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KOMATSU 140-3 SERIES DIESEL ENGINE SERVICE REPAIR MANUAL (SEBM022213) KOMATSU 140 3 SERIES – PDF DOWNLOAD
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- KOMATSU 140-3 SERIES DIESEL ENGINE SERVICE REPAIR MANUAL
- PUBLICATION NUMBER:SEBM022213
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Description
KOMATSU 140-3 SERIES DIESEL ENGINE SERVICE REPAIR MANUAL (SEBM022213) KOMATSU 140 3 SERIES
KOMATSU 140-3 SERIES DIESEL ENGINE SERVICE REPAIR MANUAL (SEBM022213) KOMATSU 140 3 SERIES – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU 140-3 SERIES DIESEL ENGINE SERVICE REPAIR MANUAL (SEBM022213) KOMATSU 140 3 SERIES
- 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 judgements. 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 further 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 understanding of the structure, but also serves as reference material for troubleshooting. In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance 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 component, 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.
TABLE OF CONTENTS:
KOMATSU 140-3 SERIES DIESEL ENGINE SERVICE REPAIR MANUAL (SEBM022213) KOMATSU 140 3 SERIES
COVER............................................................................................................................................. 1 CONTENTS.......................................................................................................................................... 2 01 GENERAL........................................................................................................................................ 27 OUTLINE....................................................................................................................................... 28 SPECIFICATIONS................................................................................................................................ 31 OVERALL DRAWING............................................................................................................................... 36 WEIGHT TABLE.................................................................................................................................. 43 ENGINE PERFORMANCE CURVE...................................................................................................................... 45 11 STRUCTURE AND FUNCTION,MAINTENANCE STANDARD.................................................................................................... 55 INTAKE,EXHAUST SYSTEM......................................................................................................................... 56 INTAKE,EXHAUST EQUIPMENT.................................................................................................................. 56 AIR CLEANER............................................................................................................................... 68 TURBOCHARGER.............................................................................................................................. 71 AFTERCOOLER............................................................................................................................... 75 ENGINE........................................................................................................................................ 77 CYLINDER HEAD............................................................................................................................. 77 CYLINDER BLOCK............................................................................................................................ 80 CYLINDER LINER............................................................................................................................ 83 MAIN MOVING PARTS......................................................................................................................... 84 CRANKSHAFT................................................................................................................................ 86 CAMSHAFT.................................................................................................................................. 87 CAM FOLLOWER AND PUSH ROD................................................................................................................. 88 PISTONใปPISTON RINGใปPISTON PIN............................................................................................................. 89 CONNECTING ROD............................................................................................................................ 91 FLYWHEEL,FLYWHEEL HOUSING................................................................................................................. 92 VIBRATION DAMPER.......................................................................................................................... 94 TIMING GEAR............................................................................................................................... 95 VALVE SYSTEM.............................................................................................................................. 99 VALVE,VALVE GUIDE.........................................................................................................................101 ROCKER ARM AND SHAFT......................................................................................................................103 CROSSHEAD AND GUIDE.......................................................................................................................104 LUBRICATION SYSTEM............................................................................................................................105 LUBRICATION SYSTEM DIAGRAM................................................................................................................105 OIL PUMP..................................................................................................................................106 OIL FILTER................................................................................................................................109 OIL COOLER................................................................................................................................110 FUEL SYSTEM...................................................................................................................................112 FUEL SYSTEM DIAGRAM.......................................................................................................................112 OUTLINE OF CRI SYSTEM.....................................................................................................................113 FUEL PIPING...............................................................................................................................126 FUEL COOLER...............................................................................................................................128 FUEL FILTER...............................................................................................................................129 COOLANT SYSTEM................................................................................................................................130 COOLING SYSTEM DIAGRAM....................................................................................................................130 WATER PUMP................................................................................................................................133 THERMOSTAT................................................................................................................................136 CORROSION RESISTOR........................................................................................................................138 COOLING FAN DRIVE.........................................................................................................................140 ACCESSORIES...................................................................................................................................151 FRONT PTO.................................................................................................................................151 AIR COMPRESSOR............................................................................................................................154 EXHAUST BRAKE.............................................................................................................................157 ELECTRICAL COMPONENTS.........................................................................................................................161 ALTERNATOR................................................................................................................................161 STARTING MOTOR............................................................................................................................168 STARTING AID..............................................................................................................................170 12 TESTING AND ADJUSTING..........................................................................................................................172 STANDARD VALUE TABLE FOR TESTING,ADJUSTING,AND TROUBLESHOOTING................................................................................173 STANDARD VALUE TABLE FOR ELECTRICAL RELATED PARTS.............................................................................................178 TOOLS FOR TESTING,ADJUSTING,AND TROUBLESHOOTING...............................................................................................180 MEASURING INTAKE AIR PRESSURE(BOOST PRESSURE).................................................................................................181 MEASURING EXHAUST TEMPERATURE.................................................................................................................181 ADJUSTING VALVE CLEARANCE.....................................................................................................................182 MEASURING COMPRESSION PRESSURE................................................................................................................183 MEASURING BLOW-BY PRESSURE....................................................................................................................184 MEASURING OIL PRESSURE........................................................................................................................185 HANDLING EQUIPMENT IN FUEL CIRCUIT............................................................................................................185 RELEASING REMAINING PRESSURE IN FUEL SYSTEM...................................................................................................186 MEASURING FUEL PRESSURE.......................................................................................................................186 REDUCED CYLINDER MODE OPERATION...............................................................................................................187 BLEEDING AIR FROM FUEL SYSTEM.................................................................................................................188 CHECK FOR LEAKAGE IN FUEL SYSTEM..............................................................................................................190 ADJUSTING SPEED SENSOR........................................................................................................................191 TESTING AND ADJUSTING ALTERNATOR BELT TENSION.................................................................................................191 TESTING AND ADJUSTING FAN BELT TENSION........................................................................................................192 HANDLING CONTROLLER HIGH VOLTAGE CIRCUIT......................................................................................................194 RUN-IN STANDARD...............................................................................................................................195 PERFORMANCE TEST STANDARDS....................................................................................................................197 TROUBLESHOOTING OF ENGINE SYSTEM(S MODE)......................................................................................................203 POINTS TO REMEMBER WHEN TROUBLESHOOTING...................................................................................................204 METHOD OF USING TROUBLESHOOTING CHARTS....................................................................................................205 S-1 STARTING PERFORMANCE IS POOR(STARTING ALWAYS TAKES TIME)..............................................................................208 S-2 ENGINE DOES NOT START.................................................................................................................209 S-3 ENGINE DOES NOT PICK UP SMOOTHLY(FOLLOW-UP IS POOR)...................................................................................212 S-4 ENGINE STOPS DURING OPERATIONS........................................................................................................213 S-5 ENGINE DOES NOT ROTATE SMOOTHLY(HUNTING)..............................................................................................214 S-6 ENGINE LACKS OUTPUT(OR LACKS POWER)...................................................................................................215 S-7 EXHAUST SMOKE IS BLACK(INCOMPLETE COMBUSTION).........................................................................................216 S-8 OIL CONSUMPTION IS EXCESSIVE(OR EXHAUST SMOKE IS BLUE)................................................................................217 S-9 OIL BECOMES CONTAMINATED QUICKLY......................................................................................................218 S-10 FUEL CONSUMPTION IS EXCESSIVE........................................................................................................219 S-11 OIL IS IN COOLING WATER(OR WATER SPURTS BACK,OR WATER LEVEL GOES DOWN)...............................................................220 S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP(DROP IN OIL PRESSURE)............................................................................221 S-13 OIL LEVEL RISES(WATER,FUEL IN OIL)...................................................................................................222 S-14 WATER TEMPERATURE BECOMES TOO HIGH(OVERHEATING)......................................................................................223 S-15 ABNORMAL NOISE IS MADE...............................................................................................................224 S-16 VIBRATION IS EXCESSIVE...............................................................................................................225 TROUBLESHOOTING OF ELECTRICAL SYSTEM(E MODE)..................................................................................................226 POINTS TO REMEMBER WHEN TROUBLESHOOTING...................................................................................................228 METHOD OF USING TROUBLESHOOTING FLOWCHART.................................................................................................229 ERROR CODE DISPLAYS AND POINTS TO REMEMBER WHEN TROUBLESHOOTING...........................................................................230 ACTION TAKEN BY CONTROLLER AND CONDITION OF MACHINE WHEN ERROR CODE IS DISPLAYED..........................................................233 E-1 ERROR CODE [E-1b] [ABNORMALITY IN NE REVOLUTION SENSOR SYSTEM]........................................................................241 E-2 ERROR CODE [E-1C] [ABNORMALITY IN G REVOLUTION SENSOR SYSTEM].........................................................................242 E-3 ERROR CODE [E-20] [ABNORMALITY IN MODEL SELECTION SYSTEM].............................................................................243 E-4 ERROR CODE [E-22] [OVERRUN]...........................................................................................................244 E-5 ERROR CODE [E-23] [OVERHEAT]..........................................................................................................244 E-6 ERROR CODE [E-24] [DROP IN OIL PRESSURE]..............................................................................................245 E-7 ERROR CODE [E-30] [ABNORMALITY IN IDLING VALIDATION SIGNAL SYSTEM]....................................................................246 E-8 ERROR CODE [E-31] [ABNORMALITY IN THROTTLE SENSOR SYSTEM].............................................................................248 E-9 ERROR CODE [E-34] [ABNORMALITY IN WATER TEMPERATURE HIGH-TEMPERATURE SENSOR SYSTEM]...................................................251 E-10 ERROR CODE [E-36] [ABNORMALITY IN OIL PRESSURE SWITCH SYSTEM]........................................................................252 E-11 ERROR CODE [E-3C] [ABNORMALITY IN BOOST PRESSURE SENSOR SYSTEM]......................................................................254 E-12 ERROR CODE [E-3D] [ABNORMALITY IN FUEL TEMPERATURE SENSOR SYSTEM]....................................................................255 E-13 ERROR CODE [E-50] [ABNORMALITY IN PREHEATING RELAY CONNECTING POINT SYSTEM]..........................................................256 E-14 ERROR CODE [E-51] [ABNORMALITY IN PREHEAT RELAY COIL SYSTEM].........................................................................257 E-15 ERROR CODE [E-54] [SHORT CIRCUIT IN STARTING SWITCH C SYSTEM]........................................................................258 E-16 ERROR CODE [E-56] [POWER SOURCE SYSTEM ABNORMALITY 1]................................................................................259 E-17 ERROR CODE [E-57] [POWER SOURCE SYSTEM ABNORMALITY 2]................................................................................261 E-18 ERROR CODE [E-5A] [ABNORMALITY IN FUEL INJECTION QUANTITY CONTROL SWITCH SIGNAL].....................................................262 E-19 ERROR CODE [E-6A] [ABNORMALITY IN WATER TEMPERATURE LOW-TEMPERATURE SENSOR SYSTEM]...................................................263 E-20 ERROR CODE [E-70] [EXCESS CURRENT IN FUEL SUPPLY PUMP PCV1 SYSTEM]...................................................................264 E-21 ERROR CODE [E-71] [EXCESS CURRENT IN FUEL SUPPLY PUMP PCV2 SYSTEM]...................................................................265 E-22 ERROR CODE [E-74] [DISCONNECTION IN FUEL SUPPLY PUMP PCV1 SYSTEM]....................................................................266 E-23 ERROR CODE [E-75] [DISCONNECTION IN FUEL SUPPLY PUMP PCV2 SYSTEM]....................................................................267 E-24 ERROR CODE [E-77] [ABNORMALITY IN COMMON RAIL FUEL PRESSURE SENSOR SYSTEM]...........................................................268 E-25 ERROR CODE [E-79] [COMMON RAIL FUEL HIGH PRESSURE ABNORMALITY 1];ERROR CODE [E-7A] [COMMON RAIL FUEL HIGH PRESSURE ABNORMALITY 2]....269 E-26 ERROR CODE [E-7b] [FUEL SUPPLY PUMP NON-FORCE FEED 1];ERROR CODE [E-7C] [FUEL SUPPLY PUMP NON-FORCE FEED 2]..........................270 E-27 ERROR CODE [E-7d] [ABNORMALITY IN COMMON RAIL FUEL PRESSURE].........................................................................272 E-28 ERROR CODE [E-80] [DEFECTIVE CONTROLLER].............................................................................................272 E-29 ERROR CODE [E-81] [DISCONNECTION IN NO.1 FUEL INJECTOR SYSTEM].......................................................................273 E-30 ERROR CODE [E-82] [DISCONNECTION IN NO.2 FUEL INJECTOR SYSTEM].......................................................................274 E-31 ERROR CODE [E-83] [DISCONNECTION IN NO.3 FUEL INJECTOR SYSTEM].......................................................................275 E-32 ERROR CODE [E-84] [DISCONNECTION IN NO.4 FUEL INJECTOR SYSTEM].......................................................................276 E-33 ERROR CODE [E-85] [DISCONNECTION IN NO.5 FUEL INJECTOR SYSTEM].......................................................................277 E-34 ERROR CODE [E-86] [DISCONNECTION IN NO.6 FUEL INJECTOR SYSTEM].......................................................................278 E-35 ERROR CODE [E-8A] [SHORT CIRCUIT IN NO.1,NO.2,NO.3 FUEL INJECTOR SYSTEM].............................................................279 E-36 ERROR CODE [E-8b] [SHORT CIRCUIT IN NO.4,NO.5,NO.6 FUEL INJECTOR SYSTEM].............................................................282 13 DISASSEMBLY AND ASSEMBLY.......................................................................................................................285 METHOD OF USING MANUAL........................................................................................................................286 PRECAUTIONS WHEN CARRYING OUT OPERATION.......................................................................................................287 SPECIAL TOOL LIST.............................................................................................................................289 GENERAL DISASSEMBLY OF ENGINE.................................................................................................................290 GENERAL ASSEMBLY OF ENGINE....................................................................................................................306 PROCEDURE FOR REMOVING AND INSTALLING FUEL SUPPLY PUMP UNIT...................................................................................338 15 REPAIR AND REPLACEMENT OF PARTS................................................................................................................340 CYLINDER HEAD.................................................................................................................................341 GRINDING OF FITTING FACE OF CYLINDER HEAD.................................................................................................341 REPLACING VALVE SEAT INSERT...............................................................................................................342 PRESSURE TEST.............................................................................................................................347 REPLACING VALVE GUIDE.....................................................................................................................348 REPLACING CROSSHEAD GUIDE.................................................................................................................349 GRINDING VALVE............................................................................................................................350 CYLINDER BLOCK................................................................................................................................351 REPLACING CAM BUSHING.....................................................................................................................351 REPLACING CRANKSHAFT GEAR.................................................................................................................354 REPLACING CAM GEAR........................................................................................................................355 REPLACING FLYWHEEL RING GEAR..............................................................................................................356 REPLACING CONNECTING ROD SMALL END BUSHING................................................................................................357
PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
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