This document provides safety guidelines and precautions for servicing and repairing Komatsu machinery. It outlines general precautions like wearing protective equipment, using lifting equipment properly, and ensuring repairs are done correctly. It also describes preparations for work like parking the machine securely, lowering attachments, and cleaning work areas. Precautions during work involve things like relieving pressure from circuits before disconnecting components and ensuring hoses and wires are installed without risk of damage.
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Comprehensive program for Agricultural Finance, the Automotive Sector, and Empowerment . We will define the full scope and provide a detailed two-week plan for identifying strategic partners in each area within Limpopo, including target areas.:
1. Agricultural : Supporting Primary and Secondary Agriculture
• Scope: Provide support solutions to enhance agricultural productivity and sustainability.
• Target Areas: Polokwane, Tzaneen, Thohoyandou, Makhado, and Giyani.
2. Automotive Sector: Partnerships with Mechanics and Panel Beater Shops
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• Target Areas: Polokwane, Lephalale, Mokopane, Phalaborwa, and Bela-Bela.
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𝘼𝙣𝙩𝙞𝙦𝙪𝙚 𝙋𝙡𝙖𝙨𝙩𝙞𝙘 𝙏𝙧𝙖𝙙𝙚𝙧𝙨 𝙞𝙨 𝙫𝙚𝙧𝙮 𝙛𝙖𝙢𝙤𝙪𝙨 𝙛𝙤𝙧 𝙢𝙖𝙣𝙪𝙛𝙖𝙘𝙩𝙪𝙧𝙞𝙣𝙜 𝙩𝙝𝙚𝙞𝙧 𝙥𝙧𝙤𝙙𝙪𝙘𝙩𝙨. 𝙒𝙚 𝙝𝙖𝙫𝙚 𝙖𝙡𝙡 𝙩𝙝𝙚 𝙥𝙡𝙖𝙨𝙩𝙞𝙘 𝙜𝙧𝙖𝙣𝙪𝙡𝙚𝙨 𝙪𝙨𝙚𝙙 𝙞𝙣 𝙖𝙪𝙩𝙤𝙢𝙤𝙩𝙞𝙫𝙚 𝙖𝙣𝙙 𝙖𝙪𝙩𝙤 𝙥𝙖𝙧𝙩𝙨 𝙖𝙣𝙙 𝙖𝙡𝙡 𝙩𝙝𝙚 𝙛𝙖𝙢𝙤𝙪𝙨 𝙘𝙤𝙢𝙥𝙖𝙣𝙞𝙚𝙨 𝙗𝙪𝙮 𝙩𝙝𝙚 𝙜𝙧𝙖𝙣𝙪𝙡𝙚𝙨 𝙛𝙧𝙤𝙢 𝙪𝙨.
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3. SAFETY SAFETY NOTICE
00-3
SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE
Proper service and repair is 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 k is used to mark safety precautions in this manual.
The cautions accompanying these symbols should always be followed carefully. If any danger-
ous situation arises or may possibly arise, first consider safety, and take the necessary actions
to deal with the situation.
GENERAL PRECAUTIONS
Mistakes in operation are extremely dangerous.
Read the Operation and Maintenance Manual care-
fully BEFORE operating the machine.
1. Before carrying out any greasing or repairs, read
all the precautions given on the decals which are
fixed to the machine.
2. When carrying out any operation, always
wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons
missing.
• Always wear safety glasses when hitting
parts with a hammer.
• Always wear safety glasses when grinding
parts with a grinder, etc.
3. If welding repairs are needed, always have a
trained, experienced welder carry out the work.
When carrying out welding work, always wear
welding gloves, apron, hand shield, cap and
other clothes suited for welding work.
4. When carrying out any operation with two or
more workers, always agree on the operating
procedure before starting. Always inform your
fellow workers before starting any step of the
operation. Before starting work, hang UNDER
REPAIR signs on the controls in the operator's
compartment.
5. Keep all tools in good condition and learn the
correct way to use them.
6. 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 or oil on the floor. Smoke only in the areas
provided for smoking. Never smoke while work-
ing.
PREPARATIONS FOR WORK
7. Before adding oil or making any repairs, park the
machine on hard, level ground, and block the
wheels or tracks to prevent the machine from
moving.
8. Before starting work, lower blade, ripper, bucket
or any other work equipment to the ground. If
this is not possible, insert the safety pin or use
blocks to prevent the work equipment from fall-
ing. In addition, be sure to lock all the control
levers and hang warning signs on them.
9. When disassembling or assembling, support the
machine with blocks, jacks or stands before
starting work.
10.Remove all mud and oil from the steps or other
places used to get on and off the machine.
Always use the handrails, ladders 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 pro-
vide safe footing.
4. SAFETY SAFETY NOTICE
00-4
PRECAUTIONS DURING WORK
11.When removing the oil filler cap, drain plug or
hydraulic pressure measuring plugs, loosen
them slowly to prevent the oil from spurting out.
Before disconnecting or removing components
of the oil, water or air circuits, first remove the
pressure completely from the circuit.
12.The water and oil in the circuits are hot when the
engine is stopped, so be careful not to get
burned.
Wait for the oil and water to cool before carry-
ing out any work on the oil or water circuits.
13.Before starting work, remove the leads from the
battery. Always remove the lead from the nega-
tive (–) terminal first.
14.When raising heavy components, use a hoist or
crane.
Check that the wire rope, chains and hooks are
free from damage.
Always use lifting equipment which has ample
capacity.
Install the lifting equipment at the correct places.
Use a hoist or crane and operate slowly to pre-
vent the component from hitting any other part.
Do not work with any part still raised by the hoist
or crane.
15.When removing covers which are under internal
pressure or under pressure from a spring,
always leave two bolts in position on opposite
sides. Slowly release the pressure, then slowly
loosen the bolts to remove.
16.When removing components, be careful not to
break or damage the wiring. Damaged wiring
may cause electrical fires.
17.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, or can even start fires.
18.As a general rule, do not use gasoline to wash
parts. In particular, use only the minimum of
gasoline when washing electrical parts.
19.Be sure to assemble all parts again in their origi-
nal places.
Replace any damaged parts with new parts.
• When installing hoses and wires, be sure
that they will not be damaged by contact
with other parts when the machine is being
operated.
20.When installing high pressure hoses, make sure
that they are not twisted. Damaged tubes are
dangerous, so be extremely careful when install-
ing tubes for high pressure circuits. Also, check
that connecting parts are correctly installed.
21.When assembling or installing parts, always use
the specified tightening torques. When installing
protective parts such as guards, or parts which
vibrate violently or rotate at high speed, be par-
ticularly careful to check that they are installed
correctly.
22.When aligning two holes, never insert your fin-
gers or hand. Be careful not to get your fingers
caught in a hole.
23.When measuring hydraulic pressure, check that
the measuring tool is correctly assembled before
taking any measurements.
24.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.
5. FOREWORD GENERAL
00-5
FOREWORD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an
accurate understanding of the product and by showing him the correct way to perform repairs and make judge-
ments. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service
workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are fur-
ther divided into the each main group of components.
STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an under-
standing of the structure, but also serves as reference material for troubleshooting.
In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and mainte-
nance standards.
TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as adjustments to
be made at completion of the checks and repairs.
Troubleshooting charts correlating "Problems" with "Causes" are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the procedures for removing, installing, disassembling and assembling each com-
ponent, as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.
NOTICE
The specifications contained in this shop manual are subject to change at any time and without any
advance notice. Use the specifications given in the book with the latest date.
6. FOREWORD HOW TO READ THE SHOP MANUAL
00-6
HOW TO READ THE SHOP MANUAL
VOLUMES
Shop manuals are issued as a guide to carrying out
repairs. They are divided as follows:
Chassis volume: Issued for every machine model
Engine volume: Issued for each engine series
Electrical volume:
Attachments volume:
These various volumes are designed to avoid dupli-
cating the same information. Therefore, to deal with
all repairs for any model , it is necessary that chas-
sis, engine, electrical and attachment volumes be
available.
DISTRIBUTION AND UPDATING
Any additions, amendments or other changes will be
sent to KOMATSU distributors. Get the most up-to-
date information before you start any work.
FILING METHOD
1. See the page number on the bottom of the page.
File the pages in correct order.
2. Following examples show how to read the page
number.
Example 1 (Chassis volume):
10 - 3
Item number (10. Structure and
Function)
Consecutive page number for each
item.
Example 2 (Engine volume):
12 - 5
Unit number (1. Engine)
Item number (2. Testing and Adjust-
ing)
Consecutive page number for each
item.
3. Additional pages: Additional pages are indicated
by a hyphen (-) and number after the page
number. File as in the example.
Example:
10-4
10-4-1
10-4-2
10-5
REVISED EDITION MARK
When a manual is revised, an edition mark
((1)(2)(3)....) is recorded on the bottom of the pages.
REVISIONS
Revised pages are shown in the LIST OF REVISED
PAGES next to the CONTENTS page.
SYMBOLS
So that the shop manual can be of ample practical
use, important safety and quality portions are
marked with the following symbols.
Symbol Item Remarks
k Safety
Special safety precautions
are necessary when per-
forming the work.
a Caution
Special technical precau-
tions or other precautions
for preserving standards
are necessary when per-
forming the work.
4 Weight
Weight of parts of sys-
tems. Caution necessary
when selecting hoisting
wire, or when working pos-
ture is important, etc.
3
Tightening
torque
Places that require special
attention for the tightening
torque during assembly.
2 Coat
Places to be coated with
adhesives and lubricants,
etc.
5 Oil, water
Places where oil, water or
fuel must be added, and
the capacity.
6 Drain
Places where oil or water
must be drained, and
quantity to be drained.
·
Each issued as one
volume to cover all
models
12-203
12-203-1
12-203-2
12-204
Added pages
8. GENERAL APPLICABLE MACHINE
01-2 114 SERIES
APPLICABLE MACHINE
Engine Engine serial No. Applicable machine
SAA6D114E-2
PC300-7 Hydraulic excavator
WA380-5 Wheel loader
GD655-3A,3C
GD675-3A,3C
Motor grader
Motor grader
CD110R-2 Crawler carrier
(3)
9. GENERAL SPECIFICATION
01-4 114 SERIES
SPECIFICATION
Engine SAA6D114E-2
Applicable model PC300-7 WA380-5 GD655-3A,3C
No. of cylinders - Bore x Stroke
Total piston displacement
Firing order
mm
¬{cc}
6 - 114 x 135
8.27 {8.268}
1-5-3-6-2-4
Overall length
Overall width
Overall height
(excluding exhaust pipe)
Overall height
(including exhaust pipe)
mm
mm
mm
mm
1,615
825
1,300
1,166
906
1,632
1,130
747
1,418
Flywheel horsepower
Max. torque
High idling speed
Low idling speed
Min. fuel consumption
ratio
kW/rpm
{HP/rpm}
Nm/rpm
{kgm/
rpm}
rpm
rpm
g/kW•h
{g/HP•h}
180/1,900
{242/1,900}
(Net)
1,080/1,400
{110/1,400}
(Net)
2,160±50
900±25
213
{159}
140/2,000
{190/2,000}
(Net)
883/1,400
{90/1,400}
(Net)
2,230±50
850+50
204
{152}
147/1,900
{197/1,900}
(Gross)
940/1,400
{96/1,400}
(Gross)
2,225±50
825±50
213
{159}
Dry weight kg 860 870 750
Fuel injection pump
Governor
BOSCH P3000 type
centrifugal, all speed type
Lubricating oil amount
(refil capacity)
¬ 40
(35)
37
(32)
24
(19)
Coolant amount ¬ 9.8 (engine only) 9.8 (engine only) 9.8 (engine only)
Alternator
Starting motor
Battery
24V, 35A
24V, 7.5Kw
12V, 108Ah x 2
24V, 60A
24V, 7.5Kw
12V, 150Ah x 2
24V, 60A or 24V, 90A
24V, 7.5Kw or 24V, 11Kw
12V, 150Ah x 2
Turbocharger
Air compressor
Others
HOLSET HX40W
with air cooled
aftercooler
HOLSET HX40W
with air cooled
aftercooler
HOLSET HX40W
with air cooled
aftercooler
0
(3)
10. GENERAL
114 SERIES 01-5
SAA6D114E-2
GD675-3A,3C CD110R-2
6 - 114 x 135
8.27 {8.268}
1-5-3-6-2-4
1,130
747
1,418
1,405
987
1,392
154/1,900
{206/1,900}
(Gross)
989/1,400
{101/1,400}
(Gross)
2,225±50
825±50
215
{160}
180/1,900
{242/1,900}
(Net)
1,080/1,400
{110/1,400}
(Net)
2,160±50
900±25
213
{160}
750 850
BOSCH P3000 type
centrifugal, all speed type
24
(19)
24
(19)
9.8 (engine only) 9.8 (engine only)
24V, 60A or 24V, 90A
24V, 7.5Kw or 24V, 11Kw
12V, 150Ah x 2
24V, 35A
24V, 7.5Kw
12V, 108Ah x 2
HOLSET HX40W
with air cooled
aftercooler
HOLSET HX40W
with air cooled
aftercooler
(3)
11. GENERAL OVERALL DRAWING
01-20 114 SERIES
OVERALL DRAWING
SAA6D114E-2 LEFT SIDE DRAWING
a. Crankshaft center
b. Flywheel housing rear surface
The diagram shows the equipment for the PC300-7.
The shape may differ according to the machine model.
(2)
12. GENERAL OVERALL DRAWING
114 SERIES 01-21
SAA6D114E-2 FRONT DRAWING
The diagram shows the equipment for the PC300-7.
The shape may differ according to the machine model.
a. Crankshaft center
b. Cylinder liner center
(2)
13. GENERAL OVERALL DRAWING
01-22 114 SERIES
DIMENSION TABLE These dimensions are reference values for use
when installing to a test bench.
(Unit:mm)
Engine Machine model
Dimensions for each part
A B C D E F G
SAA6D114E-2
PC300-7 1,357 1,300 856 444 480 345 258
WA380-5 1,166 1,632 1,235 397 445 461
GD655-3A,3C 1,130 1,418 1,093 325 424 423
GD675-3A,3C 1,130 1,418 1,093 325 424 423
CD110R-2 1,357 1,392 992 400 619 368 48
1
(3)
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21. STRUCTURE AND FUNCTION AIR CLEANER
11-6 114 SERIES
AIR CLEANER
FRG TYPE (CYCLOPACK TYPE)
Features (FRG type)
• Since this air cleaner is sealed in the radial direction, the reliability of the seal is high.
• To remove the cleaner element of the current air cleaner, the wing nut must be removed. The cleaner ele-
ment of this air cleaner can be removed, however, by just undoing latch (6).
• The inlet is installed off the center of the air cleaner so that air will swirl and separate dust with centrifugal
force as shown in Fig. 1.
Structure
• Air containing dust is sucked through inlet (2) tangentially and the dust is separated by the centrifugal
effect of the guide vanes. Furthermore, more than 99.9% of the dust is removed by outer element (4) and
clean air is sucked through inner element (5) and outlet (1) into the engine.
• The dust and water separated by the guide vanes flow along the inside wall of body (3) and enter evacu-
ator valve (7), and then they are discharged automatically.
1. Outlet 4. Outer element 7. Vacuator valve
2. Inlet 5. Inner element
3. Body 6. Latch
Engine Machine model Type Actuator valve No. of elements
SAA6D114E-2
PC300-7
WA380-5
GD655-3A,3C
GD675-3A,3C
CD110R-2
FRG (Radial seal type) Automatic discharge
Inner element x 1,
outer element x 1
The shape may differ according to the machine it
is mounted on.
FRG TYPE (RADIAL SEAL TYPE)
(3)