the machine.

SEN00172-03 00 Index and foreword
8114E-3 Series
3. Filing method
File by the brochures in the correct order of the form number printed in the shop manual composition
table.
qRevised edition mark
When a manual is revised, the ones and tens digits of the form number of each brochure is
increased by 1. (Example: 00, 01, 02 …)
qRevisions
Revised brochures are shown in the shop manual composition table.
4. Symbols
Important safety and quality portions are marked with the following symbols so that the shop manual will
be used practically.
5. 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 { }.
Symbol Item Remarks
kSafety Special safety precautions are necessary when performing work.
aCaution Special technical precautions or other precautions for preserving stan-
dards are necessary when performing work.
4Weight Weight of parts of component or parts. Caution necessary when
selecting hoisting wire, or when working posture is important, etc.
3Tightening
torque
Places that require special attention for tightening torque during
assembly.
2Coat Places to be coated with adhesives, etc. during assembly.
5Oil, coolant Places where oil, etc. must be added, and capacity.
6Drain Places where oil, etc. must be drained, and quantity to be drained.

00 Index and foreword SEN00172-03
114E-3 Series 9
Explanation of terms for maintenance standard 1
The maintenance standard values necessary for judgment of products and parts are described by the follow-
ing terms.
1. Standard size and tolerance
qTo be accurate, the finishing size of parts
is a little different from one to another.
qTo specify a finishing size of a part, a tem-
porary standard size is set and an allow-
able difference from that size is indicated.
qThe above size set temporarily is called
the “standard size” and the range of differ-
ence from the standard size is called the
“tolerance”.
qThe tolerance with the symbols of + or – is
indicated on the right side of the standard
size.
aThe tolerance may be indicated in the text
and a table as [standard size (upper limit
of tolerance/lower limit of tolerance)].
Example) 120 (–0.022/–0.126)
qUsually, the size of a hole and the size of
the shaft to be fitted to that hole are indi-
cated by the same standard size and dif-
ferent tolerances of the hole and shaft.
The tightness of fit is decided by the toler-
ance.
qIndication of size of rotating shaft and hole
and relationship drawing of them
Example:
Standard size Tolerance
120 –0.022
–0.126
Example:
Standard size To l e r a n c e
Shaft Hole
60 –0.030
–0.076
+0.046
+0

SEN00172-03 00 Index and foreword
10 114E-3 Series
2. Standard clearance and standard value
qThe clearance made when new parts are
assembled is called the “standard clear-
ance“, which is indicated by the range
from the minimum clearance to the maxi-
mum clearance.
qWhen some parts are repaired, the clear-
ance is generally adjusted to the standard
clearance.
qA value of performance and function of
new products or equivalent is called the
“standard value“, which is indicated by a
range or a target value.
qWhen some parts are repaired, the value
of performance/function is set to the stan-
dard value.
3. Standard interference
qWhen the diameter of a hole of a part
shown in the given standard size and tol-
erance table is smaller than that of the
mating shaft, the difference between those
diameters is called the “interference”.
qThe range (A – B) from the difference (A)
between the minimum size of the shaft
and the maximum size of the hole to the
difference (B) between the maximum size
of the shaft and the minimum size of the
hole is the “standard interference”.
qAfter repairing or replacing some parts,
measure the size of their hole and shaft
and check that the interference is in the
standard range.
4. Repair limit and allowable value
qThe size of a part changes because of
wear and deformation while it is used. The
limit of changed size is called the “repair
limit”.
qIf a part is worn to the repair limit must be
replaced or repaired.
qThe performance and function of a prod-
uct lowers while it is used. A value below
which the product can be used without
causing a problem is called the “allowable
value”.
qIf 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.
5. Clearance limit
qParts can be used until the clearance
between them is increased to a certain
limit. The limit at which those parts cannot
be used is called the “clearance limit”.
qIf the clearance between the parts
exceeds the clearance limit, they must be
replaced or repaired.
6. Interference limit
qThe allowable maximum interference
between the hole of a part and the shaft of
another part to be assembled is called the
“interference limit”.
qThe interference limit shows the repair
limit of the part of smaller tolerance.
qIf the interference between the parts
exceeds the interference limit, they must
be replaced or repaired.