Komatsu ENGINE 140E -5 SERIES SHOP MANUAL SEN00074-20 – PDF DOWNLOAD

Description

Komatsu ENGINE 140E -5 SERIES SHOP MANUAL SEN00074-20 – PDF DOWNLOAD

FILE DETAILS:

Komatsu ENGINE 140E -5 SERIES SHOP MANUAL SEN00074-20 – PDF DOWNLOAD

Language : English
Pages :776
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu ENGINE 140E -5 SERIES SHOP MANUAL SEN00074-20 – PDF DOWNLOAD

1. General precautions

Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully before operating the machine. In addition, read this manual and understand its contents before starting the work.

TABLE OF CONTENTS:

Komatsu ENGINE 140E -5 SERIES SHOP MANUAL SEN00074-20 – PDF DOWNLOAD

Cover 1
00 Index and foreword 3
Index 3
Composition of shop manual 4
Table of contents 5
Foreword and general information 13
Safety notice 14
How to read the shop manual 19
Explanation of terms for maintenance standard 21
Handling of electric equipment and hydraulic component 23
Handling of connectors newly used for engines 32
How to read electric wire code 35
Precautions when carrying out operation 38
Method of disassembling and connecting push-pull type coupler 41
Standard tightening torque table 44
Conversion table 48
01 Specification 55
Specification and technical data 55
Outline 56
Specifications 60
General view 79
Dimensions table119
Weight table120
Engine performance curves124
10 Structure, function and maintenance standard135
Structure, function and maintenance standard, Part 1135
Air intake and exhaust unit137
Air cleaner139
Turbocharger142
Aftercooler153
Muffler154
EGR system159
Cylinder head166
Cylinder block170
Cylinder liner173
Main moving parts174
Crankshaft176
Camshaft177
Cam follower and push rod178
Piston, piston ring and piston pin180
Connecting rod182
Flywheel and flywheel housing183
Vibration damper186
Timing gear188
Valve system192
Valve and valve guide194
Rocker arm and shaft196
Crosshead and guide197
Structure, function and maintenance standard, Part 2199
Lubrication system diagram202
Oil pump206
EGR oil pump207
Oil filter208
Oil cooler210
CRI system diagram212
Outline of CRI system214
Structure and operation of CRI system216
Structure and operation of component parts217
Fuel piping236
Fuel cooler240
Fuel filter241
Priming pump244
Electric priming pump245
Engine controller cooler246
Cooling system diagram247
Water pump252
Water pump mounting254
Thermostat255
Corrosion resistor256
Cooling fan drive258
Front PTO261
Alternator263
Starting motor276
Starting aid278
Engine controller279
20 Standard value table281
Standard service value table281
Standard service value table for testing, adjusting, and troubleshooting282
Running-in standard and performance test standard301
30 Testing and adjusting321
Testing and adjusting321
Testing and adjusting (with EGR)323
Testing and adjusting tools list323
Sketches of special tools325
Testing air boost pressure326
Testing exhaust temperature327
Adjusting valve clearance328
Testing compression pressure329
Testing blow-by pressure331
Testing engine oil pressure332
Testing EGR valve and bypass valve drive oil pressure333
Handling fuel system parts334
Releasing residual pressure in fuel system334
Testing fuel pressure335
Reduced cylinder mode operation336
No-injection cranking336
Testing fuel return rate and leakage337
Bleeding air from fuel circuit340
Testing fuel system for leakage342
Testing and adjusting alternator belt tension343
Testing and adjusting fan belt tension344
Handling controller high-voltage circuit345
Testing and adjusting (EGR-less)346
Testing and adjusting tools list346
Sketches of special tools348
Testing air boost pressure349
Testing exhaust temperature350
Adjusting valve clearance351
Testing compression pressure352
Testing blow-by pressure354
Testing engine oil pressure355
Handling fuel system parts356
Releasing residual pressure in fuel system356
Testing fuel pressure357
Reduced cylinder mode operation358
No-injection cranking358
Testing fuel return rate and leakage359
Bleeding air from fuel circuit362
Testing fuel system for leakage364
Testing and adjusting alternator belt tension365
Testing and adjusting fan belt tension366
Handling controller high-voltage circuit367
40 Troubleshooting369
General information on troubleshooting369
Points to remember when troubleshooting370
Method of displaying trouble diagnosis lamps (Method of displaying error code)371
Error codes and failure codes list373
Information in troubleshooting table378
Connection table for connector pin numbers380
T- branch box and T- branch adapter table416
Troubleshooting of mechanical system (S-mode)421
Troubleshooting of mechanical system (S-mode)424
Method of using troubleshooting charts424
S-1 Starting performance is poor428
S-2 Engine does not start430
S-3 Engine does not pick up smoothly434
S-4 Engine stops during operations435
S-5 Engine does not rotate smoothly436
S-6 Engine lacks output (or lacks power)437
S-7 Exhaust smoke is black (incomplete combustion)438
S-8 Oil consumption is excessive (or exhaust smoke is blue)440
S-9 Oil becomes contaminated quickly441
S-10 Fuel consumption is excessive442
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)443
S-12 Oil pressure drops444
S-13 Oil level rises (Entry of coolant/fuel)445
S-14 Coolant temperature becomes too high (overheating)447
S-15 Abnormal noise is made448
S-16 Vibration is excessive449
Troubleshooting of electrical system (E-mode), Part 1451
Troubleshooting of electrical system (E-mode), Part 1453
Troubleshooting method for disconnecting wiring harness of pressure sensor system453
E-1 Code [111/CA111] Engine Controller Internal Failure456
E-2 Code [115/CA115] Eng Ne and Bkup Speed Sensor Error457
E-3 Code [122/CA122] Charge (boost) Air Press Sensor High Error458
E-4 Code [123/CA123] Charge (boost) Air Press Sensor Low Error462
E-5 Code [131/CA131] Throttle Sensor High Error466
E-6 Code [132/CA132] Throttle Sensor Low Error470
E-7 Code [135/CA135] Oil Press Sensor High Error472
E-8 Code [141/CA141] Oil Press Sensor Low Error474
E-9 Code [144/CA144] Coolant Temp Sensor High Error476
E-10 Code [145/CA145] Coolant Temp Sensor Low Error478
E-11 Code [153/CA153] Charge (boost) Air Temp Sensor High Error480
E-12 Code [154/CA154] Charge (boost) Air Temp Sensor Low Error482
E-13 Code [187/CA187] Sensor Sup 2 Volt Low Error484
E-14 Code [221/CA221] Ambient Air Press Sensor High Error488
E-15 Code [222/CA222] Ambient Air Press Sensor Low Error490
E-16 Code [227/CA227] Sensor Sup 2 Volt High Error492
E-17 Code [234/CA234] Eng Overspeed492
E-18 Code [238/CA238] Ne Speed Sensor Sup Volt Error494
E-19 Code [263/CA263] Fuel Temp Sensor High Error496
E-20 Code [265/CA265] Fuel Temp Sensor Low Error498
E-21 Code [271/CA271] PCV1 Short Error500
E-22 Code [272/CA272] PCV1 Open Error502
E-23 Code [273/CA273] PCV2 Short Error504
E-24 Code [274/CA274] PCV2 Open Error506
E-25 Code [322/CA322] Injector #1 System Open/Short Error508
E-26 Code [323/CA323] Injector #5 System Open/Short Error510
E-27 Code [324/CA324] Injector #3 System Open/Short Error512
E-28 Code [325/CA325] Injector #6 System Open/Short Error514
E-29 Code [331/CA331] Injector #2 System Open/Short Error516
E-30 Code [332/CA332] Injector #4 System Open/Short Error518
E-31 Code [342/CA342] Engine Controller Data Matching Error520
E-32 Code [351/CA351] INJ Drive Circuit Error522
E-33 Code [352/CA352] Sensor Sup 1 Volt Low Error524
E-34 Code [386/CA386] Sensor Sup 1 Volt High Error525
E-35 Code [431/CA431] Idle Validation Switch Error528
E-36 Code [432/CA432] Idle Validation Process Error530
E-37 Code [441/CA441] Supply Voltage Low Error531
E-38 Code [442/CA442] Supply Voltage High Error531
Troubleshooting of electrical system (E-mode), Part 2533
Troubleshooting of electrical system (E-mode), Part 2535
E-39 Code [449/CA449] Rail Press High Error 2535
E-40 Code [451/CA451] Rail Press Sensor High Error536
E-41 Code [452/CA452] Rail Press Sensor Low Error539
E-42 Code [553/CA553] Rail Press High Error 1540
E-43 Code [554/CA554] Rail Press Sensor In Range Error541
E-44 Code [559/CA559] No-pressure Feed By Supply pump 1542
E-45 Code [689/CA689] Eng Ne Speed Sensor Error546
E-46 Code [731/CA731] Eng Bkup Speed Sensor Phase Error548
E-47 Code [757/CA757] All Engine Controller Data Lost Error548
E-48 Code [778/CA778] Eng Bkup Speed Sensor Error550
E-49 Code [1228/CA1228] EGR Valve Servo Error 1553
E-50 Code [1625/CA1625] EGR Valve Servo Error 2554
E-51 Code [1626/CA1626] Bypass Valve Solenoid Drive Short Circuit Error555
E-52 Code [1627/CA1627] Bypass Valve Solenoid Drive Open Error557
E-53 Code [1628/CA1628] Bypass Valve Servo Error 1558
E-54 Code [1629/CA1629] Bypass Valve Servo Error 2559
E-55 Code [1631/CA1631] Bypass Valve Lift Sensor High Error560
E-56 Code [1632/CA1632] Bypass Valve Lift Sensor Low Error562
E-57 Code [1633/CA1633] KOMNET Error562
E-58 Code [1642/CA1642] EGR Inlet Press Sensor Low Error563
E-59 Code [1653/CA1653] EGR Inlet Press Sensor High Error564
E-60 Code [2185/CA2185] Throttle Sens Sup Volt High Error566
E-61 Code [2186/CA2186] Throttle Sens Sup Volt Low Error570
E-62 Code [2249/CA2249] No-pressure Feed By Supply pump 2570
E-63 Code [2271/CA2271] EGR Valve Lift Sensor High Error571
E-64 Code [2272/CA2272] EGR Valve Lift Sensor Low Error573
E-65 Code [2351/CA2351] EGR Valve Solenoid Drive Short Error574
E-66 Code [2352/CA2352] EGR Valve Solenoid Drive Open Error576
E-67 Code [2555/CA2555] Intake Air Heater Relay Open Error577
E-68 Code [2556/CA2556] Intake Air Heater Relay Short Error578
E-69 Code [(143)/B@BAZG] Eng Oil Press Low Torque Derate580
E-70 Code [(146)/B@BCNS] Eng Overheat580
E-71 Code [(415)/B@BAZG] Eng Oil Press Low Speed Derate581
50 Disassembly and assembly583
General information on disassembly and assembly583
General information on disassembly and assembly584
How to read this manual584
Coating materials list586
Special tools list589
Sketches of special tools590
Disassembly and assembly, Part 1 (with EGR)595
Disassembly and assembly, Part 1 (with EGR)596
General disassembly of engine596
General assembly of engine614
Disassembly and assembly, Part 2 (EGR-less)649
Disassembly and assembly, Part 2 (EGR-less)650
General disassembly of engine650
General assembly of engine666
Disassembly and assembly, Part 3699
Disassembly and assembly, Part 3700
Removal and installation of fuel supply pump unit (with EGR)700
Removal and installation of fuel supply pump unit (EGR-less)702
Replacement of oil seal of engine mounted on machine705
90 Repair and replacement of parts711
Information related to repair and replacement711
Flowchart712
Special tool table714
Special tool sketch716
Cylinder head721
Part names related to cylinder head722
Testing and inspection of cylinder head723
Pressure test of cylinder head725
Replacement of valve guide725
Replacement of valve seat insert726
Replacement of crosshead guide733
Repair of cylinder head mounting face by grinding734
Repair of valve by grinding735
Cylinder block737
Part names related to cylinder block739
Testing and inspection of cylinder block740
Method of checking main bearing metal inside diameter with alignment bar742
Part names related to crankshaft743
Testing and inspection of crankshaft744
Part names related to connecting rod745
Testing and inspection of connecting rod746
Replacement of flywheel ring gear747
Replacement of crankshaft gear748
Replacement of camshaft gear749
Replacement of main bearing metal cap750
Replacement of connecting rod small end bushing752
Replacement of cam bushing753
Repair of cylinder block top by grinding755
Repair of counterbore by grinding756
Check and identification after repair by grinding758
Gasket sealant application procedure759
Repair standard for cylinder liner O-ring761
Replacement of engine rear seal762
Replacement of wear sleeve (when sleeve is installed)766
Repair of crankshaft by grinding767
Improvement of surface roughness of crankshaft journal772

IMAGES PREVIEW OF THE MANUAL:

S.M 26/12/24