Professional Documents
Culture Documents
140E-5 Series
140E-5 Series 1
SEN00076-16 00 Index and foreword
Shop Manual, contents binder, binder label and tabs ............................................................ SEN00074-16
01 Specification.................................................................................................................... SEN00078-07
Specification and technical data...................................................................................... SEN00079-07 q
2 140E-5 Series
00 Index and foreword SEN00076-16
Table of contents 1
00 Index and foreword
Index SEN00076-16
Composition of shop manual ................................................................................................... 2
Table of contents ..................................................................................................................... 3
Foreword and general information SEN00077-07
Safety notice............................................................................................................................ 2
How to read the shop manual.................................................................................................. 7
Explanation of terms for maintenance standard ...................................................................... 9
Handling of electric equipment and hydraulic component ....................................................... 11
Handling of connectors newly used for engines ...................................................................... 20
How to read electric wire code ................................................................................................ 23
Precautions when carrying out operation ................................................................................ 26
Method of disassembling and connecting push-pull type coupler ........................................... 29
Standard tightening torque table.............................................................................................. 32
Conversion table...................................................................................................................... 36
01 Specification
Specification and technical data SEN00079-07
Outline ..................................................................................................................................... 2
Specifications........................................................................................................................... 6
General view............................................................................................................................ 24
Weight table............................................................................................................................. 61
Engine performance curves..................................................................................................... 65
140E-5 Series 3
SEN00076-16 00 Index and foreword
4 140E-5 Series
00 Index and foreword SEN00076-16
40 Troubleshooting
General information on troubleshooting SEN00151-04
Points to remember when troubleshooting .............................................................................. 2
Method of displaying trouble diagnosis lamps (Method of displaying error code) ................... 3
Error codes and failure codes list ............................................................................................ 5
Information in troubleshooting table ........................................................................................ 10
Connection table for connector pin numbers ........................................................................... 12
T- branch box and T- branch adapter table ............................................................................. 48
Troubleshooting of mechanical system (S-mode) SEN00152-03
Troubleshooting of mechanical system (S-mode) ....................................................................... 4
Method of using troubleshooting charts................................................................................... 4
S-1 Starting performance is poor ............................................................................................. 8
S-2 Engine does not start ........................................................................................................ 10
S-3 Engine does not pick up smoothly .................................................................................... 14
S-4 Engine stops during operations ........................................................................................ 15
S-5 Engine does not rotate smoothly ...................................................................................... 16
S-6 Engine lacks output (or lacks power) ................................................................................ 17
S-7 Exhaust smoke is black (incomplete combustion) ............................................................ 18
S-8 Oil consumption is excessive (or exhaust smoke is blue)................................................. 20
S-9 Oil becomes contaminated quickly ................................................................................... 21
S-10 Fuel consumption is excessive ....................................................................................... 22
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down).............................. 23
S-12 Oil pressure drops........................................................................................................... 24
S-13 Oil level rises (Entry of coolant/fuel) ............................................................................... 25
S-14 Coolant temperature becomes too high (overheating).................................................... 27
S-15 Abnormal noise is made ................................................................................................. 28
S-16 Vibration is excessive ..................................................................................................... 29
Troubleshooting of electrical system (E-mode), Part 1 SEN00153-03
Troubleshooting of electrical system (E-mode), Part 1 ............................................................... 3
Troubleshooting method for disconnecting wiring harness of pressure sensor system .......... 3
E-1 Code [111/CA111] Engine Controller Internal Failure........................................................ 6
E-2 Code [115/CA115] Eng. Ne and Bkup Speed Sensor Error .............................................. 7
E-3 Code [122/CA122] Charge (boost) Air Press Sensor High Error ...................................... 8
E-4 Code [123/CA123] Charge (boost) Air Press Sensor Low Error....................................... 12
E-5 Code [131/CA131] Throttle Sensor High Error ................................................................. 16
E-6 Code [132/CA132] Throttle Sensor Low Error .................................................................. 20
E-7 Code [135/CA135] Oil Press. Sensor High Error .............................................................. 22
E-8 Code [141/CA141] Oil Press. Sensor Low Error............................................................... 24
E-9 Code [144/CA144] Coolant Temp. Sensor High Error ...................................................... 26
E-10 Code [145/CA145] Coolant Temp. Sensor Low Error ..................................................... 28
E-11 Code [153/CA153] Charge (boost) Air Temp. Sensor High Error.................................... 30
E-12 Code [154/CA154] Charge (boost) Air Temp. Sensor Low Error .................................... 32
140E-5 Series 5
SEN00076-16 00 Index and foreword
6 140E-5 Series
00 Index and foreword SEN00076-16
140E-5 Series 7
SEN00076-16 00 Index and foreword
8 140E-5 Series
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140E-5 Series 9
SEN00076-16
© 2012 KOMATSU
All Rights Reserved
Printed in Japan 12-12 (01)
10
SEN00077-07
140E-5 Series
140E-5 Series 1
SEN00077-07 00 Index and foreword
Safety notice 1
(Rev. 2008/08)
Important safety notice
Proper service and repair are extremely important for safe machine operation. The service and repair
techniques recommended by Komatsu and described in this manual are both effective and safe.
Some of these techniques require the use of tools specially designed by Komatsu for the specific
purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The
cautions accompanying these symbols should always be followed carefully. If any dangerous situa-
tion arises or may possibly arise, first consider safety, and take the necessary actions to deal with
the situation.
2 140E-5 Series
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140E-5 Series 3
SEN00077-07 00 Index and foreword
4 140E-5 Series
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q If the load is unstable or the wire rope 13) If the hoist stops because of a power fail-
or chains are twisted, lower the load ure, turn the power switch OFF. When
and lift it up again. turning on a switch which was turned OFF
q Do not lift up the load slantingly. by the electric shock prevention earth
13) When lifting down a load, observe the fol- leakage breaker, check that the devices
lowing. related to that switch are not in operation
q When lifting down a load, stop it tem- state.
porarily at 30 cm above the floor, and 14) If you find an obstacle around the hoist,
then lower it slowly. stop the operation.
q Check that the load is stable, and 15) After finishing the work, stop the hoist at
then remove the sling. the specified position and raise the hook
q Remove kinks and dirt from the wire to at least 2 m above the floor. Do not
ropes and chains used for the sling leave the sling installed to the hook.
work, and put them in the specified
place. 7. Selecting wire ropes
1) Select adequate ropes depending on the
5. Precautions for using mobile crane weight of parts to be hoisted, referring to
a Read the Operation and Maintenance the table below.
Manual of the crane carefully in advance
and operate the crane safely. Wire ropes
(Standard “Z” twist ropes without galvanizing)
6. Precautions for using overhead hoist crane (JIS G3525, No. 6, Type 6X37-A)
k When raising a heavy part (heavier Nominal
Allowable load
than 25 kg), use a hoist, etc. In Disas- diameter of rope
sembly and assembly, the weight of a mm kN ton
part heavier than 25 kg is indicated 10 8.8 0.9
after the mark of 4. 12 12.7 1.3
1) Before starting work, inspect the wire 14 17.3 1.7
ropes, brake, clutch, controller, rails, over 16 22.6 2.3
wind stop device, electric shock preven- 18 28.6 2.9
tion earth leakage breaker, crane collision 20 35.3 3.6
prevention device, and power application
25 55.3 5.6
warning lamp, and check safety.
30 79.6 8.1
2) Observe the signs for sling work.
40 141.6 14.4
3) Operate the hoist at a safe place.
4) Check the direction indicator plates (east, 50 221.6 22.6
west, south, and north) and the directions 60 318.3 32.4
of the control buttons without fail.
5) Do not sling a load slantingly. Do not move a The allowable load is one-sixth of the
the crane while the slung load is swinging. breaking strength of the rope used
6) Do not raise or lower a load while the (Safety coefficient: 6).
crane is moving longitudinally or laterally.
7) Do not drag a sling.
8) When lifting up a load, stop it just after it
leaves the ground and check safety, and
then lift it up.
9) Consider the travel route in advance and
lift up a load to a safe height.
10) Place the control switch on a position
where it will not be an obstacle to work
and passage.
11) After operating the hoist, do not swing the
control switch.
12) Remember the position of the main switch
so that you can turn off the power immedi-
ately in an emergency.
140E-5 Series 5
SEN00077-07 00 Index and foreword
8. Precautions for disconnecting and con- a Example of O-ring (Fitted to every joint of
necting hoses and tubes in air conditioner hoses and tubes)
circuit
1) Disconnection
k For the environment, the air condi-
tioner of this machine uses the
refrigerant (air conditioner gas:
R134a) which has fewer factors of
the depletion of the ozone layer.
However, it does not mean that you
may discharge the refrigerant into
the atmosphere as it is. Be sure to
recover the refrigerant when dis-
connecting the refrigerant gas cir-
cuit and then reuse it.
a Ask professional traders for collecting a For tightening torque, see the precautions for
and filling operation of refrigerant installation in each section of "Disassembly
(R134a). and assembly".
a Never release the refrigerant (R134a)
to the atmosphere.
k If the refrigerant gas gets in your
eyes or contacts your skin, you
may lose your sight and your skin
may be frozen. Accordingly, put
on safety glasses, safety gloves
and safety clothes when recover-
ing or adding the refrigerant.
Refrigerant gas must be recovered
and added by a qualified person.
2) Connection
1] When installing the air conditioner cir-
cuit hoses and tubes, take care that
dirt, dust, water, etc. will not enter
them.
2] When connecting the air conditioner
hoses and tubes, check that O-rings
(1) are fitted to their joints.
3] Check that each O-ring is not dam-
aged or deteriorated.
4] When connecting the refrigerant pip-
ing, apply compressor oil for refriger-
ant (R134a) (DENSO: ND-OIL8,
VA L E O T H E R M A L S Y S T E M S :
ZXL100PG (equivalent to PAG46))
to its O-rings.
6 140E-5 Series
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q Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one
of them is required, consult KOMATSU distributors.
q Materials and specifications are subject to change without notice.
q Shop manuals are divided into the “Chassis volume” and “Engine volume”. For the engine unit, see the
engine volume of the engine model mounted on the machine.
01. Specification
This section explains the specifications of the machine.
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.
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.
140E-5 Series 7
SEN00077-07 00 Index and foreword
3. Filing method
File by the brochures in the correct order of the form number printed in the shop manual composition
table.
q Revisions
Revised brochures are shown in the shop manual composition table.
4. Symbols
Important safety and quality portions are marked with the following symbols so that the shop manual will
be used practically.
4
Weight of parts of component or parts. Caution necessary when
Weight
selecting hoisting wire, or when working posture is important, etc.
3
Tightening Places that require special attention for tightening torque during
torque assembly.
5
Oil, coolant Places where oil, etc. must be added, and capacity.
6
Drain Places where oil, etc. must be drained, and quantity to be drained.
5. Units
In this shop manual, the units are indicated with International System of units (SI). For reference, con-
ventionally used Gravitational System of units is indicated in parentheses { }.
8 140E-5 Series
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Example:
Standard size Tolerance
–0.022
120
–0.126
Example:
Tolerance
Standard size
Shaft Hole
–0.030 +0.046
60
–0.076 +0
140E-5 Series 9
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10 140E-5 Series
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140E-5 Series 11
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3) Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with
a crane with the wiring still connected, or a
heavy object hits the wiring, the crimping
of the connector may separate, or the sol-
dering may be damaged, or the wiring
may be broken.
12 140E-5 Series
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140E-5 Series 13
SEN00077-07 00 Index and foreword
2) Connecting connectors
1] Check the connector visually.
Check that there is no oil, dirt, or
water stuck to the connector pins
(mating portion).
Check that there is no deformation,
defective contact, corrosion, or dam-
age to the connector pins.
Check that there is no damage or
breakage to the outside of the con-
nector.
a If there is any oil, water, or dirt
stuck to the connector, wipe it off
with a dry cloth. If any water has
got inside the connector, warm
the inside of the wiring with a
dryer, but be careful not to make
it too hot as this will cause short
circuits.
a If there is any damage or break-
age, replace the connector.
2] Fix the connector securely.
Align the position of the connector
correctly, and then insert it securely.
For connectors with the lock stopper,
push in the connector until the stop-
per clicks into position.
3] Correct any protrusion of the boot and
any misalignment of the wiring har-
ness.
For connectors fitted with boots, cor-
rect any protrusion of the boot. In
addition, if the wiring harness is mis-
aligned, or the clamp is out of posi-
tion, adjust it to its correct position.
a If the connector cannot be cor-
rected easily, remove the clamp
and adjust the position.
q If the connector clamp has been
removed, be sure to return it to
its original position. Check also
that there are no loose clamps.
14 140E-5 Series
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3) Heavy duty wire connector (DT 8-pole, 12- q Disconnection q Connection (Example of
pole) incomplete setting of (a))
Disconnection (Left of figure)
While pressing both sides of locks (a)
and (b), pull out female connector (2).
Connection (Right of figure)
1] Push in female connector (2) horizon-
tally until the lock clicks.
Arrow: 1)
2] Since locks (a) and (b) may not be set
completely, push in female connector
(2) while moving it up and down until
the locks are set normally.
Arrow: 1), 2), 3)
a Right of figure: Lock (a) is pulled
down (not set completely) and
lock (b) is set completely.
(1): Male connector
(2): Female connector
(a), (b): Locks
140E-5 Series 15
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16 140E-5 Series
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4. Handling controller
1) The controller contains a microcomputer
and electronic control circuits. These con-
trol all of the electronic circuits on the
machine, so be extremely careful when
handling the controller.
2) Do not place objects on top of the control-
ler.
3) Cover the control connectors with tape or
a vinyl bag. Never touch the connector
contacts with your hand.
4) During rainy weather, do not leave the
controller in a place where it is exposed to
rain.
5) Do not place the controller on oil, water, or
soil, or in any hot place, even for a short
time. (Place it on a suitable dry stand).
6) Precautions when carrying out arc welding
When carrying out arc welding on the
body, disconnect all wiring harness con-
nectors connected to the controller. Fit an
arc welding ground close to the welding
point.
140E-5 Series 17
SEN00077-07 00 Index and foreword
3. Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from
entering. If the opening is left open or is
blocked with a rag, there is danger of dirt
entering or of the surrounding area being
made dirty by leaking oil so never do this. Do
not simply drain oil out onto the ground, but
collect it and ask the customer to dispose of it,
or take it back with you for disposal.
18 140E-5 Series
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6. Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit. Normally, flushing is
carried out twice: primary flushing is carried
out with flushing oil, and secondary flushing is
carried out with the specified hydraulic oil.
7. Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the
machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil cir-
cuit. The oil cleaning equipment is used to
remove the ultra fine (about 3 m) particles that
the filter built in the hydraulic equipment can-
not remove, so it is an extremely effective
device.
140E-5 Series 19
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20 140E-5 Series
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q 114 engine
q 107 engine
140E-5 Series 21
SEN00077-07 00 Index and foreword
q 95, 125 – 170, 12V140 engines 4. Turn-housing type (Round green connector)
4) While pressing lock (E) of the connector, q 140 engine
pull out connector (5) in the direction of Example)
the arrow. Intake air pressure sensor in intake mani-
fold (CANNON-04): PIM etc.
Example)
Fuel pressure sensor in common rail: 1) Disconnect connector (6) according to the
PFUEL etc. (AMP-3) following procedure.
1] Turn housing (H1) in the direction of
the arrow.
a When connector is unlocked,
housing (H1) becomes heavy to
turn.
2] Pull out housing (H1) in the direction
of the arrow.
a Housing (H1) is left on the wiring har-
ness side.
Example)
Injection pressure control valve of fuel
supply pump: PCV (SUMITOMO-2)
Example)
Speed sensor of fuel supply pump:
G (SUMITOMO-3)
a Pull the connector straight up.
22 140E-5 Series
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In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by sym-
bols. The electric wire code is helpful in understanding the electric circuit diagram.
Example: AEX 0.85 L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nomi-
nal No. of 0.85
Indicates color of wire by color code.
Color codes are shown in Table 3.
(Table 1)
Using
Sym-
Type Material temperature Example of use
bol
range (°C)
Low-voltage Conduc- Annealed copper for elec-
tor tric appliance General wiring
wire for AV
(Nominal No. 5 and above)
automobile Insulator Soft polyvinyl chloride
Thin-cover Conduc- Annealed copper for elec- –30 to +60
low-voltage tor tric appliance General wiring
AVS
wire for (Nominal No. 3 and below)
automobile Insulator Soft polyvinyl chloride
140E-5 Series 23
SEN00077-07 00 Index and foreword
2. Dimensions
(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5
Number of
strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32
eter of strand
Conductor
Sectional
0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
area (mm2)
d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0
AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 –
Cov-
AV Standard – – – – – – – 4.6
er D
AEX Standard 2.0 2.2 2.7 3.0 3.1 – 3.8 4.6
24 140E-5 Series
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(Table 3)
Color Code Color of wire Color Code Color of wire
B Black LgW Light green & White
Br Brown LgY Light green & Yellow
BrB Brown & Black LR Blue & Red
BrR Brown & Red LW Blue & White
BrW Brown & White LY Blue & Yellow
BrY Brown & Yellow O Orange
Ch Charcoal P Pink
Dg Dark green R Red
G Green RB Red & Black
GB Green & Black RG Red & Green
GL Green & Blue RL Red & Blue
Gr Gray RW Red & White
GR Green & Red RY Red & Yellow
GW Green & White Sb Sky Blue
GY Green & Yellow Y Yellow
L Blue YB Yellow & Black
LB Blue & Black YG Yellow &Green
Lg Light green YL Yellow & Blue
LgB Light green & Black YR Yellow & Red
LgR Light green & Red YW Yellow & White
Remarks: In a color code consisting of 2 colors, the first color is the color of the background and
the second color is the color of the marking.
Example: “GW” means that the background is Green and marking is White.
(Table 4)
Type of wire AVS or AV AEX
Charge R WG – – – – R –
Ground B – – – – – B –
Start R – – – – – R –
Light RW RB RY RG RL – D –
Instrument Y YR YB YG YL YW Y Gr
Signal G GW GR GY GB GL G Br
L LW LR LY LB – L –
Type of
Br BrW BrR BrY BrB – – –
circuit
Lg LgR LgY LgB LgW – – –
O – – – – – – –
Others Gr – – – – – – –
P – – – – – – –
Sb – – – – – – –
Dg – – – – – – –
Ch – – – – – – –
140E-5 Series 25
SEN00077-07 00 Index and foreword
3) If the part is not under hydraulic pressure, the following corks can be used.
Nominal Dimensions
Part Number
number D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34
26 140E-5 Series
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a When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other
hydraulic equipment removed for repair, always bleed the air as follows:
1) Start the engine and run at low idle.
2) Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times, stopping the
cylinder 100 mm from the end of its stroke.
3) Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke.
4) After doing this, run the engine at normal speed.
a When using the machine for the first time after repair or long storage, follow the same procedure.
140E-5 Series 27
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28 140E-5 Series
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Type 1
1. Disconnection
1) Hold adapter (1) and push hose joint (2)
into mating adapter (3). (Fig. 1)
a The adapter can be pushed in about
3.5 mm.
a Do not hold rubber cap portion (4).
2) After hose joint (2) is pushed into adapter
(3), press rubber cap portion (4) against
adapter (3) until it clicks. (Fig. 2)
3) Hold hose adapter (1) or hose (5) and pull
it out. (Fig. 3)
a Since some hydraulic oil flows out,
prepare an oil receiving container.
2. Connection
1) Hold hose adapter (1) or hose (5) and
insert it in mating adapter (3), aligning
them with each other. (Fig. 4)
a Do not hold rubber cap portion (4).
2) After inserting the hose in the mating
adapter perfectly, pull it back to check its
connecting condition. (Fig. 5)
a When the hose is pulled back, the
rubber cap portion moves toward the
hose about 3.5 mm. This does not
indicate abnormality, however.
140E-5 Series 29
SEN00077-07 00 Index and foreword
Type 2
1. Disconnection
1) Hold the tightening portion and push body
(7) straight until sliding prevention ring (6)
contacts contact surface (a) of the hexag-
onal portion at the male end. (Fig. 6)
2) While holding the condition of Step 1), turn
lever (8) to the right (clockwise). (Fig. 7)
3) While holding the condition of Steps 1)
and 2), pull out whole body (7) to discon-
nect it. (Fig. 8)
2. Connection
q Hold the tightening portion and push body
(7) straight until sliding prevention ring (6)
contacts contact surface (a) of the hexag-
onal portion at the male end. (Fig. 9)
30 140E-5 Series
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Type 3
1. Disconnection
1) Hold the tightening portion and push body
(9) straight until sliding prevention ring (8)
contacts contact surface (b) of the hexag-
onal portion at the male end. (Fig. 10)
2) While holding the condition of Step 1),
push cover (10) straight until it contacts
contact surface (b) of the hexagonal por-
tion at the male end. (Fig. 11)
3) While holding the condition of Steps 1)
and 2), pull out whole body (9) to discon-
nect it. (Fig. 12)
2. Connection
q Hold the tightening portion and push body
(9) straight until the sliding prevention ring
contacts contact surface (b) of the hexag-
onal portion at the male end. (Fig. 13)
140E-5 Series 31
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a Fig. A a Fig. B
Remarks: The widths across flats against the thread diameters of flanged bolts (marks with "*") in Fig. A are
the ones indicated in the table for bolts shown in Fig. B.
(Values of tightening torques shown in the table for Fig. A are applied.)
32 140E-5 Series
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140E-5 Series 33
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5. Table of tightening torques for hoses (taper seal type and face seal type)
a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the
torque below.
a Apply the following torque when the threads are coated (wet) with engine oil.
7. Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts)
a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114
engine series to the torque below.
Tightening torque
Thread size
Bolts and nuts
mm Nm kgm
6 10 ± 2 1.02 ± 0.20
8 24 ± 4 2.45 ± 0.41
10 43 ± 6 4.38 ± 0.61
12 77 ± 12 7.85 ± 1.22
14 — —
34 140E-5 Series
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8. Table of tightening torques for 102, 107 and 114 engine series (Eye joints)
a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine
series to the torque below.
9. Table of tightening torques for 102, 107 and 114 engine series (Taper screws)
a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114
engine series to the torque below.
Tightening torque
Material In cast iron or steel In aluminum
Thread size (inch) Nm kgm Nm kgm
1/16 15 ± 2 1.53 ± 0.20 5±1 0.51 ± 0.10
1/8 20 ± 2 2.04 ± 0.20 15 ± 2 1.53 ± 0.20
1/4 25 ± 3 2.55 ± 0.31 20 ± 2 2.04 ± 0.20
3/8 35 ± 4 3.57 ± 0.41 25 ± 3 2.55 ± 0.31
1/2 55 ± 6 5.61 ± 0.61 35 ± 4 3.57 ± 0.41
3/4 75 ± 8 7.65 ± 0.82 45 ± 5 4.59 ± 0.51
140E-5 Series 35
SEN00077-07 00 Index and foreword
Conversion table 1
Method of using the conversion table
The conversion table in this section is provided to enable simple conversion of figures. For details of the
method of using the conversion table, see the example given below.
Example: Method of using the conversion table to convert from millimeters to inches
36 140E-5 Series
00 Index and foreword SEN00077-07
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
140E-5 Series 37
SEN00077-07 00 Index and foreword
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
kgm to ft.lb
1 kgm = 7.233 ft.lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
38 140E-5 Series
00 Index and foreword SEN00077-07
kg/cm2 to lb/in2
1 kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1,010 1,024 1,038 1,053 1,067 1,081 1,095 1,109 1,124
80 1,138 1,152 1,166 1,181 1,195 1,209 1,223 1,237 1,252 1,266
90 1,280 1,294 1,309 1,323 1,337 1,351 1,365 1,380 1,394 1,408
100 1,422 1,437 1,451 1,465 1,479 1,493 1,508 1,522 1,536 1,550
110 1,565 1,579 1,593 1,607 1,621 1,636 1,650 1,664 1,678 1,693
120 1,707 1,721 1,735 1,749 1,764 1,778 1,792 1,806 1,821 1,835
130 1,849 1,863 1,877 1,892 1,906 1,920 1,934 1,949 1,963 1,977
140 1,991 2,005 2,020 2,034 2,048 2,062 2,077 2,091 2,105 2,119
150 2,134 2,148 2,162 2,176 2,190 2,205 2,219 2,233 2,247 2,262
160 2,276 2,290 2,304 2,318 2,333 2,347 2,361 2,375 2,389 2,404
170 2,418 2,432 2,446 2,460 2,475 2,489 2,503 2,518 2,532 2,546
180 2,560 2,574 2,589 2,603 2,617 2,631 2,646 2,660 2,674 2,688
190 2,702 2,717 2,731 2,745 2,759 2,773 2,788 2,802 2,816 2,830
200 2,845 2,859 2,873 2,887 2,901 2,916 2,930 2,944 2,958 2,973
210 2,987 3,001 3,015 3,030 3,044 3,058 3,072 3,086 3,101 3,115
220 3,129 3,143 3,158 3,172 3,186 3,200 3,214 3,229 3,243 3,257
230 3,271 3,286 3,300 3,314 3,328 3,343 3,357 3,371 3,385 3,399
240 3,414 3,428 3,442 3,456 3,470 3,485 3,499 3,513 3,527 3,542
140E-5 Series 39
SEN00077-07 00 Index and foreword
Temperature
Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centi-
grade temperature reading or vice versa is to enter the accompanying table in the center (boldface column)
of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahren-
heit temperatures and read the corresponding Centigrade temperature in the column at the left.
When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centi-
grade values, and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
–40.4 –40 –40.0 –11.7 11 51.8 7.8 46 114.8 27.2 81 177.8
–37.2 –35 –31.0 –11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
–34.4 –30 –22.0 –10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
–31.7 –25 –13.0 –10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
–28.9 –20 –4.0 –9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
40 140E-5 Series
00 Index and foreword SEN00077-07
140E-5 Series 41
SEN00077-07
© 2009 KOMATSU
All Rights Reserved
Printed in Japan 01-09 (01)
42
SEN00079-07
140E-5 Series
01 Specification 1
Specification and technical data
Outline............................................................................................................................................................. 2
Specifications .................................................................................................................................................. 6
General view ................................................................................................................................................. 24
Weight table .................................................................................................................................................. 61
Engine performance curves .......................................................................................................................... 65
140E-5 Series 1
SEN00079-07 01 Specification
Outline 1
1. Applicable machine
2 140E-5 Series
01 Specification SEN00079-07
2. Outline of engine
(With EGR)
q The 140E-5 engine is a high-performance and 4) To secure the high output of the engine, the
high-efficiency engine, which passed strict twin cooling nozzle to cool the piston employed
emission regulations (USA: EPA Regulations for 140E-3 and after models is improved to
for 2006, EU: Regulations for 2006, Japan: increase the durability of the piston and lower
Construction machinery regulations for 2006) the back side temperature of the piston. As a
and attained low fuel consumption, low noise, result, the lubricating oil on the piston is not
better exhaust gas color, and high acceleration exposed to high temperature, thus it is not
performance. Accordingly, this newly devel- deteriorated. Since the high-pressure fuel
oped engine is suitable as a power source of injection system controlled electronically is
construction machinery and industrial machin- employed, less soot is produced and the drain-
ery used for various purposes. ing interval of the oil is lengthened. (While the
capacity of the oil pan is not changed, the oil
q The 140E-5 engine is the successor to the replacement interval of 500 hours is secured.)
140E-3 engine. While it is an in-line 6-cylinder,
water-cooled, common rail direct injection, 4- 5) The common rail high-pressure fuel injection
stroke diesel engine similar to 140E-3, it is system controlled electronically is employed
equipped with the cooled EGR system which is for all of 140E-3 and after models. This system
a new technology. can inject the fuel at high pressure of 120 MPa
{1,200 kg/cm2} from the low-speed range to the
1) The main components of the cooled EGR sys- high-speed range. In addition, this system can
tem are the EGR cooler of corrugated tube control the form of injection most properly by
type made of newly developed special stain- electronic control according to the speed and
less steel and the EGR valve driven hydrauli- load. The injection system of 140E-5 is further
cally and controlled electronically which improved to employ multiple injections and
KOMATSU developed by itself. The cooled increase the injection pressure up to 160 MPa
EGR system secures the optimum EGR rate {1,600 kg/cm2}. As a result, exhaust gas of the
from the low-speed range to the high-speed cleanest level in the world, good exhaust gas
range to attain both clean exhaust gas and low color, low fuel consumption, and low noise are
fuel consumption with the bypass assist circuit realized simultaneously.
consisting of the venturi system and bypass
valve which has the same function and struc- 6) As the injection pressure of the common rail
ture as those of the EGR valve. injection system employed for the 140E-3
engine and after models is increased (from
2) The special EGR oil pump is employed to gen- 120 to 160 MPa {from 1,200 to 1,600 kg/cm2}),
erate high oil pressure (1.47 MPa {15 kg/cm2}) the pressure resistance of the common rail,
as the drive power source of the EGR valve injector, and supply pump is improved for
driven hydraulically and controlled electroni- higher reliability.
cally. The engine oil pump has sufficient deliv-
ery for the EGR valve and increased output of 7) The main fuel filter of high efficiency and the
the engine. As a result, the reliability and dura- pre-fuel filter are installed as standard so that
bility of the engine are improved. the low grade fuel in the market (equivalent to
Class NAS13) can be used. In addition, the
3) While the 140E-3 engine has only 1 combina- delivery of the priming pump used to replace
tion filter of high performance and high effi- the filters is increased for higher serviceability.
ciency, the 140E-5 engine has 2 of the same
filter to meet the requirements of the EGR sys- 8) The high-quality piston made of cast iron which
tem and high-dispersion oil and improve the has been employed for the 140E-2 engine and
ability to capture the soot in the oil. In addition, after models is employed. This piston has a
the recommended sub-materials for operation less coefficient of thermal expansion, a reen-
(oil and fuel) are changed to improve the reli- trant combustion chamber, and a shaker cool-
ability and durability of the engine. ing gallery. As a result, clean exhaust gas,
good exhaust gas color, and low fuel consump-
tion are attained simultaneously, and high
durability and reliability are also obtained.
140E-5 Series 3
SEN00079-07 01 Specification
4 140E-5 Series
01 Specification SEN00079-07
(EGR-less)
q The 140E-5 engine is a high-performance and 4) As the injection pressure of the common rail
high-efficiency engine, which attained low fuel injection system employed for the 140E-3
consumption and low noise. Accordingly, this engine and after models is increased, the pres-
newly developed engine is suitable as a power sure resistance of the common rail, injector,
source of construction machinery and indus- and supply pump is improved for higher reli-
trial machinery used for various purposes. ability.
q The 140E-5 engine is the successor to the 5) The main fuel filter of high efficiency and the
140E-3 engine. While it is an in-line 6-cylinder, pre-fuel filter are installed as standard so that
water-cooled, 4-stroke diesel engine, it is the low grade fuel in the market can be used.
equipped with the common rail direct injection In addition, the delivery of the priming pump
system. used to replace the filters is increased for
higher serviceability.
1) While the 140E-3 engine has only 1 combina-
tion filter of high performance and high effi- 6) The high-quality piston made of cast iron which
ciency, the 140E-5 engine has 2 of the same has been employed for the 140E-2 engine and
filter to meet the requirements of the high-dis- after models is employed. This piston has a
persion oil and improve the ability to capture less coefficient of thermal expansion, a reen-
the soot in the oil. In addition, the recom- trant combustion chamber, and a shaker cool-
mended sub-materials for operation (oil and ing gallery. As a result, clean exhaust gas,
fuel) are changed to improve the reliability and good exhaust gas color, and low fuel consump-
durability of the engine. tion are attained simultaneously, and high
durability and reliability are also obtained.
2) To secure the high output of the engine, the
twin cooling nozzle to cool the piston employed 7) By using the above-mentioned high-pressure
for 140E-3 and after models is improved to fuel injection system controlled electronically,
increase the durability of the piston and lower the multiple injection and injection characteris-
the back side temperature of the piston. As a tics are set most properly to improve the start-
result, the lubricating oil on the piston is not ability and reduce the white exhaust smoke
exposed to high temperature, thus it is not when the temperature is low.
deteriorated. Since the high-pressure fuel
injection system controlled electronically is 8) Since the controller is mounted on the engine
employed, less soot is produced and the drain- and equipped with the automatic high-altitude
ing interval of the oil is lengthened. (While the compensation function, the engine can be
capacity of the oil pan is not changed, the oil operated at high altitude without replacing the
replacement interval of 500 hours is secured.) controller. As a result, the serviceability is
improved.
3) The common rail high-pressure fuel injection
system controlled electronically is employed 9) The improved type of the KTR110 turbo-
for all of 140E-3 and after models. This system charger manufactured by KOMATSU which
can inject the fuel at high pressure of 120 MPa has been employed for the 140E-2 engine and
{1,200 kg/cm2} from the low-speed range to the after models and which has high reliability and
high-speed range. In addition, this system can high performance is mounted. Besides; the
control the form of injection most properly by efficiency of the blower impeller is heightened
electronic control according to the speed and and the strength of its material is improved to
load. The injection system of 140E-5 is further obtain higher efficiency and pressure ratio.
improved to employ multiple injections and Since the design of the shaft is improved to
increase the injection pressure. As a result, increase the reliability, high performance is
exhaust gas of the cleanest level in the world, obtained from the low-speed range to the high-
good exhaust gas color, low fuel consumption, speed range. As a result, the engine has high
and low noise are realized simultaneously. performance and consumes less fuel and
attains high reliability.
140E-5 Series 5
SEN00079-07 01 Specification
Specifications 1
min-1{rpm} (Gross)
Max. speed with no load
min-1{rpm} 1,950 ± 50 {1,950 ± 50}
(High idle speed)
Min. speed with no load
min-1{rpm} 800 ± 25 {800 ± 25}
(Low idle speed)
g/kW·h
Fuel consumption ratio at rated point 209 {156}
{g/HP·h}
Dry weight kg 1,845
Fuel supply pump — DENSO ECD-U2
Governor — Electronic control type
Quantity of lubricating oil (refill capacity) l 48 (40)
Quantity of coolant l 24
Alternator — 24V, 60A, 90A
Starting motor — 24V, 11kW
Battery — 12V, 170Ah × 2
Turbocharger — KOMATSU KTR110L
Air compressor — —
Others — With air-cooled aftercooler
With cooled EGR
6 140E-5 Series
01 Specification SEN00079-07
min-1{rpm} (Gross)
Max. speed with no load
min-1{rpm} 1,950 ± 50 {1,950 ± 50}
(High idle speed)
Min. speed with no load
min-1{rpm} 800 ± 25 {800 ± 25}
(Low idle speed)
g/kW·h
Fuel consumption ratio at rated point 205 {153}
{g/HP·h}
Dry weight kg 1,770
Fuel supply pump — DENSO ECD-U2
Governor — Electronic control type
Quantity of lubricating oil (refill capacity) l 48 (40)
Quantity of coolant l 24
Alternator — 24V, 60A, 90A
Starting motor — 24V, 11kW
Battery — 12V, 170Ah × 2
Turbocharger — KOMATSU KTR110L
Air compressor — —
Others — With air-cooled aftercooler
140E-5 Series 7
SEN00079-07 01 Specification
min-1{rpm} (Gross)
Max. speed with no load
min-1{rpm} 1,980 ± 50 {1,980 ± 50}
(High idle speed)
Min. speed with no load
min-1{rpm} 825 ± 25 {825 ± 25}
(Low idle speed)
g/kW·h
Fuel consumption ratio at rated point 204 {152}
{g/HP·h}
Dry weight kg 1,920
Fuel supply pump — DENSO ECD-U2
Governor — Electronic control type
Quantity of lubricating oil (refill capacity) l 58 (53)
Quantity of coolant l 25 (In only engine)
Alternator — 24V, 60A, 90A
Starting motor — 24V, 11kW
Battery — 12V, 170Ah × 2
Turbocharger — KOMATSU KTR110L
Air compressor — —
Others — With air-cooled aftercooler
With cooled EGR
8 140E-5 Series
01 Specification SEN00079-07
min-1{rpm} (Gross)
Max. speed with no load
min-1{rpm} 1,980 ± 50 {1,980 ± 50}
(High idle speed)
Min. speed with no load
min-1{rpm} 825 ± 25 {825 ± 25}
(Low idle speed)
g/kW·h
Fuel consumption ratio at rated point 204 {152}
{g/HP·h}
Dry weight kg 1,850
Fuel supply pump — DENSO ECD-U2
Governor — Electronic control type
Quantity of lubricating oil (refill capacity) l 58 (53)
Quantity of coolant l 25 (In only engine)
Alternator — 24V, 60A, 90A
Starting motor — 24V, 11kW
Battery — 12V, 170Ah × 2
Turbocharger — KOMATSU KTR110L
Air compressor — —
Others — With air-cooled aftercooler
140E-5 Series 9
SEN00079-07 01 Specification
min-1{rpm} (Gross)
Max. speed with no load
min-1{rpm} 2,100 (0/–50) {2,100 (0/–50)}
(High idle speed)
Min. speed with no load
min-1{rpm} 740 (+40/0) {740 (+40/0)}
(Low idle speed)
g/kW·h
Fuel consumption ratio at rated point 215 {160}
{g/HP·h}
Dry weight kg 1,800
Fuel supply pump — DENSO ECD-U2
Governor — Electronic control type
Quantity of lubricating oil (refill capacity) l 45 (37)
Quantity of coolant l 25 (In only engine)
Alternator — 24V, 60A, 75A, 90A
Starting motor — 24V, 11kW
Battery — 12V, 170Ah × 2
Turbocharger — KOMATSU KTR110L
Air compressor — —
Others — With air-cooled aftercooler
With cooled EGR
10 140E-5 Series
01 Specification SEN00079-07
min-1{rpm} (Gross)
Max. speed with no load
min-1{rpm} 2,100 (0/–50) {2,100 (0/–50)}
(High idle speed)
Min. speed with no load
min-1{rpm} 740 (+40/0) {740 (+40/0)}
(Low idle speed)
g/kW·h
Fuel consumption ratio at rated point 215 {160}
{g/HP·h}
Dry weight kg 1,725
Fuel supply pump — DENSO ECD-U2
Governor — Electronic control type
Quantity of lubricating oil (refill capacity) l 45 (37)
Quantity of coolant l 25 (In only engine)
Alternator — 24V, 60A, 75A, 90A
Starting motor — 24V, 11kW
Battery — 12V, 170Ah × 2
Turbocharger — KOMATSU KTR110L
Air compressor — —
Others — With air-cooled aftercooler
140E-5 Series 11
SEN00079-07 01 Specification
min-1{rpm} (Gross)
Max. speed with no load
min-1{rpm} 2,200 ± 50 {2,200 ± 50}
(High idle speed)
Min. speed with no load
min-1{rpm} 700 ± 50 {700 ± 50}
(Low idle speed)
g/kW·h
Fuel consumption ratio at rated point 218 {162.3}
{g/HP·h}
Dry weight kg 1,869
Fuel supply pump — DENSO ECD-U2
Governor — Electronic control type
Quantity of lubricating oil (refill capacity) l 58 (50)
Quantity of coolant l 25 (In only engine)
Alternator — 24V, 75A, 90A
Starting motor — 24V, 11kW
Battery — 12V, 170Ah × 2
Turbocharger — KOMATSU KTR110L
Air compressor — —
Others — With air-cooled aftercooler
With cooled EGR
12 140E-5 Series
01 Specification SEN00079-07
min-1{rpm} (Gross)
Max. speed with no load
min-1{rpm} 2,200 ± 50 {2,200 ± 50}
(High idle speed)
Min. speed with no load
min-1{rpm} 700 ± 50 {700 ± 50}
(Low idle speed)
g/kW·h
Fuel consumption ratio at rated point 215 {160}
{g/HP·h}
Dry weight kg 1,800
Fuel supply pump — DENSO ECD-U2
Governor — Electronic control type
Quantity of lubricating oil (refill capacity) l 58 (50)
Quantity of coolant l 25 (In only engine)
Alternator — 24V, 75A, 90A
Starting motor — 24V, 11kW
Battery — 12V, 170Ah × 2
Turbocharger — KOMATSU KTR110L
Air compressor — —
Others — With air-cooled aftercooler
140E-5 Series 13
SEN00079-07 01 Specification
min-1{rpm} (Gross)
Max. speed with no load
min-1{rpm} 2,150 ± 50 {2,150 ± 50}
(High idle speed)
Min. speed with no load
min-1{rpm} 700 ± 25 {700 ± 25}
(Low idle speed)
g/kW·h
Fuel consumption ratio at rated point 216.2 {161.3}
{g/HP·h}
Dry weight kg 1,750
Fuel supply pump — DENSO ECD-U2
Governor — Electronic control type
Quantity of lubricating oil (refill capacity) l 45 (37)
Quantity of coolant l 25
Alternator — 24V, 75A, 90A
Starting motor — 24V, 11kW
Battery — 12V, 170Ah × 2
Turbocharger — KOMATSU KTR110L
Air compressor — —
Others — With air-cooled aftercooler
With cooled EGR
14 140E-5 Series
01 Specification SEN00079-07
min-1{rpm} (Gross)
Max. speed with no load
min-1{rpm} 2,150 ± 50 {2,150 ± 50}
(High idle speed)
Min. speed with no load
min-1{rpm} 700 ± 25 {700 ± 25}
(Low idle speed)
g/kW·h
Fuel consumption ratio at rated point 211.4 {157.7}
{g/HP·h}
Dry weight kg 1,680
Fuel supply pump — DENSO ECD-U2
Governor — Electronic control type
Quantity of lubricating oil (refill capacity) l 45 (37)
Quantity of coolant l 25
Alternator — 24V, 75A, 90A
Starting motor — 24V, 11kW
Battery — 12V, 170Ah × 2
Turbocharger — KOMATSU KTR110L
Air compressor — —
Others — With air-cooled aftercooler
140E-5 Series 15
SEN00079-07 01 Specification
min-1{rpm} (Gross)
Max. speed with no load
min-1{rpm} 2,300 ± 25 {2,300 ± 25}
(High idle speed)
Min. speed with no load
min-1{rpm} 725 ± 25 {725 ± 25}
(Low idle speed)
g/kW·h
Fuel consumption ratio at rated point 212 {158}
{g/HP·h}
Dry weight kg 1,810
Fuel supply pump — DENSO ECD-U2
Governor — Electronic control type
Quantity of lubricating oil (refill capacity) l 58 (50)
Quantity of coolant l 25 (In only engine)
Alternator — 24V, 60A, 75A
Starting motor — 24V, 11kW
Battery — 12V, 170Ah × 2
Turbocharger — KOMATSU KTR110L
Air compressor — —
Others — With air-cooled aftercooler
With cooled EGR
16 140E-5 Series
01 Specification SEN00079-07
min-1{rpm} (Gross)
Max. speed with no load
min-1{rpm} 2,300 ± 25 {2,300 ± 25}
(High idle speed)
Min. speed with no load
min-1{rpm} 725 ± 25 {725 ± 25}
(Low idle speed)
g/kW·h
Fuel consumption ratio at rated point 207 {154}
{g/HP·h}
Dry weight kg 1,740
Fuel supply pump — DENSO ECD-U2
Governor — Electronic control type
Quantity of lubricating oil (refill capacity) l 58 (50)
Quantity of coolant l 25 (In only engine)
Alternator — 24V, 60A, 75A
Starting motor — 24V, 11kW
Battery — 12V, 170Ah × 2
Turbocharger — KOMATSU KTR110L
Air compressor — —
Others — With air-cooled aftercooler
140E-5 Series 17
SEN00079-07 01 Specification
min-1{rpm} (Gross)
Max. speed with no load
min-1{rpm} 2,200 (+50/0) {2,200 (+50/0)}
(High idle speed)
Min. speed with no load
min-1{rpm} 725 ± 25 {725 ± 25}
(Low idle speed)
g/kW·h
Fuel consumption ratio at rated point 223 {166}
{g/HP·h}
Dry weight kg 1,820
Fuel supply pump — DENSO ECD-U2
Governor — Electronic control type
Quantity of lubricating oil (refill capacity) l 58 (50)
Quantity of coolant l 25 (In only engine)
Alternator — 24V, 60A, 75A
Starting motor — 24V, 11kW
Battery — 12V 170Ah × 2
Turbocharger — KOMATSU KTR110L
Air compressor — —
Others — With air-cooled aftercooler
With cooled EGR
18 140E-5 Series
01 Specification SEN00079-07
min-1{rpm} (Gross)
Max. speed with no load
min-1{rpm} 2,200 (+50/0) {2,200 (+50/0)}
(High idle speed)
Min. speed with no load
min-1{rpm} 725 ± 25 {725 ± 25}
(Low idle speed)
g/kW·h
Fuel consumption ratio at rated point 222 {165}
{g/HP·h}
Dry weight kg 1,750
Fuel supply pump — DENSO ECD-U2
Governor — Electronic control type
Quantity of lubricating oil (refill capacity) l 58 (50)
Quantity of coolant l 25 (In only engine)
Alternator — 24V, 60A, 75A
Starting motor — 24V, 11kW
Battery — 12V 170Ah × 2
Turbocharger — KOMATSU KTR110L
Air compressor — —
Others — With air-cooled aftercooler
140E-5 Series 19
SEN00079-07 01 Specification
min-1{rpm} (Gross)
Max. speed with no load
min-1{rpm} 2,200 (+50/0) {2,200 (+50/0)}
(High idle speed)
Min. speed with no load
min-1{rpm} 725 ± 25 {725 ± 25}
(Low idle speed)
g/kW·h
Fuel consumption ratio at rated point 213 {159}
{g/HP·h}
Dry weight kg 1,820
Fuel supply pump — DENSO ECD-U2
Governor — Electronic control type
Quantity of lubricating oil (refill capacity) l 58 (50)
Quantity of coolant l 25 (In only engine)
Alternator — 24V, 60A, 75A
Starting motor — 24V, 11kW
Battery — 12V, 170Ah × 2
Turbocharger — KOMATSU KTR110L
Air compressor — —
Others — With air-cooled aftercooler
With cooled EGR
20 140E-5 Series
01 Specification SEN00079-07
min-1{rpm} (Gross)
Max. speed with no load
min-1{rpm} 2,200 (+50/0) {2,200 (+50/0)}
(High idle speed)
Min. speed with no load
min-1{rpm} 725 ± 25 {725 ± 25}
(Low idle speed)
g/kW·h
Fuel consumption ratio at rated point 218 {162}
{g/HP·h}
Dry weight kg 1,750
Fuel supply pump — DENSO ECD-U2
Governor — Electronic control type
Quantity of lubricating oil (refill capacity) l 58 (50)
Quantity of coolant l 25 (In only engine)
Alternator — 24V, 60A, 75A
Starting motor — 24V, 11kW
Battery — 12V, 170Ah × 2
Turbocharger — KOMATSU KTR110L
Air compressor — —
Others — With air-cooled aftercooler
140E-5 Series 21
SEN00079-07 01 Specification
min-1{rpm} —
Max. speed with no load
min-1{rpm} —
(High idle speed)
Min. speed with no load
min-1{rpm} —
(Low idle speed)
g/kW·h
Fuel consumption ratio at rated point 222 {163}
{g/HP·h}
Dry weight kg 1,950
Fuel supply pump — DENSO ECD-U2
Governor — Electronic control type
Quantity of lubricating oil (refill capacity) l 82 (73)
Quantity of coolant (with radiator) l 53
Alternator — 24V, 35A
Starting motor — 24V, 7.5kW
Battery — —
Turbocharger — KOMATSU KTR110L
Air compressor — —
Others — With air-cooled aftercooler
With cooled EGR
22 140E-5 Series
01 Specification SEN00079-07
140E-5 Series 23
SEN00079-07 01 Specification
General view 1
SAA6D140E-5 (Left side view of engine)
Machine model: PC600-8, PC600LC-8
1. Center of crankshaft
2. Rear face of flywheel housing
24 140E-5 Series
01 Specification SEN00079-07
1. Center of crankshaft
2. Center of cylinder liner
140E-5 Series 25
SEN00079-07 01 Specification
1. Center of crankshaft
2. Rear face of flywheel housing
26 140E-5 Series
01 Specification SEN00079-07
1. Center of crankshaft
2. Center of cylinder liner
140E-5 Series 27
SEN00079-07 01 Specification
1. Center of crankshaft
2. Rear face of flywheel housing
28 140E-5 Series
01 Specification SEN00079-07
1. Center of crankshaft
2. Center of cylinder liner
140E-5 Series 29
SEN00079-07 01 Specification
1. Center of crankshaft
2. Rear face of flywheel housing
30 140E-5 Series
01 Specification SEN00079-07
1. Center of crankshaft
2. Center of cylinder liner
140E-5 Series 31
SEN00079-07 01 Specification
1. Center of crankshaft
2. Rear face of flywheel housing
32 140E-5 Series
01 Specification SEN00079-07
1. Center of crankshaft
2. Center of cylinder liner
140E-5 Series 33
SEN00079-07 01 Specification
1. Center of crankshaft
2. Rear face of flywheel housing
34 140E-5 Series
01 Specification SEN00079-07
1. Center of crankshaft
2. Center of cylinder liner
140E-5 Series 35
SEN00079-07 01 Specification
1. Center of crankshaft
2. Rear face of flywheel housing
36 140E-5 Series
01 Specification SEN00079-07
1. Center of crankshaft
2. Center of cylinder liner
140E-5 Series 37
SEN00079-07 01 Specification
1. Center of crankshaft
2. Rear face of flywheel housing
38 140E-5 Series
01 Specification SEN00079-07
1. Center of crankshaft
2. Center of cylinder liner
140E-5 Series 39
SEN00079-07 01 Specification
1. Center of crankshaft
2. Rear face of flywheel housing
40 140E-5 Series
01 Specification SEN00079-07
1. Center of crankshaft
2. Center of cylinder liner
140E-5 Series 41
SEN00079-07 01 Specification
1. Center of crankshaft
2. Rear face of flywheel housing
42 140E-5 Series
01 Specification SEN00079-07
1. Center of crankshaft
2. Center of cylinder liner
140E-5 Series 43
SEN00079-07 01 Specification
1. Center of crankshaft
2. Rear face of flywheel housing
44 140E-5 Series
01 Specification SEN00079-07
1. Center of crankshaft
2. Center of cylinder liner
140E-5 Series 45
SEN00079-07 01 Specification
1. Center of crankshaft
2. Rear face of flywheel housing
46 140E-5 Series
01 Specification SEN00079-07
1. Center of crankshaft
2. Center of cylinder liner
140E-5 Series 47
SEN00079-07 01 Specification
1. Center of crankshaft
2. Rear face of flywheel housing
48 140E-5 Series
01 Specification SEN00079-07
1. Center of crankshaft
2. Center of cylinder liner
140E-5 Series 49
SEN00079-07 01 Specification
1. Center of crankshaft
2. Rear face of flywheel housing
50 140E-5 Series
01 Specification SEN00079-07
1. Center of crankshaft
2. Center of cylinder liner
140E-5 Series 51
SEN00079-07 01 Specification
1. Center of crankshaft
2. Rear face of flywheel housing
52 140E-5 Series
01 Specification SEN00079-07
1. Center of crankshaft
2. Center of cylinder liner
140E-5 Series 53
SEN00079-07 01 Specification
1. Center of crankshaft
2. Rear face of flywheel housing
54 140E-5 Series
01 Specification SEN00079-07
1. Center of crankshaft
2. Center of cylinder liner
140E-5 Series 55
SEN00079-07 01 Specification
1. Center of crankshaft
2. Rear face of flywheel housing
56 140E-5 Series
01 Specification SEN00079-07
1. Center of crankshaft
2. Center of cylinder liner
140E-5 Series 57
SEN00079-07 01 Specification
1. Center of crankshaft
2. Rear face of flywheel housing
58 140E-5 Series
01 Specification SEN00079-07
1. Center of crankshaft
2. Center of cylinder liner
140E-5 Series 59
SEN00079-07 01 Specification
Dimensions table 1
Unit: mm
Dimension of each part
Engine Machine model
A B C D E F G H
PC600-8, PC600LC-8 1,494 1,863 441 227 143 920 1,155 1,151
PC600-8E0, PC600LC-8E0
1,412 1,867 444 227 143 920 1,155 1,061
PC700-8E0, PC700LC-8E0
PC600-8R, PC600LC-8R
PC600-8R1, PC600LC-8R1,
1,482 1,863 411 227 143 920 1,155 1,151
PC700-8R, PC700LC-8R
PC700LC-8R1
PC800-8, PC800LC-8,
PC800SE-8,
PC850-8, PC850SE-8,
PC800-8E0,
PC800LC-8E0,
PC800SE-8E0,
PC850-8E0,
1,350 1,902 594 196 196 1,000 1,185 1,176
PC850SE-8E0,
PC800-8R, PC800LC-8R,
PC800SE-8R,
PC850-8R, PC850SE-8R
SAA6D140E-5 PC800-8R1, PC800LC-8R1,
PC800SE-8R1,
PC850-8R1, PC850SE-8R1
D155AX-6, D155A-6 1,477 1,950 419 14 14 918 1,090 1,109
D275AX-5E0 1,505 2,178 542 15 15 794 966 1,135
D275A-5R 1,461 2,178 542 15 15 794 966 1,180
WA500-6 1,477 1,727 419 150 150 815 945 1,094
WA500-6R 1,465 1,727 419 150 150 815 945 1,094
HD325-7, HD405-7,
1,775 1,604 542 80 80 875 1,005 1,025
HD325-7R, HD405-7R
HM350-2, HM350-2R,
1,724 1,496 542 147 147 815 945 1,250
HM400-2, HM400-2R
HM400-3M0 1,477 1,509 542 147 147 815 945 1,112
HM400-3R 1,451 1,509 542 147 147 815 945 1,112
SDG400S-6B1
(HOKUETSU INDUS- 1,785 1,523 403 213 213 877 956 1,242
TRIES GENERATOR)
a These dimensions are given for reference when the engine is set on a test bench.
60 140E-5 Series
01 Specification SEN00079-07
Weight table 1
(With EGR)
Unit: kg
No. Item Main parts SAA6D140E-5
24 (Air-cooled) /
1 Turbocharger KOMATSU KTR110L
28 (Water-cooled)
Cylinder head, valve,
2 Cylinder head assembly 23 × 6
valve spring
Cylinder block, bearing, cap,
3 Cylinder block assembly 480
cylinder liner
4 Front cover 60
PC800-8, PC800SE-8, PC800LC-8
PC850-8, PC850SE-8
PC800-8E0, PC800SE-8E0, 36
PC800LC-8E0
PC850-8E0, PC850SE-8E0
PC600-8, PC600LC-8
PC600-8E0, PC600LC-8E0
PC700-8E0, PC700LC-8E0 30
5 Oil pan D155AX-6
WA500-6
D275AX-5E0
HD325-7, HD405-7
28
HM350-2, HM400-2
HM400-3M0
SDG400S-6B1 (HOKUETSU
62
INDUSTRIES GENERATOR)
PC600-8, PC600LC-8
PC800-8, PC800SE-8, PC800LC-8
PC850-8, PC850SE-8
PC800-8E0, PC800SE-8E0,
PC800LC-8E0 60
PC850-8E0, PC850SE-8E0
D155AX-6
6 Flywheel assembly Flywheel ring gear D275AX-5E0
WA500-6
HD325-7, HD405-7
HM350-2, HM400-2 47
HM400-3M0
SDG400S-6B1 (HOKUETSU
123
INDUSTRIES GENERATOR)
65
7 Flywheel housing assembly SDG400S-6B1 (HOKUETSU
63
INDUSTRIES GENERATOR)
8 Crankshaft assembly Crankshaft, crank gear 136
Camshaft, cam gear, thrust
9 Camshaft assembly 20
plate
Piston and connecting rod Piston, piston ring, piston
10 11 × 6
assembly pin, connecting rod
11 Oil pump 7
12 Fuel supply pump 13
13 Water pump 18
140E-5 Series 61
SEN00079-07 01 Specification
Unit: kg
No. Item Main parts SAA6D140E-5
24V, 35A 8
24V, 50A 11
14 Alternator 24V, 60A 11
24V, 75A 12.5
24V, 90A 19
24V, 7.5kW 15.5
15 Starting motor
24V, 11kW 18
16 EGR oil pump 6
17 EGR valve 10
18 Bypass valve 10
19 EGR cooler 10
62 140E-5 Series
01 Specification SEN00079-07
(EGR-less)
Unit: kg
No. Item Main parts SAA6D140E-5
24 (Air-cooled) /
1 Turbocharger KOMATSU KTR110L
28 (Water-cooled)
Cylinder head, valve,
2 Cylinder head assembly 23 × 6
valve spring
Cylinder block, bearing, cap,
3 Cylinder block assembly 480
cylinder liner
4 Front cover 60
PC800-8R, PC800SE-8R,
PC800LC-8R
PC850-8R, PC850SE-8R
36
PC800-8R1, PC800SE-8R1
PC800LC-8R1
PC850-8R1, PC850SE-8R1
PC600-8R, PC600LC-8R
PC600-8R1, PC600LC-8R1
5 Oil pan
PC700-8R, PC700LC-8R
30
PC700LC-8R1
D155A-6
WA500-6R
D275A-5R
HD325-7R, HD405-7R
28
HM350-2R, HM400-2R
HM400-3R
PC600-8R, PC600LC-8R
PC600-8R1, PC600LC-8R1
PC700LC-8R1
PC800-8R, PC800SE-8R,
PC800LC-8R
PC850-8R, PC850SE-8R
60
PC800-8R1, PC800SE-8R1
6 Flywheel assembly Flywheel ring gear PC800LC-8R1
PC850-8R1, PC850SE-8R1
D155A-6
D275A-5R
WA500-6R
HD325-7R, HD405-7R
HM350-2R, HM400-2R 47
HM400-3R
7 Flywheel housing assembly 65
8 Crankshaft assembly Crankshaft, crank gear 136
Camshaft, cam gear,
9 Camshaft assembly 20
thrust plate
Piston and connecting rod Piston, piston ring, piston pin,
10 11 × 6
assembly connecting rod
11 Oil pump 7
12 Fuel supply pump 13
13 Water pump 18
140E-5 Series 63
SEN00079-07 01 Specification
Unit: kg
No. Item Main parts SAA6D140E-5
24V, 35A 8
24V, 50A 11
14 Alternator 24V, 60A 11
24V, 75A 12.5
24V, 90A 19
15 Starting motor 24V, 11kW 18
64 140E-5 Series
01 Specification SEN00079-07
140E-5 Series 65
SEN00079-07 01 Specification
SAA6D140E-5
(Machine model: PC600-8, PC600LC-8, PC600-8R, PC600LC-8R, PC600-
8E0, PC600LC-8E0, PC600-8R1, PC600LC-8R1, PC700-8E0, PC700LC-8E0,
PC700-8R, PC700LC-8R, PC700LC-8R1)
Rated horsepower: 323 kW {433.3 HP}/1,800 min-1 {1,800 rpm} (Gross)
Max. torque: 1,944 Nm {198.4 kgm}/1,400 min-1 {1,400 rpm} (Gross)
66 140E-5 Series
01 Specification SEN00079-07
SAA6D140E-5
(Machine model: PC800-8, PC800SE-8, PC850-8, PC850SE-8, PC800LC-8,
PC800-8E0, PC800SE-8E0, PC850-8E0, PC850SE-8E0, PC800LC-8E0,
PC800-8R, PC800SE-8R, PC800LC-8R, PC850-8R, PC850SE-8R, PC800-
8R1, PC800SE-8R1, PC800LC-8R1, PC850-8R1, PC850SE-8R1)
Rated horsepower: 370 kW {496.4 HP}/1,800 min-1 {1,800 rpm} (Gross)
Max. torque: 2,195 Nm {223.8 kgm}/1,350 min-1 {1,350 rpm} (Gross)
140E-5 Series 67
SEN00079-07 01 Specification
68 140E-5 Series
01 Specification SEN00079-07
140E-5 Series 69
SEN00079-07 01 Specification
70 140E-5 Series
01 Specification SEN00079-07
140E-5 Series 71
SEN00079-07 01 Specification
72 140E-5 Series
01 Specification SEN00079-07
SAA6D140E-5
(Machine model: HM400-2, HM400-2R, HM400-3M0, HM400-3R)
Rated horsepower: 338 kW {452.6 HP}/2,000 min-1 {2,000 rpm} (Gross)
Max. torque: 2,089 Nm {213 kgm}/1,400 min-1 {1,400 rpm} (Gross)
140E-5 Series 73
SEN00079-07
© 2012 KOMATSU
All Rights Reserved
Printed in Japan 12-12 (01)
74
SEN00081-08
140E-5 Series
140E-5 Series 1
SEN00081-08 10 Structure, function and maintenance standard
Camshaft....................................................................................................................................................... 43
Cam follower and push rod ........................................................................................................................... 44
Piston, piston ring and piston pin .................................................................................................................. 46
Connecting rod.............................................................................................................................................. 48
Flywheel and flywheel housing ..................................................................................................................... 49
Vibration damper ........................................................................................................................................... 52
Timing gear ................................................................................................................................................... 54
Valve system ................................................................................................................................................. 58
Valve and valve guide ................................................................................................................................... 60
Rocker arm and shaft.................................................................................................................................... 62
Crosshead and guide .................................................................................................................................... 63
2 140E-5 Series
10 Structure, function and maintenance standard SEN00081-08
A: Air intake unit (Between air-cooled aftercooler and air intake manifold)
140E-5 Series 3
SEN00081-08 10 Structure, function and maintenance standard
A: To EGR cooler
B: To turbocharger
C: From bypass valve
4 140E-5 Series
10 Structure, function and maintenance standard SEN00081-08
Air cleaner 1
ERB type
[Air cleaner of automatic exhaust gas discharge type (radial seal type)]
A: Air inlet
B: To turbocharger (intake air)
C: To muffler (dust)
1. Pre-cleaner
2. Air cleaner casing
3. Outer element
4. Inner element
140E-5 Series 5
SEN00081-08 10 Structure, function and maintenance standard
FRG type
[Air cleaner of cyclone pack type with evacuator valve (radial seal type)]
1. Inlet
2. Outlet
3. Guide vane
4. Primary element
5. Safety element
6. Evacuator valve
7. Dust pan
8. Guide plate (sleeve)
9. Body
10. Element
6 140E-5 Series
10 Structure, function and maintenance standard SEN00081-08
Number of
Engine Machine model Type Evacuator valve
elements
PC600-8, PC600-8R,
PC600LC-8, PC600LC-8R
PC600-8E0, PC600-8R1,
PC600LC-8E0, PC600LC-8R1,
PC700-8E0, PC700LC-8E0,
PC700-8R, PC700LC-8R,
PC700LC-8R1
PC800-8, PC800LC-8,
PC800-8R, PC800LC-8R
PC800SE-8, PC800SE-8R
PC850-8, PC850-8R
PC850SE-8, PC850SE-8R FRG Automatic Inner cylinder: 1,
SAA6D140E-5
PC800-8E0, PC800LC-8E0, (radial seal type) discharge Outer cylinder: 1
PC800SE-8E0, PC850-8E0,
PC850SE-8E0
PC800-8R1, PC800LC-8R1,
PC800SE-8R1, PC850-8R1,
PC850SE-8R1
WA500-6, WA500-6R
HD325-7, HD325-7R
HD405-7, HD405-7R
HM350-2, HM350-2R,
HM400-2, HM400-2R
HM400-3M0, HM400-3R
Structure Operation
q The size of the body is reduced from the con- q Air containing dust is sucked in vertically
ventional type without changing the diameter through inlet (1) and the dust is separated by
of the element. the centrifugal effect of guide vane (3).
q Since the inlet is set in the tangential direction, q More than 99.9% of the dust is removed by pri-
air is given sufficient centrifugal force by the mary element (4) and clean air is sucked in the
simple spiral guide vane, not by the guide engine through safety element (5) and outlet
plate. (2).
q The dust and water separated by guide vane
(3) swirl along the inside wall of body (9) and
enter evacuator valve (6) and then are dis-
charged out automatically.
140E-5 Series 7
SEN00081-08 10 Structure, function and maintenance standard
Turbocharger 1
(With EGR)
Air-cooled type
Model: KTR110L
PC600-8, PC600LC-8, PC600-8E0, PC600LC-8E0, PC700-8E0, PC700LC-8E0, HD325-7, HD405-7,
WA500-6, HM350-2, HM400-2, HM400-3M0,
SDG400S-6B1 (HOKUETSU INDUSTRIES GENERATOR)
8 140E-5 Series
10 Structure, function and maintenance standard SEN00081-08
1. Blower housing
2. V-band
3. Diffuser plate
4. Center housing
5. Shroud
6. Turbine housing
7. Blower impeller
8. Seal ring
9. Bearing metal
10. Journal bearing
11. Seal ring
12. Turbine impeller
Specifications
Model: KOMATSU KTR110L (air-cooled)
Overall length: 308 mm
Overall width: 305 mm
Overall height: 287 mm
Weight: 24 kg
140E-5 Series 9
SEN00081-08 10 Structure, function and maintenance standard
(EGR-less)
Air-cooled type
Model: KTR110L
PC600-8R, PC600-8R1, PC600LC-8R, PC600LC-8R1, PC700-8R, PC700LC-8R, PC700LC-8R1, HD325-
7R, HD405-7R, WA500-6R, HM350-2R, HM400-2R, HM400-3R
10 140E-5 Series
10 Structure, function and maintenance standard SEN00081-08
1. Blower housing
2. V-band
3. Diffuser plate
4. Center housing
5. Shroud
6. Turbine housing
7. Blower impeller
8. Seal ring
9. Bearing metal
10. Journal bearing
11. Seal ring
12. Turbine impeller
Specifications
Model: KOMATSU KTR110L (air-cooled)
Overall length: 308 mm
Overall width: 305 mm
Overall height: 287 mm
Weight: 24 kg
140E-5 Series 11
SEN00081-08 10 Structure, function and maintenance standard
(With EGR)
Water-cooled type
Model: KTR110L
PC800-8, PC800LC-8, PC800SE-8, PC850-8, PC850SE-8, PC800-8E0, PC800LC-8E0, PC800SE-8E0,
PC850-8E0, PC850SE-8E0, D155AX-6, D275AX-5E0
12 140E-5 Series
10 Structure, function and maintenance standard SEN00081-08
1. Blower housing
2. V-band
3. Diffuser plate
4. Center housing
(water-cooled center housing: standard for D275AX, D155AX and PC800, and
optional for other machine models)
5. Shroud
6. Turbine housing
7. Blower impeller
8. Seal ring
9. Bearing metal
10. Journal bearing
11. Seal ring
12. Turbine impeller
Specifications
Model: KOMATSU KTR110L (water-cooled)
Overall length: 308 mm
Overall width: 305 mm
Overall height: 287 mm
Weight: 28 kg
140E-5 Series 13
SEN00081-08 10 Structure, function and maintenance standard
(EGR-less)
Water-cooled type
Model: KTR110L
PC800-8R, PC800LC-8R, PC800SE-8R, PC850-8R, PC850SE-8R, PC800-8R1, PC800LC-8R1, PC800SE-
8R1, PC850-8R1, PC850SE-8R1, D155A-6, D275A-5R
14 140E-5 Series
10 Structure, function and maintenance standard SEN00081-08
1. Blower housing
2. V-band
3. Diffuser plate
4. Center housing
(water-cooled center housing: standard for D275A, D155A and PC800, and
optional for other machine models)
5. Shroud
6. Turbine housing
7. Blower impeller
8. Seal ring
9. Bearing metal
10. Journal bearing
11. Seal ring
12. Turbine impeller
Specifications
Model: KOMATSU KTR110L (water-cooled)
Overall length: 308 mm
Overall width: 305 mm
Overall height: 287 mm
Weight: 28 kg
140E-5 Series 15
SEN00081-08 10 Structure, function and maintenance standard
Model: KTR110L
16 140E-5 Series
10 Structure, function and maintenance standard SEN00081-08
Unit: mm
Replace bearing
2 Radial play (play in radial direction) 0.43 to 0.68 0.84
parts
Clearance between blower housing and Replace bearing
3 Clearance limit (min.): 0.14
impeller parts
140E-5 Series 17
SEN00081-08 10 Structure, function and maintenance standard
Turbocharger mounting
1. Muffler
2. Turbocharger
18 140E-5 Series
10 Structure, function and maintenance standard SEN00081-08
Aftercooler 1
Air-cooled type
SAA6D140E-5 (HD325-7, HD325-7R, HD405-7, HD405-7R)
1. Tank
2. Side support
3. Tube
4. Fin
140E-5 Series 19
SEN00081-08 10 Structure, function and maintenance standard
Muffler 1
For PC600-8, PC600-8R, PC600LC-8, PC600LC-8R, PC600-8E0, PC600-8R1, PC600LC-8E0, PC600LC-
8R1, PC700-8E0, PC700-8R,PC700LC-8E0, PC700LC-8R, PC700LC-8R1
20 140E-5 Series
10 Structure, function and maintenance standard SEN00081-08
140E-5 Series 21
SEN00081-08 10 Structure, function and maintenance standard
22 140E-5 Series
10 Structure, function and maintenance standard SEN00081-08
140E-5 Series 23
SEN00081-08 10 Structure, function and maintenance standard
24 140E-5 Series
10 Structure, function and maintenance standard SEN00081-08
EGR system 1
Features
q The exhaust gas is kept clean by sensing each
part of the EGR circuit and controlling the EGR
rate according to the operating condition.
q Since the EGR circuit is monitored and trouble-
shooted, a serious trouble is prevented.
140E-5 Series 25
SEN00081-08 10 Structure, function and maintenance standard
26 140E-5 Series
10 Structure, function and maintenance standard SEN00081-08
1. EGR valve
2. Bypass valve
3. EGR cooler
4. Venturi system
5. EGR valve position sensor
6. Bypass valve position sensor
7. Bypass piping
8. EGR piping
9. EGR oil pump
Operation
q The engine controller outputs signals for open-
ing EGR valve (1) most properly according to
the load on the engine to attain both clean
exhaust gas and low fuel consumption.
q If EGR valve (1) opens, a part of the exhaust
gas (EGR gas) flows from the exhaust mani-
fold through EGR piping (8) to EGR cooler (3).
q The exhaust gas cooled by EGR cooler (3)
flows through EGR valve (1) and mixes with
the intake air in venturi system (4), and then
flows in the air intake manifold.
q In the operating range where the boost pres-
sure is higher than the exhaust pressure on the
high load side, the EGR gas does not flow to
the air intake side easily. At this time, the
engine controller opens bypass valve (2).
q If bypass valve (2) opens, the intake air flows
through bypass piping (7). As a result, the
exhaust pressure rises and more EGR gas
mixes with the intake air.
140E-5 Series 27
SEN00081-08 10 Structure, function and maintenance standard
28 140E-5 Series
10 Structure, function and maintenance standard SEN00081-08
EGR cooler
Function
q The EGR cooler cools the high-temperature
EGR gas taken out of the exhaust gas to
increase the gas density, or the EGR effi-
ciency.
Structure
q The EGR cooler is a multi-tube heat
exchanger. When the high-temperature EGR
gas flows through heat exchange tube (1), it is
cooled by the coolant flowing outside of the
tube.
q Heat exchange tube (1) is made of corrosion-
resistant stainless steel and corrugated to
increase the cooling efficiency.
140E-5 Series 29
SEN00081-08 10 Structure, function and maintenance standard
Venturi system
Structure
q The EGR gas and intake air mix together in the
venturi system.
q The venturi system consists of throat (2), ven-
turi nozzle (1), and diffuser (3).
Operation
q The boost pressure increased by the turbo-
charger is set negative temporarily with the
venturi effect of the throat to take the EGR gas
into the intake air through venturi nozzle (1).
q When the mixture of the EGR gas and intake
air flows through diffuser (3), its pressure is
increased again to the normal level and then it
flows in the intake manifold.
30 140E-5 Series
10 Structure, function and maintenance standard SEN00081-08
140E-5 Series 31
SEN00081-08 10 Structure, function and maintenance standard
Cylinder head 1
32 140E-5 Series
10 Structure, function and maintenance standard SEN00081-08
A: Intake air
B: Exhaust gas
C: To fuel tank
D: To radiator
Specifications
Cylinder head
q Direct injection type
q 4-valve type
q Split-type 1-cylinder, 1-head
q Centralized cooling system for valve bridge
and injector
q Cylinder head bolt: Plastic-region tightening
Valve seat
q Valve seat inserts are press fitted to both
intake and exhaust valves
Rocker cover
q O-ring seal
Injector
q Installation: Dry type (without sleeve)
140E-5 Series 33
SEN00081-08 10 Structure, function and maintenance standard
a Tighten the cylinder head mounting bolts in the order of (1) to (7).
Unit: mm
No. Check item Criteria Remedy
34 140E-5 Series
10 Structure, function and maintenance standard SEN00081-08
140E-5 Series 35
SEN00081-08 10 Structure, function and maintenance standard
Cylinder block 1
36 140E-5 Series
10 Structure, function and maintenance standard SEN00081-08
1. Front cover
2. Cylinder block
3. Cylinder liner
4. Clevis seal
5. Liner O-ring (water)
6. Liner O-ring (oil)
7. Thrust bearing metal
8. Main bearing metal
9. Main bearing metal cap
10. Main bearing metal cap bolt
11. Front oil seal
12. Piston cooling nozzle (front side)
13. Piston cooling nozzle (rear side)
Specifications
Cylinder block
q Crankshaft section: 7 bearings
q Camshaft section: High cam type, 7 bearings
q Main cap bolt: Plastic-region tightening
Front seal
q Single lip with dust seal
(lay-down seal)
Piston cooling
q With piston cooling nozzle
(2 pieces for each cylinder)
Cylinder liner
q Wet type
q Machining on inside: Plateau honing
Soft nitriding process
Liner ring
q Upper: Clevis seal
q Middle: O-ring (ethylene-propylene rubber)
q Lower: O-ring (silicone rubber)
140E-5 Series 37
SEN00081-08 10 Structure, function and maintenance standard
Unit: mm
38 140E-5 Series
10 Structure, function and maintenance standard SEN00081-08
Cylinder liner 1
Unit: mm
Interference of cylinder liner and Standard interference Interference limit Replace or correct cylin-
block 0.02 to 0.12 Min. 0.02 der liner or block
140E-5 Series 39
SEN00081-08 10 Structure, function and maintenance standard
40 140E-5 Series
10 Structure, function and maintenance standard SEN00081-08
Specifications
Crankshaft: Closed die forging
Journal, fillet
Induction hardening
Piston rings
140E-5 Series 41
SEN00081-08 10 Structure, function and maintenance standard
Crankshaft 1
Unit: mm
a US: Undersize
42 140E-5 Series
10 Structure, function and maintenance standard SEN00081-08
Camshaft 1
Unit: mm
140E-5 Series 43
SEN00081-08 10 Structure, function and maintenance standard
Unit: mm
+0.038
Inside diameter of cam roller 12.7 12.78 Replace
3 +0.013
Diameter of cam roller pin 12.63 ±0.006 12.56
Standard dimension Tolerance
4 Diameter of push rod ball end –0.20
12.7
–0.20
Diameter of push rod socket –0.20
5 end
13.4
–0.20
6 Bend of push rod Repair limit: 0.3 (Overall swing of indicator)
44 140E-5 Series
10 Structure, function and maintenance standard SEN00081-08
140E-5 Series 45
SEN00081-08 10 Structure, function and maintenance standard
46 140E-5 Series
10 Structure, function and maintenance standard SEN00081-08
Unit: mm
Clearance between piston pin Standard clearance Allowable clearance Replace piston or
and piston 0.035 to 0.051 0.10 piston pin
140E-5 Series 47
SEN00081-08 10 Structure, function and maintenance standard
Connecting rod 1
Unit: mm
Inside diameter of connecting Standard dimension Tolerance Repair limit Replace bushing
rod small end bushing +0.049 (Spare is half
(Ream after press fitting) 52 52.09 worked)
+0.030
1
Clearance between connect- Standard clearance Allowable clearance
Replace bushing or
ing rod small end bushing and
0.030 to 0.055 0.11 piston pin
piston pin
a Do not use a connecting rod cap mounting bolt more than 5 times.
Each time the bolt is used, make a punch mark on its head.
48 140E-5 Series
10 Structure, function and maintenance standard SEN00081-08
1. Rear seal
2. Ring gear
3. Flywheel
4. Engine speed sensor (for monitor)
5. Flywheel housing
6. Engine speed sensor
(NE sensor for engine control)
140E-5 Series 49
SEN00081-08 10 Structure, function and maintenance standard
50 140E-5 Series
10 Structure, function and maintenance standard SEN00081-08
Unit: mm
140E-5 Series 51
SEN00081-08 10 Structure, function and maintenance standard
Vibration damper 1
1. Adapter
2. Pin (between adapter and crankshaft pulley)
3. Vibration damper
4. Bolt (between adapter and vibration damper)
5. Bolt (between crankshaft and adapter)
6. Pin (between adapter and vibration damper)
52 140E-5 Series
10 Structure, function and maintenance standard SEN00081-08
140E-5 Series 53
SEN00081-08 10 Structure, function and maintenance standard
Timing gear 1
(With EGR)
54 140E-5 Series
10 Structure, function and maintenance standard SEN00081-08
A: Timing mark
[Between crank gear and main idler gear (large)]
B: Timing mark
[Between main idler gear (small) and fuel supply pump drive gear]
C: Timing mark
[Between main idler gear (small) and cam gear]
Unit: mm
140E-5 Series 55
SEN00081-08 10 Structure, function and maintenance standard
(EGR-less)
56 140E-5 Series
10 Structure, function and maintenance standard SEN00081-08
A: Timing mark
[Between crank gear and main idler gear (large)]
B: Timing mark
[Between main idler gear (small) and fuel supply pump drive gear]
C: Timing mark
[Between main idler gear (small) and cam gear]
Unit: mm
140E-5 Series 57
SEN00081-08 10 Structure, function and maintenance standard
Valve system 1
58 140E-5 Series
10 Structure, function and maintenance standard SEN00081-08
Specifications
Camshaft: Drawn steel bar (turning)
Journal and cam sections:
Induction hardening
140E-5 Series 59
SEN00081-08 10 Structure, function and maintenance standard
60 140E-5 Series
10 Structure, function and maintenance standard SEN00081-08
Unit: mm
140E-5 Series 61
SEN00081-08 10 Structure, function and maintenance standard
Unit: mm
Clearance between rocker arm Standard clearance Allowable clearance Replace rocker arm shaft
shaft and rocker arm 0.0285 to 0.0935 0.13 or rocker arm
62 140E-5 Series
10 Structure, function and maintenance standard SEN00081-08
Unit: mm
140E-5 Series 63
SEN00081-08
© 2012 KOMATSU
All Rights Reserved
Printed in Japan 12-12 (01)
64
SEN00082-06
140E-5 Series
140E-5 Series 1
SEN00082-06 10 Structure, function and maintenance standard
Fuel filter............................................................................................................................................. 43
Priming pump ..................................................................................................................................... 46
Electric priming pump......................................................................................................................... 47
Engine controller cooler...................................................................................................................... 48
Cooling system.............................................................................................................................................. 49
Cooling system diagram..................................................................................................................... 49
Water pump ........................................................................................................................................ 54
Thermostat ......................................................................................................................................... 57
Corrosion resistor ............................................................................................................................... 58
Cooling fan drive ................................................................................................................................ 60
Accessories................................................................................................................................................... 63
Front PTO........................................................................................................................................... 63
Electrical equipment...................................................................................................................................... 65
Alternator............................................................................................................................................ 65
Starting motor ..................................................................................................................................... 76
Starting aid ......................................................................................................................................... 78
Engine controller ................................................................................................................................ 79
2 140E-5 Series
10 Structure, function and maintenance standard SEN00082-06
140E-5 Series 3
SEN00082-06 10 Structure, function and maintenance standard
Lubrication system 1
Lubrication system diagram 1
(With EGR)
a The layout of the oil filter, shapes of the oil pan and piping, etc. are subject to machine models.
4 140E-5 Series
10 Structure, function and maintenance standard SEN00082-06
W: Coolant
1. Oil pan
2. Oil strainer
3. Oil pump
4. Oil pump relief valve
5. Oil cooler
6. Thermo-valve
7. Oil filter
8. Safety valve
9. Crankshaft
10. Piston cooling nozzle
11. Piston
12. Camshaft
13. Cam follower
14. Rocker arm
15. Air intake valve and exhaust valve
16. Timing gear
17. Turbocharger
18. Fuel supply pump
19. EGR oil pump
20. EGR oil pump relief valve
21. EGR valve
22. Bypass valve
23. Main gallery
24. Oil filter clogging switch (for SDG400S-6B1)
140E-5 Series 5
SEN00082-06 10 Structure, function and maintenance standard
(EGR-less)
a The layout of the oil filter, shapes of the oil pan and piping, etc. are subject to machine models.
6 140E-5 Series
10 Structure, function and maintenance standard SEN00082-06
W: Coolant
1. Oil pan
2. Oil strainer
3. Oil pump
4. Oil pump relief valve
5. Oil cooler
6. Thermo-valve
7. Oil filter
8. Safety valve
9. Crankshaft
10. Piston cooling nozzle
11. Piston
12. Camshaft
13. Cam follower
14. Rocker arm
15. Air intake valve and exhaust valve
16. Timing gear
17. Turbocharger
18. Fuel supply pump
19. Main gallery
140E-5 Series 7
SEN00082-06 10 Structure, function and maintenance standard
Oil pump 1
8 140E-5 Series
10 Structure, function and maintenance standard SEN00082-06
140E-5 Series 9
SEN00082-06 10 Structure, function and maintenance standard
Oil filter 1
Except SDG400S-6B1 (HOKUETSU INDUSTRIES GENERATOR)
10 140E-5 Series
10 Structure, function and maintenance standard SEN00082-06
140E-5 Series 11
SEN00082-06 10 Structure, function and maintenance standard
Oil cooler 1
12 140E-5 Series
10 Structure, function and maintenance standard SEN00082-06
A: Oil inlet
B: Oil outlet
C: Coolant inlet
Specifications
Oil cooler thermo-valve
Opening temperature: 85 ± 1.5°C
Full opening temperature: 100°C
Lift at full opening: 8 mm
Oil cooler
Heat dissipation surface area
SAA6D140E-5: 1.23 m2
Heat exchange rate
SAA6D140E-5: Min. 39,800 kcal/h
Unit: mm
No. Check item Criteria Remedy
Lift of thermostat at full opening Min. 8 mm (Before checking, leave valve in oil of 100°C for 4 to 5 minutes)
6 Check that valve closes fully when its temperature is lowered from 100°C Replace
Opening/Closing of thermostat for full opening to 85°C. (Before checking valve, leave it in oil for 4 to 5
minutes)
140E-5 Series 13
SEN00082-06 10 Structure, function and maintenance standard
Fuel system 1
CRI system diagram 1
(With EGR)
14 140E-5 Series
10 Structure, function and maintenance standard SEN00082-06
(EGR-less)
140E-5 Series 15
SEN00082-06 10 Structure, function and maintenance standard
Configuration
q The CRI system is divided by the function into
the fuel system and control system.
16 140E-5 Series
10 Structure, function and maintenance standard SEN00082-06
2. Control system
a Parts marked with * (2 places) are installed to only the engines with EGR.
140E-5 Series 17
SEN00082-06 10 Structure, function and maintenance standard
q The CRI system consists of the fuel supply q If the TWV is turned on (energized), the fuel
pump, common rail, injector, engine controller circuit is so changed that the high-pressure
to control them, and sensors. fuel in the control chamber will flow through the
q The fuel supply pump generates fuel pressure orifice. As a result, the needle valve is raised
in the common rail. The fuel pressure is con- to start fuel injection by the nozzle cracking
trolled by the fuel discharge rate of the supply pressure of the high-pressure fuel on the noz-
pump. zle side.
q The discharge rate is controlled by turning on q If the TWV is turned off (de-energized), the fuel
and off the PCV (pressure control valve) of the circuit is so changed that the high-pressure
fuel supply pump according to the electric sig- fuel will be applied to the control chamber
nals from the engine controller. through the orifice. As a result, the needle
q The common rail receives the pressurized fuel valve lowers and finishes fuel injection.
from the fuel supply pump and distributes it to q Accordingly, the fuel injection timing and fuel
the cylinders. injection rate are controlled respectively by the
q The fuel pressure is sensed by the common timing to turn on the TWV and the length of the
rail fuel pressure sensor installed to the com- turn-on time of the TWV.
mon rail.
q A feedback control is applied so that the actual
fuel pressure will match to the command pres-
sure set according to the engine speed and the
load on the engine.
q The fuel pressure in the common rail is applied
to the nozzle side of the injector and to the
control chamber through the fuel injection pipe
of each cylinder.
q The injector controls the fuel injection rate and
fuel injection timing by turning on and off the
TWV (2-way solenoid valve).
18 140E-5 Series
10 Structure, function and maintenance standard SEN00082-06
140E-5 Series 19
SEN00082-06 10 Structure, function and maintenance standard
Operation
20 140E-5 Series
10 Structure, function and maintenance standard SEN00082-06
140E-5 Series 21
SEN00082-06 10 Structure, function and maintenance standard
2. Common rail
1) Flow damper
Function
q The flow dampers damp the pressure pulses in
the high pressure piping and supply the fuel to
the injectors with stable pressure.
q If excessive fuel flows out, the flow dampers
block the fuel passage to prevent abnormal
outflow of the fuel.
q If the fuel flows out abnormally, high pressure
is applied to the piston, which moves to the
right until it reaches the seat to stop the fuel.
Operation
When fuel is not injected
q Piston (2) is in contact with stopper (1) (initial
position).
q The fuel for static leakage is supplied through
orifice (a) of piston (2) and clearance in the
sliding parts.
22 140E-5 Series
10 Structure, function and maintenance standard SEN00082-06
1. Ball
2. Housing
3. Spring
4. Guide
5. Body
140E-5 Series 23
SEN00082-06 10 Structure, function and maintenance standard
3. Injector
Outline
q The function of the injector is to inject the high-
pressure fuel from the common rail into each
combustion chamber of the engine in the opti-
mum timing, by the optimum quantity, at the
optimum injection rate, and under the optimum
spray condition.
q The TWV (2-way solenoid valve) controls the
start and finish of fuel injection by controlling
the pressure in the control chamber.
q The orifice limits the opening speed of the noz-
zle and controls the fuel injection rate.
q The hydraulic piston transmits the force gener-
ated by the pressure in the control chamber to
the needle valve of the nozzle.
q The nozzle sprays the fuel.
24 140E-5 Series
10 Structure, function and maintenance standard SEN00082-06
Structure
140E-5 Series 25
SEN00082-06 10 Structure, function and maintenance standard
Operation
1) No fuel injection (A) 3) Finish of fuel injection (C)
q While solenoid (6) is not energized, valve body q If solenoid (6) is de-energized, valve body (5)
(5) is pressed down by spring (7). is lowered by spring (7) and the fuel passage is
q Since the high-pressure fuel is applied from closed.
the common rail to pressure control chamber q At this time, the high-pressure fuel in the com-
(8), nozzle (1) is closed and the fuel is not mon rail is applied to pressure control chamber
injected. (8) suddenly and nozzle (1) is closed quickly,
fuel injection is finished sharply.
2) Start of fuel injection (B)
q If solenoid (6) is energized, valve body (5) is
pulled up by the electromagnetic force and the
fuel passage is opened.
q Since the fuel in pressure control chamber (8)
flows out through orifices (3) and (4), nozzle
(1) rises and fuel injection pump starts.
q The fuel injection rate is increased gradually by
the function of orifices (3) and (4).
q If solenoid (6) is kept energized, the fuel injec-
tion rate is increased to the maximum.
26 140E-5 Series
10 Structure, function and maintenance standard SEN00082-06
140E-5 Series 27
SEN00082-06 10 Structure, function and maintenance standard
28 140E-5 Series
10 Structure, function and maintenance standard SEN00082-06
Various controls
a Parts marked with * (3 places) are installed to only the engines with EGR.
q The CRI system controls the fuel injection rate 2. Fuel injection timing control function
and fuel injection timing more properly than the q The fuel injection timing control function is
mechanical governor or timer of the conven- employed instead of the function of the con-
tional fuel injection pump. ventional timer. It controls the fuel injection
q For the control of the system, calculations nec- timing most properly from the engine speed
essary to the engine controller are performed and fuel injection rate.
fr om th e si gn als se nt fr om the s en so rs
installed to the engine and machine.
q The energizing timing and energizing period of 3. Fuel injection pressure control func-
the injector are so controlled that the optimum tion (Common rail fuel pressure control
quantity of fuel will be injected in the optimum
function)
timing.
q The fuel injection pressure control function
(common rail fuel pressure control function) is
a function of measuring the fuel pressure with
1. Fuel injection rate control function
the common rail fuel pressure sensor and
q The fuel injection rate control function is
feeding it back to the engine controller to con-
employed instead of the function of the con-
trol the delivery of the fuel supply pump.
ventional governor. It controls the fuel injection
q This function performs pressure feedback con-
according to the signals of engine speed and
trol so that the fuel injection pressure will be
accelerator angle so that the fuel injection rate
the same as the optimum value (command
will be most proper.
value) set according to the engine speed and
fuel injection rate.
140E-5 Series 29
SEN00082-06 10 Structure, function and maintenance standard
30 140E-5 Series
10 Structure, function and maintenance standard SEN00082-06
140E-5 Series 31
SEN00082-06 10 Structure, function and maintenance standard
32 140E-5 Series
10 Structure, function and maintenance standard SEN00082-06
140E-5 Series 33
SEN00082-06 10 Structure, function and maintenance standard
A: Pressure inlet
B: Mounting screw: M5
Tightening torque: 4.1 to 9.5 Nm {0.4 to 1.0 kgm}
34 140E-5 Series
10 Structure, function and maintenance standard SEN00082-06
(EGR-less)
140E-5 Series 35
SEN00082-06 10 Structure, function and maintenance standard
1. Sensor
2. O-ring
A: Mounting screw: M6
Tightening torque: 5.5 ± 0.5 Nm {0.56 ± 0.05 kgm}
1. Sensor
2. O-ring
36 140E-5 Series
10 Structure, function and maintenance standard SEN00082-06
140E-5 Series 37
SEN00082-06 10 Structure, function and maintenance standard
Fuel piping 1
(with EGR)
38 140E-5 Series
10 Structure, function and maintenance standard SEN00082-06
1. Fuel injection pipe (No. 1 cylinder) 11. Oil inlet pipe (for pump lubricating oil)
2. Fuel injection pipe (No. 2 cylinder) 12. Fuel supply pump
3. Fuel injection pipe (No. 3 cylinder) 13. Drive gear (Number of teeth: 48)
4. Fuel injection pipe (No. 4 cylinder) 14. Overflow valve
5. Fuel injection pipe (No. 5 cylinder) 15. PCV
6. Fuel injection pipe (No. 6 cylinder) 16. Priming pump (main)
7. Common rail 17. Pre-fuel filter
8. Fuel return pipe 18. Main fuel filter
9. Priming pump (sub)
10. Feed pump
140E-5 Series 39
SEN00082-06 10 Structure, function and maintenance standard
(EGR-less)
40 140E-5 Series
10 Structure, function and maintenance standard SEN00082-06
1. Fuel injection pipe (No. 1 cylinder) 11. Oil inlet pipe (for pump lubricating oil)
2. Fuel injection pipe (No. 2 cylinder) 12. Fuel supply pump
3. Fuel injection pipe (No. 3 cylinder) 13. Drive gear (Number of teeth: 48)
4. Fuel injection pipe (No. 4 cylinder) 14. Overflow valve
5. Fuel injection pipe (No. 5 cylinder) 15. PCV
6. Fuel injection pipe (No. 6 cylinder) 16. Electric priming pump
7. Common rail a Manual priming pump is set for some models.
8. Fuel return pipe (See the "with EGR".)
9. Priming pump 17. Pre-fuel filter
10. Feed pump 18. Main fuel filter (double cartridges)
a Single cartridge is set for some models.
19. Air bleeding valve for electric priming pump
140E-5 Series 41
SEN00082-06 10 Structure, function and maintenance standard
Fuel cooler 1
(installed on the machine)
1. Mount bracket
2. Core
Specifications
Cooling method: Cooling with air
Type of core: Drawn cup, 23 layers
Heat dissipation surface area: 2.12 m2
42 140E-5 Series
10 Structure, function and maintenance standard SEN00082-06
Fuel filter 1
Main fuel filter
(with EGR)
A: Fuel inlet
B: Fuel outlet
Specifications
Filtration area: 1.06 m2
140E-5 Series 43
SEN00082-06 10 Structure, function and maintenance standard
(EGR-less)
A: Fuel inlet
B: Fuel outlet
Specifications
Filtration area: 1.06 m2 x 2
44 140E-5 Series
10 Structure, function and maintenance standard SEN00082-06
Pre-fuel filter
A: Fuel inlet
B: Fuel outlet
Specifications
Filtration area: 1.06 m2
with water separator
140E-5 Series 45
SEN00082-06 10 Structure, function and maintenance standard
Priming pump 1
(with EGR)
46 140E-5 Series
10 Structure, function and maintenance standard SEN00082-06
A: Fuel IN
B: Fuel OUT
1. Connector
2. Vibration prevention rubber
140E-5 Series 47
SEN00082-06 10 Structure, function and maintenance standard
1. Engine controller
2. Engine controller cooler
Outline
q The fuel is circulated as refrigerant through
engine controller cooler (2) to prevent engine
controller (1) from overheating.
48 140E-5 Series
10 Structure, function and maintenance standard SEN00082-06
Cooling system 1
Cooling system diagram 1
SAA6D140E-5 (For construction machinery)
A: Oil inlet
B: Oil outlet
C: Exhaust gas inlet
D: Exhaust gas outlet
140E-5 Series 49
SEN00082-06 10 Structure, function and maintenance standard
A: Oil inlet
B: Oil outlet
1. Radiator
2. Thermostat
3. Oil cooler
4. Water pump
5. Corrosion resistor
a Corrosion resistor is not set for some models.
6. Hydraulic cooling fan
7. Hydraulic fan motor
50 140E-5 Series
10 Structure, function and maintenance standard SEN00082-06
A: Oil inlet
B: Oil outlet
C: Exhaust gas inlet
D: Exhaust gas outlet
1. Radiator
2. Thermostat
3. Oil cooler
4. Water pump
5. EGR cooler
6. Corrosion resistor
a Corrosion resistor is not set for some models.
7. Engine-driven cooling fan
140E-5 Series 51
SEN00082-06 10 Structure, function and maintenance standard
A: Oil inlet
B: Oil outlet
1. Radiator
2. Thermostat
3. Oil cooler
4. Water pump
5. Corrosion resistor
a Corrosion resistor is not set for some models.
6. Engine-driven cooling fan
52 140E-5 Series
10 Structure, function and maintenance standard SEN00082-06
140E-5 Series 53
SEN00082-06 10 Structure, function and maintenance standard
Water pump 1
SAA6D140E-5
54 140E-5 Series
10 Structure, function and maintenance standard SEN00082-06
A: From radiator
B: To oil cooler
C: Rotation direction
D: Pump mounting face
Specifications
Type: Centrifugal type driven with gear
Speed: Engine speed × 1.56
Delivery: 785 l/min
Total head: Min. 18.5 m
Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard inter-
Interference between impeller and dimension Shaft Hole ference
10 shaft –0.082 –0.120
16 0.025 to 0.068
–0.095 –0.150
Interference between drive gear and +0.015 –0.023
11 shaft
28
+0.002 –0.055
0.025 to 0.070 Replace
+0.015 –0.023
12 Interference between flange and shaft 25
+0.002 –0.053
0.025 to 0.068
13 Clearance between impeller and body Standard clearance: 0.6 to 0.9 (including end play)
14 Wear of water seal ring Limits of size: 1.5
140E-5 Series 55
SEN00082-06 10 Structure, function and maintenance standard
1. Oil cooler
2. Thermostat housing
3. Water pump
56 140E-5 Series
10 Structure, function and maintenance standard SEN00082-06
Thermostat 1
Unit: mm
No. Check item Criteria Remedy
Min. 9 mm (Before checking, leave valve in water of 90°C for 4 to 5 min-
Lift of thermostat at full opening
utes)
3 Check that valve closes fully when its temperature is lowered from 90°C Replace
Opening/Closing of thermostat for full opening to 76.5°C. (Before checking valve, leave it in water for 4 to
5 minutes)
140E-5 Series 57
SEN00082-06 10 Structure, function and maintenance standard
Corrosion resistor 1
58 140E-5 Series
10 Structure, function and maintenance standard SEN00082-06
140E-5 Series 59
SEN00082-06 10 Structure, function and maintenance standard
60 140E-5 Series
10 Structure, function and maintenance standard SEN00082-06
Tension pulley
SAA6D140E-5 [HD325-7, HD405-7, HM350-2, HM400-2, HD325-7R, HD405-7R,
HM350-2R, HM400-2R,
SDG400S-6B1 (HOKUETSU INDUSTRIES GENERATOR)]
1. Tension pulley
2. Spacer
3. Ball bearing
4. Tension shaft
5. Oil seal
6. Adjustment bolt
7. Bracket
140E-5 Series 61
SEN00082-06 10 Structure, function and maintenance standard
62 140E-5 Series
10 Structure, function and maintenance standard SEN00082-06
Accessories 1
Front PTO 1
1. Shaft
2. Pulley
3. Oil seal
4. Bearing (2 pieces)
5. Housing
6. O-ring
7. Gear (Number of teeth: 14)
8. Snap ring
9. Sleeve
140E-5 Series 63
SEN00082-06 10 Structure, function and maintenance standard
64 140E-5 Series
10 Structure, function and maintenance standard SEN00082-06
Electrical equipment 1
Alternator 1
1. Alternator with built-in regulator (open type, 35 A)
140E-5 Series 65
SEN00082-06 10 Structure, function and maintenance standard
66 140E-5 Series
10 Structure, function and maintenance standard SEN00082-06
140E-5 Series 67
SEN00082-06 10 Structure, function and maintenance standard
68 140E-5 Series
10 Structure, function and maintenance standard SEN00082-06
Outside diameter
Engine Machine model Type Specification Weight (kg)
of pulley (mm)
PC600-8, PC600LC-8,
PC600-8R, PC600LC-8R,
PC600-8E0, PC600LC-8E0,
Open type (brushless)
PC600-8R1, PC600LC-8R1, 24V, 60A
manufactured by NIKKO DENKI
PC700-8E0, PC700LC-8E0,
PC700-8R, PC700LC-8R,
PC700LC-8R1
PC800-8, PC800LC-8, PC800-8R,
PC800LC-8R, PC800SE-8,
PC800SE-8R
PC850-8, PC850-8R, PC850SE-8,
PC850SE-8R
Open type (brushless)
SAA6D140E-5 PC800-8E0, PC800SE-8E0, 24V, 60A
manufactured by NIKKO DENKI
PC850-8E0, PC850SE-8E0,
PC800LC-8E0
PC800-8R1, PC800SE-8R1
PC850-8R1, PC850SE-8R1
PC800LC-8R1
Open type (brushless)
D155AX-6, D155A-6 24V, 60A
manufactured by NIKKO DENKI
HD325-7, HD325-7R Open type (brushless)
24V, 60A
HD405-7, HD405-7R manufactured by NIKKO DENKI
HM350-2, HM350-2R
Open type (brushless)
HM400-2, HM400-2R 24V, 60A
manufactured by NIKKO DENKI
HM400-3M0, HM400-3R
140E-5 Series 69
SEN00082-06 10 Structure, function and maintenance standard
Outside diameter of
Engine Machine model Type Specification Weight (kg)
pulley (mm)
D155AX-6, D155A-6 Open type (brushless) manufactured
24V, 75A
(If equipped) by SAWAFUJI DENKI
D275AX-5E0, Open type (brushless) manufactured
24V, 75A
D275A-5R by SAWAFUJI DENKI
Open type (brushless) manufactured
WA500-6, WA500-6R 24V, 75A
by SAWAFUJI DENKI
SAA6D140E-5 HD325-7, HD325-7R
Open type (brushless) manufactured
HD405-7, HD405-7R 24V, 75A
by SAWAFUJI DENKI
(If equipped)
HM350-2, HM350-2R
HM400-2, HM400-2R Open type (brushless) manufactured
24V, 75A
HM400-3M0, HM400-3R by SAWAFUJI DENKI
(If equipped)
70 140E-5 Series
10 Structure, function and maintenance standard SEN00082-06
140E-5 Series 71
SEN00082-06 10 Structure, function and maintenance standard
72 140E-5 Series
10 Structure, function and maintenance standard SEN00082-06
Outside diameter
Engine Machine model Type Specification Weight (kg)
of pulley (mm)
PC600-8, PC600LC-8,
PC600-8R, PC600LC-8R,
PC600-8E0, PC600LC-8E0,
PC600-8R1, PC600LC-8R1, Open type (brushless)
24V, 90A
PC700-8E0, PC700LC-8E0, manufactured by NIKKO DENKI
PC700-8R, PC700LC-8R,
PC700LC-8R1
(If equipped)
PC800-8, PC800LC-8, PC800-8R,
PC800LC-8R, PC800SE-8,
PC800SE-8R
PC850-8, PC850-8R
PC850SE-8, PC850SE-8R
SAA6D140E-5 PC800-8E0, PC800SE-8E0, Open type (brushless)
24V, 90A
PC850-8E0, PC850SE-8E0, manufactured by NIKKO DENKI
PC800LC-8E0
PC800-8R1, PC800SE-8R1
PC850-8R1, PC850SE-8R1
PC800LC-8R1
(If equipped)
D155AX-6, D155A-6 Open type (brushless)
24V, 90A
(If equipped) manufactured by NIKKO DENKI
D275AX-5E0, D275A-5R Open type (brushless)
24V, 90A
(If equipped) manufactured by NIKKO DENKI
WA500-6, WA500-6R Open type (brushless)
24V, 90A
(If equipped) manufactured by NIKKO DENKI
140E-5 Series 73
SEN00082-06 10 Structure, function and maintenance standard
Alternator mounting
1. Alternator
2. Adjustment rod
3. Nut (2 pieces)
4. Plate
5. Cover
6. V-belt (2 pieces)
7. Spacer
74 140E-5 Series
10 Structure, function and maintenance standard SEN00082-06
140E-5 Series 75
SEN00082-06 10 Structure, function and maintenance standard
Starting motor 1
Number of Type of
Engine Machine model Type Specification Weight (kg)
pinion teeth connector
SDG400S-6B1
Water-resistant, oil-resistant
(HOKUETSU
SAA6D140E-5 type manufactured by 24V, 7.5kW 12 15.5 DT
INDUSTRIES
NIKKO DENKI
GENERATOR)
76 140E-5 Series
10 Structure, function and maintenance standard SEN00082-06
Number of Type of
Engine Machine model Type Specification Weight (kg)
pinion teeth connector
Water-resistant, oil-resistant
SAA6D140E-5 All machines type manufactured by 24V, 11kW 12 18 DT
NIKKO DENKI
140E-5 Series 77
SEN00082-06 10 Structure, function and maintenance standard
Starting aid 1
Electric heater
For SAA6D140E-5
1. Body Specifications
2. Heater coil Type of heater: Electrical intake air heater
3. Terminal q Rated voltage: 22 V (DC)
4. Connection diagram q Load current: 175 A
78 140E-5 Series
10 Structure, function and maintenance standard SEN00082-06
Engine controller 1
Features
Mounting of engine controller on engine
q Since the engine controller is mounted on the
engine, the operator can service it easily in the
field.
q The engine controller cooler (if equipped) is
prepared to cool the engine controller with the
fuel to secure the reliability of the mounted
engine controller.
q Vibrations are damped by the vibration-proof
rubber.
140E-5 Series 79
SEN00082-06
© 2012 KOMATSU
All Rights Reserved
Printed in Japan 12-12 (01)
80
SEN00147-07
140E-5 Series
140E-5 Series 1
SEN00147-07 20 Standard value table
Engine SAA6D140E-5
Machine models D155AX-6
Performance Category
2
SAE5W40EOS {kg/cm } {Min. 3.5} {2.1}
Min. 80°C
Oil pressure SAE10W30DH
At low idle SAE15W40DH MPa Min. 0.10 0.08
Engine oil temperature: SAE30DH
{kg/cm2} {Min. 1.0} {0.8}
Min. 80°C
Oil temperature Whole speed range °C 90 to 110 120
Ratio to fuel consumption at continuous
Oil consumption % Max. 0.15 0.3
rated horsepower
Function of radiator Cracking pressure kPa
— —
pressure valve (Differential pressure) {kg/cm2}
Cooling system
2 140E-5 Series
20 Standard value table SEN00147-07
Engine SAA6D140E-5
Machine models D155A-6
Performance Category
140E-5 Series 3
SEN00147-07 20 Standard value table
Engine SAA6D140E-5
Machine models D275AX-5E0
Performance Category
4 140E-5 Series
20 Standard value table SEN00147-07
Engine SAA6D140E-5
Machine models D275A-5R
Performance Category
140E-5 Series 5
SEN00147-07 20 Standard value table
Engine SAA6D140E-5
PC600-8, PC600LC-8
Machine models PC600-8E0, PC600LC-8E0
PC700-8E0, PC700LC-8E0
Performance Category
6 140E-5 Series
20 Standard value table SEN00147-07
Engine SAA6D140E-5
PC600-8R, PC600LC-8R,
PC600-8R1, PC600LC-8R1,
Machine models
PC700-8R, PC700LC-8R,
PC700LC-8R1
Performance Category
140E-5 Series 7
SEN00147-07 20 Standard value table
Engine SAA6D140E-5
PC800-8, PC800SE-8, PC800LC-8
PC850-8, PC850SE-8
Machine models PC800-8E0, PC800SE-8E0,
PC800LC-8E0
PC850-8E0, PC850SE-8E0
Performance Category
8 140E-5 Series
20 Standard value table SEN00147-07
Engine SAA6D140E-5
PC800-8R, PC800SE-8R,
PC800LC-8R
PC850-8R, PC850SE-8R
Machine models
PC800-8R1, PC800SE-8R1,
PC800LC-8R1, PC850-8R1,
PC850SE-8R1
Performance Category
140E-5 Series 9
SEN00147-07 20 Standard value table
Engine SAA6D140E-5
Machine models WA500-6
Performance Category
10 140E-5 Series
20 Standard value table SEN00147-07
Engine SAA6D140E-5
Machine models WA500-6R
Performance Category
2
SAE5W40EOS {kg/cm } {Min. 3.5} {2.1}
Min. 80°C
Oil pressure SAE10W30DH
At low idle SAE15W40DH MPa Min. 0.10 0.08
Engine oil temperature: SAE30DH
{kg/cm2} {Min. 1.0} {0.8}
Min. 80°C
Oil temperature Whole speed range °C 90 to 110 120
Ratio to fuel consumption at continuous
Oil consumption % Max. 0.15 0.3
rated horsepower
Function of
Cracking pressure kPa
radiator — —
(Differential pressure) {kg/cm2}
Cooling system
pressure valve
Fan speed At rated speed rpm Hydraulically driven on machine side
Deflection under finger pressure of 98 N
Fan belt tension mm Hydraulically driven on machine side
{10 kg}
Deflection under finger pressure of 98 N
Alternator belt tension mm 13 to 16 13 to 16
{10 kg}
140E-5 Series 11
SEN00147-07 20 Standard value table
Engine SAA6D140E-5
HD325-7
Machine models
HD405-7
Performance Category
12 140E-5 Series
20 Standard value table SEN00147-07
Engine SAA6D140E-5
HD325-7R
Machine models
HD405-7R
Performance Category
140E-5 Series 13
SEN00147-07 20 Standard value table
Engine SAA6D140E-5
Machine models HM350-2
Performance Category
14 140E-5 Series
20 Standard value table SEN00147-07
Engine SAA6D140E-5
Machine models HM350-2R
Performance Category
140E-5 Series 15
SEN00147-07 20 Standard value table
Engine SAA6D140E-5
Machine models HM400-2, HM400-3M0
Performance Category
16 140E-5 Series
20 Standard value table SEN00147-07
Engine SAA6D140E-5
Machine models HM400-2R, HM400-3R
Performance Category
140E-5 Series 17
SEN00147-07 20 Standard value table
Engine SAA6D140E-5
SDG400S-6B1
Machine models
(HOKUETSU INDUSTRIES GENERATOR)
Performance Category
18 140E-5 Series
20 Standard value table SEN00147-07
Engine SAA6D140E-5
Machine models D155AX-6
Procedure
Item
1 2 3 4 5
Running time min. 1 3 6 8 2
Speed rpm 740 1,197 1,501 1,729 1,900
Dynamometer load N{kg} 0{0} 747{76} 1,192{122} 1,552{158} 1,883{192}
Output kW{HP} 0{0} 67{90} 134{181} 201{270} 268{360}
a This table shows the values when the fan is not installed.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Engine SAA6D140E-5
Machine models D155AX-6
Test item Rated horsepower Max. torque High idle speed Low idle speed
Specification value 268 kW/1,900 rpm 1,834 Nm/1,300 rpm
— 2,100(0/–50) rpm 740(+40/0) rpm
(Gross value) {359.9 HP/1,900 rpm} {187 kgm/1,300 rpm}
Speed rpm 1,900 1,300 2,100(0/–50) 740(+40/0)
N 1,823 to 1,940 2,460 to 2,607
Dynamometer load — —
{kg} {186 to 198} {251 to 266}
kW 260 to 277
Output (Gross value) — — —
{HP} {349 to 371}
Nm 1,758 to 1,868
Torque (Gross value) — — —
{kgm} {179.4 to 190.6}
Fuel consumption sec/300cc Min. 16.0 — — —
Coolant temperature °C 70 to 90 70 to 90 70 to 90 70 to 90
Lubricating oil
°C 90 to 110 90 to 110 90 to 110 80 to 110
temperature
Lubricating oil kPa 340 to 490 340 to 490 340 to 490 Min. 120
pressure {kg/cm2} {3.5 to 5.0} {3.5 to 5.0} {3.5 to 5.0} {Min. 1.2}
Exhaust temperature °C Max. 650 Max. 650 — —
a This table shows the standard values obtained by using the JIS correction coefficients.
a Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.
a This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
a Use ASTM No.1 or No. 2 diesel fuel as fuel.
a Use SAE15W-40 as lubricating oil.
140E-5 Series 19
SEN00147-07 20 Standard value table
Running-in standard
Engine SAA6D140E-5
Machine models D155A-6
Procedure
Item
1 2 3 4 5
Running time min. 1 3 6 8 2
Speed rpm 740 1,197 1,501 1,729 1,900
Dynamometer load N{kg} 0{0} 747{76} 1,192{122} 1,552{158} 1,883{192}
Output kW{HP} 0{0} 67{90} 134{181} 201{270} 268{360}
a This table shows the values when the fan is not installed.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Engine SAA6D140E-5
Machine models D155A-6
Test item Rated horsepower Max. torque High idle speed Low idle speed
Specification value 268 kW/1,900 rpm 1,834 Nm/1,300 rpm
— 2,100(0/–50) rpm 740(+40/0) rpm
(Gross value) {359.9 HP/1,900 rpm} {187 kgm/1,300 rpm}
Speed rpm 1,900 1,300 2,100(0/–50) 740(+40/0)
N 1,823 to 1,940 2,482 to 2,635
Dynamometer load — —
{kg} {186 to 198} {253 to 269}
kW 260 to 277
Output (Gross value) — — —
{HP} {349 to 371}
Nm 1,778 to 1,888
Torque (Gross value) — — —
{kgm} {181.4 to 192.6}
Fuel consumption sec/300cc Min. 16.0 — — —
Coolant temperature °C 70 to 90 70 to 90 70 to 90 70 to 90
Lubricating oil
°C 90 to 110 90 to 110 90 to 110 80 to 110
temperature
Lubricating oil kPa 340 to 490 340 to 490 340 to 490 Min. 120
pressure {kg/cm2} {3.5 to 5.0} {3.5 to 5.0} {3.5 to 5.0} {Min. 1.2}
Exhaust temperature °C Max. 670 Max. 670 — —
a This table shows the standard values obtained by using the JIS correction coefficients.
a Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.
a This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
a Use ASTM No.1 or No. 2 diesel fuel as fuel.
a Use SAE15W-40 as lubricating oil.
20 140E-5 Series
20 Standard value table SEN00147-07
Running-in standard
Engine SAA6D140E-5
Machine models D275AX-5E0
Procedure
Item
1 2 3 4 5
Running time min. 1 3 6 8 2
Speed rpm 740 1,260 1,580 1,820 2,000
Dynamometer load N{kg} 0{0} 891{91} 1,420{145} 1,850{189} 2,244{229}
Output kW{HP} 0{0} 84{113} 168{226} 253{339} 337{452}
a This table shows the values when the fan is not installed.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Engine SAA6D140E-5
Machine models D275AX-5E0
Test item Rated horsepower Max. torque High idle speed Low idle speed
Specification value 337 kW/2,000 rpm 2,030 Nm/1,400 rpm
— 2,200 ± 50 rpm 700 ± 50 rpm
(Gross value) {451.6 HP/2,000 rpm} {207 kgm/1,400 rpm}
Speed rpm 2,000 1,400 2,200 ± 50 700 ± 50
N 2,177 to 2,314 2,753 to 2,917
Dynamometer load — —
{kg} {222.0 to 236.0} {280.7 to 297.5}
Output kW 327 to 347
— — —
(Gross value) {HP} {438 to 465}
Nm 1,970 to 2,087
Torque (Gross value) — — —
{kgm} {201 to 213}
Fuel consumption sec/300cc Min. 12.8 — — —
Coolant temperature °C 70 to 90 70 to 90 70 to 90 70 to 90
Lubricating oil
°C 90 to 110 90 to 110 90 to 110 90 to 110
temperature
Lubricating oil kPa 340 to 490 340 to 490 340 to 490 Min. 120
pressure {kg/cm2} {3.5 to 5.0} {3.5 to 5.0} {3.5 to 5.0} {Min. 1.2}
Exhaust temperature °C Max. 650 Max. 650 — —
a This table shows the standard values obtained by using the JIS correction coefficients.
a Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.
a This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
a Use ASTM No.1 or No. 2 diesel fuel as fuel.
a Use SAE15W-40 as lubricating oil.
140E-5 Series 21
SEN00147-07 20 Standard value table
Running-in standard
Engine SAA6D140E-5
Machine models D275A-5R
Procedure
Item
1 2 3 4 5
Running time min. 1 3 6 8 2
Speed rpm 740 1,260 1,580 1,820 2,000
Dynamometer load N{kg} 0{0} 891{91} 1,420{145} 1,850{189} 2,244{229}
Output kW{HP} 0{0} 84{113} 168{226} 253{339} 337{452}
a This table shows the values when the fan is not installed.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Engine SAA6D140E-5
Machine models D275A-5R
Test item Rated horsepower Max. torque High idle speed Low idle speed
Specification value 337 kW/2,000 rpm 2,030 Nm/1,400 rpm
— 2,200 ± 50 rpm 700 ± 50 rpm
(Gross value) {451.6 HP/2,000 rpm} {207 kgm/1,400 rpm}
Speed rpm 2,000 1,400 2,200 ± 50 700 ± 50
N 2,177 to 2,314 2,753 to 2,917
Dynamometer load — —
{kg} {222.0 to 236.0} {280.7 to 297.5}
Output kW 327 to 347
— — —
(Gross value) {HP} {438 to 465}
Nm 1,970 to 2,087
Torque (Gross value) — — —
{kgm} {201 to 213}
Fuel consumption sec/300cc Min. 12.8 — — —
Coolant temperature °C 70 to 90 70 to 90 70 to 90 70 to 90
Lubricating oil
°C 90 to 110 90 to 110 90 to 110 90 to 110
temperature
Lubricating oil kPa 340 to 490 340 to 490 340 to 490 Min. 120
pressure {kg/cm2} {3.5 to 5.0} {3.5 to 5.0} {3.5 to 5.0} {Min. 1.2}
Exhaust temperature °C Max. 670 Max. 670 — —
a This table shows the standard values obtained by using the JIS correction coefficients.
a Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.
a This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
a Use ASTM No.1 or No. 2 diesel fuel as fuel.
a Use SAE15W-40 as lubricating oil.
22 140E-5 Series
20 Standard value table SEN00147-07
Running-in standard
Engine SAA6D140E-5
PC600-8, PC600LC-8, PC600-8E0, PC600LC-8E0
Machine models
PC700-8E0, PC700LC-8E0
Procedure
Item
1 2 3 4 5
Running time min. 1 3 6 8 2
Speed rpm 800 1,134 1,422 1,638 1,800
Dynamometer load N{kg} 0{0} 948{97} 1,513{154} 1,970{201} 2,390{244}
Output kW{HP} 0{0} 81{108} 161{217} 242{324} 323{433}
a This table shows the values when the fan is not installed.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Engine SAA6D140E-5
PC600-8, PC600LC-8, PC600-8E0, PC600LC-8E0
Machine models
PC700-8E0, PC700LC-8E0
Test item Rated horsepower Max. torque High idle speed Low idle speed
323 kW/1,800 rpm 1,944Nm/1,400rpm
Specification value
— {433.3 HP/ {198.4 kgm/ 1,950 ± 50 rpm 800 ± 25 rpm
(Gross value)
1,800 rpm} 1,400 rpm}
Speed rpm 1,800 1,400 1,950 ± 50 800 ± 25
N 2,323 to 2,470 2,626 to 2,793
Dynamometer load — —
{kg} {237 to 252} {268 to 285}
kW 313 to 333
Output (Gross value) — — —
{HP} {420 to 447}
Nm 1,882 to 1,999
Torque (Gross value) — — —
{kgm} {192 to 204}
Fuel consumption sec/300cc Min. 13.8 — — —
Coolant temperature °C 70 to 90 70 to 90 70 to 90 70 to 90
Lubricating oil
°C 90 to 110 90 to 110 90 to 110 80 to 110
temperature
Lubricating oil kPa 340 to 490 340 to 490 340 to 490 Min. 120
pressure {kg/cm2} {3.5 to 5.0} {3.5 to 5.0} {3.5 to 5.0} {Min. 1.2}
Exhaust temperature °C Max. 650 Max. 650 — —
a This table shows the standard values obtained by using the JIS correction coefficients.
a Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.
a This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
a Use ASTM No.1 or No. 2 diesel fuel as fuel.
a Use SAE15W-40 as lubricating oil.
140E-5 Series 23
SEN00147-07 20 Standard value table
Running-in standard
Engine SAA6D140E-5
PC600-8R, PC600LC-8R,
Machine models PC600-8R1, PC600LC-8R1,
PC700-8R, PC700LC-8R, PC700LC-8R1
Procedure
Item
1 2 3 4 5
Running time min. 1 3 6 8 2
Speed rpm 800 1,134 1,422 1,638 1,800
Dynamometer load N{kg} 0{0} 948{97} 1,513{154} 1,970{201} 2,390{244}
Output kW{HP} 0{0} 81{108} 161{217} 242{324} 323{433}
a This table shows the values when the fan is not installed.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Engine SAA6D140E-5
PC600-8R, PC600LC-8R,
Machine models PC600-8R1, PC600LC-8R1,
PC700-8R, PC700LC-8R, PC700LC-8R1
Test item Rated horsepower Max. torque High idle speed Low idle speed
323 kW/1,800 rpm 1,944Nm/1,400rpm
Specification value
— {433.3 HP/ {198.4 kgm/ 1,950 ± 50 rpm 800 ± 25 rpm
(Gross value)
1,800 rpm} 1,400 rpm}
Speed rpm 1,800 1,400 1,950 ± 50 800 ± 25
N 2,323 to 2,470 2,626 to 2,793
Dynamometer load — —
{kg} {237 to 252} {268 to 285}
kW 313 to 333
Output (Gross value) — — —
{HP} {420 to 447}
Nm 1,882 to 1,999
Torque (Gross value) — — —
{kgm} {192 to 204}
Fuel consumption sec/300cc Min. 13.8 — — —
Coolant temperature °C 70 to 90 70 to 90 70 to 90 70 to 90
Lubricating oil
°C 90 to 110 90 to 110 90 to 110 80 to 110
temperature
Lubricating oil kPa 340 to 490 340 to 490 340 to 490 Min. 120
pressure {kg/cm2} {3.5 to 5.0} {3.5 to 5.0} {3.5 to 5.0} {Min. 1.2}
Exhaust temperature °C Max. 700 Max. 700 — —
a This table shows the standard values obtained by using the JIS correction coefficients.
a Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.
a This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
a Use ASTM No.1 or No. 2 diesel fuel as fuel.
a Use SAE15W-40 as lubricating oil.
24 140E-5 Series
20 Standard value table SEN00147-07
Running-in standard
Engine SAA6D140E-5
PC800-8, PC800SE-8, PC800LC-8, PC850-8, PC850SE-8
Machine models
PC800-8E0, PC800SE-8E0, PC800LC-8E0, PC850-8E0, PC850SE-8E0
Procedure
Item
1 2 3 4 5
Running time min. 1 3 6 8 2
Speed rpm 825 1,134 1,422 1,638 1,800
Dynamometer load N{kg} 0{0} 1,087{111} 1,733{177} 2,257{230} 2,739{279}
Output kW{HP} 0{0} 92{124} 185{248} 277{372} 370{496}
a This table shows the values when the fan is not installed.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Engine SAA6D140E-5
PC800-8, PC800SE-8, PC800LC-8, PC850-8, PC850SE-8
Machine models
PC800-8E0, PC800SE-8E0, PC800LC-8E0, PC850-8E0, PC850SE-8E0
Test item Rated horsepower Max. torque High idle speed Low idle speed
370 kW/1,800 rpm 2,195 Nm/1,350 rpm
Specification value
— {496.4 HP/ {223.8 kgm/ 1,980 ± 50 rpm 825 ± 25 rpm
(Gross value)
1,800 rpm} 1,350 rpm}
Speed rpm 1,800 1,350 1,980 ± 50 825 ± 25
N 2,550 to 2,690 2,930 to 3,100
Dynamometer load — —
{kg} {260 to 274} {299 to 316}
kW 359 to 381
Output (Gross value) — — —
{HP} {481 to 512}
Nm 2,126 to 2,264
Torque (Gross value) — — —
{kgm} {217 to 231}
Fuel consumption sec/300cc Min. 12.3 — — —
Coolant temperature °C 70 to 90 70 to 90 70 to 90 70 to 90
Lubricating oil
°C 90 to 110 90 to 110 90 to 110 80 to 110
temperature
Lubricating oil kPa 340 to 490 340 to 490 340 to 490 Min. 120
pressure {kg/cm2} {3.5 to 5.0} {3.5 to 5.0} {3.5 to 5.0} {Min. 1.2}
Exhaust temperature °C Max. 650 Max. 650 — —
a This table shows the standard values obtained by using the JIS correction coefficients.
a Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.
a This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
a Use ASTM No.1 or No. 2 diesel fuel as fuel.
a Use SAE15W-40 as lubricating oil.
140E-5 Series 25
SEN00147-07 20 Standard value table
Running-in standard
Engine SAA6D140E-5
PC800-8R, PC800SE-8R, PC800LC-8R, PC850-8R, PC850SE-8R
Machine models
PC800-8R1, PC800SE-8R1, PC800LC-8R1, PC850-8R1, PC850SE-8R1
Procedure
Item
1 2 3 4 5
Running time min. 1 3 6 8 2
Speed rpm 825 1,134 1,422 1,638 1,800
Dynamometer load N{kg} 0{0} 1,087{111} 1,733{177} 2,257{230} 2,739{279}
Output kW{HP} 0{0} 92{124} 185{248} 277{372} 370{496}
a This table shows the values when the fan is not installed.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Engine SAA6D140E-5
PC800-8R, PC800SE-8R, PC800LC-8R, PC850-8R, PC850SE-8R
Machine models
PC800-8R1, PC800SE-8R1, PC800LC-8R1, PC850-8R1, PC850SE-8R1
Test item Rated horsepower Max. torque High idle speed Low idle speed
370 kW/1,800 rpm 2,195 Nm/1,350 rpm
Specification value
— {496.4 HP/ {223.8 kgm/ 1,980 ± 50 rpm 825 ± 25 rpm
(Gross value)
1,800 rpm} 1,350 rpm}
Speed rpm 1,800 1,350 1,980 ± 50 825 ± 25
N 2,550 to 2,690 2,969 to 3,162
Dynamometer load — —
{kg} {260 to 274} {303 to 323}
kW 359 to 381
Output (Gross value) — — —
{HP} {481 to 512}
Nm 2,126 to 2,264
Torque (Gross value) — — —
{kgm} {217 to 231}
Fuel consumption sec/300cc Min. 12.3 — — —
Coolant temperature °C 70 to 90 70 to 90 70 to 90 70 to 90
Lubricating oil
°C 90 to 110 90 to 110 90 to 110 80 to 110
temperature
Lubricating oil kPa 340 to 490 340 to 490 340 to 490 Min. 120
pressure {kg/cm2} {3.5 to 5.0} {3.5 to 5.0} {3.5 to 5.0} {Min. 1.2}
Exhaust temperature °C Max. 700 Max. 700 — —
a This table shows the standard values obtained by using the JIS correction coefficients.
a Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.
a This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
a Use ASTM No.1 or No. 2 diesel fuel as fuel.
a Use SAE15W-40 as lubricating oil.
26 140E-5 Series
20 Standard value table SEN00147-07
Running-in standard
Engine SAA6D140E-5
Machine models WA500-6
Procedure
Item
1 2 3 4 5
Running time min. 1 3 6 8 2
Speed rpm 675 1,197 1,501 1,729 1,900
Dynamometer load N{kg} 0{0} 712{73} 1,136{116} 1,479{151} 1,795{183}
Output kW{HP} 0{0} 64{86} 128{172} 192{257} 266{357}
a This table shows the values when the fan is not installed.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Engine SAA6D140E-5
Machine models WA500-6
Test item Rated horsepower Max. torque High idle speed Low idle speed
Specification value 266 kW/1,900 rpm 1,803 Nm/1,250 rpm
— 2,150 ± 50 rpm 700 ± 25 rpm
(Gross value) {357 HP/1,900 rpm} {184 kgm/1,250 rpm}
Speed rpm 1,900 1,250 2,150 ± 50 700 ± 25
N 1,744 to 1,852 2,440 to 2,597
Dynamometer load — —
{kg} {178 to 189} {249 to 265}
kW 248 to 263
Output (Gross value) — — —
{HP} {333 to 353}
Nm 1,744 to 1,862
Torque (Gross value) — — —
{kgm} {178 to 190}
Fuel consumption sec/300cc Min. 16.8 — — —
Coolant temperature °C 70 to 90 70 to 90 70 to 90 70 to 90
Lubricating oil
°C 90 to 110 90 to 110 90 to 110 80 to 110
temperature
Lubricating oil kPa 340 to 490 340 to 490 340 to 490 Min. 120
pressure {kg/cm2} {3.5 to 5.0} {3.5 to 5.0} {3.5 to 5.0} {Min. 1.2}
Exhaust temperature °C Max. 650 Max. 650 — —
a This table shows the standard values obtained by using the JIS correction coefficients.
a Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.
a This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
a Use ASTM No.1 or No. 2 diesel fuel as fuel.
a Use SAE15W-40 as lubricating oil.
140E-5 Series 27
SEN00147-07 20 Standard value table
Running-in standard
Engine SAA6D140E-5
Machine models WA500-6R
Procedure
Item
1 2 3 4 5
Running time min. 1 3 6 8 2
Speed rpm 675 1,197 1,501 1,729 1,900
Dynamometer load N{kg} 0{0} 712{73} 1,136{116} 1,479{151} 1,795{183}
Output kW{HP} 0{0} 64{86} 128{172} 192{257} 266{357}
a This table shows the values when the fan is not installed.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Engine SAA6D140E-5
Machine models WA500-6R
Test item Rated horsepower Max. torque High idle speed Low idle speed
Specification value 266 kW/1,900 rpm 1,803 Nm/1,250 rpm
— 2,150 ± 50 rpm 700 ± 25 rpm
(Gross value) {357 HP/1,900 rpm} {184 kgm/1,250 rpm}
Speed rpm 1,900 1,250 2,150 ± 50 700 ± 25
N 1,814 to 1,922 2,440 to 2,597
Dynamometer load — —
{kg} {185 to 196} {249 to 265}
kW 258 to 274
Output (Gross value) — — —
{HP} {346 to 368}
Nm 1,744 to 1,862
Torque (Gross value) — — —
{kgm} {178 to 190}
Fuel consumption sec/300cc Min. 16.8 — — —
Coolant temperature °C 70 to 90 70 to 90 70 to 90 70 to 90
Lubricating oil
°C 90 to 110 90 to 110 90 to 110 80 to 110
temperature
Lubricating oil kPa 340 to 490 340 to 490 340 to 490 Min. 120
pressure {kg/cm2} {3.5 to 5.0} {3.5 to 5.0} {3.5 to 5.0} {Min. 1.2}
Exhaust temperature °C Max. 670 Max. 670 — —
a This table shows the standard values obtained by using the JIS correction coefficients.
a Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.
a This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
a Use ASTM No.1 or No. 2 diesel fuel as fuel.
a Use SAE15W-40 as lubricating oil.
28 140E-5 Series
20 Standard value table SEN00147-07
Running-in standard
Engine SAA6D140E-5
HD325-7
Machine models
HD405-7
Procedure
Item
1 2 3 4 5
Running time min. 1 3 6 8 2
Speed rpm 725 1,260 1,580 1,820 2,000
Dynamometer load N{kg} 0{0} 1,021{104} 1,628{166} 2,120{216} 2,573{263}
Output kW{HP} 0{0} 97{129} 193{259} 290{388} 386{518}
a This table shows the values when the fan is not installed.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Engine SAA6D140E-5
HD325-7
Machine models
HD405-7
Test item Rated horsepower Max. torque High idle speed Low idle speed
Specification value 386 kW/2,000 rpm 2,170 Nm/1,400 rpm
— 2,300 ± 25 rpm 725 ± 25 rpm
(Gross value) {517.7 HP/2,000 rpm} {221.3 kgm/1,400 rpm}
Speed rpm 2,000 1,400 2,300 ± 25 725 ± 25
N 2,499 to 2,646 2,930 to 3,120
Dynamometer load — —
{kg} {255 to 270} {299 to 318}
kW 374 to 398
Output (Gross value) — — —
{HP} {502 to 533}
Nm 2,100 to 2,230
Torque (Gross value) — — —
{kgm} {214 to 228}
Fuel consumption sec/300cc Min. 11.4 — — —
Coolant temperature °C 70 to 90 70 to 90 70 to 90 70 to 90
Lubricating oil
°C 90 to 110 90 to 110 90 to 110 80 to 110
temperature
Lubricating oil kPa 340 to 490 340 to 490 340 to 490 Min. 120
pressure {kg/cm2} {3.5 to 5.0} {3.5 to 5.0} {3.5 to 5.0} {Min. 1.2}
Exhaust temperature °C Max. 650 Max. 650 — —
a This table shows the standard values obtained by using the JIS correction coefficients.
a Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.
a This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
a Use ASTM No.1 or No. 2 diesel fuel as fuel.
140E-5 Series 29
SEN00147-07 20 Standard value table
Running-in standard
Engine SAA6D140E-5
HD325-7R
Machine models
HD405-7R
Procedure
Item
1 2 3 4 5
Running time min. 1 3 6 8 2
Speed rpm 725 1,260 1,580 1,820 2,000
Dynamometer load N{kg} 0{0} 1,021{104} 1,628{166} 2,120{216} 2,573{263}
Output kW{HP} 0{0} 97{129} 193{259} 290{388} 386{518}
a This table shows the values when the fan is not installed.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Engine SAA6D140E-5
HD325-7R
Machine models
HD405-7R
Test item Rated horsepower Max. torque High idle speed Low idle speed
Specification value 386 kW/2,000 rpm 2,170 Nm/1,400 rpm
— 2,300 ± 25 rpm 725 ± 25 rpm
(Gross value) {517.7 HP/2,000 rpm} {221.3 kgm/1,400 rpm}
Speed rpm 2,000 1,400 2,300 ± 25 725 ± 25
N 2,499 to 2,646 2,930 to 3,120
Dynamometer load — —
{kg} {255 to 270} {299 to 318}
kW 374 to 398
Output (Gross value) — — —
{HP} {502 to 533}
Nm 2,100 to 2,230
Torque (Gross value) — — —
{kgm} {214 to 228}
Fuel consumption sec/300cc Min. 11.4 — — —
Coolant temperature °C 70 to 90 70 to 90 70 to 90 70 to 90
Lubricating oil
°C 90 to 110 90 to 110 90 to 110 80 to 110
temperature
Lubricating oil kPa 340 to 490 340 to 490 340 to 490 Min. 120
pressure {kg/cm2} {3.5 to 5.0} {3.5 to 5.0} {3.5 to 5.0} {Min. 1.2}
Exhaust temperature °C Max. 680 Max. 680 — —
a This table shows the standard values obtained by using the JIS correction coefficients.
a Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.
a This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
a Use ASTM No.1 or No. 2 diesel fuel as fuel.
a Use SAE15W-40 as lubricating oil.
30 140E-5 Series
20 Standard value table SEN00147-07
Running-in standard
Engine SAA6D140E-5
Machine models HM350-2
Procedure
Item
1 2 3 4 5
Running time min. 1 3 6 8 2
Speed rpm 725 1,260 1,580 1,820 2,000
Dynamometer load N{kg} 0{0} 803{82} 1,281{131} 1,668{170} 2,024{207}
Output kW{HP} 0{0} 76{102} 152{204} 228{306} 304{407}
a This table shows the values when the fan is not installed.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Engine SAA6D140E-5
Machine models HM350-2
Test item Rated horsepower Max. torque High idle speed Low idle speed
Specification value 304 kW/2,000 rpm 1,990 Nm/1,400 rpm
— 2,200(+50/0) rpm 725 ± 25 rpm
(Gross value) {407.2 HP/2,000 rpm} {203 kgm/1,400 rpm}
Speed rpm 2,000 1,400 2,200(+50/0) 725 ± 25
N 1,960 to 2,087 2,695 to 2,862
Dynamometer load — —
{kg} {200 to 213} {275 to 292}
kW 295 to 315
Output (Gross value) — — —
{HP} {395 to 419}
Nm 1,931 to 2,048
Torque (Gross value) — — —
{kgm} {197 to 209}
Fuel consumption sec/300cc Min. 13.8 — — —
Coolant temperature °C 70 to 90 70 to 90 70 to 90 70 to 90
Lubricating oil tem-
°C 90 to 110 90 to 110 90 to 110 80 to 110
perature
Lubricating oil pres- kPa 340 to 490 340 to 490 340 to 490 Min. 120
sure {kg/cm2} {3.5 to 5.0} {3.5 to 5.0} {3.5 to 5.0} {Min. 1.2}
Exhaust temperature °C Max. 650 Max. 650 — —
a This table shows the standard values obtained by using the JIS correction coefficients.
a Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.
a This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
a Use ASTM No.1 or No. 2 diesel fuel as fuel.
a Use SAE15W-40 as lubricating oil.
140E-5 Series 31
SEN00147-07 20 Standard value table
Running-in standard
Engine SAA6D140E-5
Machine models HM350-2R
Procedure
Item
1 2 3 4 5
Running time min. 1 3 6 8 2
Speed rpm 725 1,260 1,580 1,820 2,000
Dynamometer load N{kg} 0{0} 803{82} 1,281{131} 1,668{170} 2,024{207}
Output kW{HP} 0{0} 76{102} 152{204} 228{306} 304{407}
a This table shows the values when the fan is not installed.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Engine SAA6D140E-5
Machine models HM350-2R
Test item Rated horsepower Max. torque High idle speed Low idle speed
Specification value 304 kW/2,000 rpm 1,991 Nm/1,400 rpm
— 2,200(+50/0) rpm 725 ± 25 rpm
(Gross value) {407.2 HP/2,000 rpm} {203 kgm/1,400 rpm}
Speed rpm 2,000 1,400 2,200(+50/0) 725 ± 25
N 1,960 to 2,087 2,695 to 2,862
Dynamometer load — —
{kg} {200 to 213} {275 to 292}
kW 295 to 315
Output (Gross value) — — —
{HP} {395 to 419}
Nm 1,931 to 2,048
Torque (Gross value) — — —
{kgm} {197 to 209}
Fuel consumption sec/300cc Min. 13.8 — — —
Coolant temperature °C 70 to 90 70 to 90 70 to 90 70 to 90
Lubricating oil tem-
°C 90 to 110 90 to 110 90 to 110 80 to 110
perature
Lubricating oil pres- kPa 340 to 490 340 to 490 340 to 490 Min. 120
sure {kg/cm2} {3.5 to 5.0} {3.5 to 5.0} {3.5 to 5.0} {Min. 1.2}
Exhaust temperature °C Max. 670 Max. 670 — —
a This table shows the standard values obtained by using the JIS correction coefficients.
a Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.
a This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
a Use ASTM No.1 or No. 2 diesel fuel as fuel.
a Use SAE15W-40 as lubricating oil.
32 140E-5 Series
20 Standard value table SEN00147-07
Running-in standard
Engine SAA6D140E-5
Machine models HM400-2, HM400-3M0
Procedure
Item
1 2 3 4 5
Running time min. 1 3 6 8 2
Speed rpm 725 1,260 1,580 1,820 2,000
Dynamometer load N{kg} 0{0} 893{91} 1,423{145} 1,854{189} 2,249{230}
Output kW{HP} 0{0} 84{113} 169{227} 253{339} 338{453}
a This table shows the values when the fan is not installed.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Engine SAA6D140E-5
Machine models HM400-2, HM400-3M0
Test item Rated horsepower Max. torque High idle speed Low idle speed
Specification value 338 kW/2,000 rpm 2,090 Nm/1,400 rpm
— 2,200(+50/0) rpm 725 ± 25 rpm
(Gross value) {452.6 HP/2,000 rpm} {213 kgm/1,400 rpm}
Speed rpm 2,000 1,400 2,200(+50/0) 725 ± 25
N 2,185 to 2,313 2,832 to 2,999
Dynamometer load — —
{kg} {223 to 236} {289 to 306}
kW 327 to 348
Output (Gross value) — — —
{HP} {439 to 466}
Nm 2,029 to 2,146
Torque (Gross value) — — —
{kgm} {207 to 219}
Fuel consumption sec/300cc Min. 13.0 — — —
Coolant temperature °C 70 to 90 70 to 90 70 to 90 70 to 90
Lubricating oil
°C 90 to 110 90 to 110 90 to 110 80 to 110
temperature
Lubricating oil kPa 340 to 490 340 to 490 340 to 490 Min. 120
pressure {kg/cm2} {3.5 to 5.0} {3.5 to 5.0} {3.5 to 5.0} {Min. 1.2}
Exhaust temperature °C Max. 650 Max. 650 — —
a This table shows the standard values obtained by using the JIS correction coefficients.
a Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.
a This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
a Use ASTM No.1 or No. 2 diesel fuel as fuel.
a Use SAE15W-40 as lubricating oil.
140E-5 Series 33
SEN00147-07 20 Standard value table
Running-in standard
Engine SAA6D140E-5
Machine models HM400-2R, HM400-3R
Procedure
Item
1 2 3 4 5
Running time min. 1 3 6 8 2
Speed rpm 725 1,260 1,580 1,820 2,000
Dynamometer load N{kg} 0{0} 893{91} 1,423{145} 1,854{189} 2,249{230}
Output kW{HP} 0{0} 84{113} 169{227} 253{339} 338{453}
a This table shows the values when the fan is not installed.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Engine SAA6D140E-5
Machine models HM400-2R, HM400-3R
Test item Rated horsepower Max. torque High idle speed Low idle speed
Specification value 338 kW/2,000 rpm 2,090 Nm/1,400 rpm
— 2,200(+50/0) rpm 725 ± 25 rpm
(Gross value) {452.6 HP/2,000 rpm} {213 kgm/1,400 rpm}
Speed rpm 2,000 1,400 2,200(+50/0) 725 ± 25
N 2,185 to 2,313 2,832 to 2,999
Dynamometer load — —
{kg} {223 to 236} {289 to 306}
kW 327 to 348
Output (Gross value) — — —
{HP} {439 to 466}
Nm 2,029 to 2,146
Torque (Gross value) — — —
{kgm} {207 to 219}
Fuel consumption sec/300cc Min. 13.0 — — —
Coolant temperature °C 70 to 90 70 to 90 70 to 90 70 to 90
Lubricating oil
°C 90 to 110 90 to 110 90 to 110 80 to 110
temperature
Lubricating oil kPa 340 to 490 340 to 490 340 to 490 Min. 120
pressure {kg/cm2} {3.5 to 5.0} {3.5 to 5.0} {3.5 to 5.0} {Min. 1.2}
Exhaust temperature °C Max. 670 Max. 670 — —
a This table shows the standard values obtained by using the JIS correction coefficients.
a Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.
a This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
a Use ASTM No.1 or No. 2 diesel fuel as fuel.
a Use SAE15W-40 as lubricating oil.
34 140E-5 Series
20 Standard value table SEN00147-07
Running-in standard
Engine SAA6D140E-5
Machine models SDG400S-6B1 (HOKUETSU INDUSTRIES GENERATOR)
Procedure
Item
1 2 3 4 5
Running time min. 1 3 6 8 2
Speed rpm 875 1,134 1,422 1,638 1,800
Dynamometer load N{kg} 0{0} 1,087{111} 1,733{177} 2,253{230} 2,751{281}
Output kW{HP} 0{0} 92{123} 185{248} 277{371} 371{498}
a This table shows the values when the fan is not installed.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Engine SAA6D140E-5
Machine models SDG400S-6B1 (HOKUETSU INDUSTRIES GENERATOR)
Test item Rated horsepower Max. torque High idle speed Low idle speed
Specification value 371 kW/1,800 rpm —
— 1,890 ± 50 rpm 875 ± 25 rpm
(Gross value) {498 HP/1,800 rpm} —
Speed rpm 1,800 — 1,890 ± 50 875 ± 25
N 2,695 to 2,813 —
Dynamometer load — —
{kg} {275 to 287} —
kW 360 to 382
Output (Gross value) — — —
{HP} {483 to 512}
Nm
Torque (Gross value) — — — —
{kgm}
Fuel consumption sec/300cc Min. 10.8 — — —
Coolant temperature °C 70 to 90 — 70 to 90 70 to 90
Lubricating oil
°C 90 to 110 — 90 to 110 80 to 110
temperature
Lubricating oil kPa 340 to 490 — 340 to 490 Min. 120
pressure {kg/cm2} {3.5 to 5.0} {—} {3.5 to 5.0} {Min. 1.2}
Exhaust temperature °C Max. 670 — — —
a This table shows the standard values obtained by using the JIS correction coefficients.
a Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.
a This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
a Use ASTM No.1 or No. 2 diesel fuel as fuel.
a Use SAE15W-40 as lubricating oil.
140E-5 Series 35
SEN00147-07
© 2012 KOMATSU
All Rights Reserved
Printed in Japan 12-12 (01)
36
SEN00149-05
140E-5 Series
140E-5 Series 1
SEN00149-05 30 Testing and adjusting
2 140E-5 Series
30 Testing and adjusting SEN00149-05
Testing fuel pressure G 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
2 799-401-2320 Gauge 1 Pressure gauge: 1 MPa {10 kg/cm2}
795-471-1450 Adapter 1 8 × 1.25 mm o R1/8
3
07005-00812 Gasket 1
1 6151-51-8490 Spacer 1 Inside diameter: 14 mm
2 6206-71-1770 Joint 1 Inside diameter of joint: 10 mm
Commercially
3 Hose 1 ∅5mm × 2 – 3 m
available
Testing fuel return rate Commercially
and leakage
H 4 Hose 1 ∅15mm × 2 – 3 m
available
Commercially
5 Measuring cylinder 1
available
Commercially
6 Stopwatch 1
available
140E-5 Series 3
SEN00149-05 30 Testing and adjusting
4 140E-5 Series
30 Testing and adjusting SEN00149-05
Socket
140E-5 Series 5
SEN00149-05 30 Testing and adjusting
6 140E-5 Series
30 Testing and adjusting SEN00149-05
140E-5 Series 7
SEN00149-05 30 Testing and adjusting
Adjusting valve clearance 1 3. While fixing adjustment screw (3), loosen lock-
nut (4).
a Adjusting tool for valve clearance a After setting the No. 1 cylinder to the com-
pression top dead center, adjust the valve
Symbol Part No. Part name clearance of the No. 1 cylinder.
Commercially
C Clearance gauge
available
4. Insert clearance gauge C in the clearance
between rocker arm (5) and crosshead (6) and
1. Remove 6 cylinder head covers (1). adjust the valve clearance with adjustment
screw (3).
a With the clearance gauge inserted, turn
the adjustment screw to a degree that you
can move the thickness gauge lightly.
a Valve clearance
Intake valve: 0.35 mm, Exhaust valve:
0.57 mm
8 140E-5 Series
30 Testing and adjusting SEN00149-05
140E-5 Series 9
SEN00149-05 30 Testing and adjusting
10 140E-5 Series
30 Testing and adjusting SEN00149-05
140E-5 Series 11
SEN00149-05 30 Testing and adjusting
12 140E-5 Series
30 Testing and adjusting SEN00149-05
Testing EGR valve and bypass 3. Connect hydraulic tester [2] (Component part
valve drive oil pressure 1 of tool F1) to the nipple.
140E-5 Series 13
SEN00149-05 30 Testing and adjusting
14 140E-5 Series
30 Testing and adjusting SEN00149-05
Testing fuel pressure 1 3. Run the engine at high idle and measure the
fuel pressure.
a If the fuel pressure is in the following
a Testing tools for fuel pressure range, it is normal.
Symbol Part No. Part name
799-101-5002 Hydraulic tester Engine speed Fuel pressure
1
790-261-1204 Digital hydraulic tester 0.15 – 0.3 MPa
High idle
G 2 799-401-2320 Gauge {1.5 – 3 kg/cm2}
795-471-1450 Adapter
3
07005-00812 Gasket
140E-5 Series 15
SEN00149-05 30 Testing and adjusting
16 140E-5 Series
30 Testing and adjusting SEN00149-05
140E-5 Series 17
SEN00149-05 30 Testing and adjusting
18 140E-5 Series
30 Testing and adjusting SEN00149-05
140E-5 Series 19
SEN00149-05 30 Testing and adjusting
20 140E-5 Series
30 Testing and adjusting SEN00149-05
140E-5 Series 21
SEN00149-05 30 Testing and adjusting
22 140E-5 Series
30 Testing and adjusting SEN00149-05
Testing
Press the intermediate point of the belt between
alternator pulley and drive pulley with a finger and
measure deflection (a) of the belt.
a Pressing force: Approx. 98 N {Approx. 10 kg}
a Deflection (a): 13 – 16 mm (1 piece)
Adjusting
a If the deflection is out of the standard range,
adjust it according to the following procedure.
140E-5 Series 23
SEN00149-05 30 Testing and adjusting
Testing
Press the intermediate point (at the arrow) of the
belt (1) between fan pulley and crankshaft pulley
with a finger and measure the deflection of the belt.
a Check the belts one by one.
a Pressing force: Approx. 98 N {Approx. 10 kg}
a Deflection: 15 – 17 mm (When new)
19 – 21 mm (When retightened)
Adjusting
a If the deflection is out of the standard range,
adjust it according to the following procedure.
24 140E-5 Series
30 Testing and adjusting SEN00149-05
140E-5 Series 25
SEN00149-05 30 Testing and adjusting
Testing fuel pressure G 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
2 799-401-2320 Gauge 1 Pressure gauge: 1 MPa {10 kg/cm2}
795-471-1450 Adapter 1 8 × 1.25 mm o R1/8
3
07005-00812 Gasket 1
1 6151-51-8490 Spacer 1 Inside diameter: 14 mm
2 6206-71-1770 Joint 1 Inside diameter of joint: 10 mm
Commercially
3 Hose 1 ∅5mm × 2 – 3 m
available
Testing fuel return rate Commercially
and leakage
H 4 Hose 1 ∅15mm × 2 – 3 m
available
Commercially
5 Measuring cylinder 1
available
Commercially
6 Stopwatch 1
available
26 140E-5 Series
30 Testing and adjusting SEN00149-05
140E-5 Series 27
SEN00149-05 30 Testing and adjusting
Socket
28 140E-5 Series
30 Testing and adjusting SEN00149-05
140E-5 Series 29
SEN00149-05 30 Testing and adjusting
30 140E-5 Series
30 Testing and adjusting SEN00149-05
Adjusting valve clearance 1 3. While fixing adjustment screw (3), loosen lock-
nut (4).
a Adjusting tool for valve clearance a After setting the No. 1 cylinder to the com-
pression top dead center, adjust the valve
Symbol Part No. Part name clearance of the No. 1 cylinder.
Commercially
C Clearance gauge
available
4. Insert clearance gauge C in the clearance
between rocker arm (5) and crosshead (6) and
1. Remove 6 cylinder head covers (1). adjust the valve clearance with adjustment
screw (3).
a With the clearance gauge inserted, turn
the adjustment screw to a degree that you
can move the thickness gauge lightly.
a Valve clearance
Intake valve: 0.35 mm, Exhaust valve:
0.57 mm
140E-5 Series 31
SEN00149-05 30 Testing and adjusting
32 140E-5 Series
30 Testing and adjusting SEN00149-05
140E-5 Series 33
SEN00149-05 30 Testing and adjusting
34 140E-5 Series
30 Testing and adjusting SEN00149-05
140E-5 Series 35
SEN00149-05 30 Testing and adjusting
36 140E-5 Series
30 Testing and adjusting SEN00149-05
Testing fuel pressure 1 3. Run the engine at high idle and measure the
fuel pressure.
a If the fuel pressure is in the following
a Testing tools for fuel pressure range, it is normal.
Symbol Part No. Part name
799-101-5002 Hydraulic tester Engine speed Fuel pressure
1
790-261-1204 Digital hydraulic tester 0.15 – 0.3 MPa
High idle
G 2 799-401-2320 Gauge {1.5 – 3 kg/cm2}
795-471-1450 Adapter
3
07005-00812 Gasket
140E-5 Series 37
SEN00149-05 30 Testing and adjusting
a Reduced cylinder mode operation means to a No-injection cranking means to crank the
run the engine with the fuel injectors of 1 or engine with the starting motor while all the
more cylinders disabled electrically to reduce injections are stopped electrically. The pur-
the number of effective cylinders. The pur- pose and effect of this operation are as follows.
poses and effects of this operation are as fol- q Before the engine is started after it or the
lows. machine has been stored for a long period, the
1. This operation is used to find out a cylinder no-injection cranking is performed to lubricate
which does not output power normally (or, the engine parts and protect them from sei-
combustion in it is abnormal). zure.
2. When a cylinder is selected for the reduced a Perform the no-injection operation with the
cylinder mode operation, if the engine speed engine mounted on the machine or connected
and output do not change from the normal to INSITE (bench test tool). Before perform-
operation (all-cylinder operation), that cylinder ing, see Testing method in the shop manual for
has 1 or more defects. The possible defects the machine or INSITE (bench test tool).
are as follows.
q Leakage of compression through cylinder
head gasket
q Defective injection
q Defective piston, piston ring, or cylinder
liner
q Defective valve mechanism (Moving valve
system)
q Defect in electrical system
3. Since the common rail fuel injection system
controls the injector of each cylinder electroni-
cally, the operator can perform the reduced cyl-
inder mode operation easily with switches to
find out a defective cylinder.
a Perform the reduced cylinder mode opera-
tion with the engine mounted on the
machine or connected to INSITE (bench
test tool). Before performing, see Testing
method in the shop manual for the
machine or INSITE (bench test tool).
38 140E-5 Series
30 Testing and adjusting SEN00149-05
140E-5 Series 39
SEN00149-05 30 Testing and adjusting
40 140E-5 Series
30 Testing and adjusting SEN00149-05
140E-5 Series 41
SEN00149-05 30 Testing and adjusting
Bleeding air from fuel circuit 1 4. Turn “ON” switch (3) of electric priming pump
(2) installed to the chassis.
Reference: The electric priming pump switch is a The electric priming pump operates and
installed to the chassis. lamp (4) blinks.
a Manual priming pump is set for some models.
(See the "with EGR".)
a Bleed air from the fuel circuit in the following
cases according to this procedure.
q When the fuel filter is replaced
q When fuel is used up
q When the engine is started for the first
time after the fuel piping or supply pump is
replaced
a If the fuel filter was replaced, do not fill the
main filter and prefilter with the fuel.
2. Check that the fuel valve on the fuel tank side a The electric priming pump has a timer in it
is open. to start and stop itself automatically (See
the following figure).
3. Turn lever (1) of the air bleeding piping to the a The electric priming pump stops while the
parallel position with the piping to open the cir- lamp is blinking. This phenomenon is not
cuit valve. abnormal, however.
a If the switch is turned to the “OFF” position
while the lamp is blinking, the lamp goes
off and the electric priming pump stops.
k While the electric priming pump is
operating, pressure is applied to the
fuel circuit. Do not loosen the air
bleeding plug at this time, since the
fuel may spout out.
42 140E-5 Series
30 Testing and adjusting SEN00149-05
140E-5 Series 43
SEN00149-05 30 Testing and adjusting
44 140E-5 Series
30 Testing and adjusting SEN00149-05
Testing
Press the intermediate point of the belt between
alternator pulley and drive pulley with a finger and
measure deflection (a) of the belt.
a Pressing force: Approx. 98 N {Approx. 10 kg}
a Deflection (a): 13 – 16 mm (1 piece)
Adjusting
a If the deflection is out of the standard range,
adjust it according to the following procedure.
140E-5 Series 45
SEN00149-05 30 Testing and adjusting
Testing
Press the intermediate point (at the arrow) of the
belt (1) between fan pulley and crankshaft pulley
with a finger and measure the deflection of the belt.
a Check the belts one by one.
a Pressing force: Approx. 98 N {Approx. 10 kg}
a Deflection: 15 – 17 mm (When new)
19 – 21 mm (When retightened)
Adjusting
a If the deflection is out of the standard range,
adjust it according to the following procedure.
46 140E-5 Series
30 Testing and adjusting SEN00149-05
140E-5 Series 47
SEN00149-05
© 2010 KOMATSU
All Rights Reserved
Printed in Japan 04-10
48
SEN00151-04
140E-5 Series
40 Troubleshooting 1
General information on troubleshooting
Points to remember when troubleshooting ..................................................................................................... 2
Method of displaying trouble diagnosis lamps (Method of displaying error code) .......................................... 3
Error codes and failure codes list.................................................................................................................... 5
Information in troubleshooting table.............................................................................................................. 10
Connection table for connector pin numbers ................................................................................................ 12
T- branch box and T- branch adapter table ................................................................................................... 48
140E-5 Series 1
SEN00151-04 40 Troubleshooting
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent
reoccurrence of the failure. When carrying out troubleshooting, an important point is of course to understand
the structure and function. However, a short cut to effective troubleshooting is to ask the operator various ques-
tions to form some idea of possible causes of the failure that would produce the reported symptoms.
1. When carrying out troubleshooting, do not 3) Check other inspection items, if neces-
hurry to disassemble the components. sary.
If components are disassembled immediately 4) Some other maintenance items can be
after any failure occurs: checked externally, so check any item that
q Parts that have no connection with the fail- is considered to be necessary.
ure or other unnecessary parts will be dis- 5) Check the controller for display of an error.
assembled.
q It will become impossible to find the cause 4. Confirming failure
of the failure. Confirm the extent of the failure yourself, and
It will also cause a waste of manhours, parts, judge whether to handle it as a real failure or
or oil or grease, and at the same time, will also as a problem with the method of operation, etc.
lose the confidence of the user or operator. a When operating the machine or engine to
For this reason, when carrying out troubleshoot- reenact the troubleshooting symptoms, do
ing, it is necessary to carry out thorough prior not carry out any investigation or mea-
investigation and to carry out troubleshooting in surement that may make the problem
accordance with the fixed procedure. worse.
2 140E-5 Series
40 Troubleshooting SEN00151-04
Combination of trouble diagnosis lamps and diagnosis lamp indication selector switch
Normal display mode Error code display mode
Item (While starting switch is ON or engine is running) (While starting switch is ON and engine is stopped)
When normal When error occurs When error occurs
Diagnosis lamp
indication selector OFF ON
switch
R Error code is indicated by number of flashes.
Lamp off Either lamp lights up
Y Lamp off
140E-5 Series 3
SEN00151-04 40 Troubleshooting
Indication in normal display mode (when diagnosis lamp indication selector switch is OFF)
q The normal display mode means the state in which the diagnosis lamp indication selector switch is kept
OFF while the starting switch is ON or the engine is running.
q While the engine controller system is operating normally in the normal state, the red lamp and yellow
lamp are turned OFF. If the system has an error, either lamp is turned ON.
Indication in error code display mode (when diagnosis lamp indication selector switch is ON)
q The error code display mode means the state in which the diagnosis lamp indication selector switch is
kept ON while the engine is stopped (with the starting switch is ON).
q In this state, the red lamp indicates the error code by the number of flashes. The yellow lamp is kept
turned OFF at this time.
q When starting the engine, turn the diagnosis lamp indication selector switch OFF. Do not turn the diag-
nosis lamp indication selector switch ON while the engine is running.
4 140E-5 Series
40 Troubleshooting SEN00151-04
140E-5 Series 5
SEN00151-04 40 Troubleshooting
Machine failure
INSITE error code Failure phenomenon Reference document No.
code
449 CA449 Rail Press. High Error 2
451 CA451 Rail Press. Sensor High Error
452 CA452 Rail Press. Sensor Low Error
553 CA553 Rail Press. High Error 1
554 CA554 Rail Press Sensor In Range Error
559 CA559 No-pressure Feed By Supply pump 1
689 CA689 Eng. Ne Speed Sensor Error
731 CA731 Eng. Bkup Speed Sensor Phase Error
757 CA757 All Engine Controller Data Lost Error
778 CA778 Eng. Bkup Speed Sensor Error
1228 CA1228 EGR Valve Servo Error 1
1625 CA1625 EGR Valve Servo Error 2
1626 CA1626 Bypass Valve Solenoid Drive Short Circuit Error
1627 CA1627 Bypass Valve Solenoid Drive Open Error
1628 CA1628 Bypass Valve Servo Error 1
1629 CA1629 Bypass Valve Servo Error 2 Troubleshooting of
electrical system
1631 CA1631 Bypass Valve Lift Sensor High Error
(E-mode), Part 2
1632 CA1632 Bypass Valve Lift Sensor Low Error SEN00154-02
1633 CA1633 KOMNET Error
1642 CA1642 EGR Inlet Press Sensor Low Error
1653 CA1653 EGR Inlet Press Sensor High Error
2185 CA2185 Throttle Sens. Sup. Volt. High Error
2186 CA2186 Throttle Sens. Sup. Volt. Low Error
2249 CA2249 No-pressure Feed By Supply pump 2
2271 CA2271 EGR Valve Lift Sensor High Error
2272 CA2272 EGR Valve Lift Sensor Low Error
2351 CA2351 EGR Valve Solenoid Drive Short Error
2352 CA2352 EGR Valve Solenoid Drive Open Error
2555 CA2555 Intake Air Heater Relay Open Error
2556 CA2556 Intake Air Heater Relay Short Error
(143) B@BAZG Eng. Oil Press Low Torque Derate
(146) B@BCNS Eng. Overheat
(415) B@BAZG Eng. Oil Press. Low Speed Derate
6 140E-5 Series
40 Troubleshooting SEN00151-04
For generator
Machine failure
Failure phenomenon Reference document No.
code
A8 Speed Adj. Vol. High (Isochronous) A8
A9 Speed Adj. Vol. Low (Isochronous) A9
AA Speed Adj. Vol. High (Droop) AA
AB Speed Adj. Vol. Low (Droop) AB
AF KOMNET Error (CR710) AF
b6 Droop Rate Adj. Vol. High b6
b7 Droop Rate Adj. Vol. Low b7 –
b8 Low Idle Speed Adj. Vol. High b8
b9 Low Idle Speed Adj. Vol. Low b9
bc Speed Adj. Vol. High (Default) bc
bd Speed Adj. Vol. Low (Default) bd
bE Ramptime Adj. Vol. High bE
bF Ramptime Adj. Vol. Low bF
CA111 Engine Controller Internal Failure
CA115 Eng. Ne and Bkup Speed Sensor Error
CA122 Charge (boost) Air Press Sensor High Error
CA123 Charge (boost) Air Press Sensor Low Error
CA135 Oil Press. Sensor High Error
CA141 Oil Press. Sensor Low Error
CA144 Coolant Temp. Sensor High Error
CA145 Coolant Temp. Sensor Low Error
CA153 Charge (boost) Air Temp. Sensor High Error
CA154 Charge (boost) Air Temp. Sensor Low Error
CA187 Sensor Sup. 2 Volt. Low Error
CA221 Ambient Air Press. Sensor High Error
Troubleshooting of
CA222 Ambient Air Press. Sensor Low Error electrical system
CA227 Sensor Sup. 2 Volt. High Error (E-mode), Part 1
SEN00153-02
CA234 Eng. Overspeed
CA238 Ne Speed Sensor Sup. Volt. Error
CA263 Fuel Temp. Sensor High Error
CA265 Fuel Temp. Sensor Low Error
CA271 PCV1 Short Error
CA272 PCV1 Open Error
CA273 PCV2 Short Error
CA274 PCV2 Open Error
CA322 Injector #1 System Open/Short Error
CA323 Injector #5 System Open/Short Error
CA324 Injector #3 System Open/Short Error
CA325 Injector #6 System Open/Short Error
140E-5 Series 7
SEN00151-04 40 Troubleshooting
Machine failure
Failure phenomenon Reference document No.
code
CA331 Injector #2 System Open/Short Error
CA332 Injector #4 System Open/Short Error
CA342 Engine Controller Data Matching Error
Troubleshooting of
CA351 INJ. Drive Circuit Error electrical system
CA352 Sensor Sup. 1 Volt. Low Error (E-mode), Part 1
SEN00153-02
CA386 Sensor Sup. 1 Volt. High Error
CA441 Supply Voltage Low Error
CA442 Supply Voltage High Error
CA449 Rail Press. High Error 2
CA451 Rail Press. Sensor High Error
CA452 Rail Press. Sensor Low Error
CA553 Rail Press. High Error 1
CA559 No-pressure Feed By Supply pump 1
CA689 Eng. Ne Speed Sensor Error
CA731 Eng. Bkup Speed Sensor Phase Error
CA757 All Engine Controller Data Lost Error
CA778 Eng. Bkup Speed Sensor Error
CA1228 EGR Valve Servo Error 1
CA1625 EGR Valve Servo Error 2 Troubleshooting of
electrical system
CA1633 KOMNET Error
(E-mode), Part 2
CA2185 Throttle Sens. Sup. Volt. High Error SEN00154-02
CA2186 Throttle Sens. Sup. Volt. Low Error
CA2249 No-pressure Feed By Supply pump 2
CA2271 EGR Valve Lift Sensor High Error
CA2272 EGR Valve Lift Sensor Low Error
CA2351 EGR Valve Solenoid Drive Short Error
CA2352 EGR Valve Solenoid Drive Open Error
CA2555 Intake Air Heater Relay Open Error
CA2556 Intake Air Heater Relay Short Error
CA143 Eng. Oil Press Low Torque Derate
CA146 Eng. Overheat
8 140E-5 Series
40 Troubleshooting SEN00151-04
140E-5 Series 9
SEN00151-04 40 Troubleshooting
10 140E-5 Series
40 Troubleshooting SEN00151-04
140E-5 Series 11
SEN00151-04 40 Troubleshooting
a The terms of male and female refer to the pins, while the terms of male housing and female housing
refer to the mating portion of the housing.
12 140E-5 Series
40 Troubleshooting SEN00151-04
140E-5 Series 13
SEN00151-04 40 Troubleshooting
14 140E-5 Series
40 Troubleshooting SEN00151-04
140E-5 Series 15
SEN00151-04 40 Troubleshooting
16 140E-5 Series
40 Troubleshooting SEN00151-04
140E-5 Series 17
SEN00151-04 40 Troubleshooting
18 140E-5 Series
40 Troubleshooting SEN00151-04
140E-5 Series 19
SEN00151-04 40 Troubleshooting
20 140E-5 Series
40 Troubleshooting SEN00151-04
140E-5 Series 21
SEN00151-04 40 Troubleshooting
22 140E-5 Series
40 Troubleshooting SEN00151-04
140E-5 Series 23
SEN00151-04 40 Troubleshooting
24 140E-5 Series
40 Troubleshooting SEN00151-04
140E-5 Series 25
SEN00151-04 40 Troubleshooting
26 140E-5 Series
40 Troubleshooting SEN00151-04
140E-5 Series 27
SEN00151-04 40 Troubleshooting
28 140E-5 Series
40 Troubleshooting SEN00151-04
140E-5 Series 29
SEN00151-04 40 Troubleshooting
30 140E-5 Series
40 Troubleshooting SEN00151-04
140E-5 Series 31
SEN00151-04 40 Troubleshooting
32 140E-5 Series
40 Troubleshooting SEN00151-04
140E-5 Series 33
SEN00151-04 40 Troubleshooting
34 140E-5 Series
40 Troubleshooting SEN00151-04
140E-5 Series 35
SEN00151-04 40 Troubleshooting
36 140E-5 Series
40 Troubleshooting SEN00151-04
140E-5 Series 37
SEN00151-04 40 Troubleshooting
38 140E-5 Series
40 Troubleshooting SEN00151-04
140E-5 Series 39
SEN00151-04 40 Troubleshooting
40 140E-5 Series
40 Troubleshooting SEN00151-04
140E-5 Series 41
SEN00151-04 40 Troubleshooting
42 140E-5 Series
40 Troubleshooting SEN00151-04
140E-5 Series 43
SEN00151-04 40 Troubleshooting
44 140E-5 Series
40 Troubleshooting SEN00151-04
140E-5 Series 45
SEN00151-04 40 Troubleshooting
46 140E-5 Series
40 Troubleshooting SEN00151-04
140E-5 Series 47
SEN00151-04 40 Troubleshooting
a The vertical column indicates a part number of T-branch box or T-branch adapter while the horizontal
column indicates a part number of harness checker assembly.
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol
48 140E-5 Series
40 Troubleshooting SEN00151-04
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol
140E-5 Series 49
SEN00151-04 40 Troubleshooting
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol
799-601-9330 Case q
799-601-9340 Case q
799-601-9350 Adapter for DRC 40 DRC-40 q
799-601-9360 Adapter for DRC 24 DRC-24 q
799-601-9410* Socket for engine (CRI-T2) 2 G q
Adapter for engine (CRI-T2)
799-601-9420 Adapter for engine (CRI-T3) PFUEL 3 A3 q q
Oil pressure sensor
Socket for engine (CRI-T2)
799-601-9430* 2 P q q
Socket for engine (CRI-T3) PCV
799-601-9440* Socket for engine (CRI-T2) 3 1,2,3 q
795-799-5520* Socket for engine (HPI-T2) 2 S q
Socket for engine (HPI-T2)
795-799-5530* Socket for engine (CRI-T3) 2 C q q
Temperature sensor
Socket for engine (HPI-T2)
795-799-5540* 2 A q q
Socket for engine (CRI-T3) TIM
795-799-5460 Cable for engine (HPI-T2) 3 — q
795-799-5470 Cable for engine (HPI-T2) 3 — q
795-799-5480 Cable for engine (HPI-T2) 3 — q
799-601-4110 Adapter for engine (140-T3) PIM 4 ITT3N q q
799-601-4130 Adapter for engine (CRI-T3) NE, CAM 3 FCIN q q
Adapter for engine (CRI-T3)
799-601-4140 3 FCIG q q
Atomosphere pressure
799-601-4150 Adapter for engine (CRI-T3) POIL 3 FCIB q q
Adapter for engine (CRI-T3)
799-601-4160 2 4160 q q
Oil pressure switch
799-601-4180 Adapter for engine (CRI-T3) PEVA 3 4180 q q
Socket for engine (CRI-T3)
799-601-4190* 3 1,2,3L q q
Commonrail pressure
Socket for engine (CRI-T3)
799-601-4230* 4 1,2,3,4C q q
Air intake pressure/temperature
799-601-4240* Socket for engine (CRI-T3) PAMB 3 1,2,3A q q
799-601-4250* Socket for engine (CRI-T3) PIM 3 1,2,3B q q
799-601-4330* Socket for engine (CRI-T3) G 3 1,2,3,G q q
Socket for engine (CRI-T3)
799-601-4340* 2 2,PA q q
Pump actuator
Socket for engine (CRI-T3)(95)
799-601-4380* 4 1,2,3,4T q
Air intake pressure/temperature
799-601-4260 Adapter for controller (ENG) 4 DTP4 q q
799-601-4211 Adapter for controller (ENG) 50 DRC50 q
799-601-4220 Adapter for controller (ENG) 60 DRC60 q
799-601-4390* Socket for controller (95 ENG) 60 — q
799-601-4280* Box for controller (PUMP) 121 — q
799-601-9720 Adapter for controller (HST) 16 HST16A q
799-601-9710 Adapter for controller (HST) 16 HST16B q
799-601-9730 Adapter for controller (HST) 26 HST26A q
2,
Multi-adapter for
799-601-9890 3, — q
DT2 – 4 and DTM2
4,
50 140E-5 Series
40 Troubleshooting SEN00151-04
140E-5 Series 51
SEN00151-04
© 2009 KOMATSU
All Rights Reserved
Printed in Japan 09-09 (01)
52
SEN00152-03
140E-5 Series
40 Troubleshooting 1
Troubleshooting of mechanical system
(S-mode)
Troubleshooting of mechanical system (S-mode)........................................................................................... 4
Method of using troubleshooting charts ............................................................................................... 4
S-1 Starting performance is poor ......................................................................................................... 8
S-2 Engine does not start................................................................................................................... 10
S-3 Engine does not pick up smoothly............................................................................................... 14
S-4 Engine stops during operations ................................................................................................... 15
S-5 Engine does not rotate smoothly ................................................................................................. 16
S-6 Engine lacks output (or lacks power)........................................................................................... 17
S-7 Exhaust smoke is black (incomplete combustion) ....................................................................... 18
S-8 Oil consumption is excessive (or exhaust smoke is blue) ........................................................... 20
S-9 Oil becomes contaminated quickly .............................................................................................. 21
S-10 Fuel consumption is excessive.................................................................................................. 22
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) ........................................ 23
S-12 Oil pressure drops ..................................................................................................................... 24
140E-5 Series 1
SEN00152-03 40 Troubleshooting
2 140E-5 Series
40 Troubleshooting SEN00152-03
140E-5 Series 3
SEN00152-03 40 Troubleshooting
Questions:
Items to be drawn from the user or operator. They correspond to A and B in the chart on the right.
The items in A are basic ones. The items in B can be drawn from the user or operator, depending on their
level.
Check items:
Simple check items used by the serviceman to narrow the causes. They correspond to C in the chart on the
right.
Causes:
Items to be narrowed from the questions and check items.
The serviceman narrows down the probable causes from A, B, and C.
Troubleshooting:
Items used to find out the true cause by verifying the narrowed causes finally in order from the most probable
one by applying troubleshooting tools or direct inspection.
Items listed in the [Questions] and [Check items] and related to the [Causes] are marked with E, Q, and w.
E: Causes to be referred to for questions and check items
Q: Causes related to questions and check items
w: Causes highly probable among ones marked with Q
a When narrowing the “causes”, apply the items marked with w before those marked with Q.
When narrowing the “causes”, do not apply the items marked with E (If no items have other marks and
the causes cannot be narrowed, however, you may apply them.)
4 140E-5 Series
40 Troubleshooting SEN00152-03
140E-5 Series 5
SEN00152-03 40 Troubleshooting
6 140E-5 Series
40 Troubleshooting SEN00152-03
There is a causal relationship between 3 items in the [Questions] and [Check items] sections and 6 items in
the [Causes] sections.
The method of pinpointing the [cause] from the causal relationship and approaching the [troubleshooting] is
explained according to Step 1 — Step 3 shown below.
140E-5 Series 7
SEN00152-03 40 Troubleshooting
a The common rail fuel injection system (CRI) controls the fuel
Defective injector
["with EGR" only]
injection timing electrically. Accordingly, even if the starting
operation is carried out, the engine may not start until the crank-
shaft revolves 2 turns at maximum. This phenomenon does not
indicate a trouble, however.
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Clean
Clean
Clean
Clean
Remedy
8 140E-5 Series
40 Troubleshooting SEN00152-03
140E-5 Series 9
SEN00152-03 40 Troubleshooting
Degree of use of
machine
Operated for long period E EE
Condition of horn when Horn does not sound Q Q w
starting switch is turned
ON Horn volume is low w
Battery electrolyte is low w
Battery terminal is loose w
When starting switch is turned ON, there is no operating sound from battery relay Q w
When starting switch is turned to START, starting pinion does not move out Q Q w
Check items
When specific gravity of electrolyte and voltage of battery are measured, they are low q
Troubleshooting
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Remedy —
10 140E-5 Series
40 Troubleshooting SEN00152-03
140E-5 Series 11
SEN00152-03 40 Troubleshooting
machine
Operated for long period EEE
Exhaust smoke suddenly stopped coming out (when starting again) wQwww EE
Replacement of filters has not been carried out according to Operation and Main-
tenance Manual
ww E Q
When fuel tank is inspected, it is found to be empty w
Air breather hole of fuel tank cap is clogged w
Rust and water are found when fuel tank is drained QQQ QQ
When fuel filter is removed, there is not fuel in it w w
Fuel is leaking from fuel piping w
Check items
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Clean
Clean
Remedy
Add
12 140E-5 Series
40 Troubleshooting SEN00152-03
c) Exhaust smoke comes out but engine does not start (fuel is being injected) Causes
While engine is cranked If air bleeding plug of fuel filter is removed, fuel does not flow out Q ww
with starting motor, If spill hose from injector is disconnected, little fuel spills w
When exhaust manifold is touched immediately after starting engine, temperature of some
cylinders is low
w
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Clean
Clean
Remedy
140E-5 Series 13
SEN00152-03 40 Troubleshooting
Black
When engine is cranked, abnormal sound is generated around cylinder head w
When engine is cranked, interference sound is generated around turbocharger w
High idle speed under no load is normal, but speed suddenly drops when load is
applied Q w w
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Clean
Clean
Clean
Clean
Remedy
*1: Code [1228/CA1228] and code [1625/CA1625] or code [1628/CA1628] and code [1629/CA1629] in E-
mode
*2: Code [559/CA559] and code [2249/CA2249] in E-mode
14 140E-5 Series
40 Troubleshooting SEN00152-03
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Clean
Clean
Clean
Add
Remedy —
140E-5 Series 15
SEN00152-03 40 Troubleshooting
Carry out troubleshooting according to “Abnormality in EGR valve servo (*1)” in E-mode q
["with EGR" only]
Carry out troubleshooting according to “Abnormality in bypass valve servo (*2)” in E-
q
mode ["with EGR" only]
Troubleshooting
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Clean
Add
Remedy
16 140E-5 Series
40 Troubleshooting SEN00152-03
Suddenly
Power was lost
Gradually Q Q Q Q Q Q Q
Non-specified fuel is being used Q Q
Replacement of filters has not been carried out according to Operation and Mainte-
nance Manual
w
Engine oil must be added more frequently Q Q Q
Dust indicator is red (if indicator is installed) w
Air breather hole of fuel tank cap is clogged w
Fuel is leaking from fuel piping w
Output becomes insufficient after short stop of operation w
Black w w w
Color of exhaust gas
Blue under light load w
When exhaust manifold is touched immediately after starting engine, temperature of
some cylinders is low
w
w
Check items
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Clean
Clean
140E-5 Series 17
SEN00152-03 40 Troubleshooting
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Adjust
Adjust
Clean
Remedy
18 140E-5 Series
40 Troubleshooting SEN00152-03
*1: Code [1228/CA1228] and code [1625/CA1625] or code [1628/CA1628] and code [1629/CA1629] in E-
mode
*2: EGR inlet pressure pipings
Remove 2 EGR inlet pressure pipings (2) and check their inside for clogging.
Reference: EGR inlet pressure sensor is applied to only machines Serial No. up to 530896.
140E-5 Series 19
SEN00152-03 40 Troubleshooting
Turbocharger
• Long-time operation of engine at low idle or high idle (Do not run engine
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
20 140E-5 Series
40 Troubleshooting SEN00152-03
machine
Non-specified fuel is being used Q
Engine oil must be added more frequently Q w
Even when engine oil temperature rises, oil filter clogging monitor indi-
w Q
cates clogging (if monitor is installed)
Metal particles are found when oil is drained Q Q
Inside of exhaust pipe is dirty with oil w
Engine oil temperature rises quickly w
w
Check items
Replace
Replace
Replace
Clean
Clean
Remedy —
140E-5 Series 21
SEN00152-03 40 Troubleshooting
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Remedy
22 140E-5 Series
40 Troubleshooting SEN00152-03
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)1
Broken hydraulic oil cooler or power train oil cooler on applicable machine side
• Internal leakage in lubrication system
Remedy —
140E-5 Series 23
SEN00152-03 40 Troubleshooting
• Selection of oil by the temperature etc. specified in the Operation and Main-
tenance Manual is not observed.
machine
Oil pressure monitor indicates low oil pressure (if monitor is installed) Q w
Non-specified oil is being used Q Q
Replacement of filters has not been carried out according to Operation and
w
Maintenance Manual
Indicates pressure drop at low idle w Q Q
Oil pressure Indicates pressure drop at low, high idle Q w w w Q Q Q
monitor
Indicates pressure drop on slopes w
(if installed)
Sometimes indicates pressure drop w Q Q
Oil level monitor indicates oil level drop (if monitor is installed) w w
Oil level in oil pan is low w
External hydraulic piping is leaking, crushed w w
Check items
Valve and spring of oil pump relief valve are fatigued, damaged q
See S-13
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Clean
Clean
Remedy —
Add
24 140E-5 Series
40 Troubleshooting SEN00152-03
Degree of use of
Operated for long period EE E E
machine
Fuel must be added more frequently w w
Coolant must be added more frequently Q Q
There is oil in coolant Q Q Q w
Oil smells of diesel fuel w w
Oil is milky Q Q
When engine is started, drops of water come from muffler Q Q
When radiator cap is removed and engine is run at low idle, an abnormal number of
w Q
bubbles appear, or coolant spurts back
Check items
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Remedy
140E-5 Series 25
SEN00152-03 40 Troubleshooting
26 140E-5 Series
40 Troubleshooting SEN00152-03
machine
Condition of Sudden overheated Q Q w Q
overheating Always tends to overheat Q w w Q
Coolant temperature Rises quickly Q w
gauge (if installed) Does not go down from red range w
Radiator coolant level monitor indicates drop of coolant level (if monitor is installed) Q w
Engine oil level has risen, oil is milky w Q
Fan belt tension is low w
When fan pulley is turned, it has play w
Milky oil is floating on coolant w
There are excessive air bubbles in radiator, coolant spurts back w
When light bulb is held behind radiator core, no light passes through w
Check items
Radiator shroud, inside of underguard on applicable machine side are clogged with
w w
dirt or mud
Coolant is leaking because of cracks in hose or loose clamps w
Coolant flows out from radiator overflow hose w
Fan belt whines under sudden acceleration w
Power train oil temperature enters red range faster than engine coolant temperature
w
(if oil temperature gauge and coolant temperature gauge are installed)
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Remedy —
Add
140E-5 Series 27
SEN00152-03 40 Troubleshooting
belt
Confirm recent repair history
Degree of use of
Operated for long period E
Questions
machine
Condition of Gradually occurred Q Q
abnormal noise Sudden occurred Q Q Q Q
Non-specified fuel is being used Q
Oil must be added more frequently w
Metal particles are found when oil filter is drained w w
Air leaks between turbocharger and cylinder head w
When engine is cranked, interference sound is generated around turbocharger w
When engine is cranked, abnormal sound is generated around EGR gas piping
w
["with EGR" only]
When engine is cranked, abnormal sound is generated around cylinder head w w
When engine is cranked, beat noise is generated around muffler w
Check items
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Remedy
28 140E-5 Series
40 Troubleshooting SEN00152-03
• Abnormal combustion
Replace
Replace
Adjust
Remedy
140E-5 Series 29
SEN00152-03
© 2009 KOMATSU
All Rights Reserved
Printed in Japan 01-09 (01)
30
SEN00153-03
140E-5 Series
40 Troubleshooting 1
Troubleshooting of electrical system
(E-mode), Part 1
Troubleshooting of electrical system (E-mode), Part 1 ................................................................................... 3
Troubleshooting method for disconnecting wiring harness of pressure sensor system ....................... 3
E-1 Code [111/CA111] Engine Controller Internal Failure .................................................................... 6
E-2 Code [115/CA115] Eng. Ne and Bkup Speed Sensor Error........................................................... 7
E-3 Code [122/CA122] Charge (boost) Air Press Sensor High Error................................................... 8
E-4 Code [123/CA123] Charge (boost) Air Press Sensor Low Error ................................................. 12
E-5 Code [131/CA131] Throttle Sensor High Error ............................................................................ 16
E-6 Code [132/CA132] Throttle Sensor Low Error............................................................................. 20
E-7 Code [135/CA135] Oil Press. Sensor High Error......................................................................... 22
E-8 Code [141/CA141] Oil Press. Sensor Low Error ......................................................................... 24
E-9 Code [144/CA144] Coolant Temp. Sensor High Error ................................................................. 26
E-10 Code [145/CA145] Coolant Temp. Sensor Low Error................................................................ 28
E-11 Code [153/CA153] Charge (boost) Air Temp. Sensor High Error .............................................. 30
E-12 Code [154/CA154] Charge (boost) Air Temp. Sensor Low Error ............................................... 32
140E-5 Series 1
SEN00153-03 40 Troubleshooting
2 140E-5 Series
40 Troubleshooting SEN00153-03
Procedure
1. Measure and record resistance of pressure sensor unit.
1) Disconnect pressure sensor connector (1) and connect socket (2) to the sensor.
2) Measure resistances R1 and R2 between pins.
a If tester probes polarities to apply are reversed, measured values may change. Therefore, when
measuring resistances, apply the same tester probe polarities to the pressure sensor in steps 1 and
2.
a If measured value is infinite, take measurements with tester probes polarities exchanged each oth-
er and record the finite value obtained as a measured value.
a Since measured values may be different from each other, take several measurements. Cause of
the differences appears to be that the sensor may be charged by the tester. Take several measure-
ment in both steps 1 and 2. Take the fact into consideration this differences when determining
whether the wiring harness is disconnected in step 3.
2. Measure and record resistance with wiring harness between pressure sensor and engine controller
connected
1) Since 5 V power supply to pressure sensor is supplied to other sensors, disconnect the other sensor
connectors first.(*)
2) Connect the pressure sensor to be measured, disconnect connector (3) on engine controller side, and
connect T-adapter (4) to wiring harness side.
3) Connect T-box (5) to T-adapter (4) and measure respective pins for resistances R1' and R2'.
140E-5 Series 3
SEN00153-03 40 Troubleshooting
*: When measuring R2', disconnect the following connectors. (See circuit diagram related to code [187/
CA187])
q When measuring R2' of charge pressure sensor
(CA123)
Connectors of resistance RES, engine oil pressure sensor, ambient pressure sensor, and G sensor
q When measuring R2' of ambient pressure sen-
sor (CA222)
Connectors of charge pressure sensor, resistance RES, engine oil pressure sensor, and G sensor
4 140E-5 Series
40 Troubleshooting SEN00153-03
Measurement record (For measuring locations, see circuit diagram related to each code)
Sensor + Wiring harness
Sensor unit (Measuring
(Measuring location on
Sensor location on sensor pin Measured value Measured value
wiring harness side of
side)
engine controller)
R1: Between (1) (+) and
R2: Between (1) and (3)
Charge pressure (2) (-)
sensor R1': Between (44) and
R1: Between (2) and (3)
(47)
R2': Between (37) and
R2: Between (1) and (3)
(38) (*)
Ambient pressure R1: Between (2) (+) and R1': Between (3) (+)
sensor (1) (-) and (38) (-)
R1: Between (1) (+) and R1': Between (38) (+)
(2) (-) and (3) (-)
140E-5 Series 5
SEN00153-03 40 Troubleshooting
6 140E-5 Series
40 Troubleshooting SEN00153-03
140E-5 Series 7
SEN00153-03 40 Troubleshooting
E-3 Code [122/CA122] Charge (boost) Air Press Sensor High Error 1
a For “with EGR”
8 140E-5 Series
40 Troubleshooting SEN00153-03
140E-5 Series 9
SEN00153-03 40 Troubleshooting
a For “EGR-less”
10 140E-5 Series
40 Troubleshooting SEN00153-03
140E-5 Series 11
SEN00153-03 40 Troubleshooting
E-4 Code [123/CA123] Charge (boost) Air Press Sensor Low Error 1
12 140E-5 Series
40 Troubleshooting SEN00153-03
140E-5 Series 13
SEN00153-03 40 Troubleshooting
a For "EGR-less"
Cause Standard value in normal state/Remarks on troubleshooting
Defective power supply sys-
If code [187/CA187] or [227/CA227] is indicated, carry out
1 tem of charge pressure sen-
troubleshooting for it first.
sor (boost pressure sensor)
1. Turn starting switch to OFF position.
2. Disconnect connectors ENG and PIM.
Short circuit in wiring har- 3. Connect T-adapter to female side of ENG.
2
ness
Resis- Min.
Between ENG (female) (44) and (47)
tance 1 Mz
1. Turn starting switch to OFF position, then carry out trouble-
shooting.
Ground fault in wiring har- 2. Disconnect connectors ENG and PIM, and connect T-
3 ness adapter to female side of ENG.
Possible causes and (contact with ground circuit)
standard value in Resis- Min.
Between ENG (female) (44) and ground
normal state tance 1 Mz
Disconnection in wiring har- If cause is not found by the above checks, wiring harness may
4
ness be disconnected. (*)
a If causes 1 - 4 are not the cause for the trouble and check
result of cause 5 is abnormal, sensor is defective.
Defective charge pressure 1. Turn starting switch to OFF position.
(boost pressure) sensor 2. Connect T-adapter to connector ENG.
5
(lmproper input voltage of 3. Turn starting switch to ON position.
engine controller)
Sensor 0.3 – 4.7
Between ENG (44) and (47) Voltage
output V
If no abnormality is found by the above checks, the engine
controller is defective.
6 Defective engine controller
(Since the failure is in it, troubleshooting cannot be per-
formed.)
*: Refer to "Troubleshooting method for disconnected wiring harness of pressure sensor system."
14 140E-5 Series
40 Troubleshooting SEN00153-03
140E-5 Series 15
SEN00153-03 40 Troubleshooting
16 140E-5 Series
40 Troubleshooting SEN00153-03
Circuit diagram related to throttle sensor of accelerator pedal type (Case of HD325/405-7)
140E-5 Series 17
SEN00153-03 40 Troubleshooting
1
Throttle sensor of fuel control dial type (Case of PC800/800SE/850/850SE/850LC-8)
18 140E-5 Series
40 Troubleshooting SEN00153-03
140E-5 Series 19
SEN00153-03 40 Troubleshooting
20 140E-5 Series
40 Troubleshooting SEN00153-03
140E-5 Series 21
SEN00153-03 40 Troubleshooting
22 140E-5 Series
40 Troubleshooting SEN00153-03
a For “EGR-less”
140E-5 Series 23
SEN00153-03 40 Troubleshooting
24 140E-5 Series
40 Troubleshooting SEN00153-03
a For "EGR-less"
140E-5 Series 25
SEN00153-03 40 Troubleshooting
Open or short circuit in wir- Between ENG (female) (15) and (38)
2 (Coolant temperature: Min. 0 °C)
ing harness
a The resistance is the same as that 700 z –
Resistance
shown in the resistance character- 37 kz
istics table of the coolant tempera-
ture sensor of cause 1.
If no failure is found by above checks, engine controller is
3 Defective engine controller defective. (Since this is an internal failure, troubleshooting
cannot be performed.)
26 140E-5 Series
40 Troubleshooting SEN00153-03
a There are not connector SBP and line to the SBP for “EGR-less” in above figure.
140E-5 Series 27
SEN00153-03 40 Troubleshooting
Short circuit in wiring har- Between ENG (female) (15) and (38)
2 (Coolant temperature: Min. 0 °C)
ness
a The resistance is the same as that Resis- 700 z –
shown in the resistance characteristics tance 37 kz
table of the coolant temperature sen-
sor of cause 1.
1. Turn starting switch to OFF position.
Ground fault of wiring har- 2. Disconnect connectors ENG and TWTR, and connect T-
3 ness adapter to female side of ENG.
(contact with ground circuit) Resis- Min.
Between ENG (female) (15) and ground
tance 1 Mz
If no failure is found by above checks, engine controller is
4 Defective engine controller defective. (Since this is an internal failure, troubleshooting can-
not be performed.)
28 140E-5 Series
40 Troubleshooting SEN00153-03
a There are not connector SBP and line to the SBP for "EGR-less" in above figure.
140E-5 Series 29
SEN00153-03 40 Troubleshooting
E-11 Code [153/CA153] Charge (boost) Air Temp. Sensor High Error 1
30 140E-5 Series
40 Troubleshooting SEN00153-03
a Pin number of connector PIM is not "2" but "3" for “EGR-less” in above figure.
140E-5 Series 31
SEN00153-03 40 Troubleshooting
E-12 Code [154/CA154] Charge (boost) Air Temp. Sensor Low Error 1
32 140E-5 Series
40 Troubleshooting SEN00153-03
a Pin number of connector PIM is not "2" but "3" for "EGR-less" in above figure.
140E-5 Series 33
SEN00153-03 40 Troubleshooting
34 140E-5 Series
40 Troubleshooting SEN00153-03
140E-5 Series 35
SEN00153-03 40 Troubleshooting
36 140E-5 Series
40 Troubleshooting SEN00153-03
140E-5 Series 37
SEN00153-03 40 Troubleshooting
38 140E-5 Series
40 Troubleshooting SEN00153-03
a There are not connector SBP and line to the SBP for "EGR-less" in above figure.
140E-5 Series 39
SEN00153-03 40 Troubleshooting
*: Refer to "Troubleshooting method for open circuit in wiring harness of pressure sensor system".
40 140E-5 Series
40 Troubleshooting SEN00153-03
a There are not connector SBP and line to the SBP for "EGR-less" in above figure.
140E-5 Series 41
SEN00153-03 40 Troubleshooting
42 140E-5 Series
40 Troubleshooting SEN00153-03
140E-5 Series 43
SEN00153-03 40 Troubleshooting
44 140E-5 Series
40 Troubleshooting SEN00153-03
140E-5 Series 45
SEN00153-03 40 Troubleshooting
Open or short circuit in wir- Between ENG (female) (30) and (47)
2 (Fuel temperature: Min. 0 °C)
ing harness
a The resistance is the same as that 700 z –
Resistance
shown in the resistance character- 37 kz
istics table of the coolant tempera-
ture sensor of cause 1.
If no failure is found by above checks, engine controller is
3 Defective engine controller defective. (Since this is an internal failure, troubleshooting
cannot be performed.)
46 140E-5 Series
40 Troubleshooting SEN00153-03
a Pin number of connector PIM is not "2" but "3" for “EGR-less” in above figure.
140E-5 Series 47
SEN00153-03 40 Troubleshooting
Short circuit in wiring har- Between ENG (female) (30) and (47)
2 (Fuel temperature: Min. 0 °C)
ness
a The resistance is the same as that Resis- 700 z –
shown in the resistance characteristics tance 37 kz
table of the coolant temperature sen-
sor of cause 1.
1. Turn starting switch to OFF position.
Ground fault in wiring har- 2. Disconnect connector TFUEL, and connect T-adapter to
3 ness female side of ENG.
(contact with ground circuit) Resis- Min.
Between ENG (female) (30) and ground
tance 1 Mz
If no failure is found by above checks, engine controller is
4 Defective engine controller defective. (Since this is an internal failure, troubleshooting can-
not be performed.)
48 140E-5 Series
40 Troubleshooting SEN00153-03
a Pin number of connector PIM is not "2" but "3" for "EGR-less" in above figure.
140E-5 Series 49
SEN00153-03 40 Troubleshooting
50 140E-5 Series
40 Troubleshooting SEN00153-03
140E-5 Series 51
SEN00153-03 40 Troubleshooting
52 140E-5 Series
40 Troubleshooting SEN00153-03
140E-5 Series 53
SEN00153-03 40 Troubleshooting
54 140E-5 Series
40 Troubleshooting SEN00153-03
140E-5 Series 55
SEN00153-03 40 Troubleshooting
56 140E-5 Series
40 Troubleshooting SEN00153-03
140E-5 Series 57
SEN00153-03 40 Troubleshooting
58 140E-5 Series
40 Troubleshooting SEN00153-03
a For “EGR-less”
Q: Injector wiring harness (H) is in good condition x: Injector wiring harness (H) is in bad condition
being laid close to injector (N) without being laid close to injector (N)
a: Injector wiring harness (H) may interfere with
rocker arm.
140E-5 Series 59
SEN00153-03 40 Troubleshooting
60 140E-5 Series
40 Troubleshooting SEN00153-03
a For “EGR-less”
Q: Injector wiring harness (H) is in good condition x: Injector wiring harness (H) is in bad condition
being laid close to injector (N) without being laid close to injector (N)
a: Injector wiring harness (H) may interfere with
rocker arm.
140E-5 Series 61
SEN00153-03 40 Troubleshooting
62 140E-5 Series
40 Troubleshooting SEN00153-03
a For “EGR-less”
Q: Injector wiring harness (H) is in good condition x: Injector wiring harness (H) is in bad condition
being laid close to injector (N) without being laid close to injector (N)
a: Injector wiring harness (H) may interfere with
rocker arm.
140E-5 Series 63
SEN00153-03 40 Troubleshooting
64 140E-5 Series
40 Troubleshooting SEN00153-03
a For “EGR-less”
Q: Injector wiring harness (H) is in good condition x: Injector wiring harness (H) is in bad condition
being laid close to injector (N) without being laid close to injector (N)
a: Injector wiring harness (H) may interfere with
rocker arm.
140E-5 Series 65
SEN00153-03 40 Troubleshooting
66 140E-5 Series
40 Troubleshooting SEN00153-03
a For “EGR-less”
Q: Injector wiring harness (H) is in good condition x: Injector wiring harness (H) is in bad condition
being laid close to injector (N) without being laid close to injector (N)
a: Injector wiring harness (H) may interfere with
rocker arm.
140E-5 Series 67
SEN00153-03 40 Troubleshooting
68 140E-5 Series
40 Troubleshooting SEN00153-03
a For “EGR-less”
Q: Injector wiring harness (H) is in good condition x: Injector wiring harness (H) is in bad condition
being laid close to injector (N) without being laid close to injector (N)
a: Injector wiring harness (H) may interfere with
rocker arm.
140E-5 Series 69
SEN00153-03 40 Troubleshooting
70 140E-5 Series
40 Troubleshooting SEN00153-03
140E-5 Series 71
SEN00153-03 40 Troubleshooting
72 140E-5 Series
40 Troubleshooting SEN00153-03
140E-5 Series 73
SEN00153-03 40 Troubleshooting
74 140E-5 Series
40 Troubleshooting SEN00153-03
140E-5 Series 75
SEN00153-03 40 Troubleshooting
a There are not connect for PEVA and line to the PEVA for serial No. 530897 and up.
76 140E-5 Series
40 Troubleshooting SEN00153-03
140E-5 Series 77
SEN00153-03 40 Troubleshooting
78 140E-5 Series
40 Troubleshooting SEN00153-03
Fig. 1
Throttle: Signal voltage of throttle sensor
Idle validation: Signal voltage of idle validation
switch
Operating range: Operating range of accelerator
pedal
140E-5 Series 79
SEN00153-03 40 Troubleshooting
80 140E-5 Series
40 Troubleshooting SEN00153-03
140E-5 Series 81
SEN00153-03
© 2010 KOMATSU
All Rights Reserved
Printed in Japan 06-10
82
SEN00154-02
140E-5 Series
40 Troubleshooting 1
Troubleshooting of electrical system
(E-mode), Part 2
Troubleshooting of electrical system (E-mode), Part 2 ................................................................................... 3
E-39 Code [449/CA449] Rail Press. High Error 2 ................................................................................ 3
E-40 Code [451/CA451] Rail Press. Sensor High Error ....................................................................... 4
E-41 Code [452/CA452] Rail Press. Sensor Low Error........................................................................ 7
E-42 Code [553/CA553] Rail Press. High Error 1 ................................................................................ 8
E-43 Code [554/CA554] Rail Press Sensor In Range Error................................................................. 9
E-44 Code [559/CA559] No-pressure Feed By Supply pump 1......................................................... 10
E-45 Code [689/CA689] Eng. Ne Speed Sensor Error ...................................................................... 14
E-46 Code [731/CA731] Eng. Bkup Speed Sensor Phase Error........................................................ 16
E-47 Code [757/CA757] All Engine Controller Data Lost Error .......................................................... 16
E-48 Code [778/CA778] Eng. Bkup Speed Sensor Error................................................................... 18
E-49 Code [1228/CA1228] EGR Valve Servo Error 1 ........................................................................ 21
E-50 Code [1625/CA1625] EGR Valve Servo Error 2 ........................................................................ 22
E-51 Code [1626/CA1626] Bypass Valve Solenoid Drive Short Circuit Error .................................... 23
140E-5 Series 1
SEN00154-02 40 Troubleshooting
2 140E-5 Series
40 Troubleshooting SEN00154-02
140E-5 Series 3
SEN00154-02 40 Troubleshooting
4 140E-5 Series
40 Troubleshooting SEN00154-02
140E-5 Series 5
SEN00154-02 40 Troubleshooting
6 140E-5 Series
40 Troubleshooting SEN00154-02
140E-5 Series 7
SEN00154-02 40 Troubleshooting
8 140E-5 Series
40 Troubleshooting SEN00154-02
140E-5 Series 9
SEN00154-02 40 Troubleshooting
10 140E-5 Series
40 Troubleshooting SEN00154-02
Note 1: Check the low-pressure circuit parts for the following items.
1) Fuel level
2) Clogging of fuel tank breather
3) Sticking and wear of feed pump and clogging of filter
4) Leakage through and clogging of low-pressure fuel piping
5) Defective operation of bypass valve and installation of wrong part (See Fig. 1)
6) Clogging of fuel filter
7) Fuel in oil pan (Fuel leakage inside head cover)
Fig. 1: Locations of overflow valve (1), bypass valve (2), and fuel inlet joint (3)
q Overflow valve (1): Spring is seen through both holes.
q Bypass valve (2): Spring is seen through hole on nut side.
q Fuel inlet joint (3): Gauze filter is seen through both holes.
Note 2: Check, clean, and replace the filters and strainers according to the following procedure.
1) Gauze filter: Disassemble and check. If clogged, clean.
2) Upstream strainer of gauze filter: If the gauze filter is clogged, clean the upstream filter, too.
3) Fuel filter: If the trouble is not solved by performing 1) and 2) above, replace the fuel filter.
140E-5 Series 11
SEN00154-02 40 Troubleshooting
B. Check with machine monitor (Fault history function, monitoring function, and reduced cylinder mode function) Good NG
3 Check of error/failure code / / / /
Check of monitoring information
Standard value
Code Displayed item Checking condition Unit Measured value Good NG
(Reference value)
Low idle rpm <By models>
*1 Engine speed High idle rpm <By models>
Equivalent to rating <By models> rpm <By models>
Low idle % 0
*2 Throttle opening
High idle % 100
Fuel injection com-
*3 Equivalent to rating <By models> mm3 — — —
mand
4 Common rail pres-
*4 Equivalent to rating <By models> MPa
sure command
Common rail fuel
*5 Equivalent to rating <By models> MPa
pressure
Low idle CA — — —
Fuel injection tim-
*6 High idle CA — — —
ing command
Equivalent to rating <By models> CA — — —
*7 Boost pressure Equivalent to rating <By models> kPa — — —
Engine coolant tem-
*8 Low idle °C — — —
perature
*9 Fuel temperature Low idle °C — — —
Check of reduced cylinder mode operation (Engine speed)
Standard value
Function Reduced cylinder Checking condition Unit Measured value Good NG
(Reference value)
No. 1 cylinder Low idle rpm — — —
5 No. 2 cylinder Low idle rpm — — —
No. 3 cylinder Low idle rpm — — —
*10
No. 4 cylinder Low idle rpm — — —
No. 5 cylinder Low idle rpm — — —
No. 6 cylinder Low idle rpm — — —
Standard value
C. Check of fuel circuit pressure Checking condition Unit Measured value Good NG
(Reference value)
Fuel low-pressure circuit pres- High idle or equivalent to rated load MPa 0.15 – 0.3
6
sure [by models]) {kg/cm2} {1.5 – 3.0}
12 140E-5 Series
40 Troubleshooting SEN00154-02
*1 – *10:
When inspecting with INSITE (bench test tool), see Operation and Maintenance Manual (Testing method).
When inspecting with the monitoring function of the machine, use the codes specified for each machine
model.
140E-5 Series 13
SEN00154-02 40 Troubleshooting
14 140E-5 Series
40 Troubleshooting SEN00154-02
140E-5 Series 15
SEN00154-02 40 Troubleshooting
16 140E-5 Series
40 Troubleshooting SEN00154-02
140E-5 Series 17
SEN00154-02 40 Troubleshooting
18 140E-5 Series
40 Troubleshooting SEN00154-02
140E-5 Series 19
SEN00154-02 40 Troubleshooting
20 140E-5 Series
40 Troubleshooting SEN00154-02
Improper EGR valve drive Engine speed EGR valve drive pressure
2
pressure Low idle 1.18 MPa {12 kg/cm2}
High idle 1.43 MPa {14.6 kg/cm2}
If EGR valve drive pressure is abnormal, check causes 3 and
4.
a For check of engine oil pressure, see TESTING AND
ADJUSTING, Testing engine oil pressure.
Possible causes and
Engine speed Engine oil pressure
standard value in Defective engine oil pres-
normal state 3 Low idle 0.08 MPa {0.8 kg/cm2}
sure system (main circuit)
High idle 0.21 MPa {2.1 kg/cm2}
If engine oil pressure is abnormal, carry out troubleshooting for
mechanical system (S-12 Oil pressure lowers).
Defective oil pump for EGR
4 Check oil pump and relief valve for EGR valve circuit directly.
valve
Defective oil feed piping for
5 Check oil feed piping for EGR valve circuit directly.
EGR valve
Defective oil return piping
6 Check oil return piping for EGR valve circuit directly.
for EGR valve
7 Defective EGR valve Check mechanical section of EGR valve directly.
If causes 1 – 7 are not detected, engine controller may be
8 Defective engine controller defective. (Since trouble is in system, troubleshooting cannot
be carried out.)
140E-5 Series 21
SEN00154-02 40 Troubleshooting
22 140E-5 Series
40 Troubleshooting SEN00154-02
140E-5 Series 23
SEN00154-02 40 Troubleshooting
24 140E-5 Series
40 Troubleshooting SEN00154-02
140E-5 Series 25
SEN00154-02 40 Troubleshooting
Improper EGR valve drive Engine speed Bypass valve drive pressure
2
pressure Low idle 1.18 MPa {12 kg/cm2}
High idle 1.43 MPa {14.6 kg/cm2}
If EGR valve drive pressure is abnormal, check causes 3 and
4.
a For check of engine oil pressure, see TESTING AND
ADJUSTING, Testing engine oil pressure.
Possible causes and
Engine speed Engine oil pressure
standard value in Defective engine oil pres-
normal state 3 Low idle 0.08 MPa {0.8 kg/cm2}
sure system (main circuit)
High idle 0.21 MPa {2.1 kg/cm2}
If engine oil pressure is abnormal, carry out troubleshooting
for mechanical system (S-12 Oil pressure lowers).
Defective oil pump for Check oil pump and relief valve for bypass valve circuit
4
bypass valve directly.
Defective oil feed piping for
5 Check oil feed piping for bypass valve circuit directly.
bypass valve
Defective oil return piping
6 Check oil return piping for bypass valve circuit directly.
for bypass valve
7 Defective bypass valve Check mechanical section of bypass valve directly.
If causes 1 – 7 are not detected, engine controller may be
8 Defective engine controller defective. (Since trouble is in system, troubleshooting cannot
be carried out.)
26 140E-5 Series
40 Troubleshooting SEN00154-02
140E-5 Series 27
SEN00154-02 40 Troubleshooting
28 140E-5 Series
40 Troubleshooting SEN00154-02
140E-5 Series 29
SEN00154-02 40 Troubleshooting
30 140E-5 Series
40 Troubleshooting SEN00154-02
Reference: EGR inlet pressure sensor is applied to only machines Serial No. up to 530896.
140E-5 Series 31
SEN00154-02 40 Troubleshooting
32 140E-5 Series
40 Troubleshooting SEN00154-02
Reference: EGR inlet pressure sensor is applied to only machines Serial No. up to 530896.
140E-5 Series 33
SEN00154-02 40 Troubleshooting
34 140E-5 Series
40 Troubleshooting SEN00154-02
Circuit diagram related to throttle sensor of accelerator pedal type (Case of HD325/405-7)
140E-5 Series 35
SEN00154-02 40 Troubleshooting
36 140E-5 Series
40 Troubleshooting SEN00154-02
Circuit diagram related to throttle sensor of fuel control dial type (Case of PC800/800SE/850/850SE/
850LC-8)
140E-5 Series 37
SEN00154-02 40 Troubleshooting
38 140E-5 Series
40 Troubleshooting SEN00154-02
140E-5 Series 39
SEN00154-02 40 Troubleshooting
40 140E-5 Series
40 Troubleshooting SEN00154-02
140E-5 Series 41
SEN00154-02 40 Troubleshooting
42 140E-5 Series
40 Troubleshooting SEN00154-02
140E-5 Series 43
SEN00154-02 40 Troubleshooting
44 140E-5 Series
40 Troubleshooting SEN00154-02
140E-5 Series 45
SEN00154-02 40 Troubleshooting
46 140E-5 Series
40 Troubleshooting SEN00154-02
140E-5 Series 47
SEN00154-02 40 Troubleshooting
48 140E-5 Series
40 Troubleshooting SEN00154-02
140E-5 Series 49
SEN00154-02
© 2007 KOMATSU
All Rights Reserved
Printed in Japan 03-07 (01)
50
SEN00156-05
140E-5 Series
140E-5 Series 1
SEN00156-05 50 Disassembly and assembly
4:
ber respectively. Weight of part or component
R: Tools made available by redesign-
ing the existing tools which were
Installation
developed for other models. Each
of them has a new part number q Unless otherwise instructed, installation of
assigned by setting forward the parts is to be done in the reverse order to
part number of the existing tool. removal.
Blank : Tools already available for other q Instructions and precautions for parts installa-
models. They can be used without tion is shown with the mark ([*1], [*2]...) which
any modification. corresponds to the mark in “Removal” section.
3) Circle mark Q in sketch column: q Common tools that are necessary for installa-
q The sketch of the special tool is pre- tion are described as [1], [2]••• etc. and their
sented in the section of “Sketches of part numbers, part names and quantities are
special tools”. not described.
q Part No. of special tools starting with q Marks shown in the “Installation” section stand
for the following.
79 T-
* *** ****
- :
means that they are not available
from Komatsu Ltd. (i.e. tools to be k : Precautions related to work safety
made locally). a : Guidance or precautions for the work
2 : Type of coating material
3 : Tightening torque
2 140E-5 Series
50 Disassembly and assembly SEN00156-05
140E-5 Series 3
SEN00156-05 50 Disassembly and assembly
Cate- Komatsu
Part number Q'ty Container Main features and applications
gory code
• Used to prevent rubber gaskets, rubber cush-
LT-1A 790-129-9030 150 g Tube
ions, and cork plugs from coming out.
• Used for plastic (except polyethylene,
polypropylene, tetrafluoroethylene and vinyl
20 g Polyethylene
LT-1B 790-129-9050 chloride), rubber, metal, and non-metal parts
(2 pcs.) container
which require immediate and strong adhe-
sion.
Polyethylene • Features: Resistance to heat and chemicals.
LT-2 09940-00030 50 g
container • Used to fix and seal bolts and plugs.
790-129-9060
Adhesive: 1 kg • Used to stick and seal metal, glass, and plas-
LT-3 (Set of adhesive Can
Hardener: 500 g tics.
and hardener)
Adhesive
Polyethylene
LT-4 790-129-9040 250 g • Used to seal plugs.
container
Holtz MH 705 790-129-9120 75 g Tube • Heat-resistant seal used to repair engines.
• Quick-setting adhesive.
ThreeBond Polyethylene • Setting time: Within 5 sec. to 3 min.
790-129-9140 50 g
1735 container • Used mainly to stick metals, rubbers, plastics,
and woods.
• Quick-setting adhesive.
• Quick-setting type.
Aron-alpha Polyethylene
790-129-9130 2g (max. strength is obtained after 30 minutes)
201 container
• Used mainly to stick rubbers, plastics, and
metals.
• Features: Resistance to heat and chemicals.
Loctite Polyethylene
79A-129-9110 50 cc • Used for fitted portions used at high tempera-
648-50 container
tures.
• Used to seal various threaded portions, pipe
Polyethylene joints, and flanges.
LG-5 790-129-9080 1 kg
container • Used to seal tapered plugs, elbows, and nip-
ples of hydraulic piping.
• Features: Silicon-based heat and cold-resis-
tant sealant.
Gasket sealant
LG-6 790-129-9160 200 g Tube • Used to seal flange surfaces and threaded
portions.
• Used to seal oil pan, final drive case, etc.
• Features: Silicon-based quick-setting sealant.
LG-7 790-129-9170 1 kg Tube • Used to seal flywheel housing, intake mani-
fold, oil pan, thermostat housing, etc.
• Features: Silicon-based, heat and cold-resis-
LG-8
tant, vibration-resistant, impact-resistant seal-
ThreeBond 419-15-18131 100 g Tube
ant.
1207B
• Used to seal transfer case, etc.
4 140E-5 Series
50 Disassembly and assembly SEN00156-05
Cate-
Komatsu code Part number Q'ty Container Main features and applications
gory
• Used for rough surfaces such as the circle gear
LG-9 top seal which does not need to be clamped,
ThreeBond 790-129-9310 200 g Tube water resistance of the clearance at the welded
1206D area, etc.
• Can be coated with paint.
Gasket sealant
• Spray type
• Thin molybdenum disulphide films are made on
metal surfaces to prevent the metals from scuff-
— 09995-00250 190 g Can
ing each other.
• Applicable for the drive shaft splines, needle
bearings, pins and bolts of various links, etc.
• Feature: Seizure and scuffing prevention com-
compound
prevention
LC-G
— — Can • Used for the mounting bolt in the high tempera-
NEVER-SEEZ
ture area of the exhaust manifold and the turbo-
charger, etc.
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
G2-LI • Feature: Lithium grease with extreme pressure
SYG2-160LI
G0-LI Various Various lubrication performance.
SYGA-160CNLI
*: For cold district • General purpose type.
SYG0-400LI-A (*)
SYG0-160CNLI
(*)
• Used for parts under heavy load.
Caution:
Molybdenum SYG2-400M 400 g x 10 Bellows-type • Do not apply grease to rolling bearings like
disulfide grease SYG2-400M-A 400 g x 20 container swing circle bearings, etc. and spline.
Grease
LM-G (G2-M) SYGA-16CNM 16 kg Can • The grease should be applied to work equipment
pins at their assembly only, not applied for
greasing afterwards.
• Seizure resistance, heat resistance and water
Hyper White SYG2-400T-A
400 g Bellows-type resistance higher than molybdenum disulfide
Grease G2-T, SYG2-16CNT
container grease.
G0-T (*) SYG0-400T-A (*)
16 kg Can • Not conspicuous on machine since color is
*: For cold district SYG0-16CNT (*)
white.
Biogrease SYG2-400B
G2-B, G2-BT (*) SYGA-16CNB 400 g Bellows-type • Since this grease is decomposed by natural bac-
*: For use at high SYG2-400BT (*) container teria in short period, it has less effects on micro-
temperature and SYGA-16CNBT 16 kg Can organisms, animals, and plants.
under high load (*)
140E-5 Series 5
SEN00156-05 50 Disassembly and assembly
Cate-
Komatsu code Part number Q'ty Container Main features and applications
gory
• Feature: Silicone grease with wide using tem-
G2-S perature range, high resistance to thermal-oxi-
ThreeBond — 200 g Tube dative degradation and performance to prevent
1855 deterioration of rubber and plastic parts.
Grease
facture)
SUNSTAR Ecocart • Used as adhesive for glass.
PENGUINE 22M-54-27210 320 ml (Special (Using limit: 6 months after date of manu-
SUPER 560 container) facture)
SUNSTAR • Used to seal joints of glass parts.
Polyethylene
PENGUINE 417-926-3920 320 ml (Using limit: 4 months after date of manu-
container
SEAL No. 2505 facture)
Caulking material
6 140E-5 Series
50 Disassembly and assembly SEN00156-05
New / Remodel
Necessity
Symbol
Sketch
Q'ty
Work item Part No. Part name Remarks
140E-5 Series 7
SEN00156-05 50 Disassembly and assembly
8 140E-5 Series
50 Disassembly and assembly SEN00156-05
Note) We will not be liable for any result of use of special tools manufactured according to the following
drawings.
140E-5 Series 9
SEN00156-05 50 Disassembly and assembly
Note) We will not be liable for any result of use of special tools manufactured according to the following
drawings.
10 140E-5 Series
50 Disassembly and assembly SEN00156-05
140E-5 Series 11
SEN00156-05
© 2011 KOMATSU
All Rights Reserved
Printed in Japan 10-11
12
SEN00157-05
140E-5 Series
140E-5 Series 1
SEN00157-05 50 Disassembly and assembly
1. Preparation work
Before disassembling the engine, check its
parts for cracking, damage, etc. and clean it
generally and carefully for accurate inspection
of its parts and quick disassembly and assem-
bly.
a Before cleaning the engine, carefully seal
or remove the openings, electric parts,
and wiring connectors so that water will
not enter them. 4. Air cleaner bracket
1) Disconnect wiring harness clamp (1).
2. Setting engine assembly 2) Remove air cleaner bracket (2).
1) Prepare stable engine stands (Blocks [1]) a The type of the bracket depends on
and place the engine assembly on them the applicable machines.
4 Air cleaner bracket: 30 kg
so that it will not tip over.
a The weight depends on the applica-
ble machines.
4 Engine assembly: 2,000 kg
5. EGR cover
1) Remove covers (1), (2), and (3).
2) Drain the engine coolant and engine oil.
a The quantity of the oil depends on the
applicable machines.
6 Engine oil: Approx. 53 l
2 140E-5 Series
50 Disassembly and assembly SEN00157-05
2) Remove covers (4), (5), (6), and (7). 8. Clamp and bracket
a Cover (6) is not installed to all the 1) Remove clamp (1) and brackets (2) and
models. (3).
2) Remove bracket (4).
140E-5 Series 3
SEN00157-05 50 Disassembly and assembly
4 140E-5 Series
50 Disassembly and assembly SEN00157-05
14. Bracket
Remove bracket (12).
3) Remove wiring harness (4) and 4 turbo-
charger lubrication tube clamps (5) and
remove turbocharger lubrication tube (6).
140E-5 Series 5
SEN00157-05 50 Disassembly and assembly
6 140E-5 Series
50 Disassembly and assembly SEN00157-05
22. Oil filter, fuel filter, and corrosion resistor 25. Oil filter head
Remove oil filter (1), pre-fuel filter (2), main fuel 1) Remove oil tubes (1) and (2) and the block
filter (3), and corrosion resistor (4). on the cylinder block side as a unit.
a Pre-fuel filter (2) may be installed on the 2) Remove oil filter head (3).
applicable machine side. a The type of the oil filter head depends
a Corrosion resistor is not set for some on the applicable machines.
models.
140E-5 Series 7
SEN00157-05 50 Disassembly and assembly
8 140E-5 Series
50 Disassembly and assembly SEN00157-05
140E-5 Series 9
SEN00157-05 50 Disassembly and assembly
6) Disconnect fuel pressure sensor connec- 35. EGR oil pump assembly
tor PFUEL (15) and POIL (16). Remove the bolts and EGR oil pump assembly
7) Remove clamp (17) and the eye joint of (1).
tube (18) on the common rail side.
8) Remove special bolts (19) and remove
common rail (20).
10 140E-5 Series
50 Disassembly and assembly SEN00157-05
5) Disconnect the injector connector accord- a After removing the suction tube, sling the
ing to the following procedure. engine. Set stable blocks at the front,
1] Apply flat-head screwdriver [1] to the rear, right, and left under the cylinder
stepped part (part (a)). block and place the engine on them.
2] While pressing stopper (1a), move a Arrange the above blocks so that you can
flat-head screwdriver [1] in direction rotate the crankshaft.
(X) to disconnect the connector.
40. Flywheel
1) Using sling [1], lift up flywheel (1) tempo-
rarily.
2) Remove the 8 mounting bolts and lift off
the flywheel.
a Take care that the flywheel will not
contact the Ne sensor on the back
side.
4 Flywheel: 65 kg
140E-5 Series 11
SEN00157-05 50 Disassembly and assembly
12 140E-5 Series
50 Disassembly and assembly SEN00157-05
140E-5 Series 13
SEN00157-05 50 Disassembly and assembly
14 140E-5 Series
50 Disassembly and assembly SEN00157-05
54. Camshaft
1) Match the holes of cam gear (1) to mount-
52. Front oil seal ing bolts (2) and remove bolts (2).
Remove front oil seal (1) from the front cover.
140E-5 Series 15
SEN00157-05 50 Disassembly and assembly
55. Oil pump assembly and sub idler gear 58. Piston cooling nozzle
1) Remove oil pump assembly (1). Remove the mounting bolts and piston cooling
2) Remove sub idler gear (2). nozzles (1) and (2).
a Be sure to remove the piston cooling noz-
zles before pulling out the piston.
16 140E-5 Series
50 Disassembly and assembly SEN00157-05
60. Crankshaft
a Before removing the crankshaft, measure
its end play with dial gauge [1], if neces-
sary.
140E-5 Series 17
SEN00157-05 50 Disassembly and assembly
1) Remove mounting bolts (2) of main cap 4) Remove upper thrust bearing (5).
(1).
2) Insert the bolts in the bolt holes of the
main cap and remove the cap, while shak-
ing it.
18 140E-5 Series
50 Disassembly and assembly SEN00157-05
140E-5 Series 19
SEN00157-05 50 Disassembly and assembly
1. Cylinder block
1) Install tool A2 to the cylinder block, and
then sling the cylinder block and set it to
tool A1.
4 Cylinder block: 390 kg
20 140E-5 Series
50 Disassembly and assembly SEN00157-05
140E-5 Series 21
SEN00157-05 50 Disassembly and assembly
5) Insert cylinder liner (1) in the cylinder 10) Using tool H, measure the projection of
block slowly, taking care not to damage the cylinder liner.
the O-ring. a When measuring the projection of the
6) Push in cylinder liner (1) further with both liner, tighten the liner with a plate so
hands. that it will not be lifted by the O-ring.
a If the liner does not enter the cylinder q Projection of liner: 0.07 – 0.15 mm
smoothly, the O-ring may be broken. a If the gasket sealant is projected from
In this case, check the cylinder block the fitting parts of the cylinder block
for burrs. and cylinder liner up to the top of the
7) Using tool F, press fit cylinder liner (1) to cylinder block, wipe it off.
the cylinder block.
9) Remove the cylinder head and wipe off 2) Drive the dowel pin so that it will be pro-
the gasket sealant projected from the jected by 2.7 – 3.4 mm from the block end
counterbored part. and then install upper thrust bearing (5) to
a Be sure to perform steps 8) and 9) the No. 7 journal.
above since the projected gasket a Install the thrust bearing with the
sealant can deform the grommet of grooved surface on the crankshaft
the head gasket. side.
22 140E-5 Series
50 Disassembly and assembly SEN00157-05
3) Sling crankshaft (4) and install it to the cyl- 6) Make sure that the journal No. stamped at
inder block. the center of main cap (2) and the journal
a When replacing the crank gear, heat it No. of the cylinder block are the same and
with a bearing heater (30 A) (Set tem- then install the main cap.
perature: 150°C) and fit it just after it a Install the main cap with the cast let-
is heated. ter (F) toward the front of the engine.
a When installing the crankshaft, take
care not to hit its sliding surfaces
against the cylinder block.
4 Crankshaft: 140 kg
2 Cylinder block journal:
Engine oil (EO30)
140E-5 Series 23
SEN00157-05 50 Disassembly and assembly
8) Tighten main cap mounting bolts (1) 10) Check that the crankshaft turns smoothly.
according to the following procedure. 11) Measure the end play of the crankshaft
a Tighten the bolts from the center one with dial gauge [1].
to the outer ones in order. a End play: 0.140 – 0.315 mm
2 Threaded portion of mounting bolt a If the end play is out of the standard,
and washer: correct it. For details, see “Structure,
Engine oil (EO30) function and maintenance standard”.
3 Mounting bolt
1st time:
108 – 128 Nm {11 – 13 kgm}
2nd time:
230 – 240 Nm {23.5 – 24.5 kgm}
3rd time:
Using tool J, tighten the bolt by
90° (+30°/0).
24 140E-5 Series
50 Disassembly and assembly SEN00157-05
2) Set the abutment joint of each piston ring 7) Insert piston and connecting rod assembly
as shown in the following figure. (8) in the cylinder block so that the cast
a Adjust oil ring so that the joint of the part number on the connecting rod will be
expander will be at 180° to the abut- directed to the front of the engine (the
ment joint of the oil ring. stamped cylinder number will be on the
camshaft side).
a Referring to step 2), check the abut-
ment joint of each piston ring again.
2 Inside of connecting rod bearing and
inside of cylinder:
Engine oil (EO30)
140E-5 Series 25
SEN00157-05 50 Disassembly and assembly
26 140E-5 Series
50 Disassembly and assembly SEN00157-05
13) After tightening the bolt, make a punch 2) Install piston cooling nozzles (1) and (2) to
mark (c) on its head. each cylinder in order.
a When a new bolt is used, do not a Install the piston cooling nozzles hav-
make a punch mark on its head. ing the stamps of (F1) to the front side
of the cylinder and install those hav-
ing the stamps of (N1) to the rear side
of the cylinder.
a Push in each piston cooling nozzle
with the hand until its flange touches
the cylinder block and then tighten the
mounting bolt.
a Take care not to mistake the hexago-
nal part of the nozzle for the mounting
bolt.
3 Mounting bolt:
59 – 74 Nm {6.0 – 7.5 kgm}
6. Underframe
Install underframes (1).
a The number of the underframes depends
on the applicable machines.
140E-5 Series 27
SEN00157-05 50 Disassembly and assembly
9. Camshaft
1) Install camshaft (1) to the cylinder block,
turning it so that it will not damage the
cam bushing.
a If the cam gear is replaced, heat the
new gear in an electric oven, etc. and
heat it at 220 – 240°C for 30 – 60
minutes and then install it by shrink
fit.
4 Camshaft: 20 kg
2 Camshaft journal surface:
8. Sub idler gear and oil pump assembly
Engine oil (EO30)
1) Install sub idler gear (2), shaft (4) and
plate (3) together.
a Direct the stamp of TOP on shaft (4)
up and direct the chamfered inside
edge toward the gear.
3 Sub idler gear mounting bolt:
377.6 – 426.6 Nm {38.5 – 43.5 kgm}
2) Install oil pump assembly (1).
3 Oil pump assembly mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
28 140E-5 Series
50 Disassembly and assembly SEN00157-05
2) Matching the stamped (C) of the camshaft 4) Fit the O-ring and install cover (3).
gear to that of the main idler gear, tighten 3 Mounting bolt:
mounting bolt (2). 9.8 – 12.7 Nm {1.0 – 1.3 kgm}
3 Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
140E-5 Series 29
SEN00157-05 50 Disassembly and assembly
3) Install fuel supply pump drive gear (3) to q Standard backlash of each gear
the fuel supply pump shaft and tighten
Position Range (mm)
mounting nut (1).
a When installing to the fuel supply A 0.141 – 0.425
pump shaft, set stamp (B) of fuel sup- B 0.129 – 0.391
ply pump drive gear (3) to stamp (B) C 0.129 – 0.391
of the main idler gear (circled in the
D 0.141 – 0.425
figure).
3 Mounting nut: E 0.080 – 0.417
176 – 196 Nm {18 – 20 kgm} F 0.095 – 0.346
G 0.118 – 0.369
30 140E-5 Series
50 Disassembly and assembly SEN00157-05
14. Front cover and front support 1) Set large inside diameter side (a) of plas-
a The front cover and front support are tic inside cylinder (2) to the end of crank-
installed with the same mounting bolts. shaft (3).
1) Fit the gasket and install front cover (1) a Take care not to mistake the direction
temporarily, using eyebolt [1]. of the plastic inside cylinder.
4 Front cover: 70 kg
140E-5 Series 31
SEN00157-05 50 Disassembly and assembly
32 140E-5 Series
50 Disassembly and assembly SEN00157-05
3 Mounting bolt:
a Tighten the mounting bolts according
to the following procedure.
1st time:
137 – 157 Nm {14 – 16 kgm}
2nd time:
284 – 294 Nm {29.0 – 30.0 kgm}
3rd time:
Using tool J, tighten the bolt by
90° (+30°/0).
140E-5 Series 33
SEN00157-05 50 Disassembly and assembly
34 140E-5 Series
50 Disassembly and assembly SEN00157-05
140E-5 Series 35
SEN00157-05 50 Disassembly and assembly
5) Tighten clamps and brackets (7), (8), (9), 22. Rocker arm and shaft assembly
(10), (11) and (12) with the hand first, then Install rocker arm and shaft assembly (1) and
tighten clamp side permanently. tighten mounting bolts (2), (3) and (4).
3 Clamp bolt: a Note that the lengths of the mounting bolts
9.8 ± 1.0 Nm {1.0 ± 0.1 kgm} are different.
6) Tighten clamps and brackets (7), (8), (9), Mounting bolt (2): Stem length; 120 mm
(10), (11) and (12) of bracket side perma- Mounting bolt (3): Stem length; 90 mm
nently. Mounting bolt (4): Stem length; 75 mm
7) Install covers (13) and (14) to the sleeve a Before tightening the mounting bolts,
nut. check that the ball of the adjustment screw
a Direct the cut of cover (13) down and is fitted to the socket of the push rod.
direct the cut of cover (14) toward the 3 Mounting bolt:
cylinder block. 93 – 103 Nm {9.5 – 10.5 kgm}
36 140E-5 Series
50 Disassembly and assembly SEN00157-05
140E-5 Series 37
SEN00157-05 50 Disassembly and assembly
38 140E-5 Series
50 Disassembly and assembly SEN00157-05
140E-5 Series 39
SEN00157-05 50 Disassembly and assembly
4) Tighten the 4 bolts evenly to press fit 2nd time: Using tool J, tighten the bolts by 90°
sleeve and rear seal assembly (9) until the (+30°/0) in the order of (1) – (8).
end of tool N3 reaches the end of crank-
shaft (6).
a Tighten tool N3 (for press fitting the
seal) first until the bolt without washer
stops and then tighten the bolt with 2
washers.
a After press fitting the seal, remove the
red sealant layer from its periphery.
a Rear seal driving depth:
13.2 ± 0.2 mm from end
of crankshaft
40 140E-5 Series
50 Disassembly and assembly SEN00157-05
140E-5 Series 41
SEN00157-05 50 Disassembly and assembly
42 140E-5 Series
50 Disassembly and assembly SEN00157-05
140E-5 Series 43
SEN00157-05 50 Disassembly and assembly
2) Install brackets (7), (8), (9), (10) and (11). 37. Air intake connector assembly
3) Install brackets (2), (3), (4), (5) and (6). 1) Install joint housing (6) to bracket (7).
2) Install venturi nozzle, air heater (5) and
connector (4) to joint housing (6).
a Direct the terminal of the air heater
toward the original direction of the
engine. (The direction of the terminal
depends on the applicable
machines.)
44 140E-5 Series
50 Disassembly and assembly SEN00157-05
140E-5 Series 45
SEN00157-05 50 Disassembly and assembly
46 140E-5 Series
50 Disassembly and assembly SEN00157-05
140E-5 Series 47
SEN00157-05 50 Disassembly and assembly
5) Fit the gasket and install turbocharger oil 2) Install bracket (8).
drain tube (2). 3) Fit the O-ring and the gasket and install
6) Install exhaust connector (3) and heat EGR cooler coolant inlet tube (10).
insulation cover (1). 3 Rubber hose:
(Nut of tube clamp U-bolt)
10.8 – 26.5 Nm {1.1 – 2.7 kgm}
4) Fit the gasket and install EGR cooler gas
inlet tube (9).
2 Threaded portion and seat of bolt:
Seizure prevention compound (LC-G)
3 Mounting bolt:
44.1 – 53.9 Nm {4.5 – 5.5 kgm}
5) Install air vent tube (7).
3 Joint bolt:
19.6 – 29.4 Nm {2.0 – 3.0 kgm}
6) Install turbocharger drain tube clamps (6).
49. Bracket
Install exhaust manifold cover bracket (12).
48 140E-5 Series
50 Disassembly and assembly SEN00157-05
140E-5 Series 49
SEN00157-05 50 Disassembly and assembly
4) Connect wiring harness connectors BP (2) 57. Bracket and tube clamp
and SBP (1) and install the clamp. 1) Install brackets (7), (6) and (5).
2) Install clamps (4), (3), (2) and (1).
50 140E-5 Series
50 Disassembly and assembly SEN00157-05
140E-5 Series 51
SEN00157-05 50 Disassembly and assembly
52 140E-5 Series
50 Disassembly and assembly SEN00157-05
140E-5 Series 53
SEN00157-05
© 2011 KOMATSU
All Rights Reserved
Printed in Japan 10-11
54
SEN00158-05
140E-5 Series
140E-5 Series 1
SEN00158-05 50 Disassembly and assembly
1. Preparation work
Before disassembling the engine, check its
parts for cracking, damage, etc. and clean it
generally and carefully for accurate inspection
of its parts and quick disassembly and assem-
bly.
a Before cleaning the engine, carefully seal
or remove the openings, electric parts,
and wiring connectors so that water will
not enter them. 4. Air cleaner bracket
1) Disconnect wiring harness clamp (1).
2. Setting engine assembly 2) Remove air cleaner bracket (2).
1) Prepare stable engine stands (Blocks [1]) a The type of the bracket depends on
and place the engine assembly on them the applicable machines.
4 Air cleaner bracket: 30 kg
so that it will not tip over.
a The weight depends on the applica-
ble machines.
4 Engine assembly: 1,900 kg
2 140E-5 Series
50 Disassembly and assembly SEN00158-05
8. Turbocharger assembly
1) Remove heat insulation cover (1) and oil 9. Exhaust manifold
drain tube (2). Remove the 24 mounting bolts and exhaust
manifold (1).
4 Exhaust manifold: 25 kg
140E-5 Series 3
SEN00158-05 50 Disassembly and assembly
4 140E-5 Series
50 Disassembly and assembly SEN00158-05
14. Corrosion resistor, oil filter and fuel filter 16. Fuel filter head
1) Remove corrosion resistor. 1) Remove fuel tube clamp (1), then remove
2) Remove oil filters (1) and main fuel filters fuel tubes (2) and (3).
(2). 2) Remove fuel tube (4).
a The locations of the fuel filter and oil filter 3) Remove fuel filter head (5).
may be different from the photo, depend-
ing on the applicable machine.
a Corrosion resistor is not set for some
models.
140E-5 Series 5
SEN00158-05 50 Disassembly and assembly
6 140E-5 Series
50 Disassembly and assembly SEN00158-05
24. Plate
Remove plate (3).
140E-5 Series 7
SEN00158-05 50 Disassembly and assembly
8 140E-5 Series
50 Disassembly and assembly SEN00158-05
28. Wiring harness assembly and sensor con- a Move lock [1] of the housing of con-
nector nector (6) in the direction of the arrow,
1) Disconnect the clamps of coolant temper- push down lock [2], and pull out con-
ature sensor connector TWTR (1) and wir- nector (6).
ing harnesses (2) and (3) and remove
bracket (4).
140E-5 Series 9
SEN00158-05 50 Disassembly and assembly
10 140E-5 Series
50 Disassembly and assembly SEN00158-05
140E-5 Series 11
SEN00158-05 50 Disassembly and assembly
12 140E-5 Series
50 Disassembly and assembly SEN00158-05
140E-5 Series 13
SEN00158-05 50 Disassembly and assembly
45. Camshaft
1) Match the holes of cam gear (1) to mount-
ing bolts (2) and remove bolts (2).
14 140E-5 Series
50 Disassembly and assembly SEN00158-05
50. Piston and connecting rod assembly 6) Push in and remove the piston and con-
a Before removing the piston and connect- necting rod assembly with a wood bar, etc.
ing rod assembly, measure its end play from the oil pan side, while supporting pis-
with dial gauge [1], if necessary. ton (6) on the cylinder head side.
a Take care not to damage the inside of
the cylinder with a corner of the con-
necting rod.
7) Remove the other piston and connecting
rod assemblies according to the above
procedure.
a Take care not to damage the sliding
portions of the pistons and bearings.
a Assemble each connecting rod and
cap temporarily so that they will not
be assembled with other ones and
keep them and the bearing together.
140E-5 Series 15
SEN00158-05 50 Disassembly and assembly
3] Using tool D, remove piston ring (7). a The No. 7 main cap has lower thrust
a Keep the piston, connecting rod, con- bearing (3).
necting rod bearing, piston rings, and
piston pin by cylinder.
1) Remove mounting bolts (2) of main cap 4) Remove upper thrust bearing (5).
(1).
2) Insert the bolts in the bolt holes of the
main cap and remove the cap, while shak-
ing it.
16 140E-5 Series
50 Disassembly and assembly SEN00158-05
140E-5 Series 17
SEN00158-05 50 Disassembly and assembly
1. Cylinder block
1) Install tool A2 to the cylinder block, and
then sling the cylinder block and set it to
tool A1.
4 Cylinder block: 390 kg
18 140E-5 Series
50 Disassembly and assembly SEN00158-05
140E-5 Series 19
SEN00158-05 50 Disassembly and assembly
5) Insert cylinder liner (1) in the cylinder 10) Using tool H, measure the projection of
block slowly, taking care not to damage the cylinder liner.
the O-ring. a When measuring the projection of the
6) Push in cylinder liner (1) further with both liner, tighten the liner with a plate so
hands. that it will not be lifted by the O-ring.
a If the liner does not enter the cylinder q Projection of liner: 0.07 – 0.15 mm
smoothly, the O-ring may be broken. a If the gasket sealant is projected from
In this case, check the cylinder block the fitting parts of the cylinder block
for burrs. and cylinder liner up to the top of the
7) Using tool F, press fit cylinder liner (1) to cylinder block, wipe it off.
the cylinder block.
9) Remove the cylinder head and wipe off 2) Drive the dowel pin so that it will be pro-
the gasket sealant projected from the jected by 2.7 – 3.4 mm from the block end
counterbored part. and then install upper thrust bearing (5) to
a Be sure to perform steps 8) and 9) the No. 7 journal.
above since the projected gasket a Install the thrust bearing with the
sealant can deform the grommet of grooved surface on the crankshaft
the head gasket. side.
20 140E-5 Series
50 Disassembly and assembly SEN00158-05
3) Sling crankshaft (4) and install it to the cyl- 6) Make sure that the journal No. stamped at
inder block. the center of main cap (2) and the journal
a When replacing the crank gear, heat it No. of the cylinder block are the same and
with a bearing heater (30 A) (Set tem- then install the main cap.
perature: 150°C) and fit it just after it a Install the main cap with the cast let-
is heated. ter (F) toward the front of the engine.
a When installing the crankshaft, take
care not to hit its sliding surfaces
against the cylinder block.
4 Crankshaft: 140 kg
2 Cylinder block journal:
Engine oil (EO30)
140E-5 Series 21
SEN00158-05 50 Disassembly and assembly
8) Tighten main cap mounting bolts (1) 10) Check that the crankshaft turns smoothly.
according to the following procedure. 11) Measure the end play of the crankshaft
a Tighten the bolts from the center one with dial gauge [1].
to the outer ones in order. a End play: 0.140 – 0.315 mm
2 Threaded portion of mounting bolt a If the end play is out of the standard,
and washer: correct it. For details, see “Structure,
Engine oil (EO30) function and maintenance standard”.
3 Mounting bolt
1st time:
108 – 128 Nm {11 – 13 kgm}
2nd time:
230 – 240 Nm {23.5 – 24.5 kgm}
3rd time:
Using tool J, tighten the bolt by
90° (+30°/0).
22 140E-5 Series
50 Disassembly and assembly SEN00158-05
2) Set the abutment joint of each piston ring 7) Insert piston and connecting rod assembly
as shown in the following figure. (8) in the cylinder block so that the cast
a Adjust oil ring so that the joint of the part number on the connecting rod will be
expander will be at 180° to the abut- directed to the front of the engine (the
ment joint of the oil ring. stamped cylinder number will be on the
camshaft side).
a Referring to step 2), check the abut-
ment joint of each piston ring again.
2 Inside of connecting rod bearing and
inside of cylinder:
Engine oil (EO30)
140E-5 Series 23
SEN00158-05 50 Disassembly and assembly
24 140E-5 Series
50 Disassembly and assembly SEN00158-05
13) After tightening the bolt, make a punch 2) Install piston cooling nozzles (1) and (2) to
mark (c) on its head. each cylinder in order.
a When a new bolt is used, do not a Install the piston cooling nozzles hav-
make a punch mark on its head. ing the stamps of (F1) to the front side
of the cylinder and install those hav-
ing the stamps of (N1) to the rear side
of the cylinder.
a Push in each piston cooling nozzle
with the hand until its flange touches
the cylinder block and then tighten the
mounting bolt.
a Take care not to mistake the hexago-
nal part of the nozzle for the mounting
bolt.
3 Mounting bolt:
59 – 74 Nm {6.0 – 7.5 kgm}
6. Underframe
Install underframes (1).
a The number of the underframes depends
on the applicable machines.
140E-5 Series 25
SEN00158-05 50 Disassembly and assembly
9. Camshaft
1) Install camshaft (1) to the cylinder block,
turning it so that it will not damage the
cam bushing.
a If the cam gear is replaced, heat the
new gear in an electric oven, etc. and
heat it at 220 – 240°C for 30 – 60
minutes and then install it by shrink
fit.
4 Camshaft: 20 kg
2 Camshaft journal surface:
8. Sub idler gear and oil pump assembly
Engine oil (EO30)
1) Install sub idler gear (2), shaft (4) and
plate (3) together.
a Direct the stamp of TOP on shaft (4)
up and direct the chamfered inside
edge toward the gear.
3 Sub idler gear mounting bolt:
377.6 – 426.6 Nm {38.5 – 43.5 kgm}
2) Install oil pump assembly (1).
3 Oil pump assembly mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
26 140E-5 Series
50 Disassembly and assembly SEN00158-05
2) Matching the stamped (C) of the camshaft 4) Fit the O-ring and install cover (3).
gear to that of the main idler gear, tighten 3 Mounting bolt:
mounting bolt (2). 9.8 – 12.7 Nm {1.0 – 1.3 kgm}
3 Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
140E-5 Series 27
SEN00158-05 50 Disassembly and assembly
28 140E-5 Series
50 Disassembly and assembly SEN00158-05
140E-5 Series 29
SEN00158-05 50 Disassembly and assembly
30 140E-5 Series
50 Disassembly and assembly SEN00158-05
3 Mounting bolt:
a Tighten the mounting bolts according
to the following procedure.
1st time:
137 – 157 Nm {14 – 16 kgm}
2nd time:
284 – 294 Nm {29.0 – 30.0 kgm}
3rd time:
Using tool J, tighten the bolt by
90° (+30°/0).
140E-5 Series 31
SEN00158-05 50 Disassembly and assembly
32 140E-5 Series
50 Disassembly and assembly SEN00158-05
140E-5 Series 33
SEN00158-05 50 Disassembly and assembly
a If sleeve nut (5) does not catch the 13) Tighten clamps and brackets (15), (16),
threads, press its end with a small rod, (17), (18), (19) and (20) of bracket side
etc. toward the injector and turn the span- permanently.
ner.
34 140E-5 Series
50 Disassembly and assembly SEN00158-05
140E-5 Series 35
SEN00158-05 50 Disassembly and assembly
36 140E-5 Series
50 Disassembly and assembly SEN00158-05
1. Procedure for installing standard seal 4) Tighten the 4 bolts evenly to press fit rear
a When installing rear seal (4), do not apply seal (4) until the end of tool N1 (for press
oil or grease to the shaft and seal lip. fitting the seal) reaches the end of crank-
1) Set large inside diameter side (b) of guide shaft (6).
(8) of rear seal (4) to the end of crankshaft a Tighten tool N1 (for press fitting the
(6). seal) first until the bolt without washer
a Take care extremely not to mistake stops and then tighten the bolt with 2
the direction of the plastic inside cylin- washers.
der. a When press fitting the seal, take care
not to damage the lip with the tool set
etc.
a After press fitting the seal, remove the
red sealant layer from its periphery.
140E-5 Series 37
SEN00158-05 50 Disassembly and assembly
2) Set sleeve (7) of the rear seal to the end of 27. Flywheel
crankshaft (6) and tighten the 4 bolts Using eyebolt [1] (12 mm, P = 1.75), sling fly-
evenly to press fit sleeve and rear seal wheel (1) and install it to the crankshaft and
assembly (9) until the end of tool N2 tighten the mounting bolts.
reaches the end of crankshaft (6). a When installing the flywheel, match the
a Tighten tool N2 (for press fitting the dowel pin of the crankshaft to the hole of
sleeved seal) until the bolt with the flywheel.
washer stops. a Take care not to bring the flywheel in con-
tact with the speed sensor.
2 Threaded portion and seat of bolt:
Engine oil (EO30)
4 Flywheel: 60 kg
38 140E-5 Series
50 Disassembly and assembly SEN00158-05
140E-5 Series 39
SEN00158-05 50 Disassembly and assembly
5] Install wiring harness terminal (6) to 6) Connect coolant temperature sensor con-
fuel injector (5) and tighten 2 nuts (7). nector TWTR (18).
a Stretch the wiring harness with-
out slack and press it against the
injector body.
a Tighten the nuts alternately.
3 Terminal nut:
2 ± 0.2 Nm {0.2 ± 0.02 kgm}
40 140E-5 Series
50 Disassembly and assembly SEN00158-05
31. Piping and wiring of supply pump 9) Connect sensor connectors PCV2 (20),
1) Install bracket (1). PCV1 (21) and G (22).
2) Install fuel high-pressure pipings (2) and
(3).
3 Sleeve nut of tube:
(Pump side)
39.2 – 49 Nm {4 – 5 kgm}
(Common rail side)
39.2 – 58.8 Nm {4 – 6 kgm}
3) Install the splash prevention cover and
install clamps (4), (5), and (6).
a Direct the cut of the splash prevention
cover on the supply pump side toward
the block and direct that on the com-
mon rail side down.
a Tighten clamps (4), (5) and (6) with
the hand first, and then tighten them
permanently. 32. Electric priming pump and air bleeding
a Tighten the clamps permanently in valve
the order of (4), (5) and (6). a Manual priming pump is set for some
3 Clamping bolt: models. (See the procedure of "with
9.8 ± 1 Nm {1.0 ± 0.1 kgm} EGR" )
4) Install fuel tubes (7), (8) and (9). 1) Install the assembly of electric priming
3 pump (1) and bracket (2).
q Joint bolt of tube (7) 2) Install oil filler bracket (3).
(Pump side) 3) Install the assembly of air bleeding valve
14.8 – 19.6 Nm {1.5 – 2.0 kgm} (4) and bracket (5).
(Common rail side) 4) Install fuel tube (6).
17.7 – 22.6 Nm {1.8 – 2.3 kgm} a Fuel tube (6) was installed tempo-
q Joint bolt of tube (8) rarily in the previous step.
(Pump side) 3 Joint bolt of tube (6)
14.8 – 19.6 Nm {1.5 – 2.0 kgm} (Supply pump side)
q Sleeve nut of tube (8) 14.8 – 19.6 Nm {1.5 – 2.0 kgm}
(Fuel cooler side) (Electric priming pump side)
43 – 47 Nm {4.4 – 4.8 kgm} 19.6 – 29.4 Nm {2.0 – 3.0 kgm}
q Joint bolt of tube (9) 5) Install fuel tube (7).
(Pump side) 3 Joint bolt of tube (7)
14.8 – 19.6 Nm {1.5 – 2.0 kgm} 19.6 – 29.4 Nm {2.0 – 3.0 kgm}
5) Install fuel tube (10) temporarily. 6) Install fuel tubes (8) and (9).
a After installing the electric priming a Fuel tubes (8) and (9) were installed
pump, tighten the joint bolt to the temporarily in the previous step.
specified torque. 3
6) Install oil tube (11). q Joint bolt of tube (8), (9)
3 Joint bolt of tube (11): (Supply pump side)
(Pump side) 14.8 – 19.6 Nm {1.5 – 2.0 kgm}
7.9 – 12.7 Nm {0.8 – 1.3 kgm} q Sleeve nut of tube (8)
(Cylinder block side) (Electric priming pump side)
9.8 – 12.7 Nm {1.0 – 1.3 kgm} 43 – 47 Nm {4.4 – 4.8 kgm}
7) Tighten clamps (12), (13), (14), (15), (17) 7) Install fuel tubes (10) and (11).
and (18) with the hand first, and then 3 Joint bolt of tubes (10) and (11).
tighten them permanently. 19.6 – 29.4 Nm {2.0 – 3.0 kgm}
3 Mounting bolt of clamps (12), (13),
(14): 9.8 ± 1.0 Nm {1.0 ± 0.1 kgm}
8) Install fuel tube (19) temporarily.
a After installing the electric priming
pump, tighten the joint bolt and sleeve
nut to the specified torque.
140E-5 Series 41
SEN00158-05 50 Disassembly and assembly
33. Breather remote tube and corrosion resis- 35. Engine controller
tor tube Install engine controller (2) and connect con-
1) Install breather remote tube (1). nector (1).
2) Install corrosion resistor tubes (2) and (3)
temporarily.
a Corrosion resistor is not set for some
models.
42 140E-5 Series
50 Disassembly and assembly SEN00158-05
2) Install brackets (7), (8), (9), (10) and (11). 37. Air intake connector assembly
3) Install brackets (2), (3), (4), (5) and (6). 1) Install joint housing (2) to bracket (1).
2) Install venturi nozzle, air heater (3) and
connector (4) to joint housing (2).
a Direct the terminal of the air heater
toward the original direction. (The
direction of the terminal depends on
the applicable machines.)
140E-5 Series 43
SEN00158-05 50 Disassembly and assembly
44 140E-5 Series
50 Disassembly and assembly SEN00158-05
42. Oil cooler assembly 3) Fit the gasket and install thermostat
Using eyebolts [1] and guide bolt [2], fit the assembly (5).
gasket, install oil cooler assembly (1) and 4) Insert bypass tube (4) in the water pump
tighten the 16 mounting bolts. assembly and install snap ring (6).
4
5) Tighten the water pump assembly mount-
Oil cooler assembly: 35 kg
ing bolts permanently.
6) Fit the gasket and install tubes (7) and (8).
7) Install alternator drive pulley (9).
140E-5 Series 45
SEN00158-05 50 Disassembly and assembly
45. Exhaust manifold 3) Fit the gasket and install lubrication tube
1) Apply heat-resistant sealant to the mating (5) and 4 clamps (4).
portions of exhaust manifold (between 3 Tube joint bolt:
ports No. 2 and No. 3 and between ports 24.5 – 34.3 Nm {2.5 – 3.5 kgm}
No. 4 and No. 5). 4) Install wiring harness (3).
2 Mating portion:
Heat-resistant sealant (Holtz MH 705)
2) Fit the gasket and sling and install exhaust
manifold and then tighten the mounting
bolts in the following order.
4 Exhaust manifold: 25 kg
a Tighten the 3 bolts of (1) – (3) tempo-
rarily first in the numerical order, and
tighten the bolts (4) – (24) temporarily
in the numerical order. Then, tighten
all the bolts again to the specified
torque in the numerical order.
2 Mounting bolt:
Seizure prevention compound (LC-G)
3 Mounting bolt: 5) Fit the gasket and install turbocharger
58.8 – 73.5 Nm {6 – 7.5 kgm} lubrication drain tube (3) and tube clamps
(4).
6) Install connector (2) and heat insulation
cover (1).
46 140E-5 Series
50 Disassembly and assembly SEN00158-05
140E-5 Series 47
SEN00158-05 50 Disassembly and assembly
53. Checking for fuel leakage 9) Check the fuel piping and devices for fuel
a If fuel supply pump (2), common rail (1), or leakage.
high-pressure pipe is removed and a Check mainly around the high-pres-
installed, after assembling the engine, sure circuit parts coated with the color
check for fuel leakage according to the fol- checker for fuel leakage.
lowing procedure. a If any fuel leakage is detected, repair
it and check again from step 2).
a If no fuel leakage is detected, check
is completed.
48 140E-5 Series
50 Disassembly and assembly SEN00158-05
140E-5 Series 49
SEN00158-05
© 2011 KOMATSU
All Rights Reserved
Printed in Japan 10-11
50
SEN00159-04
140E-5 Series
140E-5 Series 1
SEN00159-04 50 Disassembly and assembly
2. Rotate the crankshaft forward and set interme- 6. Remove the clamp and fuel tubes (10) and
diate point (a) between stamped “2/5 TOP” (11) and then disconnect fuel tubes (12) and
and “3/4 TOP” on damper (2) to pointer (3). (13) and fuel hose (14). [*3]
a At this time, check that the forcing tap of
the drive gear is set to the bolt hole at the 7. Remove the clamp and oil tubes (15) and (16).
top of cover (1). [*4]
(If not, rotate the crankshaft 1 more turn.)
a At this point, the key of the shaft is turned 8. Remove the splash prevention cover, clamps
clockwise by 15° from the top. (17), (18), (19), and bracket (20), and then
remove high-pressure tube (21). [*5]
2 140E-5 Series
50 Disassembly and assembly SEN00159-04
[*2]
3 Sleeve nut of EGR oil tube (4):
43 – 47 Nm {4.4 – 4.8 kgm}
[*3]
3 Joint bolt of fuel tube (12) (Pump side):
14.8 – 19.6 Nm {1.5 – 2.0 kgm}
Joint bolt of fuel tube (13):
(Pump side)
14.8 – 19.6 Nm {1.5 – 2.0 kgm}
(Common rail side)
17.7 – 22.6 Nm {1.8 – 2.3 kgm}
10. Set tool P to the drive gear, tighten center bolt Joint bolt of fuel tubes (10) and (11):
of P, and remove gear (25) from the shaft. (Pump side)
14.8 – 19.6 Nm {1.5 – 2.0 kgm}
11. Remove mounting bolts (23) which have been
left and remove supply pump assembly (22). [*4]
a If tool P is removed, the gear falls down. 3 Joint bolt of oil tubes (15) and (16):
Accordingly, keep it installed until the (Pump side)
pump is installed. 7.9 – 12.7 Nm {0.8 – 1.3 kgm}
(Cylinder block side)
9.8 – 12.7 Nm {1.0 – 1.3 kgm}
[*5]
1) Tighten fuel tube (21) with the hand first,
and then tighten it permanently.
3 Sleeve nut:
(Pump side)
39.2 – 49.0 Nm {4.0 – 5.0 kgm}
(Common rail side)
39.2 – 58.8 Nm {4.0 – 6.0 kgm}
2) Tighten clamps (17), (18), and (19) with
the hand first, and then tighten them per-
manently.
a Tighten clamps permanently in the
order of (17), (18) and (19).
3 Clamp mounting bolt:
9.8 ± 1 Nm {1 ± 0.1 kgm}
3) Direct the notch of the splash prevention
cover on the supply pump side toward the
block and direct that on the common rail
side down.
140E-5 Series 3
SEN00159-04 50 Disassembly and assembly
Removal and installation of fuel 4. Remove fuel filters (1) and oil filters (2). [*2]
supply pump unit (EGR-less) 1 a Single cartridge is set for some models.
4 140E-5 Series
50 Disassembly and assembly SEN00159-04
7. Remove sensor connectors (10), (11) and (12). 14. Remove mounting bolts (32) and remove
bracket (33) from supply pump assembly (31).
8. Remove the scatter prevention cover bracket a Leave bolts (32) tightened by 2 – 3
(13). threads to prevent the pump from falling
down.
9. Remove clamps (14), (15) and (16) and high-
pressure pipes (17) and (18). [*5]
140E-5 Series 5
SEN00159-04 50 Disassembly and assembly
Installation [*7]
q Carry out installation in the reverse order to 3
[*5]
1) Tighten fuel high-pressure tubes (17), (18)
with the hand first, and then tighten them
permanently.
3 Sleeve nut:
(Pump side)
39.2 – 49.0 Nm {4.0 – 5.0 kgm}
(Common rail side)
39.2 – 58.8 Nm {4.0 – 6.0 kgm}
2) Tighten clamps (14), (15), and (16) with
the hand first, and then tighten them per-
manently.
a Tighten clamps permanently in the
order of (14), (15) and (16).
3 Clamp mounting bolt:
9.8 ± 1 Nm {1 ± 0.1 kgm}
3) Direct the notch of the splash prevention
cover on the supply pump side toward the
block and direct that on the common rail
side down.
[*6]
3 Clamps (21), (22) and (23) mounting bolt:
9.8 ± 1 Nm {1 ± 0.1 kgm}
6 140E-5 Series
50 Disassembly and assembly SEN00159-04
Replacement of oil seal of engine q Left: Standard seal, Right: Sleeved seal
mounted on machine 1
a There are standard seal and sleeved seal.
(Refer to the "Installation")
140E-5 Series 7
SEN00159-04 50 Disassembly and assembly
a Clean, degrease, and dry the contact sur- 1. Procedure for installing standard seal
face against the flywheel housing. a When installing rear seal (4), do not apply
a Clean, degrease, and dry the seal lip sur- oil or grease to the shaft and seal lip.
face (periphery of the crankshaft). 1) Set large inside diameter side (b) of guide
a Check that the end corners and lip sliding (8) of rear seal (4) to the end of crankshaft
surfaces of the crankshaft are free from (6).
flaw, burr, and rust of the housing. a Take care extremely not to mistake
the direction of the plastic inside cylin-
der.
8 140E-5 Series
50 Disassembly and assembly SEN00159-04
4) Tighten the 4 bolts evenly to press fit rear 2) Set sleeve (7) of the rear seal to the end of
seal (4) until the end of tool N1 (for press crankshaft (6) and tighten the 4 bolts
fitting the seal) reaches the end of crank- evenly to press fit sleeve and rear seal
shaft (6). assembly (9) until the end of tool N2
a Tighten tool N1 (for press fitting the reaches the end of crankshaft (6).
seal) first until the bolt without washer a Tighten tool N2 (for press fitting the
stops and then tighten the bolt with 2 sleeved seal) until the bolt with
washers. washer stops.
a When press fitting the seal, take care
not to damage the lip with the tool set
etc.
a After press fitting the seal, remove the
red sealant layer from its periphery.
140E-5 Series 9
SEN00159-04 50 Disassembly and assembly
Removal
a For the work up to removal of the damper, see
the Shop manual for the applicable machine.
1) Remove front oil seal (1).
Installation
a Check the seal by checking the wear of the
shaft and replace it with the "standard seal" or
"sleeved seal".
If the shaft is worn to the degree of luster (If
wear which you feel with your finger is less
Removal with tool L than 10 mm) and does not have any flaw, install
1) Drill several holes about 3 mm in diameter into "standard seal A". In other cases, install
front oil seal (1). "sleeved seal B".
2) Replace the tip of tool L with the drill type one. a (7): Plastic inside cylinder which is also used
3) Insert the top end of tool L into the drilled hole, as installation guide.
and remove the front seal by the impact of a (6): Sleeve.
slide hammer (SH). (Apply the slide hammer a Do not remove installation guide (7) from front
evenly not to tilt the front seal.) seal (3) before installing the front seal.
a Remove the metal powders completely. a Handle front seal (3) and sleeve (6) as an
a When the sleeve is attached, cut sleeve assembly and never separate them from each
(6) using a gad and hammer to remove it. other.
a Take care not to damage crankshaft (5).
Standard spare seal Sleeved seal
10 140E-5 Series
50 Disassembly and assembly SEN00159-04
1. Procedure for installing standard seal 2) Push the metal ring of front seal (3)
a Before installing the seal, check that the evenly as if you are passing over the large
end corners and lip sliding surfaces of the inside diameter side of plastic inside cylin-
crankshaft are free from flaw, burr, and der (7).
rust of the housing. a Hit the metal ring of front seal with
a When installing the seal, do not apply oil plastic hammer evenly.
or grease to the shaft and seal lip. Wipe a Do not hit it strongly.
off the oil from the shaft. 3) After pushing in the seal, remove plastic
inside cylinder (7).
a Never remove inside plastic cylinder (7) of
a When removing the inside cylinder,
the replacement seal before installing the take care not to damage the seal lip.
seal.
1) Set large inside diameter side (b) of plas-
tic inside cylinder (7) to the end of crank-
shaft (5).
a Take care not to mistake the direction
of the plastic inside cylinder.
140E-5 Series 11
SEN00159-04
© 2010KOMATSU
All Rights Reserved
Printed in Japan 04-10
12
SEN05198-00
140E-5 Series
140E-5 Series 1
SEN05198-00 90 Repair and replacement of parts
Flowchart
Repair of cylinder block top and counterbore by grinding
a For removal, installation, disassembly and assembly of the engine, see the Shop Manual, "Disassembly
and assembly".
a If the judgment of No. 9 is NO, examine A.
2 140E-5 Series
90 Repair and replacement of parts SEN05198-00
140E-5 Series 3
SEN05198-00 90 Repair and replacement of parts
4 140E-5 Series
90 Repair and replacement of parts SEN05198-00
Replacement/Rebuilding
Symbol Part No. Part name Q'ty Remarks
item
N 795-931-1100 Seal puller assembly 1 For pulling out
1 795T-421-1260 Sleeve jig 1 For press fitting standard
2 01050-31640 Bolt 3 seal
3 01643-31645 Washer 3 (For wet type)
140E-5 Series 5
SEN05198-00 90 Repair and replacement of parts
6 140E-5 Series
90 Repair and replacement of parts SEN05198-00
Note) We will not be liable for any result of use of special tools manufactured according
to the following drawings.
P7. Sleeve jig
140E-5 Series 7
SEN05198-00 90 Repair and replacement of parts
Note) We will not be liable for any result of use of special tools manufactured according
to the following drawings.
Q7. Sleeve jig
8 140E-5 Series
90 Repair and replacement of parts SEN05198-00
140E-5 Series 9
SEN05198-00
© 2009 KOMATSU
All Rights Reserved
Printed in Japan 05-09 (01)
10
SEN05199-02
140E-5 Series
140E-5 Series 1
SEN05199-02 90 Repair and replacement of parts
1. Cylinder head
2. Crosshead guide
3. Valve guide
4. Valve seat insert (intake side)
5. Valve (intake valve)
6. Valve (exhaust valve)
7. Valve seat insert (exhaust side)
2 140E-5 Series
90 Repair and replacement of parts SEN05199-02
140E-5 Series 3
SEN05199-02 90 Repair and replacement of parts
Fig. A Fig. D
a: Sink e: Projection
1. Crosshead guide
Fig. B 2. Cylinder head
Fig. C
d: Projection
4 140E-5 Series
90 Repair and replacement of parts SEN05199-02
q If the cylinder head parts were repaired, per- Pulling out of valve guide
form the test according to the following proce- q Using tool C1, pull out the valve guide.
dure.
140E-5 Series 5
SEN05199-02 90 Repair and replacement of parts
6 140E-5 Series
90 Repair and replacement of parts SEN05199-02
6. Push in 3 claws (10) of puller head (9) of tool D When pulling out valve seat insert (a) by weld-
with the hand and put them in valve seat insert ing a bar to it
(a). 1. Weld bar (b) (Length: 0.1 – 0.5 mm shorter
than valve seat inside diameter, Diameter:
7. Tighten screw (12) to press 3 claws (10) Approx. 10 mm) to the inside of valve seat
against the inside groove of valve seat insert insert (a).
(a). a Take care that welding spatters will not
a If screw (12) is tightened too strongly, the stick to the head.
insert will be broken and become difficult
to pull out. Accordingly, stop tightening 2. After the temperature of the welded parts has
when 3 claws (10) reach the groove fully. decreased to around the ambient temperature,
insert an unnecessary valve (c) in the reverse
8. Put bridge (8) in the outside of puller head (9), direction and hit its head with a small hammer
place plates (11) and (7) on the bridge, and to pull out valve seat insert (a).
tighten nut (6) to pull out valve seat insert (a). a If a large impact is given, the welded parts
may come off. Take care.
140E-5 Series 7
SEN05199-02 90 Repair and replacement of parts
8 140E-5 Series
90 Repair and replacement of parts SEN05199-02
140E-5 Series 9
SEN05199-02 90 Repair and replacement of parts
a OS: Oversize
a OS: Oversize
10 140E-5 Series
90 Repair and replacement of parts SEN05199-02
140E-5 Series 11
SEN05199-02 90 Repair and replacement of parts
2. Fit the contact surface of the valve seat insert Final inspection
to the valve by using compound. q Thinly apply red lead to the valve seat insert
1) Thinly apply rough compound mixed with contact surface of a new valve and insert that
oil to the seat surface of a valve and insert valve in the valve guide.
that valve in the valve guide. q Lightly press the valve against the valve seat
2) Install the fitting rod to the valve head and insert and rotate it 10°.
lightly hit valve against the valve seat q Check the valve seat insert contact surface of
while rotating it with both hands to fit the the valve and ensure that the contact is even
valve to the valve seat. and is not broken.
3) After the valve and valve seat are fitted q Or, make marks (m) (about 20 places) on the
and their surfaces become smooth, wipe valve seat insert contact surface of a new
off the compound. valve with a pencil and insert that valve in the
4) Apply fine compound and fit the valve and valve guide.
valve seat again similarly to the above q Lightly press the valve against the valve seat
until they are fitted to each other without insert and rotate it 10°.
breakage. q Ensure that all the pencil marks (m) have been
erased evenly.
When master valve is used
12 140E-5 Series
90 Repair and replacement of parts SEN05199-02
140E-5 Series 13
SEN05199-02 90 Repair and replacement of parts
14 140E-5 Series
90 Repair and replacement of parts SEN05199-02
Repair of valve by grinding a Apply dial gauge (1) to the facial runout mea-
suring point of seat contact surface (c) of the
a Valve grinding tool valve and rotate the valve to measure its facial
Symbol Part No. Part name runout while pressing it toward left (d).
Commercially Intake valve: Max. 0.045 mm (TIR)
H Valve refacer
available Exhaust valve: Max. 0.030 mm (TIR)
a TIR is an abbreviation for Total Indicator Read-
Grinding of seat contact surface of valve ing, which is the difference between the maxi-
q Using tool H, grind the seat contact surface of mum and minimum readings in runout
the valve. measurement.
140E-5 Series 15
SEN05199-02
© 2010 KOMATSU
All Rights Reserved
Printed in Japan 10-10
16
SEN05200-01
140E-5 Series
140E-5 Series 1
SEN05200-01 90 Repair and replacement of parts
2 140E-5 Series
90 Repair and replacement of parts SEN05200-01
1. Cylinder liner
2. Clevis seal
3. Cylinder liner O-ring
4. Cylinder block
5. Main bearing metal cap bolt
6. Main bearing metal cap (No. 1, 2, 3, 4, 5 and 6 are same)
7. Camshaft bushing
140E-5 Series 3
SEN05200-01 90 Repair and replacement of parts
4 140E-5 Series
90 Repair and replacement of parts SEN05200-01
Fig. A Fig. D
Fig. B Fig. E
Fig. C Fig. F
140E-5 Series 5
SEN05200-01 90 Repair and replacement of parts
Roundness 0.005
Straightness 0.010
i: Upper section
j: Lower section Length Min. 1,300
6 140E-5 Series
90 Repair and replacement of parts SEN05200-01
1. Crankshaft
2. Main bearing metal (upper)
3. Main bearing metal (lower)
4. Thrust metal (All of upper x 1 and lower x 2 are the same)
140E-5 Series 7
SEN05200-01 90 Repair and replacement of parts
8 140E-5 Series
90 Repair and replacement of parts SEN05200-01
140E-5 Series 9
SEN05200-01 90 Repair and replacement of parts
Scuffing on bolt seat surface Scuffing on bolt seat surface Replace bolt
a If all the items of this criteria (particularly the wave of the large end hole) cannot be measured after the
connecting rod is rebuilt, do not rebuild since the accuracy of the connecting rod large end hole after
rebuilding cannot be confirmed.
a When reusability is judged, if there are honing marks left on the inside of the connecting rod large end
hole, it is not required to measure the surface roughness of the inside and wave of the large end hole.
a Do not reuse the connecting rod cap mounting bolt more than 5 times.
Each time the bolt is tightened, make a punch mark on it.
10 140E-5 Series
90 Repair and replacement of parts SEN05200-01
Removal of gear
q Make a notch at the tooth bottom of the gear
with a grinder and break the gear to remove
with a chisel.
k Take care in handling the grinder and
chisel.
b: Inspection range
c: Streaks
d: Lengthwise direction
140E-5 Series 11
SEN05200-01 90 Repair and replacement of parts
Replacement of crankshaft gear 4. Using the drive tool, press fit the gear with the
timing mark out until its side contacts the
a Crankshaft gear replacement tools crankshaft flange.
Symbol Part No. Part name a Press fit the gear quickly before it cools
1 790-101-2800 Bearing puller down.
K
2 790-101-2300 Push puller
Removal of gear
q Make a notch at the tooth bottom of the gear
with a grinder, assemble tools K1 and K2, and
rotate the nut to pull out the gear.
a If the gear cannot be pulled out by the above
method, make a notch at the tooth bottom of
the gear with a grinder, heat the gear with a
gas burner, and drive out the gear with a cop-
per rod etc.
a Take care not to damage the crankshaft.
12 140E-5 Series
90 Repair and replacement of parts SEN05200-01
Removal of gear
Set the camshaft assembly on the press stand and
press the camshaft to pull out the gear.
5. Using the drive tool, press fit the gear with the
timing mark out until its side contacts the cam-
shaft flange.
a Press fit the gear quickly before it cools
down.
140E-5 Series 13
SEN05200-01 90 Repair and replacement of parts
2nd time 196 {20} 191 – 201 {19.5 – 20.5} Side machining of main bearing metal cap
(Machine only No. 7 main bearing metal cap)
Tightening by
3rd time 90° +30°
0 1. Insert cast iron bushing (3) and pass arbor (4)
90°
through it.
3. Set the cylinder block mounting jig on the table
of the horizontal boring machine and install the 2. Install facing tool (5) to the arbor.
cylinder block by fitting its cylinder liner mount-
ing hole to the datum line of the jig. 3. Cut main bearing metal cap (1) to the degree
that facing tool almost touches the cylinder
block surface.
14 140E-5 Series
90 Repair and replacement of parts SEN05200-01
140E-5 Series 15
SEN05200-01 90 Repair and replacement of parts
a Connecting rod small end bushing replace- 2. Install the bushing to push tool (1), set push
ment tool tool (2), and fix them with nut (4).
Symbol Part No. Part name a Match the oil holes of the bushing and
L 795-240-6401 Push tool (KIT) connecting rod to each other.
16 140E-5 Series
90 Repair and replacement of parts SEN05200-01
Replacement of cam bushing 3. Pulling out of No. 3, No. 4 and No. 5 bushings
1) Assemble bar (1), push tool (2), collar (3)
a Cam bushing replacement tools and guide (4).
Symbol Part No. Part name 2) While hitting bar (1), drive out the bushing
M 795-213-1200 Push tool (KIT) from the cylinder block.
Removal
1. Pulling out of No. 1 and No. 7 bushings
1) Assemble push tool (2), collar (3) and bar
(1) of tool M.
2) While hitting bar (1), drive out the bushing
from the cylinder block.
Installation
a Cam bushing installation drawing
140E-5 Series 17
SEN05200-01 90 Repair and replacement of parts
1. Press fitting of No. 3, No. 4 and No. 5 bushings 3. Press fitting of No. 1 and No. 7 bushings
1) Install bar (1), push tool (2), collar (3) and 1) Install bar (1), push tool (2) and collar (3)
guide (4) to the bushing. to the bushing.
2) Press fit the bushing until the oil holes of 2) Press fit the bushing until the oil holes of
the cylinder block and bushing are the cylinder block and bushing are
matched to each other. matched to each other.
a Ensure that the pin 2 mm in diameter goes a Ensure that the pin 2 mm in diameter goes
smoothly through the drilled hole of the smoothly through the drilled hole of the
cylinder block and oil holes (upper and cylinder block and oil holes (upper and
lower) of the bushing. lower) of the bushing.
2. Press fitting of No. 2 and No. 6 bushings 4. Measurement after bushing is press fitted
1) Install bar (1), push tool (2), collar (3) and 1) Using dial inside gauge (a), measure the
guide (4) to the bushing. inside diameter of the bushing.
2) Press fit the bushing until the oil holes of
the cylinder block and bushing are
matched to each other.
a Ensure that the pin 2 mm in diameter goes
smoothly through the drilled hole of the
cylinder block and oil holes (upper and
lower) of the bushing.
18 140E-5 Series
90 Repair and replacement of parts SEN05200-01
Fig. 1
140E-5 Series 19
SEN05200-01 90 Repair and replacement of parts
20 140E-5 Series
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140E-5 Series 21
SEN05200-01 90 Repair and replacement of parts
Q — OS
— Q SH
Q Q WS
22 140E-5 Series
90 Repair and replacement of parts SEN05200-01
1. Wipe off dirt, oil etc. from cylinder block top (c)
and the cylinder liner flange contact surface
with cloths.
3. Press fit cylinder liner to the cylinder block. 4. Set the cylinder liner to the cylinder block,
At this time, apply a little amount of rubber install the used head gasket, and tighten the
lubricant (RF-1) to cylinder block contact sur- cylinder head temporarily.
face (d) of the O-ring and seal of the cylinder At this time, tighten the bolts in the following
liner. order.
a Apply the engine oil just before press fit- 3 Tightening torque:
140E-5 Series 23
SEN05200-01 90 Repair and replacement of parts
24 140E-5 Series
90 Repair and replacement of parts SEN05200-01
1 ø167
2 ø161.45 ± 0.25
3 ø160.67 ± 0.064
6 ø158 +0.040
+0
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SEN05200-01 90 Repair and replacement of parts
Replacement of engine rear seal 2. Pull slide hammer (1) of the seal puller to pull
out the seal with impacts.
a Engine rear seal replacement tools a Rear seal (c) can be pulled out easily, if it
Symbol Part No. Part name is driven in a little to separate it from the
O 795-931-1100 Seal puller assembly flywheel housing in advance.
a Do not damage the crankshaft.
a For disassembly and assembly of flywheel and a Do not use a drill since chips will enter the
flywheel housing, see "Disassembly and engine.
assembly".
26 140E-5 Series
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2. Screw drill end (6) into the metal ring of rear a Before installing the rear seal, remove all
seal (c) and pull slide hammer (1) of the seal flaws, sharp edges, burrs, rust, etc. from the
puller to pull out the seal with impacts. end corners and sliding surfaces of the crank-
a Rear seal (c) can be pulled out easily, if it shaft and from the flywheel housing.
is driven in a little to separate it from the a Do not apply oil or grease to the sliding sur-
flywheel housing in advance. faces of the crankshaft and lip (e) of the rear
a Do not damage the crankshaft. seal.
a Do not use a drill since chips will enter the Wipe off the oil from the sliding surfaces of the
engine. crankshaft thoroughly.
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SEN05200-01 90 Repair and replacement of parts
4. Install sleeve jig (1) and clamp bolts (2) (Stem Installation of rear seal (with sleeve)
length: 40 mm (wet), 45 mm (dry)). a Handle the spare rear seal and sleeve (n) as
a Do not install washers to the bolts. an assembly and do not separate them.
28 140E-5 Series
90 Repair and replacement of parts SEN05200-01
2. Install sleeve jig (4), clamp bolts (5) (Stem 5. Remove clamp bolts (8) (Stem length: 45 mm),
length: 45 mm), and 1 washer (6). install 2 washers (9) each, and tighten bolts (8)
evenly again to press fit the rear seal until end
3. Evenly tighten clamp bolts (5) to press fit the (q) of sleeve jig (7) touches end (r) of the
rear seal until they stop. crankshaft.
a Be sure to press fit rear seal (c) and a After press fitting, remove the gasket seal-
sleeve (n) as an assembly. ant projected around the periphery.
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30 140E-5 Series
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Repair of crankshaft by grinding Pin journal oil hole (See figure below)
q Finish part (d) with sandpaper.
q When the crankshaft is worn, seized or dam- q Check part (e) extremely carefully since
aged slightly and needs to be repaired, grind it quenching crack tends to occur in that part.
to one of the following undersizes.
Undersizes: 0.25, 0.50, 0.75, 1.00 mm
q If the crankshaft is bent or worn unevenly, it
should not be repaired but should be replaced.
(Repairing the crankshaft requires high tech-
nologies)
q Finish fillet portion (R), shoulder portion (r) and
area (R) around the hole of the crankshaft with
extreme care.
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SEN05200-01 90 Repair and replacement of parts
Inspection before repair by grinding Check during and after repair by grinding
Magnaflux inspection
q Before using the repaired crankshaft, check it
by magnaflux inspection to ensure that it has
no crack.
q Extremely closely check journal fillet portion (a)
which is in the dangerous area of each web of
the crankshaft.
q After the magnaflux inspection, be sure to
demagnetize the crankshaft.
32 140E-5 Series
90 Repair and replacement of parts SEN05200-01
Standard
52.25 +0.050 52.375 +0.050 52.50 +0.050
0.25 size 0 0 0
OS Repair 52.310 52.435 52.560
limit
q Squareness of thrust surface (TIR)
Permissible deviation: 0.04 mm
Roundness, cylindricality (TIR) and surface Roundness, cylindricality (TIR) and surface
roughness of main journal roughness of pin journal
Permissible deviation: Max. 0.009 mm Permissible deviation: Max. 0.009 mm
Surface roughness: 0.6S Surface roughness: 0.6S
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Grinding of sides of main journal and pin journal Prevention of grinding burn
q When repairing worn surfaces (c) of main jour- q Apply the flange grinding method.
nal (a) and pin journal (b), limit the grinding q Use all the width of the grinding stone.
quantity to the minimum. Avoid grinding the boss surface.
q (d) is thickness of worn surface. q Apply cooling oil sufficiently.
q Width of crankpin journal q Set the standard peripheral speed of the grind-
When only 1 side is ground ing stone to 2,000 m/min when the crankshaft
Standard: 58 +0.074
0 mm rotation speed is 50 rpm.
q Width of main journal (#7 only)
Standard: 52 +0.05
0 mm Finishing of surface
q Squareness of thrust surface (TIR) q Surface roughness standard
Permissible deviation: 0.04 mm Journal surface (c):
0.6S (finished with sandpaper)
Thrust surface and fillet portion (d): Max. 3.2S
Front seal insertion portion (e) (Range of 33
mm from end): 1 – 2.5S
q Polish finishing margin: 0.007 – 0.008 mm
34 140E-5 Series
90 Repair and replacement of parts SEN05200-01
Work after repair by grinding 2. Measure the outside diameter of the main jour-
q Ensure again that each dimension is as speci- nal in directions (X) and (Y) at 2 places ((1)
fied. and (2)) and that of the pin journal in directions
q Clean each part thoroughly and apply rust-pre- (X) and (Y) at 2 places ((1) and (2)) with a
ventive oil. micrometer or an air micrometer.
q When storing the crankshaft for a long period,
support it on 3 points or keep it erected with a
sling.
Balancing (Reference)
Avoid performing repair that may affect the crank-
shaft balancing.
q Allowable limit of unbalance: 110 gcm
Limits for reading balance accurately
Bend of crankshaft: 0.09 mm (TIR)
Rotation speed of crankshaft: Max. 325 rpm
q When balancing, perform the following correc-
tions.
Front key way: 30.7 gcm
q Correct the balance by drilling holes in or grind
the counterweight, if necessary.
Repair quantity limit of counterweight: 56 g
Drilling direction: Radial direction or in parallel
with each other
Number of holes: Max. 6
Hole diameter: 13 mm or 15 mm
Hole depth: Max. 40 mm
Distance between hole and side:
Min. 5 mm
Distance between holes: Min. 5 mm
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38 140E-5 Series
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140E-5 Series 39
SEN05200-01
© 2010 KOMATSU
All Rights Reserved
Printed in Japan 06-10
40