Service Manual for Komatsu 140-3 Series Engine SEBM022214 PDF

Description

Komatsu 140-3 Series Diesel Engine Shop Manual SEBM022214 – PDF DOWNLOAD

FILE DETAILS:

Komatsu 140-3 Series Diesel Engine Shop Manual SEBM022214 – PDF DOWNLOAD

Language : English
Pages :372
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu 140-3 Series Diesel Engine Shop Manual SEBM022214 – PDF DOWNLOAD

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 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 Shop Manual SEBM022214 – PDF DOWNLOAD

140-3 SERIES 1
CONTENTS 2
01 GENERAL 23
OUTLINE 24
SPECIFICATIONS 28
OVERALL DRAWING 34
WEIGHT TABLE 42
ENGINE PERFORMANCE CURVE 44
11 STRUCTURE AND FUNCTION,MAINTENANCE STANDARD 55
INTAKE, EXHAUST EQUIPMENT 56
AIR CLEANER 68
TURBOCHARGER 72
AFTERCOOLER 76
CYLINDER HEAD 78
CYLINDER BLOCK 82
CYLINDER LINER 85
MAIN MOVING PARTS 86
CRANKSHAFT 88
CAMSHAFT 89
CAM FOLLOWER AND PUSH ROD 90
PISTON • PISTON RING • PISTON PIN 92
CONNECTING ROD 94
FLYWHEEL, FLYWHEEL HOUSING 95
VIBRATION DAMPER 97
TIMING GEAR 98
VALVE SYSTEM102
VALVE, VALVE GUIDE104
ROCKER ARM AND SHAFT106
CROSSHEAD AND GUIDE107
LUBRICATION SYSTEM DIAGRAM108
OIL PUMP109
OIL FILTER112
OIL COOLER113
FUEL SYSTEM DIAGRAM116
OUTLINE OF CRI SYSTEM117
FUEL PIPING130
FUEL COOLER132
FUEL FILTER133
COOLING SYSTEM DIAGRAM134
WATER PUMP138
THERMOSTAT141
CORROSION RESISTOR143
COOLING FAN DRIVE145
FRONT PTO158
AIR COMPRESSOR161
EXHAUST BRAKE164
ALTERNATOR169
STARTING MOTOR176
STARTING AID178
12 TESTING AND ADJUSTING181
STANDARD VALUE TABLE FOR TESTING, ADJUSTING,AND TROUBLESHOOTING182
STANDARD VALUE TABLE FOR ELECTRICAL RELATED PARTS188
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING190
MEASURING INTAKE AIRPRESSURE(BOOST PRESSURE)191
MEASURING EXHAUSTTEMPERATURE191
ADJUSTING VALVE CLEARANCE192
MEASURING COMPRESSION PRESSURE193
MEASURING BLOW-BY PRESSURE194
MEASURING OIL PRESSURE195
HANDLING EQUIPMENT INFUEL CIRCUIT195
RELEASING REMAININGPRESSURE IN FUEL SYSTEM196
MEASURING FUEL PRESSURE196
REDUCED CYLINDER MODE OPERATION197
BLEEDING AIR FROM FUEL SYSTEM198
CHECK FOR LEAKAGE IN FUEL SYSTEM201
ADJUSTING SPEED SENSOR202
TESTING AND ADJUSTINGALTERNATOR BELT TENSION202
TESTING AND ADJUSTING FAN BELT TENSION203
HANDLING CONTROLLER HIGH VOLTAGE CIRCUIT205
RUN-IN STANDARD206
PERFORMANCE TEST STANDARDS208
TROUBLESHOOTING OF ENGINESYSTEM (S MODE)215
POINTS TO REMEMBER WHEN TROUBLESHOOTING216
METHOD OF USING TROUBLESHOOTING CHARTS217
S-1 Starting performance is poor (starting always takes time)221
S-2 Engine does not start222
S-3 Engine does not pick up smoothly (follow-up is poor)225
S-4 Engine stops during operations226
S-5 Engine does not rotate smoothly (hunting)227
S-6 Engine lacks output (or lacks power)228
S-7 Exhaust smoke is black (incomplete combustion)229
S-8 Oil consumption is excessive (or exhaust smoke is blue)230
S-9 Oil becomes contaminated quickly231
S-10 Fuel consumption is excessive232
S-11 Oil is in cooling water (or water spurts back, or water level goes down)233
S-12 Oil pressure caution lamp lights up (drop in oil pressure)234
S-13 Oil level rises (water, fuel in oil)235
S-14 Water temperature becomes too high (overheating)236
S-15 Abnormal noise is made237
S-16 Vibration is excessive238
TROUBLESHOOTING OFELECTRICAL SYSTEM (E MODE)239
POINTS TO REMEMBER WHEN TROUBLESHOOTING241
METHOD OF USING TROUBLESHOOTING FLOWCHART242
ERROR CODE DISPLAYS AND POINTS TO REMEMBER WHENTROUBLESHOOTING243
ACTION TAKEN BY CONTROLLER AND CONDITION OFMACHINE WHEN ERROR CODE IS DISPLAYED246
E-1 Error code [E-1b] [Abnormality in NE revolution sensor system]255
E-2 Error code [E-1C] [Abnormality in G revolution sensor system]256
E-3 Error code [E-20] [Abnormality in model selection system]257
E-4 Error code [E-22] [Overrun]258
E-5 Error code [E-23] [Overheat]258
E-6 Error code [E-24] [Drop in oil pressure]259
E-7 Error code [E-30] [Abnormality in idling validation signal system]260
E-8 Error code [E-31] [Abnormality in throttle sensor system]262
E-9 Error code [E-34] [Abnormality in water temperature high-temperature sensor system]265
E-10 Error code [E-36] [Abnormality in oil pressure switch system]266
E-11 Error code [E-3C] [Abnormality in boost pressure sensor system]268
E-12 Error code [E-3d] [Abnormality in fuel temperature sensor system]269
E-13 Error code [E-50] [Abnormality in preheating relay connecting point system]270
E-14 Error code [E-51] [Abnormality in preheat relay coil system]271
E-15 Error code [E-54] [Short circuit in starting switch C system]272
E-16 Error code [E-56] [Power source system abnormality 1]273
E-17 Error code [E-57] [Power source system abnormality 2]275
E-18 Error code [E-5A] [Abnormality in fuel injection quantity control switch signal]276
E-19 Error code [E-6A] [Abnormality in water temperature low-temperature sensor system]277
E-20 Error code [E-70] [Excess current in fuel supply pump PCV1 system]278
E-21 Error code [E-71] [Excess current in fuel supply pump PCV2 system]279
E-22 Error code [E-74] [Disconnection in fuel supply pump PCV1 system]280
E-23 Error code [E-75] [Disconnection in fuel supply pump PCV2 system]281
E-24 Error code [E-77] [Abnormality in common rail fuel pressure sensor system]282
E-25 Error code [E-79] [Common rail fuel high pressure abnormality 1] Error code [E-7A] [Common rail fuel high pressure abnormality 2]283
E-26 Error code [E-7b] [Fuel supply pump non-force feed 1] Error code [E-7C] [Fuel supply pump non-force feed 2]284
E-27 Error code [E-7d] [Abnormality in common rail fuel pressure]286
E-28 Error code [E-80] [Defective controller]286
E-29 Error code [E-81] [Disconnection in No 1 fuel injector system]287
E-30 Error code [E-82] [Disconnection in No 2 fuel injector system]288
E-31 Error code [E-83] [Disconnection in No 3 fuel injector system]289
E-32 Error code [E-84] [Disconnection in No 4 fuel injector system]290
E-33 Error code [E-85] [Disconnection in No 5 fuel injector system]291
E-34 Error code [E-86] [Disconnection in No 6 fuel injector system]292
E-35 Error code [E-8A] [Short circuit in No 1, No 2, No 3 fuel injector system]293
E-36 Error code [E-8b] [Short circuit in No 4, No 5, No 6 fuel injector system]296
13 DISASSEMBLY AND ASSEMBLY299
METHOD OF USING MANUAL300
PRECAUTIONS WHEN CARRYING OUT OPERATION301
SPECIAL TOOL LIST303
GENERAL DISASSEMBLY OF ENGINE304
GENERAL ASSEMBLY OF ENGINE320
PROCEDURE FOR REMOVING AND INSTALLING FUEL SUPPLYPUMP UNIT352
15 REPAIR AND REPLACEMENTOF PARTS355
GRINDING OF FITTING FACE OF CYLINDER HEAD356
REPLACING VALVE SEAT INSERT357
PRESSURE TEST362
REPLACING VALVE GUIDE363
REPLACING CROSSHEAD GUIDE364
GRINDING VALVE365
REPLACING CAM BUSHING366
REPLACING CRANKSHAFT GEAR369
REPLACING CAM GEAR370
REPLACING FLYWHEEL RING GEAR371
REPLACING CONNECTING ROD SMALL END BUSHING372

IMAGES PREVIEW OF THE MANUAL:

S.M 20/12/24