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KOMATSU 140-3 Series Diesel Engine Shop Manual SEBM022214 – PDF DOWNLOAD
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KOMATSU 140-3 Series Diesel Engine Shop Manual SEBM022214 – PDF DOWNLOAD
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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
IMAGES PREVIEW OF THE MANUAL:
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 SYSTEM..................................................................................................................................102 VALVE, VALVE GUIDE............................................................................................................................104 ROCKER ARM AND SHAFT..........................................................................................................................106 CROSSHEAD AND GUIDE...........................................................................................................................107 LUBRICATION SYSTEM DIAGRAM....................................................................................................................108 OIL PUMP......................................................................................................................................109 OIL FILTER....................................................................................................................................112 OIL COOLER....................................................................................................................................113 FUEL SYSTEM DIAGRAM...........................................................................................................................116 OUTLINE OF CRI SYSTEM.........................................................................................................................117 FUEL PIPING...................................................................................................................................130 FUEL COOLER...................................................................................................................................132 FUEL FILTER...................................................................................................................................133 COOLING SYSTEM DIAGRAM........................................................................................................................134 WATER PUMP....................................................................................................................................138 THERMOSTAT....................................................................................................................................141 CORROSION RESISTOR............................................................................................................................143 COOLING FAN DRIVE.............................................................................................................................145 FRONT PTO.....................................................................................................................................158 AIR COMPRESSOR................................................................................................................................161 EXHAUST BRAKE.................................................................................................................................164 ALTERNATOR....................................................................................................................................169 STARTING MOTOR................................................................................................................................176 STARTING AID..................................................................................................................................178 12 TESTING AND ADJUSTING..........................................................................................................................181 STANDARD VALUE TABLE FOR TESTING, ADJUSTING,AND TROUBLESHOOTING...............................................................................182 STANDARD VALUE TABLE FOR ELECTRICAL RELATED PARTS.............................................................................................188 TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING.............................................................................................190 MEASURING INTAKE AIRPRESSURE(BOOST PRESSURE)..................................................................................................191 MEASURING EXHAUSTTEMPERATURE..................................................................................................................191 ADJUSTING VALVE CLEARANCE.....................................................................................................................192 MEASURING COMPRESSION PRESSURE................................................................................................................193 MEASURING BLOW-BY PRESSURE....................................................................................................................194 MEASURING OIL PRESSURE........................................................................................................................195 HANDLING EQUIPMENT INFUEL CIRCUIT.............................................................................................................195 RELEASING REMAININGPRESSURE IN FUEL SYSTEM....................................................................................................196 MEASURING FUEL PRESSURE.......................................................................................................................196 REDUCED CYLINDER MODE OPERATION...............................................................................................................197 BLEEDING AIR FROM FUEL SYSTEM.................................................................................................................198 CHECK FOR LEAKAGE IN FUEL SYSTEM..............................................................................................................201 ADJUSTING SPEED SENSOR........................................................................................................................202 TESTING AND ADJUSTINGALTERNATOR BELT TENSION..................................................................................................202 TESTING AND ADJUSTING FAN BELT TENSION........................................................................................................203 HANDLING CONTROLLER HIGH VOLTAGE CIRCUIT......................................................................................................205 RUN-IN STANDARD...............................................................................................................................206 PERFORMANCE TEST STANDARDS....................................................................................................................208 TROUBLESHOOTING OF ENGINESYSTEM (S MODE)......................................................................................................215 POINTS TO REMEMBER WHEN TROUBLESHOOTING...................................................................................................216 METHOD OF USING TROUBLESHOOTING CHARTS....................................................................................................217 S-1 Starting performance is poor (starting always takes time).............................................................................221 S-2 Engine does not start.................................................................................................................222 S-3 Engine does not pick up smoothly (follow-up is poor)..................................................................................225 S-4 Engine stops during operations........................................................................................................226 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 quickly......................................................................................................231 S-10 Fuel consumption is excessive........................................................................................................232 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 made...............................................................................................................237 S-16 Vibration is excessive...............................................................................................................238 TROUBLESHOOTING OFELECTRICAL SYSTEM (E MODE)..................................................................................................239 POINTS TO REMEMBER WHEN TROUBLESHOOTING...................................................................................................241 METHOD OF USING TROUBLESHOOTING FLOWCHART.................................................................................................242 ERROR CODE DISPLAYS AND POINTS TO REMEMBER WHENTROUBLESHOOTING............................................................................243 ACTION TAKEN BY CONTROLLER AND CONDITION OFMACHINE WHEN ERROR CODE IS DISPLAYED...........................................................246 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 ASSEMBLY.......................................................................................................................299 METHOD OF USING MANUAL........................................................................................................................300 PRECAUTIONS WHEN CARRYING OUT OPERATION.......................................................................................................301 SPECIAL TOOL LIST.............................................................................................................................303 GENERAL DISASSEMBLY OF ENGINE.................................................................................................................304 GENERAL ASSEMBLY OF ENGINE....................................................................................................................320 PROCEDURE FOR REMOVING AND INSTALLING FUEL SUPPLYPUMP UNIT....................................................................................352 15 REPAIR AND REPLACEMENTOF PARTS.................................................................................................................355 GRINDING OF FITTING FACE OF CYLINDER HEAD.....................................................................................................356 REPLACING VALVE SEAT INSERT...................................................................................................................357 PRESSURE TEST.................................................................................................................................362 REPLACING VALVE GUIDE.........................................................................................................................363 REPLACING CROSSHEAD GUIDE.....................................................................................................................364 GRINDING VALVE................................................................................................................................365 REPLACING CAM BUSHING.........................................................................................................................366 REPLACING CRANKSHAFT GEAR.....................................................................................................................369 REPLACING CAM GEAR............................................................................................................................370 REPLACING FLYWHEEL RING GEAR..................................................................................................................371 REPLACING CONNECTING ROD SMALL END BUSHING....................................................................................................372
DESCRIPTION:
KOMATSU 140-3 Series Diesel Engine Shop Manual SEBM022214 – PDF DOWNLOAD
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.
S.S 17/12/24
