Komatsu 140E-7 Series Engine Shop Manual SEN06498-09 – PDF DOWNLOAD

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Komatsu 140E-7 Series Engine Shop Manual SEN06498-09 – PDF DOWNLOAD

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Komatsu 140E-7 Series Engine Shop Manual SEN06498-09 – PDF DOWNLOAD

FOREWORD, SAFETY, BASIC INFORMATION:
HOW TO READ THE ENGINE SHOP MANUAL:
• Some of the attachments and options described in this shop manual may not be available in some areas. If
they are required, consult your Komatsu distributor.
• The materials and specifications are subject to change without notice.
• Shop manuals are available for “machine part” and “engine part”. For the engine unit, see the shop manual
for the machine which has the same engine model.
• Actual machine may differ from the images which are contained in this manual. A typical model is shown in
the illustrations of this shop manual.
Composition of the shop manual:
This shop manual contains technical information necessary to perform services in workshops. It is divided into
the following chapters for the ease of use.
00 INDEX AND FOREWORD
This section describes the index, foreword, safety, and basic information.
01 SPECIFICATIONS
This section describes the specifications of the machine.
10 STRUCTURE AND FUNCTION
This section describes the structure and operation of each component with respect to each system. “STRUCTURE
AND FUNCTION” is helpful in not only understanding the structure of each component but performing
troubleshooting.
20 STANDARD VALUE TABLE
This section describes the standard values for new machine and failure criteria for testing and adjusting, and
troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge
troubles in troubleshooting.
50 DISASSEMBLY AND ASSEMBLY
This section describes the special tools, work procedures, and safety precautions necessary for removal, installation,
disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and
weight of the coating materials, lubricants, and coolant necessary to these works are shown.
60 MAINTENANCE STANDARD
This section describes the maintenance standard value of each component. The maintenance standard shows
the criteria and remedies for disassembly and assembly.

TABLE OF CONTENTS:

Komatsu 140E-7 Series Engine Shop Manual SEN06498-09 – PDF DOWNLOAD

COVER 1
00 INDEX AND FOREWORD 3
INDEX 4
ABBREVIATION LIST 6
FOREWORD, SAFETY, BASIC INFORMATION 12
HOW TO READ THE ENGINE SHOP MANUAL 12
SAFETY NOTICE FOR OPERATION 14
PRECAUTIONS TO PREVENT FIRE 22
ACTIONS IF FIRE OCCURS 24
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 25
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS 26
PRECAUTIONS FOR DEF 27
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING 27
PRECAUTIONS FOR ADDING 27
PRECAUTIONS FOR STORING 27
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE 27
THE OTHER PRECAUTIONS 27
STORE AdBlue/DEF 28
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 29
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS 32
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT 39
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 41
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 42
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 43
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER 43
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER 44
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER 45
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 47
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR 51
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR 52
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL 54
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH 55
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 57
HOW TO READ ELECTRICAL WIRE CODE 58
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 62
STANDARD TIGHTENING TORQUE TABLE 65
CONVERSION TABLE 72
01 SPECIFICATIONS 77
CONTENTS 78
ABBREVIATION LIST 79
SPECIFICATIONS 85
OUTLINE OF EXHAUST GAS REGULATION 85
SYSTEM DRAWINGS OF ENGINE CONFORMED TO TIER4 REGULATION 86
IMPROVED POINTS OF ENGINE CONFORMED TO TIER4 REGULATION 87
LIST OF APPLICABLE MACHINES: 140E-7 88
SPECIFICATIONS 89
SPECIFICATIONS: SAA6D140E-7 (D155AX-8, D155AX-8E0, D155AXI-8, D155AXI-8E0) 89
SPECIFICATIONS: SAA6D140E-7 (HD325-8, HD325-8E0, HD405-8, HD405-8E0) 90
SPECIFICATIONS: SAA6D140E-7 (HM400-5, HM400-5E0) 91
SPECIFICATIONS: SAA6D140E-7 (PC650LC-11) 92
SPECIFICATIONS: SAA6D140E-7 (WA500-8) 93
ENGINE GENERAL VIEW 94
ENGINE GENERAL VIEW: SAA6D140E-7 (D155AX-8, D155AX-8E0, D155AXI-8, D155AXI-8E0) 94
ENGINE GENERAL VIEW: SAA6D140E-7 (HD325-8, HD325-8E0, HD405-8, HD405-8E0) 98
ENGINE GENERAL VIEW: SAA6D140E-7 (HM400-5, HM400-5E0) 102
ENGINE GENERAL VIEW: SAA6D140E-7 (PC650LC-11) 106
ENGINE GENERAL VIEW: SAA6D140E-7 (WA500-8) 110
WEIGHT TABLE 114
WEIGHT TABLE: 140E-7 114
ENGINE PERFORMANCE CURVE 116
ENGINE PERFORMANCE CURVE: SAA6D140E-7 (D155AX-8, D155AX-8E0, D155AXI-8, D155AXI-8E0) 116
ENGINE PERFORMANCE CURVE: SAA6D140E-7 (HD325-8, HD325-8E0, HD405-8, HD405-8E0) 117
ENGINE PERFORMANCE CURVE: SAA6D140E-7 (HM400-5, HM400-5E0) 118
ENGINE PERFORMANCE CURVE: SAA6D140E-7 (PC650LC-11) 119
ENGINE PERFORMANCE CURVE: SAA6D140E-7(WA500-8) 120
10 STRUCTURE AND FUNCTION 121
CONTENTS 122
ABBREVIATION LIST 124
UREA SCR SYSTEM 130
LAYOUT DRAWING OF UREA SCR SYSTEM 130
UREA SCR SYSTEM DIAGRAM 133
FUNCTION OF UREA SCR SYSTEM 134
FUNCTION OF AdBlue/DEF SUPPLY SYSTEM 134
INDUCEMENT STRATEGY 137
COMPONENT PARTS OF UREA SCR SYSTEM 151
AdBlue/DEF MIXING TUBE 151
SCR ASSEMBLY 152
AdBlue/DEF TANK 154
AdBlue/DEF PUMP 156
AdBlue/DEF INJECTOR 157
AdBlue/DEF HOSE 158
AdBlue/DEF TANK HEATING VALVE 159
ENGINE SYSTEM 160
LAYOUT OF ENGINE COMPONENTS 160
LAYOUT DRAWING OF ENGINE COMPONENTS 160
INTAKE AND EXHAUST SYSTEM PARTS 162
LAYOUT DRAWING OF INTAKE AND EXHAUST SYSTEM 162
INTAKE AND EXHAUST SYSTEM CIRCUIT DIAGRAM 163
FUNCTION OF INTAKE AND EXHAUST SYSTEM 163
AIR CLEANER 165
ENGINE MAIN BODY PARTS 166
CYLINDER HEAD 166
CYLINDER BLOCK 168
MAIN MOVING PARTS 171
VIBRATION DAMPER 174
TIMING GEAR 175
FRONT COVER 176
VALVE SYSTEM 177
FLYWHEEL AND FLYWHEEL HOUSING 179
TURBOCHARGER SYSTEM 180
CIRCUIT DIAGRAM OF VGT SYSTEM 180
FUNCTION OF VGT SYSTEM 181
VGT 183
EGR SYSTEM 187
EGR VALVE 189
EGR COOLER 191
MIXING CONNECTOR 192
KCCV SYSTEM 193
KCCV VENTILATOR 197
KDPF 199
LUBRICATION SYSTEM 203
LAYOUT DRAWING OF LUBRICATION SYSTEM PARTS 203
LUBRICATION SYSTEM CIRCUIT DIAGRAM 204
ENGINE OIL PUMP 205
ENGINE BOOST OIL PUMP 207
ENGINE OIL FILTER 209
ENGINE OIL COOLER 210
ENGINE OIL PAN 212
FUEL SYSTEM 213
LAYOUT DRAWING OF FUEL SYSTEM PARTS 213
FUEL SYSTEM CIRCUIT DIAGRAM 215
FUNCTION OF FUEL SYSTEM 216
OPERATION OF FUEL SYSTEM 216
CRI SYSTEM 217
SUPPLY PUMP 221
COMMON RAIL 224
INJECTOR 227
FUEL DOSING SYSTEM 230
FUEL PREFILTER 232
FUEL MAIN FILTER 233
COOLING SYSTEM 234
LAYOUT DRAWING OF COOLING SYSTEM PARTS 234
COOLING SYSTEM CIRCUIT DIAGRAM 235
WATER PUMP 236
THERMOSTAT 238
ELECTRICAL SYSTEM 240
COMPONENT PARTS OF ELECTRICAL SYSTEM 240
ALTERNATOR 240
ALTERNATOR MOUNTING 243
STARTING MOTOR 244
ENGINE WIRING HARNESS 246
ENGINE CONTROLLER 248
FUEL FEED PUMP 256
FUEL FEED PUMP SWITCH 257
SENSOR 258
LAYOUT DRAWING OF ENGINE SENSOR 258
STRUCTURE OF AMBIENT PRESSURE SENSOR 261
FUNCTION OF AMBIENT PRESSURE SENSOR 261
STRUCTURE OF ENGINE OIL PRESSURE SENSOR 262
FUNCTION OF ENGINE OIL PRESSURE SENSOR 262
STRUCTURE OF CHARGE PRESSURE SENSOR 263
FUNCTION OF CHARGE PRESSURE SENSOR 263
STRUCTURE OF CHARGE TEMPERATURE SENSOR 264
FUNCTION OF CHARGE TEMPERATURE SENSOR 264
STRUCTURE OF COOLANT TEMPERATURE SENSOR 265
FUNCTION OF COOLANT TEMPERATURE SENSOR 265
STRUCTURE OF NE (CRANKSHAFT) SPEED SENSOR 266
FUNCTION OF NE (CRANKSHAFT) SPEED SENSOR 266
STRUCTURE OF Bkup (CAMSHAFT) SPEED SENSOR 267
FUNCTION OF Bkup (CAMSHAFT) SPEED SENSOR 267
STRUCTURE OF COMMON RAIL PRESSURE SENSOR 268
FUNCTION OF COMMON RAIL PRESSURE SENSOR 268
STRUCTURE OF EGR VALVE LIFT SENSOR 269
FUNCTION OF EGR VALVE LIFT SENSOR 269
STRUCTURE OF VGT SPEED SENSOR 270
FUNCTION OF VGT SPEED SENSOR 270
STRUCTURE OF VGT POSITION SENSOR 271
FUNCTION OF VGT POSITION SENSOR 271
STRUCTURE OF MASS AIR FLOW AND TEMPERATURE SENSOR 272
FUNCTION OF MASS AIR FLOW AND TEMPERATURE SENSOR 272
STRUCTURE OF DOSING FUEL PRESSURE SENSOR 273
FUNCTION OF DOSING FUEL PRESSURE SENSOR 273
STRUCTURE OF KDPF DIFFERENTIAL PRESSURE AND OUTLET PRESSURE SENSOR 274
FUNCTION OF KDPF DIFFERENTIAL PRESSURE AND OUTLET PRESSURE SENSOR 274
STRUCTURE OF CRANKCASE PRESSURE SENSOR 275
FUNCTION OF CRANKCASE PRESSURE SENSOR 275
STRUCTURE OF ENGINE OIL LEVEL SENSOR 276
FUNCTION OF ENGINE OIL LEVEL SENSOR 276
STRUCTURE OF AIR CLEANER CLOGGING SENSOR 277
FUNCTION OF AIR CLEANER CLOGGING SENSOR 277
20 STANDARD VALUE TABLE 279
CONTENTS 280
ABBREVIATION LIST 281
STANDARD VALUE TABLE FOR ENGINE 287
STANDARD VALUE TABLE FOR ENGINE: SAA6D140E-7 (D155AX-8, D155AX-8E0, D155AXI-8, D155AXI-8E0) 287
STANDARD VALUE TABLE FOR ENGINE: SAA6D140E-7 (HD325-8, HD325-8E0, HD405-8, HD405-8E0) 289
STANDARD VALUE TABLE FOR ENGINE: SAA6D140E-7 (HM400-5, HM400-5E0) 291
STANDARD VALUE TABLE FOR ENGINE: SAA6D140E-7 (PC650LC-11) 293
STANDARD VALUE TABLE FOR ENGINE: SAA6D140E-7 (WA500-8) 295
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD 297
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA6D140E-7 (D155AX-8, D155AX-8E0, D155AXI-8, D155AXI-8E0) 297
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA6D140E-7 (HD325-8, HD325-8E0, HD405-8, HD405-8E0) 299
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA6D140E-7 (HM400-5, HM400-5E0) 301
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA6D140E-7 (PC650LC-11) 303
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA6D140E-7 (WA500-8) 305
50 DISASSEMBLY AND ASSEMBLY 307
CONTENTS 308
ABBREVIATION LIST 309
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY 315
HOW TO READ THIS MANUAL 315
COATING MATERIALS LIST 317
SPECIAL TOOLS LIST 321
SKETCHES OF SPECIAL TOOLS 323
ENGINE SYSTEM 326
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY 326
METHOD FOR DISASEMBLING ENGINE GENERALLY 327
METHOD FOR ASEMBLING ENGINE GENERALLY 351
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY 394
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY 394
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY 394
REMOVE AND INSTALL ENGINE FRONT OIL SEAL 398
METHOD FOR REMOVING ENGINE FRONT OIL SEAL 398
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL 399
REMOVE AND INSTALL ENGINE REAR OIL SEAL 401
METHOD FOR REMOVING ENGINE REAR OIL SEAL 401
METHOD FOR INSTALLING ENGINE REAR OIL SEAL 402
60 MAINTENANCE STANDARD 407
CONTENTS 408
ABBREVIATION LIST 409
ENGINE SYSTEM 415
INTAKE AND EXHAUST SYSTEM PARTS 415
MAINTENANCE STANDARD OF VGT 415
ENGINE MAIN BODY PARTS 416
MAINTENANCE STANDARD OF CYLINDER HEAD 416
MAINTENANCE STANDARD OF CYLINDER BLOCK 418
MAINTENANCE STANDARD OF CYLINDER LINER 420
MAINTENANCE STANDARD OF CRANKSHAFT 422
MAINTENANCE STANDARD OF CAM FOLLOWER AND PUSH ROD 424
MAINTENANCE STANDARD OF PISTON 426
MAINTENANCE STANDARD OF CONROD 428
MAINTENANCE STANDARD OF VIBRATION DAMPER 430
MAINTENANCE STANDARD OF TIMING GEAR 431
MAINTENANCE STANDARD OF CAMSHAFT 433
MAINTENANCE STANDARD OF VALVE AND VALVE GUIDE 434
MAINTENANCE STANDARD OF ROCKER ARM 436
MAINTENANCE STANDARD OF CROSSHEAD AND GUIDE 437
MAINTENANCE STANDARD OF FLYWHEEL 438
LUBRICATION SYSTEM 440
MAINTENANCE STANDARD OF RELIEF VALVE OF ENGINE OIL PUMP 440
MAINTENANCE STANDARD OF RELIEF VALVE OF ENGINE BOOST OIL PUMP 441
MAINTENANCE STANDARD OF SAFETY VALVE OF ENGINE OIL FILTER 442
COOLING SYSTEM 443
MAINTENANCE STANDARD OF OIL COOLER 443
MAINTENANCE STANDARD OF WATER PUMP 445
MAINTENANCE STANDARD OF THERMOSTAT 447
INDEX 449

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