Komatsu 140E-5 Series Engine Shop Manual SEN00074-06 PDF

Description

Komatsu 140E-5 Series Engine Shop Manual SEN00074-06 – PDF DOWNLOAD

FILE DETAILS:

Komatsu 140E-5 Series Engine Shop Manual SEN00074-06 – PDF DOWNLOAD 

Language : English
Pages : 614
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu 140E-5 Series Engine Shop Manual SEN00074-06 – PDF DOWNLOAD 

MAIN MENU 0
COVER 1
00 INDEX AND FOREWORD 3
INDEX 3
COMPOSITION OF SHOP MANUAL 4
TABLE OF CONTENTS 5
FOREWORD AND GENERAL INFORMATION 11
SAFETY NOTICE 12
HOW TO READ THE SHOP MANUAL 17
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 19
HANDLING OF ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENT 21
HANDLING OF CONNECTORS NEWLY USED OF FOR ENGINES 30
HOW TO READ ELECTRIC WIRE CODE 33
PRECAUTIONS WHEN CARRYING OUT OPERATION 36
METHOD OF DISASSEMBLING AND CONNECTING PUSH-PULL TYPE COUPLER 39
STANDARD TIGHTENING TORQUE TABLE 42
CONVERSION TABLE 46
01 SPECIFICATION 53
SPECIFICATION AND TECHNICAL DATA 53
OUTLINE 54
SPECIFICATIONS 58
GENERAL VIEW 74
WEIGHT TABLE 95
ENGINE PERFORMANCE CURVES 97
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 107
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD, PART 1 107
AIR INTAKE AND EXHAUST SYSTEM 109
AIR INTAKE AND EXHAUST UNIT 109
AIR CLEANER 111
TURBOCHARGER 114
AFTERCOOLER 125
MUFFLER 126
EGR SYSTEM 130
ENGINE UNIT 138
CYLINDER HEAD 138
CYLINDER BLOCK 142
CYLINDER LINER 145
MIAN MOVING PARTS 146
CRANKSHAFT 148
CAMSHAFT 149
CAM FOLLOWER AND PUSH ROD 150
PISTON, PISTON RING AND PISTON PIN 152
CONNECTING ROD 154
FLYWHEEL AND FLYWHEEL HOUSING 155
VIBRATION DAMPER 158
TIMING GEAR 160
VALVE SYSTEM 164
VALVE AND VALVE GUIDE 166
ROCKER ARM AND SHAFT 168
CROSSHEAD AND GUIDE 169
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD, PART 2 171
LUBRICATION SYSTEM 174
LUBRICATION SYSTEM DIAGRAM 174
OIL PUMP 178
EGR OIL PUMP 179
OIL FILTER 180
OIL COOLER 182
FUEL SYSTEM 184
CRI SYSTEM DIAGRAM 184
OUTLINE OF CRI SYSTEM 186
FUEL PIPING 208
FUEL COOLER 212
FUEL FILTER 213
PRIMING PUMP 216
ELECTRIC PRIMING PUMP 217
ENGINE CONTROLLER COOLER 218
COOLING SYSTEM 219
COOLING SYSTEM DIAGRAM 219
WATER PUMP 224
THERMOSTAT 227
CORROSION RESISTOR 228
COOLING FAN DRIVE 230
ACCESSORIES 233
FRONT PTO 233
ELECTRICAL EQUIPMENT 235
ALTENATOR 235
STARTING MOTOR 242
STARTING AID 243
ENGING CONTROLLER 244
20 STANDARD VALUE TABLE 247
STANDARD SERVICE VALUE TABLE 247
STANDARD SERVICE VALUE TABLE FOR TESTING, ADJUSTING, AND TROUBLESHOOTING 248
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD 264
30 TESTING AND ADJUSTING 281
TESTING AND ADJUSTING 281
TESTING AND ADJUSTING (WITH EGR) 283
TESTING AND ADJUSTING TOOLS LIST 283
TESTING AIR BOOST PRESSURE 285
TESTING EXHAUST TEMPERATURE 286
ADJUSTING VALVE CLEARANCE 287
TESTING COMPRESSION PRESSURE 288
TESTING BLOW-BY PRESSURE 290
TESTING ENGINE OIL PRESSURE 291
TESTING EGR VALVE AND BYPASS VALVE DRIVE OIL PRESSURE 292
HANDLING FUEL SYSTEM PARTS 293
RELEASING RESIDUAL PRESSURE IN FUEL SYSTEM 293
TESTING FUEL PRESSURE 294
REDUCED CYLINDER MODE OPERATION 295
NO-INJECTION CRANKING 295
TESTING FUEL RETURN RATE AND LEAKAGE 296
BLEEDING AIR FROM FUEL CIRCUIT 299
TESTING FUEL SYSTEM FOR LEAKAGE 301
TESTING AND ADJUSTING ALTERNATOR BELT TENSION 302
TESTING AND ADJUSTING FAN BELT TENSION 303
HANDLING CONTROLLER HIGH-VOLTAGE CIRCUIT 304
TESTING AND ADJUSTING (EGR-LESS) 305
TESTING AND ADJUSTING TOOLS LIST 305
TESTING AIR BOOST PRESSURE 307
TESTING EXHAUST TEMPERATURE 308
ADJUSTING VALVE CLEARANCE 309
TESTING COMPRESSION PRESSURE 310
TESTING BLOW-BY PRESSURE 312
TESTING ENGINE OIL PRESSURE 313
HANDLING FUEL SYSTEM PARTS 314
RELEASING RESIDUAL PRESSURE IN FUEL SYSTEM 314
TESTING FUEL PRESSURE 315
REDUCED CYLINDER MODE OPERATION 316
NO-INJECTION CRANKING 316
TESTING FUEL RETURN RATE AND LEAKAGE 317
BLEEDING AIR FROM FUEL CIRCUIT 320
TESTING FUEL SYSTEM FOR LEAKAGE 322
TESTING AND ADJUSTING ALTERNATOR BELT TENSION 323
TESTING AND ADJUSTING FAN BELT TENSION 324
HANDLING CONTROLLER HIGH-VOLTAGE CIRCUIT 325
40 TROUBLESHOOTING 327
GENERAL INFORMATION ON TROUBLESHOOTING 327
POINTS TO REMEMBER WHEN TROUBLESHOOTING 328
ERROR CODES AND FAILURE CODES LIST 329
INFORMATION IN TROUBLESHOOTING TABLE 332
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE), PART 1 335
E-1 CODE [111/CA111] ENGINE CONTROLLER INTERNAL FAILURE 337
E-2 CODE [115/CA115] ENG NE AND BKUP SPEED SENSOR ERROR 338
E-3 CODE [122/CA122] CHARGE (BOOST) AIR PRESS SENSOR HIGH ERROR 340
E-4 CODE [123/CA123] CHARGE (BOOST) AIR PRESS SENSOR LOW ERROR 344
E-5 CODE [131/CA131] THROTTLE SENSOR HIGH ERROR 346
E-6 CODE [132/CA132] THROTTLE SENSOR LOW ERROR 350
E-7 CODE [135/CA135] OIL PRESS SENSOR HIGH ERROR 351
E-8 CODE [141/CA141] OIL PRESS SENSOR LOW ERROR 353
E-9 CODE [144/CA144] COOLANT TEMP SENSOR HIGH ERROR 354
E-10 CODE [145/CA145] COOLANT TEMP SENSOR LOW ERROR 356
E-11 CODE [153/CA153] CHARGE (BOOST) AIR TEMP SENSOR HIGH ERROR 357
E-12 CODE [154/CA154] CHARGE (BOOST) AIR TEMP SENSOR LOW ERROR 359
E-13 CODE [187/CA187] SENSOR SUP 2 VOLT LOW ERROR 359
E-14 CODE [221/CA221] AMBIENT AIR PRESS SENSOR HIGH ERROR 360
E-15 CODE [222/CA222] AMBIENT AIR PRESS SENSOR LOW ERROR 364
E-16 CODE [227/CA227] SENSOR SUP 2 VOLT HIGH ERROR 365
E-17 CODE [234/CA234] ENG OVERSPEED 369
E-18 CODE [238/CA238] NE SPEED SENSOR SUP VOLT ERROR 370
E-19 CODE [263/CA263] FUEL TEMP SENSOR HIGH ERROR 372
E-20 CODE [265/CA265] FUEL TEMP SENSOR LOW ERROR 374
E-21 CODE [271/CA271] PVC1 SHORT CIRCUIT 376
E-22 CODE [272/CA272] PCV1 OPEN ERROR 378
E-23 CODE [273/CA273] PCV2 SHORT ERROR 380
E-24 CODE [274/CA274] PVC2 OPEN ERROR 382
E-25 CODE [322/CA322] INJECTOR #1 SYSTEM OPEN/SHORT ERROR 384
E-26 CODE [323/CA323] INJECTOR #5 SYSTEM OPEN/SHORT ERROR 386
E-27 CODE [324/CA324] INJECTOR #3 SYSTEM OPEN/SHORT ERROR 388
E-28 CODE [325/CA325] INJECTOR #6 SYSTEM OPEN/SHORT ERROR 390
E-29 CODE [331/CA331] INJECTOR #2 SYSTEM OPEN/SHORT ERROR 392
E-30 CODE [332/CA332] INJECTOR #4 SYSTEM OPEN/SHORT ERROR 394
E-31 CODE [342/CA342] ENGINE CONTROLLER DATA MATCHING ERROR 396
E-32 CODE [351/CA351] INJ DRIVE CIRCUIT ERROR 397
E-33 CODE [352/CA352] SENSOR SUP 1 VOLT LOW ERROR 399
E-34 CODE [386/CA386] SENSOR SUP 1 VOLT HIGH ERROR 400
E-35 CODE [431/CA431] IDLE VALIDATION SWITCH ERROR 404
E-36 CODE [432/CA432] IDLE VALIDATION PROCESS ERROR 406
E-37 CODE [441/CA441] SUPPLY VOLTAGE LOW ERROR 407
E-38 CODE [442/CA442] SUPPLY VOLTAGE HIGH ERROR 407
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE), PART 2 409
E-39 CODE [449/CA449] RAIL PRESS HIGH ERROR 2 411
E-40 CODE [451/CA451] RAIL PRESS SENSOR HIGH ERROR 412
E-41 CODE [452/CA452] RAIL PRESS SENSOR LOW ERROR 415
E-42 CODE [553/CA553] RAIL PRESS HIGH ERROR 1 416
E-43 CODE [554/CA554] RAIL PRESS SENSOR IN RANGE ERROR 417
E-44 CODE [559/CA559] NO-PRESSURE FEED BY SUPPLY PUMP 1 418
E-45 CODE [689/CA689] ENG NE SPEED SENSOR ERROR 422
E-46 CODE [731/CA731] ENG BKUP SPEED SENSOR PHASE ERROR 424
E-47 CODE [757/CA757] ALL ENGINE CONTROLLER DATA LOST ERROR 424
E-48 CODE [778/CA778] ENG BKUP SPEED SENSOR ERROR 426
E-49 CODE [1228/CA1228] EGR VALVE SERVO ERROR 1 429
E-50 CODE [1625/CA1625] EGR VALVE SERVO ERROR 2 430
E-51 CODE [1626/CA1626] BYPASS VALVE SOLENOID DRIVE SHORT CIRCUIT ERROR 431
E-52 CODE [1627/CA1627] BYPASS VALVE SOLENOID DRIVE OPEN ERROR 433
E-53 CODE [1628/CA1628] BYPASS VALVE SERVO ERROR 1 434
E-54 CODE [1629/CA1629] BYPASS VALVE SERVO ERROR 2 435
E-55 CODE [1631/CA1631] BYPASS VALVE LIFT SENSOR HIGH ERROR 436
E-56 CODE [1632/CA1632] BYPASS VALVE LIFT SENSOR LOW ERROR 438
E-57 CODE [1633/CA1633] KOMNET ERROR 438
E-58 CODE [1642/CA1642] EGR INLET PRESS SENSOR LOW ERROR 439
E-59 CODE [1653/CA1653] EGR INLET PRESS SENSOR HIGH ERROR 440
E-60 CODE [2185/CA2185] THROTTLE SENS SUP VOLT HIGH ERROR 442
E-61 CODE [2186/CA2186] THROTTLE SENS SUP VOLT LOW ERROR 446
E-62 CODE [2249/CA2249] NO-PRESSURE FEED BY SUPPLY PUMP 2 446
E-63 CODE [2271/CA2271] EGR VALVE LIFT SENSOR HIGH ERROR 447
E-64 CODE [2272/CA2272] EGR VALVE LIFT SENSOR LOW ERROR 449
E-65 CODE [2351/CA2351] EGR VALVE SOLENOID DRIVE SHORT ERROR 450
E-66 CODE [2352/CA2352] EGR VALVE SOLENOID DRIVE OPEN ERROR 452
E-67 CODE [2555/CA2555] INTAKE AIR HEATER RELAY OPEN ERROR 453
E-68 CODE [2556/CA2556] INTAKE AIR HEATER RELAY SHORT ERROR 454
E-69 CODE [(143)/B@BAZG] ENG OIL PRESS LOW TORQUE DERATE 456
E-70 CODE [(146)/B@BCNS] ENG OVERHEAT 456
E-71 CODE [(415)/B@AZG] ENG OIL PRESS LOW SPEED DERATE 457
TROUBLESHOOTING OF MECHANICAL SYSTEM (S-MODE) 459
METHOD OF USING TROUBLESHOOTING CHARTS 462
S-1 STARTING PERFORMANCE IS POOR 466
S-2 ENGINE DOES NOT START 468
S-3 ENGINE DOSE NOT PICK UP SMOOTHLY 472
S-4 ENGINE STOPS DURING OPERATIONS 473
S-5 ENGINE DOES NOT ROTATE SMOOTHLY 474
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER) 475
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION) 476
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE) 478
S-9 OIL BECOMES CONTAMINATED QUICKLY 479
S-10 FUEL CONSUMPTION IS EXCESSIVE 480
S-11 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) 481
S-12 OIL PRESSURE DROPS 482
S-13 OIL LEVEL RISES (ENTRY OF COOLANT/FUEL) 483
S-14 COOLANT TEMPERATURE BECOMES TOO HIGH (OVERHEATING) 485
S-15 ABNORMAL NOISE IS MADE 486
S-16 VIBRATION IS EXCESSIVE 487
50 DISASSEMBLY AND ASSEMBLY 489
GENERAL INFORMATION ON DISASSEMBLY AND ASSEMBLY 489
HOW TO READ THIS MANUAL 490
COATING MATERIALS LIST 492
SPECIAL TOOLS LIST 495
SKETCHES OF SPECIAL TOOLS 496
DISASSEMBLY AND ASSEMBLY, PART 1 (WITH EGR) 499
GENERAL DISASSEMBLY OF ENGINE 500
GENERAL ASSEMBLY OF ENGINE 518
DISASSEMBLY AND ASSEMBLY, PART 2 (EGR-LESS) 553
GENERAL DISASSEMBLY OF ENGINE 554
GENERAL ASSEMBLY OF ENGINE 570
DISASSEMBLY AND ASSEMBLY, PART 3 603
REMOVAL AND INSTALLATION OF FUEL SUPPLY PUMP UNIT (WITH EGR) 604
REMOVAL AND INSTALLATION OF FUEL SUPPLY PUMP UNIT (EGR-LESS) 606
REPLACEMENT OF OIL SEAL OF ENGINE MOUNTED ON MACHINE 609

DESCRIPTION:

Komatsu 140E-5 Series Engine Shop Manual SEN00074-06 – PDF DOWNLOAD 

How to read the shop manual 
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 disassembly
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)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
This section explains the method of reproducing, repairing, and replacing parts.

S.V 24/12/24