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SEN00074-16

ENGINE

140E

-5

SERIES

SEN00076-16

ENGINE
1SHOP MANUAL

140E-5 Series

00 Index and foreword

Index
Composition of shop manual .......................................................................................................................... 2
Table of contents ............................................................................................................................................. 3

140E-5 Series

SEN00076-16

00 Index and foreword

Composition of shop manual

The contents of this shop manual are shown together with Form No. in a list.
Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly.
The marks shown to the right of Form No. denote the following:
Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.)
Note 2: This shop manual can be supplied for each Form No.
Note 3: To file this shop manual in the special binder for management, handle it as follows:
Place a divider on the top of each section in the file after matching the Tub No. with No. indicated
next to each Section Name shown in the table below:
File overview and other materials in sections in the order shown below and utilize them accordingly.
Section Title

Form Number

Shop Manual, contents binder, binder label and tabs ............................................................ SEN00074-16
00 Index and foreword ......................................................................................................... SEN00075-16
Index ............................................................................................................................... SEN00076-16 q
Foreword and general information .................................................................................. SEN00077-07
01 Specification.................................................................................................................... SEN00078-07
Specification and technical data...................................................................................... SEN00079-07 q
10 Structure, function and maintenance standard ............................................................... SEN00080-08
Structure, function and maintenance standard, Part 1.................................................... SEN00081-08 q
Structure, function and maintenance standard, Part 2.................................................... SEN00082-06 q
20 Standard value table ....................................................................................................... SEN00083-07
Standard service value table........................................................................................... SEN00147-07 q
30 Testing and adjusting ...................................................................................................... SEN00148-05
Testing and adjusting ...................................................................................................... SEN00149-05
40 Troubleshooting .............................................................................................................. SEN00150-06
General information on troubleshooting.......................................................................... SEN00151-04
Troubleshooting of mechanical system (S-mode)........................................................... SEN00152-03
Troubleshooting of electrical system (E-mode), Part 1 ................................................... SEN00153-03
Troubleshooting of electrical system (E-mode), Part 2 ................................................... SEN00154-02
50 Disassembly and assembly ............................................................................................ SEN00155-07
General information on disassembly and assembly ....................................................... SEN00156-05
Disassembly and assembly, Part 1 (with EGR) .............................................................. SEN00157-05
Disassembly and assembly, Part 2 (EGR-less) .............................................................. SEN00158-05
Disassembly and assembly, Part 3 ................................................................................. SEN00159-04
90 Repair and replacement of parts..................................................................................... SEN05197-02
Information related to repair and replacement ................................................................ SEN05198-00
Cylinder head.................................................................................................................. SEN05199-02
Cylinder block ................................................................................................................. SEN05200-01

140E-5 Series

00 Index and foreword

SEN00076-16

Table of contents

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
10 Structure, function and maintenance standard
Structure, function and maintenance standard, Part 1
SEN00081-08
Air intake and exhaust unit ......................................................................................................
3
Air cleaner ...............................................................................................................................
5
Turbocharger ...........................................................................................................................
8
Aftercooler ............................................................................................................................... 19
Muffler...................................................................................................................................... 20
EGR system ............................................................................................................................ 25
Cylinder head .......................................................................................................................... 32
Cylinder block .......................................................................................................................... 36
Cylinder liner............................................................................................................................ 39
Main moving parts ................................................................................................................... 40
Crankshaft ............................................................................................................................... 42
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
Structure, function and maintenance standard, Part 2
SEN00082-06
Lubrication system ......................................................................................................................
4
Lubrication system diagram.....................................................................................................
4
Oil pump ..................................................................................................................................
8
EGR oil pump ..........................................................................................................................
9
Oil filter .................................................................................................................................... 10
Oil cooler ................................................................................................................................. 12
140E-5 Series

SEN00076-16

00 Index and foreword

Fuel system .................................................................................................................................


CRI system diagram ................................................................................................................
Outline of CRI system..............................................................................................................
Fuel piping ...............................................................................................................................
Fuel cooler ...............................................................................................................................
Fuel filter ..................................................................................................................................
Priming pump...........................................................................................................................
Electric priming pump ..............................................................................................................
Engine controller cooler ...........................................................................................................
Cooling system............................................................................................................................
Cooling system diagram ..........................................................................................................
Water pump .............................................................................................................................
Thermostat...............................................................................................................................
Corrosion resistor ....................................................................................................................
Cooling fan drive......................................................................................................................
Accessories .................................................................................................................................
Front PTO ................................................................................................................................
Electrical equipment ....................................................................................................................
Alternator .................................................................................................................................
Starting motor ..........................................................................................................................
Starting aid...............................................................................................................................
Engine controller......................................................................................................................

14
14
16
38
42
43
46
47
48
49
49
54
57
58
60
63
63
65
65
76
78
79

20 Standard value table


Standard service value table
SEN00147-07
Standard service value table for testing, adjusting, and troubleshooting .................................
2
Running-in standard and performance test standard .............................................................. 19
30 Testing and adjusting
Testing and adjusting
SEN00149-05
Testing and adjusting (with EGR) ................................................................................................
3
Testing and adjusting tools list .................................................................................................
3
Sketches of special tools .........................................................................................................
5
Testing air boost pressure........................................................................................................
6
Testing exhaust temperature ...................................................................................................
7
Adjusting valve clearance ........................................................................................................
8
Testing compression pressure .................................................................................................
9
Testing blow-by pressure ......................................................................................................... 11
Testing engine oil pressure ...................................................................................................... 12
Testing EGR valve and bypass valve drive oil pressure .......................................................... 13
Handling fuel system parts ...................................................................................................... 14
Releasing residual pressure in fuel system ............................................................................. 14
Testing fuel pressure................................................................................................................ 15
Reduced cylinder mode operation ........................................................................................... 16
No-injection cranking ............................................................................................................... 16
Testing fuel return rate and leakage ........................................................................................ 17
Bleeding air from fuel circuit .................................................................................................... 20
Testing fuel system for leakage ............................................................................................... 22
Testing and adjusting alternator belt tension ........................................................................... 23
Testing and adjusting fan belt tension...................................................................................... 24
Handling controller high-voltage circuit.................................................................................... 25
Testing and adjusting (EGR-less)................................................................................................ 26
Testing and adjusting tools list ................................................................................................. 26
Sketches of special tools ......................................................................................................... 28
Testing air boost pressure........................................................................................................ 29
Testing exhaust temperature ................................................................................................... 30
Adjusting valve clearance ........................................................................................................ 31

140E-5 Series

00 Index and foreword

SEN00076-16

Testing compression pressure.................................................................................................


Testing blow-by pressure.........................................................................................................
Testing engine oil pressure......................................................................................................
Handling fuel system parts ......................................................................................................
Releasing residual pressure in fuel system .............................................................................
Testing fuel pressure ...............................................................................................................
Reduced cylinder mode operation...........................................................................................
No-injection cranking ...............................................................................................................
Testing fuel return rate and leakage ........................................................................................
Bleeding air from fuel circuit ....................................................................................................
Testing fuel system for leakage ...............................................................................................
Testing and adjusting alternator belt tension ...........................................................................
Testing and adjusting fan belt tension .....................................................................................
Handling controller high-voltage circuit....................................................................................

32
34
35
36
36
37
38
38
39
42
44
45
46
47

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

SEN00076-16

00 Index and foreword

E-13 Code [187/CA187] Sensor Sup. 2 Volt. Low Error .......................................................... 34


E-14 Code [221/CA221] Ambient Air Press. Sensor High Error .............................................. 38
E-15 Code [222/CA222] Ambient Air Press. Sensor Low Error............................................... 40
E-16 Code [227/CA227] Sensor Sup. 2 Volt. High Error ......................................................... 42
E-17 Code [234/CA234] Eng. Overspeed................................................................................ 42
E-18 Code [238/CA238] Ne Speed Sensor Sup. Volt. Error .................................................... 44
E-19 Code [263/CA263] Fuel Temp. Sensor High Error .......................................................... 46
E-20 Code [265/CA265] Fuel Temp. Sensor Low Error........................................................... 48
E-21 Code [271/CA271] PCV1 Short Error.............................................................................. 50
E-22 Code [272/CA272] PCV1 Open Error ............................................................................. 52
E-23 Code [273/CA273] PCV2 Short Error.............................................................................. 54
E-24 Code [274/CA274] PCV2 Open Error ............................................................................. 56
E-25 Code [322/CA322] Injector #1 System Open/Short Error ............................................... 58
E-26 Code [323/CA323] Injector #5 System Open/Short Error ............................................... 60
E-27 Code [324/CA324] Injector #3 System Open/Short Error ............................................... 62
E-28 Code [325/CA325] Injector #6 System Open/Short Error ............................................... 64
E-29 Code [331/CA331] Injector #2 System Open/Short Error ............................................... 66
E-30 Code [332/CA332] Injector #4 System Open/Short Error ............................................... 68
E-31 Code [342/CA342] Engine Controller Data Matching Error............................................. 70
E-32 Code [351/CA351] INJ. Drive Circuit Error...................................................................... 72
E-33 Code [352/CA352] Sensor Sup. 1 Volt. Low Error .......................................................... 74
E-34 Code [386/CA386] Sensor Sup. 1 Volt. High Error ......................................................... 75
E-35 Code [431/CA431] Idle Validation Switch Error............................................................... 78
E-36 Code [432/CA432] Idle Validation Process Error ............................................................ 80
E-37 Code [441/CA441] Supply Voltage Low Error ................................................................. 81
E-38 Code [442/CA442] Supply Voltage High Error ................................................................ 81
Troubleshooting of electrical system (E-mode), Part 2
SEN00154-02
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
E-52 Code [1627/CA1627] Bypass Valve Solenoid Drive Open Error ..................................... 25
E-53 Code [1628/CA1628] Bypass Valve Servo Error 1.......................................................... 26
E-54 Code [1629/CA1629] Bypass Valve Servo Error 2.......................................................... 27
E-55 Code [1631/CA1631] Bypass Valve Lift Sensor High Error............................................. 28
E-56 Code [1632/CA1632] Bypass Valve Lift Sensor Low Error ............................................. 30
E-57 Code [1633/CA1633] KOMNET Error ............................................................................. 30
E-58 Code [1642/CA1642] EGR Inlet Press Sensor Low Error............................................... 31
E-59 Code [1653/CA1653] EGR Inlet Press Sensor High Error .............................................. 32
E-60 Code [2185/CA2185] Throttle Sens. Sup. Volt. High Error ............................................. 34
E-61 Code [2186/CA2186] Throttle Sens. Sup. Volt. Low Error .............................................. 38
E-62 Code [2249/CA2249] No-pressure Feed By Supply pump 2 .......................................... 38
E-63 Code [2271/CA2271] EGR Valve Lift Sensor High Error................................................. 39
E-64 Code [2272/CA2272] EGR Valve Lift Sensor Low Error ................................................. 41
E-65 Code [2351/CA2351] EGR Valve Solenoid Drive Short Error ......................................... 42
E-66 Code [2352/CA2352] EGR Valve Solenoid Drive Open Error ......................................... 44
E-67 Code [2555/CA2555] Intake Air Heater Relay Open Error.............................................. 45
E-68 Code [2556/CA2556] Intake Air Heater Relay Short Error .............................................. 46

140E-5 Series

00 Index and foreword

SEN00076-16

E-69 Code [(143)/B@BAZG] Eng. Oil Press Low Torque Derate............................................ 48


E-70 Code [(146)/B@BCNS] Eng. Overheat........................................................................... 48
E-71 Code [(415)/B@BAZG] Eng. Oil Press. Low Speed Derate............................................ 49
50 Disassembly and assembly
General information on disassembly and assembly
SEN00156-05
General information on disassembly and assembly....................................................................
2
How to read this manual..........................................................................................................
2
Coating materials list ...............................................................................................................
4
Special tools list .......................................................................................................................
7
Sketches of special tools .........................................................................................................
8
Disassembly and assembly, Part 1 (with EGR)
SEN00157-05
Disassembly and assembly, Part 1 (with EGR)...........................................................................
2
General disassembly of engine ...............................................................................................
2
General assembly of engine.................................................................................................... 20
Disassembly and assembly, Part 2 (EGR-less)
SEN00158-05
Disassembly and assembly, Part 2 (EGR-less)...........................................................................
2
General disassembly of engine ...............................................................................................
2
General assembly of engine.................................................................................................... 18
Disassembly and assembly, Part 3
SEN00159-04
Disassembly and assembly, Part 3 .............................................................................................
2
Removal and installation of fuel supply pump unit (with EGR) ................................................
2
Removal and installation of fuel supply pump unit (EGR-less)................................................
4
Replacement of oil seal of engine mounted on machine.........................................................
7
90 Repair and replacement of parts
Information related to repair and replacement
SEN05198-00
Flowchart .................................................................................................................................
2
Special tool table .....................................................................................................................
4
Special tool sketch...................................................................................................................
6
Cylinder head
SEN05199-02
Part names related to cylinder head........................................................................................
2
Testing and inspection of cylinder head...................................................................................
3
Pressure test of cylinder head .................................................................................................
5
Replacement of valve guide ....................................................................................................
5
Replacement of valve seat insert ............................................................................................
6
Replacement of crosshead guide ............................................................................................ 13
Repair of cylinder head mounting face by grinding ................................................................. 14
Repair of valve by grinding ...................................................................................................... 15
Cylinder block
SEN05200-01
Part names related to cylinder block .......................................................................................
3
Testing and inspection of cylinder block ..................................................................................
4
Method of checking main bearing metal inside diameter with alignment bar ..........................
6
Part names related to crankshaft.............................................................................................
7
Testing and inspection of crankshaft .......................................................................................
8
Part names related to connecting rod......................................................................................
9
Testing and inspection of connecting rod ................................................................................ 10
Replacement of flywheel ring gear .......................................................................................... 11
Replacement of crankshaft gear.............................................................................................. 12
Replacement of camshaft gear................................................................................................ 13
Replacement of main bearing metal cap ................................................................................. 14
Replacement of connecting rod small end bushing................................................................. 16
Replacement of cam bushing .................................................................................................. 17
Repair of cylinder block top by grinding................................................................................... 19
Repair of counterbore by grinding ........................................................................................... 20
Check and identification after repair by grinding...................................................................... 22
140E-5 Series

SEN00076-16

00 Index and foreword

Gasket sealant application procedure .....................................................................................


Repair standard for cylinder liner O-ring ..................................................................................
Replacement of engine rear seal.............................................................................................
Replacement of wear sleeve (when sleeve is installed) ..........................................................
Repair of crankshaft by grinding ..............................................................................................
Improvement of surface roughness of crankshaft journal........................................................

23
25
26
30
31
36

140E-5 Series

00 Index and foreword

140E-5 Series

SEN00076-16

SEN00076-16

KOMATSU 140E-5 Series engine


Form No. SEN00076-16

2012 KOMATSU
All Rights Reserved
Printed in Japan 12-12 (01)

10

SEN00077-07

ENGINE
1SHOP MANUAL

140E-5 Series

00 Index and foreword

Foreword and general information


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

140E-5 Series

SEN00077-07

00 Index and foreword

Safety notice

(Rev. 2008/08)
1

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 situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with
the situation.
1.

General precautions
k Mistakes in operation are extremely
dangerous. Read the Operation and
Maintenance Manual carefully before
operating the machine. In addition,
read this manual and understand its
contents before starting the work.
1) Before carrying out any greasing or
repairs, read all the safety labels stuck to
the machine. For the locations of the
safety labels and detailed explanation of
precautions, see the Operation and Maintenance Manual.
2) Decide a place in the repair workshop to
keep tools and removed parts. Always
keep the tools and parts in their correct
places. Always keep the work area clean
and make sure that there is no dirt, water,
or oil on the floor. Smoke only in the areas
provided for smoking. Never smoke while
working.
3) When carrying out any operation, always
wear safety shoes and helmet. Do not
wear loose work clothes, or clothes with
buttons missing.
q
Always wear safety glasses when hitting parts with a hammer.
q
Always wear safety glasses when
grinding parts with a grinder, etc.
4) When carrying out any operation with 2 or
more workers, always agree on the operating procedure before starting. Always
inform your fellow workers before starting
any step of the operation. Before starting
work, hang UNDER REPAIR warning
signs in the operator's compartment.
5) Only qualified workers must carry out work
and operation which require license or
qualification.
6) Keep all tools in good condition, learn the
correct way to use them, and use the
proper ones of them. Before starting work,
thoroughly check the tools, machine, forklift, service car, etc.

7)

8)

9)

If welding repairs are needed, always


have a trained and experienced welder
carry out the work. When carrying out
w elding work, alw ays wear welding
gloves, apron, shielding goggles, cap and
other clothes suited for welding work.
Before starting work, warm up your body
thoroughly to start work under good condition.
Avoid continuing work for long hours and
take rests at proper intervals to keep your
body in good condition. Take rests in
specified safe places.

Safety points
1 Good arrangement
2 Correct work clothes
3 Following work standard
4 Making and checking signs
5

Prohibition of operation and handling by


unlicensed workers

6 Safety check before starting work


7

Wearing protective goggles


(for cleaning or grinding work)

Wearing shielding goggles and protectors


(for welding work)

9 Good physical condition and preparation


10

Precautions against work which you are


not used to or you are used to too much

140E-5 Series

00 Index and foreword

2.

3.

SEN00077-07

Preparations for work


1) Before adding oil or making any repairs,
park the machine on a hard and level
ground, and apply the parking brake and
block the wheels or tracks to prevent the
machine from moving.
2) Before starting work, lower the work
equipment (blade, ripper, bucket, etc.) to
the ground. If this is not possible, insert
the lock pin or use blocks to prevent the
work equipment from falling. In addition,
be sure to lock all the control levers and
hang warning signs on them.
3) When disassembling or assembling, support the machine with blocks, jacks, or
stands before starting work.
4) Remove all mud and oil from the steps or
other places used to get on and off the
machine. Always use the handrails, ladders or steps when getting on or off the
m a c h i n e . N e v e r j u m p o n o r o ff t h e
machine. If it is impossible to use the
handrails, ladders or steps, use a stand to
provide safe footing.

6)

Precautions during work


1) Before disconnecting or removing components of the oil, water, or air circuits, first
release the pressure completely from the
circuit. When removing the oil filler cap, a
drain plug, or an oil pressure pickup plug,
loosen it slowly to prevent the oil from
spurting out.
2) The coolant and oil in the circuits are hot
when the engine is stopped, so be careful
not to get scalded. Wait for the oil and
coolant to cool before carrying out any
work on the oil or water circuits.
3) Before starting work, stop the engine.
When working on or around a rotating
part, in particular, stop the engine. When
checking the machine without stopping
the engine (measuring oil pressure,
revolving speed, temperature, etc.), take
extreme care not to get rolled or caught in
rotating parts or moving parts.
4) Before starting work, remove the leads
from the battery. Always remove the lead
from the negative () terminal first.
5) When raising a heavy component (heavier
than 25 kg), use a hoist or crane. Before
starting work, check that the slings (wire
ropes, chains, and hooks) are free from
damage. Always use slings which have
ample capacity and install them to proper
places. Operate the hoist or crane slowly
to prevent the component from hitting any
other part. Do not work with any part still
raised by the hoist or crane.

11)

140E-5 Series

7)

8)

9)

10)

12)

13)

14)

15)

16)

When removing a cover which is under


internal pressure or under pressure from a
spring, always leave 2 bolts in diagonal
positions. Loosen those bolts gradually
and alternately to release the pressure,
and then remove the cover.
When removing components, be careful
not to break or damage the electrical wiring. Damaged wiring may cause electrical
fires.
When removing piping, stop the fuel or oil
from spilling out. If any fuel or oil drips
onto the floor, wipe it up immediately. Fuel
or oil on the floor can cause you to slip
and can even start fires.
As a general rule, do not use gasoline to
wash parts. Do not use it to clean electrical parts, in particular.
Be sure to assemble all parts again in their
original places. Replace any damaged
parts and parts which must not be reused
with new parts. When installing hoses and
wires, be sure that they will not be damaged by contact with other parts when the
machine is operated.
When installing high pressure hoses,
make sure that they are not twisted. Damaged tubes are dangerous, so be
extremely careful when installing tubes for
high pressure circuits. In addition, check
t h a t c o n n e c t i n g pa r ts a r e c o r r e c t l y
installed.
When assembling or installing parts,
always tighten them to the specified
torques. When installing protective parts
such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are
installed correctly.
When aligning 2 holes, never insert your
fingers or hand. Be careful not to get your
fingers caught in a hole.
When measuring hydraulic pressure,
check that the measuring tools are correctly assembled.
Take care when removing or installing the
tracks of track-type machines. When
removing the track, the track separates
suddenly, so never let anyone stand at
either end of the track.
If the engine is operated for a long time in
a place which is not ventilated well, you
may suffer from gas poisoning. Accordingly, open the windows and doors to ventilate well.

SEN00077-07

4.

Precautions for sling work and making


signs
1) Only one appointed worker must make
signs and co-workers must communicate
with each other frequently. The appointed
sign maker must make specified signs
clearly at a place where he is well seen
from the operator's seat and where he can
see the working condition easily. The sign
maker must always stand in front of the
load and guide the operator safely.
q
Do not stand under the load.
q
Do not step on the load.
2) Check the slings before starting sling
work.
3) Keep putting on gloves during sling work.
(Put on leather gloves, if available.)
4) Measure the weight of the load by the eye
and check its center of gravity.
5) Use proper sling according to the weight
of the load and method of slinging. If too
thick wire ropes are used to sling a light
load, the load may slip and fall.
6) Do not sling a load with 1 wire rope alone.
If it is slung so, it may rotate and may slip
out of the rope. Install 2 or more wire
ropes symmetrically.
k Slinging with 1 rope may cause
turning of the load during hoisting,
untwisting of the rope, or slipping
of the rope from its original winding position on the load, which can
result in a dangerous accident.
7) Limit the hanging angle to 60, as a rule.
Do not sling a heavy load with ropes forming a wide hanging angle from the hook.
When hoisting a load with 2 or more
ropes, the force subjected to each rope
will increase with the hanging angle. The
table below shows the variation of allowable load in kN {kg} when hoisting is made
with 2 ropes, each of which is allowed to
sling up to 9.8 kN {1,000 kg} vertically, at
various hanging angles. When the 2 ropes
sling a load vertically, up to 19.6 kN {2,000
kg} of total weight can be suspended.
This weight is reduced to 9.8 kN {1,000
kg} when the 2 ropes make a hanging
angle of 120. If the 2 ropes sling a 19.6
kN {2,000 kg} load at a lifting angle of
150, each of them is subjected to a force
as large as 39.2 kN {4,000 kg}.

00 Index and foreword

8)

When installing wire ropes to an angular


load, apply pads to protect the wire ropes.
If the load is slippery, apply proper material to prevent the wire rope from slipping.
9) Use the specified eyebolts and fix wire
ropes, chains, etc. to them with shackles,
etc.
10) Apply wire ropes to the middle portion of
the hook.
q
Slinging near the tip of the hook may
cause the rope to slip off the hook
during hoisting. The hook has the
maximum strength at the middle portion.

11) Do not use twisted or kinked wire ropes.


12) When lifting up a load, observe the following.
q
Wind in the crane slowly until wire
ropes are stretched. When settling
the wire ropes with the hand, do not
grasp them but press them from
above. If you grasp them, your fingers
may be caught.
q
After the wire ropes are stretched,
stop the crane and check the condition of the slung load, wire ropes, and
pads.

140E-5 Series

00 Index and foreword

If the load is unstable or the wire rope


or chains are twisted, lower the load
and lift it up again.
q
Do not lift up the load slantingly.
13) When lifting down a load, observe the following.
q
When lifting down a load, stop it temporarily at 30 cm above the floor, and
then lower it slowly.
q
Check that the load is stable, and
then remove the sling.
q
Remove kinks and dirt from the wire
ropes and chains used for the sling
work, and put them in the specified
place.

SEN00077-07

13) If the hoist stops because of a power failure, turn the power switch OFF. When
turning on a switch which was turned OFF
by the electric shock prevention earth
leakage breaker, check that the devices
related to that switch are not in operation
state.
14) If you find an obstacle around the hoist,
stop the operation.
15) After finishing the work, stop the hoist at
the specified position and raise the hook
to at least 2 m above the floor. Do not
leave the sling installed to the hook.

5.

6.

Precautions for using mobile crane


a Read the Operation and Maintenance
Manual of the crane carefully in advance
and operate the crane safely.
Precautions for using overhead hoist crane
k When raising a heavy part (heavier
than 25 kg), use a hoist, etc. In Disassembly and assembly, the weight of a
part heavier than 25 kg is indicated
after the mark of 4.
1) Before starting work, inspect the wire
ropes, brake, clutch, controller, rails, over
wind stop device, electric shock prevention earth leakage breaker, crane collision
prevention device, and power application
warning lamp, and check safety.
2) Observe the signs for sling work.
3) Operate the hoist at a safe place.
4) Check the direction indicator plates (east,
west, south, and north) and the directions
of the control buttons without fail.
5) Do not sling a load slantingly. Do not move
the crane while the slung load is swinging.
6) Do not raise or lower a load while the
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 immediately in an emergency.

140E-5 Series

7.

Selecting wire ropes


1) Select adequate ropes depending on the
weight of parts to be hoisted, referring to
the table below.

Wire ropes
(Standard Z twist ropes without galvanizing)
(JIS G3525, No. 6, Type 6X37-A)
Nominal
Allowable load
diameter of rope
mm
kN
ton
10
8.8
0.9
12
12.7
1.3
14
17.3
1.7
16
22.6
2.3
18
28.6
2.9
20
35.3
3.6
25
55.3
5.6
30
79.6
8.1
40
141.6
14.4
50
221.6
22.6
60
318.3
32.4

The allowable load is one-sixth of the


breaking strength of the rope used
(Safety coefficient: 6).

SEN00077-07

8.

Precautions for disconnecting and connecting hoses and tubes in air conditioner
circuit
1) Disconnection
k For the environment, the air conditioner 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 disconnecting the refrigerant gas circuit and then reuse it.
a Ask professional traders for collecting
and filling operation of refrigerant
(R134a).
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 recovering or adding the refrigerant.
Refrigerant gas must be recovered
and added by a qualified person.
2)

00 Index and foreword


a

Example of O-ring (Fitted to every joint of


hoses and tubes)

For tightening torque, see the precautions for


installation in each section of "Disassembly
and assembly".

Connection
1] When installing the air conditioner circuit 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 damaged or deteriorated.
4] When connecting the refrigerant piping, apply compressor oil for refrigerant (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.

140E-5 Series

00 Index and foreword

How to read the shop manual


q
q
q

1.

SEN00077-07

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.
Materials and specifications are subject to change without notice.
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.
Composition of shop manual
This shop manual contains the necessary technical information for services performed in a workshop.
For ease of understanding, the manual is divided into the following sections.
00. Index and foreword
This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard
This section explains the structure, function, and maintenance standard values of each component.
The structure and function sub-section explains the structure and function of each component. It
serves not only to give an understanding of the structure, but also serves as reference material for
troubleshooting. The maintenance standard sub-section explains the criteria and remedies for disassembly and service.
20. Standard value table
This section explains the standard values for new machine and judgement criteria for testing,
adjusting, and troubleshooting. This standard value table is used to check the standard values in
testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting
This section explains measuring instruments and measuring methods for testing and adjusting, and
method of adjusting each part. The standard values and judgement criteria for testing and adjusting
are explained in Testing and adjusting.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is
divided by failure modes. The S mode of the troubleshooting related to the engine may be also
explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly
This section explains the special tools and procedures for removing, installing, disassembling, and
assembling each component, as well as precautions for them. In addition, tightening torque and
quantity and weight of coating material, oil, grease, and coolant necessary for the work are also
explained.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
q
Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q
Engine volume
This section explains the method of reproducing, repairing, and replacing parts.

2.

Revision and distribution


Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most
up-to-date information before you start any work.

140E-5 Series

SEN00077-07

3.

4.

00 Index and foreword

Filing method
File by the brochures in the correct order of the form number printed in the shop manual composition
table.
q

Revised edition mark


When a manual is revised, the ones and tens digits of the form number of each brochure is
increased by 1. (Example: 00, 01, 02 )

Revisions
Revised brochures are shown in the shop manual composition table.

Symbols
Important safety and quality portions are marked with the following symbols so that the shop manual will
be used practically.
Symbol

Item

Safety

Caution

Special technical precautions or other precautions for preserving standards are necessary when performing work.

Weight

Weight of parts of component or parts. Caution necessary when


selecting hoisting wire, or when working posture is important, etc.

Tightening
torque

Coat

Oil, coolant

Drain

Remarks
Special safety precautions are necessary when performing work.

Places that require special attention for tightening torque during


assembly.
Places to be coated with adhesives, etc. during assembly.
Places where oil, etc. must be added, and capacity.
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, conventionally used Gravitational System of units is indicated in parentheses { }.

140E-5 Series

00 Index and foreword

SEN00077-07

Explanation of terms for maintenance standard

The maintenance standard chapter explains the criteria for replacing or reusing products and parts in the
machine maintenance work. The following terms are used to explain the criteria.
1.

Standard size and tolerance


q
To be accurate, the finishing size of parts
is a little different from one to another.
q
To specify a finishing size of a part, a temporary standard size is set and an allowable difference from that size is indicated.
q
The above size set temporarily is called
the standard size and the range of difference from the standard size is called the
tolerance.
q
The tolerance with the symbols of + or is
indicated on the right side of the standard
size.
Example:
Standard size
120

Tolerance
0.022
0.126

The tolerance may be indicated in the text


and a table as [standard size (upper limit
of tolerance/lower limit of tolerance)].
Example) 120 (0.022/0.126)

Usually, the size of a hole and the size of


the shaft to be fitted to that hole are indicated by the same standard size and different tolerances of the hole and shaft.
The tightness of fit is decided by the tolerance.
Indication of size of rotating shaft and hole
and relationship drawing of them

Example:
Standard size
60

140E-5 Series

Tolerance
Shaft
Hole
0.030
+0.046
0.076
+0

SEN00077-07

2.

Standard clearance and standard value


q
The clearance made when new parts are
assembled is called the standard clearance, which is indicated by the range
from the minimum clearance to the maximum clearance.
q
When some parts are repaired, the clearance is generally adjusted to the standard
clearance.
q
A value of performance and function of
new products or equivalent is called the
standard value, which is indicated by a
range or a target value.
q
When some parts are repaired, the value
of performance/function is set to the standard value.

3.

Standard interference
q
When the diameter of a hole of a part
shown in the given standard size and tolerance table is smaller than that of the
mating shaft, the difference between those
diameters is called the interference.
q
The range (A B) from the difference (A)
between the minimum size of the shaft
and the maximum size of the hole to the
difference (B) between the maximum size
of the shaft and the minimum size of the
hole is the standard interference.
q
After repairing or replacing some parts,
measure the size of their hole and shaft
and check that the interference is in the
standard range.

4.

Repair limit and allowable value or allowable dimension


q
The size of a part changes because of
wear and deformation while it is used. The
limit of changed size is called the repair
limit.
q
If a part is worn to the repair limit, it must
be replaced or repaired.
q
The performance and function of a product lowers while it is used. A value which
the product can be used without causing a
problem is called the allowable value or
allowable dimension.
q
If a product is worn to the allowable value,
it must be checked or repaired. Since the
permissible value is estimated from various tests or experiences in most cases,
however, it must be judged after considering the operating condition and customer's
requirement.

10

00 Index and foreword

5.

Clearance limit
Parts can be used until the clearance
between them is increased to a certain
limit. The limit at which those parts cannot
be used is called the clearance limit.
q
If the clearance between the parts
exceeds the clearance limit, they must be
replaced or repaired.
q

6.

Interference limit
The allowable maximum interference
between the hole of a part and the shaft of
another part to be assembled is called the
interference limit.
q
The interference limit shows the repair
limit of the part of smaller tolerance.
q
If the interference between the parts
exceeds the interference limit, they must
be replaced or repaired.
q

140E-5 Series

00 Index and foreword

Handling of electric equipment and hydraulic component

SEN00077-07

To maintain the performance of the machine over a long period, and to prevent failures or other troubles
before they occur, correct operation, maintenance and inspection, troubleshooting, and repairs must
be carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at
improving the quality of repairs. For this purpose, it gives sections on Handling electric equipment and
Handling hydraulic equipment (particularly gear oil and hydraulic oil).

Points to remember when handling electric


equipment
1. Handling wiring harnesses and connectors
Wiring harnesses consist of wiring connecting
one component to another component, connectors used for connecting and disconnecting
one wire from another wire, and protectors or
tubes used for protecting the wiring.
Compared with other electrical components fitted in boxes or cases, wiring harnesses are
more likely to be affected by the direct effects
of rain, water, heat, or vibration. Furthermore,
during inspection and repair operations, they
are frequently removed and installed again, so
they are likely to suffer deformation or damage.
For this reason, it is necessary to be extremely
careful when handling wiring harnesses.
2.

Main failures occurring in wiring harness


1) Defective contact of connectors (defective contact between male and female)
Problems with defective contact are likely
to occur because the male connector is
not properly inserted into the female connector, or because one or both of the connectors is deformed or the position is not
correctly aligned, or because there is corrosion or oxidization of the contact surfaces. The corroded or oxidized contact
surfaces may become shiny again (and
contact may become normal) by connecting and disconnecting the connector about
10 times.
2)

Defective crimping or soldering of connectors


The pins of the male and female connectors are in contact at the crimped terminal
or soldered portion, but if there is excessive force brought to bear on the wiring,
the plating at the joint will peel and cause
improper connection or breakage.

140E-5 Series

11

SEN00077-07

12

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 soldering may be damaged, or the wiring
may be broken.

4)

High-pressure water entering connector


The connector is designed to make it difficult for water to enter (drip-proof structure), but if high-pressure water is sprayed
directly on the connector, water may enter
the connector, depending on the direction
of the water jet. Accordingly, take care not
to splash water over the connector. The
connector is designed to prevent water
from entering, but at the same time, if
water does enter, it is difficult for it to be
drained. Therefore, if water should get into
the connector, the pins will be short-circuited by the water, so if any water gets in,
immediately dry the connector or take
other appropriate action before passing
electricity through it.

5)

Oil or dirt stuck to connector


If oil or grease are stuck to the connector
and an oil film is formed on the mating surface between the male and female pins,
the oil will not let the electricity pass, so
there will be defective contact. If there is
oil or grease stuck to the connector, wipe it
off with a dry cloth or blow it dry with compressed air and spray it with a contact
restorer.
a When wiping the mating portion of the
connector, be careful not to use
excessive force or deform the pins.
a If there is oil or water in the compressed air, the contacts will become
even dirtier, so remove the oil and
water from the compressed air completely before cleaning with compressed air.

00 Index and foreword

140E-5 Series

00 Index and foreword

3.

SEN00077-07

Removing, installing, and drying connectors and wiring harnesses


1) Disconnecting connectors
1] Hold the connectors when disconnecting.
When disconnecting the connectors,
hold the connectors. For connectors
held by a screw, loosen the screw
fully, then hold the male and female
connectors in each hand and pull
apart. For connectors which have a
lock stopper, press down the stopper
with your thumb and pull the connectors apart.
a Never pull with one hand.
2]
q

When removing from clips


Both of the connector and clip have
stoppers, which are engaged with
each other when the connector is
installed.

When removing a connector from a


clip, pull the connector in a parallel
direction to the clip for removing stoppers.
a If the connector is twisted up and
down or to the left or right, the
housing may break.

3]

Action to take after removing connectors


After removing any connector, cover it
with a vinyl bag to prevent any dust,
dirt, oil, or water from getting in the
connector portion.
a If the machine is left disassembled for a long time, it is particularly easy for improper contact to
occur, so always cover the connector.

140E-5 Series

13

SEN00077-07

2)

14

00 Index and foreword

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 damage to the connector pins.
Check that there is no damage or
breakage to the outside of the connector.
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 breakage, 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 stopper clicks into position.
3] Correct any protrusion of the boot and
any misalignment of the wiring harness.
For connectors fitted with boots, correct any protrusion of the boot. In
addition, if the wiring harness is misaligned, or the clamp is out of position, adjust it to its correct position.
a If the connector cannot be corrected 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.

140E-5 Series

00 Index and foreword

3)

Heavy duty wire connector (DT 8-pole, 12pole)


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) horizontally 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

SEN00077-07

Disconnection

Connection (Example of
incomplete setting of (a))

15

SEN00077-07

4)

16

00 Index and foreword

Drying wiring harness


If there is any oil or dirt on the wiring harness, wipe it off with a dry cloth. Avoid
washing it in water or using steam. If the
connector must be washed in water, do
not use high-pressure water or steam
directly on the wiring harness. If water
gets directly on the connector, do as follows.
1] Disconnect the connector and wipe
off the water with a dry cloth.
a If the connector is blown dry with
compressed air, there is the risk
that oil in the air may cause
defective contact, so remove all
oil and water from the compressed air before blowing with
air.
2] Dry the inside of the connector with a
dryer.
If water gets inside the connector, use
a dryer to dry the connector.
a Hot air from the dryer can be
used, but regulate the time that
the hot air is used in order not to
make the connector or related
parts too hot, as this will cause
deformation or damage to the
connector.
3] Carry out a continuity test on the connector.
After drying, leave the wiring harness
disconnected and carry out a continuity test to check for any short circuits
between pins caused by water.
a After completely drying the conn e c t o r, b l o w i t w i t h c o n ta c t
restorer and reassemble.

140E-5 Series

00 Index and foreword

4.

Handling controller
1) The controller contains a microcomputer
and electronic control circuits. These control 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 controller.
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 connectors connected to the controller. Fit an
arc welding ground close to the welding
point.

5.

Points to remember when troubleshooting


electric circuits
1) Always turn the power OFF before disconnecting or connecting connectors.
2) Before carrying out troubleshooting, check
that all the related connectors are properly
inserted.
a Disconnect and connect the related
connectors several times to check.
3) Always connect any disconnected connectors before going on to the next step.
a If the power is turned ON with the
connectors still disconnected, unnecessary abnormality displays will be
generated.
4) When carrying out troubleshooting of circuits (measuring the voltage, resistance,
continuity, or current), move the related
wiring and connectors several times and
check that there is no change in the reading of the tester.
a If there is any change, there is probably defective contact in that circuit.

140E-5 Series

SEN00077-07

17

SEN00077-07

00 Index and foreword

Points to remember when handling hydraulic equipment


With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt
(foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling
hydraulic equipment, it is necessary to be particularly careful.

1.

Be careful of the operating environment.


Avoid adding hydraulic oil, replacing filters, or
repairing the machine in rain or high winds, or
places where there is a lot of dust.

2.

Disassembly and maintenance work in the


field
If disassembly or maintenance work is carried
out on hydraulic equipment in the field, there is
danger of dust entering the equipment. It is
also difficult to check the performance after
repairs, so it is desirable to use unit exchange.
Disassembly and maintenance of hydraulic
equipment should be carried out in a specially
prepared dustproof workshop, and the performance should be checked with special test
equipment.

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.

4.

Do not let any dirt or dust get in during


refilling operations
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers. If an oil cleaning device is used, it is possible to filter out the
dirt that has collected during storage, so this is
an even more effective method.

18

140E-5 Series

00 Index and foreword

5.

Change hydraulic oil when the temperature


is high
When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be
drained out easily from the circuit together with
the oil, so it is best to change the oil when it is
still warm. When changing the oil, as much as
possible of the old hydraulic oil must be
drained out. (Drain the oil from the hydraulic
tank; also drain the oil from the filter and from
the drain plug in the circuit.) If any old oil is left,
the contaminants and sludge in it will mix with
the new oil and will shorten the life of the
hydraulic oil.

6.

Flushing operations
After disassembling and assembling the equipment, 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 circuit. The oil cleaning equipment is used to
remove the ultra fine (about 3 m) particles that
the filter built in the hydraulic equipment cannot remove, so it is an extremely effective
device.

140E-5 Series

SEN00077-07

19

SEN00077-07

00 Index and foreword

Handling of connectors newly used for engines


a

1.

Mainly, following engines are object for following connectors.


q
95E-5
q
107E-1
q
114E-3
q
125E-5
q
140E-5
q
170E-5
q
12V140E-3
Slide lock type
(FRAMATOME-3, FRAMATOME-2)
q
95 170, 12V140 engines
q
Various pressure sensors and NE
speed sensor
Examples)
Intake air pressure sensor in intake
manifold: PIM
(125, 170, 12V140 engines)
Oil pressure sensor: POIL
(125, 170, 12V140 engines)
Oil pressure switch
(95, 107, 114 engines)
Ne speed sensor of flywheel housing:
NE
(95 170, 12V140 engines)
Ambient pressure sensor: PAMB
(125, 170, 12V140 engines)

2.

Pull lock type (PACKARD-2)


95 170, 12V140 engines
q
Various temperature sensors
Example)
Intake air temperature sensor in
intake manifold: TIM
Fuel temperature sensor: TFUEL
Oil temperature sensor: TOIL
Coolant temperature sensor: TWTR,
etc.
Disconnect the connector by pulling lock
(B) (on the wiring harness side) of connector (2) outward.

Disconnect connector (1) according to the following procedure.


1) Slide lock (L1) to the right.
2) While pressing lock (L2), pull out connector (1) toward you.
a Even if lock (L2) is pressed, connector (1) cannot be pulled out toward
you, if part A does not float. In this
case, float part A with a small screwdriver while press lock (L2), and then
pull out connector (1) toward you.

20

140E-5 Series

00 Index and foreword

3.

SEN00077-07

Push lock type


q
95, 107, 114 engines
Example)
Fuel pressure sensor in common rail
(BOSCH-03)
Disconnect connector (3) according to the following procedure.
1) While pressing lock (C), pull out connector
(3) in the direction of the arrow.
q

114 engine

107, 114 engines


Example)
Intake air pressure/temperature sensor in
intake manifold
(SUMITOMO-04)

3)

While pressing lock (D), pull out connector


(4) in the direction of the arrow.

107 engine

2)

If the lock is on the underside, use


flat-head screwdriver [1] since you
cannot insert your fingers.
While pressing up lock (C) of the connector with flat-head screwdriver [1], pull out
connector (3) in the direction of the arrow.

140E-5 Series

21

SEN00077-07

4)

95, 125 170, 12V140 engines


While pressing lock (E) of the connector,
pull out connector (5) in the direction of
the arrow.
Example)
Fuel pressure sensor in common rail:
PFUEL etc. (AMP-3)

00 Index and foreword

4.

Turn-housing type (Round green connector)


140 engine
Example)
Intake air pressure sensor in intake manifold (CANNON-04): PIM etc.

1)

Disconnect connector (6) according to the


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 harness side.

2)

Connect the connector according to the


following procedure.
1] Insert the connector to the end, while
setting its groove.
2] Turn housing (H1) in the direction of
the arrow until it clicks.

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

00 Index and foreword

SEN00077-07

How to read electric wire code


a

The information about the wires unique to each machine model is described in Troubleshooting section,
Relational information of troubleshooting.

In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by symbols. 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 nominal No. of 0.85
Indicates color of wire by color code.
Color codes are shown in Table 3.
Indicates size of wire by nominal No.
Size (Nominal No.) is shown in Table 2.
Indicates type of wire by symbol.
Type, symbol, and material of wire are shown in Table 1.
(Since AV and AVS are classified by size (nominal No.), they are not indicated.)

1.

Type, symbol, and material


AV and AVS are different in only thickness and outside diameter of the cover. AEX is similar to AV in
thickness and outside diameter of AEX and different from AV and AVS in material of the cover.

(Table 1)
Type
Low-voltage
wire for
automobile
Thin-cover
low-voltage
wire for
automobile

Symbol
AV

AVS

Heat-resistant low-voltAEX
age wire for
automobile

140E-5 Series

Material
Conductor
Insulator
Conductor

Annealed copper for electric appliance


Soft polyvinyl chloride
Annealed copper for electric appliance

Insulator

Soft polyvinyl chloride

Conductor

Annealed copper for electric appliance


Heat-resistant crosslinked
polyethylene

Insulator

Using
temperature
range (C)

Example of use
General wiring
(Nominal No. 5 and above)

30 to +60
General wiring
(Nominal No. 3 and below)
General wiring in extremely
50 to +110 cold district, wiring at high-temperature place

23

SEN00077-07

2.

00 Index and foreword

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

CovAV
Standard

4.6
er D
AEX
Standard
2.0
2.2
2.7
3.0
3.1

3.8
4.6

Nominal No.
Number of
strands/Diameter of strand
Conductor
Sectional
area (mm2)
d (approx.)
AVS
Standard
CovAV
Standard
er D
AEX
Standard

15

20

30

40

50

60

85

100

50/0.45

84/0.45

41/0.80

70/0.80

85/0.80

7.95

13.36

20.61

35.19

42.73

54.29

63.84

84.96

109.1

3.7

5.5
5.3

4.8

7.0
7.0

6.0

8.2
8.2

8.0

10.8
10.8

8.6

11.4
11.4

9.8

13.0
13.0

10.4

13.6
13.6

12.0

16.0
16.0

13.6

17.6
17.6

108/0.80 127/0.80 169/0.80 217/0.80

f of nominal No. denotes flexible.

24

140E-5 Series

00 Index and foreword

3.

SEN00077-07

Color codes table

(Table 3)
Color Code
B
Br
BrB
BrR
BrW
BrY
Ch
Dg
G
GB
GL
Gr
GR
GW
GY
L
LB
Lg
LgB
LgR

Color of wire

Color Code
LgW
LgY
LR
LW
LY
O
P
R
RB
RG
RL
RW
RY
Sb
Y
YB
YG
YL
YR
YW

Black
Brown
Brown & Black
Brown & Red
Brown & White
Brown & Yellow
Charcoal
Dark green
Green
Green & Black
Green & Blue
Gray
Green & Red
Green & White
Green & Yellow
Blue
Blue & Black
Light green
Light green & Black
Light green & Red

Color of wire
Light green & White
Light green & Yellow
Blue & Red
Blue & White
Blue & Yellow
Orange
Pink
Red
Red & Black
Red & Green
Red & Blue
Red & White
Red & Yellow
Sky Blue
Yellow
Yellow & Black
Yellow &Green
Yellow & Blue
Yellow & Red
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.

4.

Types of circuits and color codes

(Table 4)
Type of wire
Charge
Ground
Start
Light
Instrument
Signal
Type of
circuit

Others

140E-5 Series

AVS or AV
R
B
R
RW
Y
G
L
Br
Lg
O
Gr
P
Sb
Dg
Ch

AEX

R
B
R
D
Y
G
L

WG

RB
YR
GW
LW
BrW
LgR

RY
YB
GR
LR
BrR
LgY

RG
YG
GY
LY
BrY
LgB

RL
YL
GB
LB
BrB
LgW

YW
GL

Gr
Br

25

SEN00077-07

00 Index and foreword

Precautions when carrying out operation

[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general
precautions given below when carrying out the operation.]
1.
q
q
q
q
q
q
q
q
q
q

Precautions when carrying out removal work


If the coolant contains antifreeze, dispose of it correctly.
After disconnecting hoses or tubes, cover them or fit plugs to prevent dirt or dust from entering.
When draining oil, prepare a container of adequate size to catch the oil.
Confirm the match marks showing the installation position, and make match marks in the necessary
places before removal to prevent any mistake when assembling.
To prevent any excessive force from being applied to the wiring, always hold the connectors when disconnecting the connectors. Do not pull the wires.
Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.
Check the number and thickness of the shims, and keep in a safe place.
When raising components, be sure to use lifting equipment of ample strength.
When using forcing screws to remove any components, tighten the forcing screws uniformly in turn.
Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from
entering after removal.
Precautions when handling piping during disassembly
Fit the following plugs into the piping after disconnecting it during disassembly operations.
1) Face seal type hoses and tubes
Nominal
number
02
03
04
05
06
10
12
2)

26

Sleeve nut (elbow end)

07376-70210
07376-70315
07376-70422
07376-70522
07376-70628
07376-71034
07376-71234

02789-20210
02789-20315
02789-20422
02789-20522
02789-20628
07221-21034
07221-21234

Split flange type hoses and tubes


Nominal
number
04
05

3)

Plug (nut end)

Flange (hose end)

Sleeve head (tube end)

Split flange

07379-00400
07379-00500

07378-10400
07378-10500

07371-30400
07371-30500

If the part is not under hydraulic pressure, the following corks can be used.
Nominal
number

Part Number

06
08
10
12
14
16
18
20
22
24

07049-00608
07049-00811
07049-01012
07049-01215
07049-01418
07049-01620
07049-01822
07049-02025
07049-02228
07049-02430

Dimensions
D
d
L
6
5
8
8
6.5
11
10
8.5
12
12
10
15
14
11.5
18
16
13.5
20
18
15
22
20
17
25
22
18.5
28
24
20
30

27

07049-02734

27

22.5

34

140E-5 Series

00 Index and foreword

2.
q
q
q
q
q
q
q
q
q
q
q
q
q

a
3.

SEN00077-07

Precautions when carrying out installation work


Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any.
Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
Bend the cotter pins and lock plates securely.
When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion with 2 3 drops of adhesive.
When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is
no dirt or damage, then coat uniformly with gasket sealant.
Clean all parts, and correct any damage, dents, burrs, or rust.
Coat rotating parts and sliding parts with engine oil.
When press fitting parts, coat the surface with anti-friction compound (LM-P).
After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
securely.
When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align
the direction of the hook.
When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
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.
When using the machine for the first time after repair or long storage, follow the same procedure.
Precautions when completing the operation
1) Refilling with coolant, oil and grease
q
If the coolant has been drained, tighten the drain valve, and add coolant to the specified level.
Run the engine to circulate the coolant through the system. Then check the coolant level
again.
q
If the hydraulic equipment has been removed and installed again, add engine oil to the specified level. Run the engine to circulate the oil through the system. Then check the oil level
again.
q
If the piping or hydraulic equipment have been removed, always bleed the air from the system
after reassembling the parts.
a For details, see Testing and adjusting, Bleeding air.
q
Add the specified amount of grease (molybdenum disulphide grease) to the work equipment
parts.
2) Checking cylinder head and manifolds for looseness
Check the cylinder head and intake and exhaust manifold for looseness.
If any part is loosened, retighten it.
q
For the tightening torque, see Disassembly and assembly.
3) Checking engine piping for damage and looseness
Intake and exhaust system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for air
suction and exhaust gas leakage.
If any part is loosened or damaged, retighten or repair it.
Cooling system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for
coolant leakage.
If any part is loosened or damaged, retighten or repair it.
Fuel system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel
leakage.
If any part is loosened or damaged, retighten or repair it.

140E-5 Series

27

SEN00077-07

4)

5)

28

00 Index and foreword

Checking muffler and exhaust pipe for damage and looseness


1] Visually check the muffler, exhaust pipe and their mounting parts for a crack and damage.
If any part is damaged, replace it.
2] Check the mounting bolts and nuts of the muffler, exhaust pipe and their mounting parts for
looseness.
If any bolt or nut is loosened, retighten it.
Checking muffler function
Check the muffler for abnormal sound and sound different from that of a new muffler.
If any abnormal sound is heard, repair the muffler, referring to Troubleshooting and Disassembly
and assembly.

140E-5 Series

00 Index and foreword

SEN00077-07

Method of disassembling and connecting push-pull type coupler


k
k

Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to
release the residual pressure from the hydraulic tank.
Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly, prepare an oil receiving container.

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 hexagonal 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 disconnect 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 hexagonal portion at the male end. (Fig. 9)

30

140E-5 Series

00 Index and foreword

SEN00077-07

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 hexagonal 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 portion at the male end. (Fig. 11)
3) While holding the condition of Steps 1)
and 2), pull out whole body (9) to disconnect 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 hexagonal portion at the male end. (Fig. 13)

140E-5 Series

31

SEN00077-07

00 Index and foreword

Standard tightening torque table


1.

Table of tightening torques for bolts and nuts


a Unless there are special instructions, tighten metric nuts and bolts to the torque below.
a

The following table applies to the bolts in Fig. A.

Thread diameter of bolt


mm
6
8
10
12
14
16
18
20
22
24
27
30
33
36
39
a

Tightening torque
Nm
11.8 14.7
27 34
59 74
98 123
157 196
245 309
343 427
490 608
662 829
824 1,030
1,180 1,470
1,520 1,910
1,960 2,450
2,450 3,040
2,890 3,630

kgm
1.2 1.5
2.8 3.5
6.0 7.5
10.0 12.5
16 20
25 31.5
35 43.5
50 62
67.5 84.5
84 105
120 150
155 195
200 250
250 310
295 370

The following table applies to the bolts in Fig. B.

Thread diameter of bolt


mm
6
8
10
12
a Fig. A

Width across flats


mm
10
13
17
19
22
24
27
30
32
36
41
46
50
55
60

Width across flats


mm
10
12
14
17

Tightening torque
Nm
kgm
5.9 9.8
0.6 1.0
13.7 23.5
1.4 2.4
34.3 46.1
3.5 4.7
74.5 90.2
7.6 9.2
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

00 Index and foreword

2.

Table of tightening torques for split flange bolts


a Unless there are special instructions, tighten split flange bolts to the torque below.

Thread diameter of bolt


mm
10
12
16

3.

Width across flats


mm
14
17
22

Tightening torque
Nm
59 74
98 123
235 285

kgm
6.0 7.5
10.0 12.5
23.5 29.5

Table of tightening torques for O-ring boss piping joints


a Unless there are special instructions, tighten O-ring boss piping joints to the torque below.
Thread diameter
mm
14
20
24
33
42

Nominal No.
02
03,04
05,06
10,12
14

4.

SEN00077-07

Width across flats


mm

Tightening torque Nm {kgm}


Range
Target
35 63 { 3.5 6.5}
44 { 4.5}
84 132 { 8.5 13.5}
103 {10.5}
Varies depending
on type of connec- 128 186 {13.0 19.0}
157 {16.0}
tor.
363 480 {37.0 49.0}
422 {43.0}
746 1,010 {76.0 103}
883 {90.0}

Table of tightening torques for O-ring boss plugs


a Unless there are special instructions, tighten O-ring boss plugs to the torque below.
Nominal
No.
08
10
12
14
16
18
20
24
30
33
36
42
52

Thread diameter
mm
8
10
12
14
16
18
20
24
30
33
36
42
52

140E-5 Series

Width across flats


mm
14
17
19
22
24
27
30
32
32

36

Tightening torque Nm {kgm}


Range
Target
5.88 8.82 {0.6 0.9}
7.35 {0.75}
9.81 12.74 {1.0 1.3}
11.27 {1.15}
14.7 19.6 {1.5 2.0}
17.64 {1.8}
19.6 24.5 {2.0 2.5}
22.54 {2.3}
24.5 34.3 {2.5 3.5}
29.4 {3.0}
34.3 44.1 {3.5 4.5}
39.2 {4.0}
44.1 53.9 {4.5 5.5}
49.0 {5.0}
58.8 78.4 {6.0 8.0}
68.6 {7.0}
93.1 122.5 { 9.5 12.5}
107.8 {11.0}
107.8 147.0 {11.0 15.0}
127.4 {13.0}
127.4 176.4 {13.0 18.0}
151.9 {15.5}
181.3 240.1 {18.5 24.5}
210.7 {21.5}
274.4 367.5 {28.0 37.5}
323.4 {33.0}

33

SEN00077-07

5.

00 Index and foreword

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.
Tightening torque Nm {kgm}

Nominal
No. of
hose

Width
across
flats

02

19

03
04
05
06
(10)
(12)
(14)

6.

22
24
27
32
36
41
46
55

Range
34 54 { 3.5 5.5}
34 63 { 3.5 6.5}
54 93 { 5.5 9.5}
59 98 { 6.0 10.0}
84 132 { 8.5 13.5}
128 186 {13.0 19.0}
177 245 {18.0 25.0}
177 245 {18.0 25.0}
197 294 {20.0 30.0}
246 343 {25.0 35.0}

Target

44 { 4.5}
74 { 7.5}
78 { 8.0}
103 {10.5}
157 {16.0}
216 {22.0}
216 {22.0}
245 {25.0}
294 {30.0}

Taper seal
Thread size
(mm)

14

18
22
24
30
33
36
42

Face seal
Nominal No.
Thread
Number of
diameter (mm)
threads, type of
(Reference)
thread
9/16-18UN
14.3

11/16-16UN
17.5

13/16-16UN
20.6
1-14UNS
25.4
1-3/16-12UN
30.2

Table of tightening torques for face seal joints


a Tighten the face seal joints (sleeve nut type) made of plated steel pipes for low pressure service to
be used for engines etc. to the torque shown in the following table.
a Apply the following torque to the face seal joint while their threaded parts are coated with engine oil
(wetted).

Outer
diameter
of pipe
(mm)

Width
across
flats
(mm)

8
10
12
15 (16)
22 (20)

19
22
24 (27)
30 (32)
36

Tightening torque Nm {kgm}


Range

Target

14 16 {1.4 1.6}
24 27 {2.4 2.7}
43 47 {4.4 4.8}
60 68 {6.1 6.8}
90 95 {9.2 9.7}

15 {1.5}
25.5 {2.6}
45 {4.6}
64 {6.5}
92.5 {9.4}

Face seal
Thread diameter
Nominal No.
(mm)
Number of threads,
(Reference)
type of thread
9/16-18UN
14.3
11/16-16UN
17.5
13/16-16UN
20.6
1-14UN
25.4
1-3/16-12UN
30.2

Reference: The face seal joints of the dimensions in ( ) are also used, depending on the specification.

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
Bolts and nuts

Thread size
mm
6
8
10
12
14

34

Nm
10 2
24 4
43 6
77 12

kgm
1.02 0.20
2.45 0.41
4.38 0.61
7.85 1.22

140E-5 Series

00 Index and foreword

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.
Thread size
mm
6
8
10
12
14

9.

SEN00077-07

Tightening torque
Nm
82
10 2
12 2
24 4
36 5

kgm
0.81 0.20
1.02 0.20
1.22 0.20
2.45 0.41
3.67 0.51

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.

Material
Thread size (inch)
1/16
1/8
1/4
3/8
1/2
3/4

140E-5 Series

Tightening torque
In cast iron or steel
In aluminum
Nm
kgm
Nm
kgm
15 2
1.53 0.20
51
0.51 0.10
20 2
2.04 0.20
15 2
1.53 0.20
25 3
2.55 0.31
20 2
2.04 0.20
35 4
3.57 0.41
25 3
2.55 0.31
55 6
5.61 0.61
35 4
3.57 0.41
75 8
7.65 0.82
45 5
4.59 0.51

35

SEN00077-07

00 Index and foreword

Conversion table

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
1.

Convert 55 mm into inches.


1) Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a horizontal line from (A).
2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down
from (B).
3) Take the point where the 2 lines cross as (C). This point (C) gives the value when converting from
millimeters to inches. Therefore, 55 mm = 2.165 inches.

2.

Convert 550 mm into inches.


1) The number 550 does not appear in the table, so divide it by 10 (move the decimal point one place
to the left) to convert it to 55 mm.
2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal
point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.

Millimeters to inches

(A)

36

(B)

0
10
20
30
40

0
0
0.394
0.787
1.181
1.575

1
0.039
0.433
0.827
1.220
1.614

2
0.079
0.472
0.866
1.260
1.654

3
0.118
0.512
0.906
1.299
1.693

4
0.157
0.551
0.945
1.339
1.732

50
60
70
80
90

1.969
2.362
2.756
3.150
3.543

2.008
2.402
2.795
3.189
3.583

2.047
2.441
2.835
3.228
3.622

2.087
2.480
2.874
3.268
3.661

2.126
2.520
2.913
3.307
3.701

5
0.197
0.591
0.984
1.378
1.772
(C)
2.165
2.559
2.953
3.346
3.740

6
0.236
0.630
1.024
1.417
1.811

7
0.276
0.669
1.063
1.457
1.850

2.205
2.598
2.992
3.386
3.780

2.244
2.638
3.032
3.425
3.819

1 mm = 0.03937 in
8
9
0.315
0.354
0.709
0.748
1.102
1.142
1.496
1.536
1.890
1.929
2.283
2.677
3.071
3.465
3.858

2.323
2.717
3.110
3.504
3.898

140E-5 Series

00 Index and foreword

SEN00077-07

Millimeters to inches

0
10
20
30
40

0
0
0.394
0.787
1.181
1.575

1
0.039
0.433
0.827
1.220
1.614

2
0.079
0.472
0.866
1.260
1.654

3
0.118
0.512
0.906
1.299
1.693

4
0.157
0.551
0.945
1.339
1.732

5
0.197
0.591
0.984
1.378
1.772

6
0.236
0.630
1.024
1.417
1.811

1 mm = 0.03937 in
7
8
9
0.276
0.315
0.354
0.669
0.709
0.748
1.063
1.102
1.142
1.457
1.496
1.536
1.850
1.890
1.929

50
60
70
80
90

1.969
2.362
2.756
3.150
3.543

2.008
2.402
2.795
3.189
3.583

2.047
2.441
2.835
3.228
3.622

2.087
2.480
2.874
3.268
3.661

2.126
2.520
2.913
3.307
3.701

2.165
2.559
2.953
3.346
3.740

2.205
2.598
2.992
3.386
3.780

2.244
2.638
3.032
3.425
3.819

1 kg = 2.2046 lb
6
7
8
9
13.23
15.43 17.64
19.84
35.27
37.48 39.68
41.89
57.32
59.53 61.73
63.93
79.37
81.57 83.78
85.98
101.41 103.62 105.82 108.03

2.283
2.677
3.071
3.465
3.858

2.323
2.717
3.110
3.504
3.898

Kilogram to pound

0
10
20
30
40

0
0
22.05
44.09
66.14
88.18

1
2.20
24.25
46.30
68.34
90.39

2
4.41
26.46
48.50
70.55
92.59

3
6.61
28.66
50.71
72.75
94.80

4
8.82
30.86
51.91
74.96
97.00

5
11.02
33.07
55.12
77.16
99.21

50
60
70
80
90

110.23
132.28
154.32
176.37
198.42

112.44
134.48
156.53
178.57
200.62

114.64
136.69
158.73
180.78
202.83

116.85
138.89
160.94
182.98
205.03

119.05
141.10
163.14
185.19
207.24

121.25
143.30
165.35
187.39
209.44

123.46
145.51
167.55
189.60
211.64

125.66
147.71
169.76
191.80
213.85

127.87
149.91
171.96
194.01
216.05

130.07
152.12
174.17
196.21
218.26

Liters to U.S. Gallons

0
10
20
30
40

0
1
2
0
0.264 0.528
2.642
2.906 3.170
5.283
5.548 5.812
7.925
8.189 8.454
10.567 10.831 11.095

3
0.793
3.434
6.076
8.718
11.359

4
1.057
3.698
6.340
8.982
11.624

1 l = 0.2642 U.S.Gal
5
6
7
8
9
1.321
1.585
1.849
2.113
2.378
3.963
4.227
4.491 4.755
5.019
6.604
6.869
7.133 7.397
7.661
9.246
9.510
9.774 10.039 10.303
11.888 12.152 12.416 12.680 12.944

50
60
70
80
90

13.209
15.850
18.492
21.134
23.775

14.001
16.643
19.285
21.926
24.568

14.265
16.907
19.549
22.190
24.832

14.529
17.171
19.813
22.455
25.096

140E-5 Series

13.473
16.115
18.756
21.398
24.040

13.737
16.379
19.020
21.662
24.304

14.795
17.435
20.077
22.719
25.361

15.058
17.700
20.341
22.983
25.625

15.322
17.964
20.605
23.247
25.889

15.586
18.228
20.870
23.511
26.153

37

SEN00077-07

00 Index and foreword

Liters to U.K. Gallons

0
10
20
30
40

0
0
2.200
4.399
6.599
8.799

1
0.220
2.420
4.619
6.819
9.019

2
0.440
2.640
4.839
7.039
9.239

3
0.660
2.860
5.059
7.259
9.459

4
0.880
3.080
5.279
7.479
9.679

5
1.100
3.300
5.499
7.699
9.899

50
60
70
80
90

10.998
13.198
15.398
17.598
19.797

11.281
13.418
15.618
17.818
20.017

11.438
13.638
15.838
18.037
20.237

11.658
13.858
16.058
18.257
20.457

11.878
14.078
16.278
18.477
20.677

12.098
14.298
16.498
18.697
20.897

1 l = 0.21997 U.K.Gal
6
7
8
9
1.320
1.540 1.760
1.980
3.520
3.740 3.950
4.179
5.719
5.939 6.159
6.379
7.919
8.139 8.359
8.579
10.119 10.339 10.559 10.778
12.318
14.518
16.718
18.917
21.117

12.528
14.738
16.938
19.137
21.337

12.758
14.958
17.158
19.357
21.557

12.978
15.178
17.378
19.577
21.777

kgm to ft.lb

0
10
20
30
40

0
0
72.3
144.7
217.0
289.3

1
7.2
79.6
151.9
224.2
296.6

2
14.5
86.8
159.1
231.5
303.8

3
21.7
94.0
166.4
238.7
311.0

4
28.9
101.3
173.6
245.9
318.3

5
36.2
108.5
180.8
253.2
325.5

6
43.4
115.7
188.1
260.4
332.7

1 kgm = 7.233 ft.lb


7
8
9
50.6
57.9
65.1
123.0 130.2
137.4
195.3 202.5
209.8
267.6 274.9
282.1
340.0 347.2
354.4

50
60
70
80
90

361.7
434.0
506.3
578.6
651.0

368.9
441.2
513.5
585.9
658.2

376.1
448.5
520.8
593.1
665.4

383.4
455.7
528.0
600.3
672.7

390.6
462.9
535.2
607.6
679.9

397.8
470.2
542.5
614.8
687.1

405.1
477.4
549.7
622.0
694.4

412.3
484.6
556.9
629.3
701.6

419.5
491.8
564.2
636.5
708.8

426.8
499.1
571.4
643.7
716.1

100
110
120
130
140

723.3
730.5 737.8
745.0
752.2 759.5
766.7
773.9 781.2
788.4
795.6
802.9 810.1
817.3
824.6 831.8
839.0
846.3 853.5
860.7
868.0
875.2 882.4
889.7
896.9 904.1
911.4
918.6 925.8
933.1
940.3
947.5 954.8
962.0
969.2 976.5
983.7
990.9 998.2 1005.4
1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7

150
160
170
180
190

1084.9
1157.3
1129.6
1301.9
1374.3

38

1092.2
1164.5
1236.8
1309.2
1381.5

1099.4
1171.7
1244.1
1316.4
1388.7

1106.6
1179.0
1251.3
1323.6
1396.0

1113.9
1186.2
1258.5
1330.9
1403.2

1121.1
1193.4
1265.8
1338.1
1410.4

1128.3
1200.7
1273.0
1345.3
1417.7

1135.6
1207.9
1280.1
1352.6
1424.9

1142.8
1215.1
1287.5
1359.8
1432.1

1150.0
1222.4
1294.7
1367.0
1439.4

140E-5 Series

00 Index and foreword

SEN00077-07

kg/cm2 to lb/in2

0
10
20
30
40

0
0
142.2
284.5
426.7
568.9

1
14.2
156.5
298.7
440.9
583.2

2
28.4
170.7
312.9
455.1
597.4

3
42.7
184.9
327.1
469.4
611.6

4
56.9
199.1
341.4
483.6
625.8

5
71.1
213.4
355.6
497.8
640.1

6
85.3
227.6
369.8
512.0
654.3

1 kg/cm2 = 14.2233 lb/in2


7
8
9
99.6
113.8
128.0
241.8
256.0
270.2
384.0
398.3
412.5
526.3
540.5
554.7
668.5
682.7
696.9

50
60
70
80
90

711.2
853.4
995.6
1,138
1,280

725.4
867.6
1,010
1,152
1,294

739.6
881.8
1,024
1,166
1,309

753.8
896.1
1,038
1,181
1,323

768.1
910.3
1,053
1,195
1,337

782.3
924.5
1,067
1,209
1,351

796.5
938.7
1,081
1,223
1,365

810.7
953.0
1,095
1,237
1,380

825.0
967.2
1,109
1,252
1,394

839.2
981.4
1,124
1,266
1,408

100
110
120
130
140

1,422
1,565
1,707
1,849
1,991

1,437
1,579
1,721
1,863
2,005

1,451
1,593
1,735
1,877
2,020

1,465
1,607
1,749
1,892
2,034

1,479
1,621
1,764
1,906
2,048

1,493
1,636
1,778
1,920
2,062

1,508
1,650
1,792
1,934
2,077

1,522
1,664
1,806
1,949
2,091

1,536
1,678
1,821
1,963
2,105

1,550
1,693
1,835
1,977
2,119

150
160
170
180
190

2,134
2,276
2,418
2,560
2,702

2,148
2,290
2,432
2,574
2,717

2,162
2,304
2,446
2,589
2,731

2,176
2,318
2,460
2,603
2,745

2,190
2,333
2,475
2,617
2,759

2,205
2,347
2,489
2,631
2,773

2,219
2,361
2,503
2,646
2,788

2,233
2,375
2,518
2,660
2,802

2,247
2,389
2,532
2,674
2,816

2,262
2,404
2,546
2,688
2,830

200
210
220
230
240

2,845
2,987
3,129
3,271
3,414

2,859
3,001
3,143
3,286
3,428

2,873
3,015
3,158
3,300
3,442

2,887
3,030
3,172
3,314
3,456

2,901
3,044
3,186
3,328
3,470

2,916
3,058
3,200
3,343
3,485

2,930
3,072
3,214
3,357
3,499

2,944
3,086
3,229
3,371
3,513

2,958
3,101
3,243
3,385
3,527

2,973
3,115
3,257
3,399
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 Centigrade 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 Fahrenheit 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 Centigrade values, and read the corresponding Fahrenheit temperature on the right.

1C = 33.8F
F

40.4
37.2
34.4
31.7
28.9

40
35
30
25
20

40.0
31.0
22.0
13.0
4.0

11.7
11.1
10.6
10.0
9.4

11
12
13
14
15

51.8
53.6
55.4
57.2
59.0

7.8
8.3
8.9
9.4
10.0

46
47
48
49
50

114.8
116.6
118.4
120.2
122.0

27.2
27.8
28.3
28.9
29.4

81
82
83
84
85

177.8
179.6
181.4
183.2
185.0

28.3
27.8
27.2
26.7
26.1

19
18
17
16
15

2.2
0.4
1.4
3.2
5.0

8.9
8.3
7.8
7.2
6.7

16
17
18
19
20

60.8
62.6
64.4
66.2
68.0

10.6
11.1
11.7
12.2
12.8

51
52
53
54
55

123.8
125.6
127.4
129.2
131.0

30.0
30.6
31.1
31.7
32.2

86
87
88
89
90

186.8
188.6
190.4
192.2
194.0

25.6
25.0
24.4
23.9
23.3

14
13
12
11
10

6.8
8.6
10.4
12.2
14.0

6.1
5.6
5.0
4.4
3.9

21
22
23
24
25

69.8
71.6
73.4
75.2
77.0

13.3
13.9
14.4
15.0
15.6

56
57
58
59
60

132.8
134.6
136.4
138.2
140.0

32.8
33.3
33.9
34.4
35.0

91
92
93
94
95

195.8
197.6
199.4
201.2
203.0

22.8
22.2
21.7
21.1
20.6

9
8
7
6
5

15.8
17.6
19.4
21.2
23.0

3.3
2.8
2.2
1.7
1.1

26
27
28
29
30

78.8
80.6
82.4
84.2
86.0

16.1
16.7
17.2
17.8
18.3

61
62
63
64
65

141.8
143.6
145.4
147.2
149.0

35.6
36.1
36.7
37.2
37.8

96
97
98
99
100

204.8
206.6
208.4
210.2
212.0

20.0
19.4
18.9
18.3
17.8

4
3
2
1
0

24.8
26.6
28.4
30.2
32.0

0.6
0
0.6
1.1
1.7

31
32
33
34
35

87.8
89.6
91.4
93.2
95.0

18.9
19.4
20.0
20.6
21.1

66
67
68
69
70

150.8
152.6
154.4
156.2
158.0

40.6
43.3
46.1
48.9
51.7

105
110
115
120
125

221.0
230.0
239.0
248.0
257.0

17.2
16.7
16.1
15.6
15.0

1
2
3
4
5

33.8
35.6
37.4
39.2
41.0

2.2
2.8
3.3
3.9
4.4

36
37
38
39
40

96.8
98.6
100.4
102.2
104.0

21.7
22.2
22.8
23.3
23.9

71
72
73
74
75

159.8
161.6
163.4
165.2
167.0

54.4
57.2
60.0
62.7
65.6

130
135
140
145
150

266.0
275.0
284.0
293.0
302.0

14.4
13.9
13.3
12.8
12.2

6
7
8
9
10

42.8
44.6
46.4
48.2
50.0

5.0
5.6
6.1
6.7
7.2

41
42
43
44
45

105.8
107.6
109.4
111.2
113.0

24.4
25.0
25.6
26.1
26.7

76
77
78
79
80

168.8
170.6
172.4
174.2
176.0

68.3
71.1
73.9
76.7
79.4

155
160
165
170
175

311.0
320.0
329.0
338.0
347.0

40

140E-5 Series

00 Index and foreword

140E-5 Series

SEN00077-07

41

SEN00077-07

KOMATSU 140E-5 Series engine


Form No. SEN00077-07

2009 KOMATSU
All Rights Reserved
Printed in Japan 01-09 (01)

42

SEN00079-07

ENGINE
1SHOP MANUAL

140E-5 Series

01 Specification

Specification and technical data


Outline............................................................................................................................................................. 2
Specifications .................................................................................................................................................. 6
General view ................................................................................................................................................. 24
Weight table .................................................................................................................................................. 61
Engine performance curves .......................................................................................................................... 65

140E-5 Series

SEN00079-07

01 Specification

Outline

1. Applicable machine
Engine

SAA6D140E-5

Engine serial No.

Machine models
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
PC800-8, PC800SE-8, PC800LC-8
PC850-8, PC850SE-8
PC800-8R, PC800SE-8R, PC800LC-8R
PC850-8R, PC850SE-8R
PC800-8R1, PC800SE-8R1, PC800LC-8R1
PC850-8R1, PC850SE-8R1
PC800-8E0, PC800SE-8E0, PC800LC-8E0
PC850-8E0, PC850SE-8E0
D155AX-6, D155A-6
D275AX-5E0, D275A-5R
WA500-6, WA500-6R
HD325-7, HD405-7, HD325-7R, HD405-7R
HM350-2, HM350-2R
HM400-2, HM400-2R
HM400-3M0, HM400-3R
SDG400S-6B1 (HOKUETSU INDUSTRIES)

Hydraulic excavator
Hydraulic excavator
Hydraulic excavator
Hydraulic excavator
Hydraulic excavator
Hydraulic excavator
Hydraulic excavator
Hydraulic excavator
Hydraulic excavator
Hydraulic excavator
Hydraulic excavator
Hydraulic excavator
Hydraulic excavator
Bulldozer
Bulldozer
Wheel loader
Dump truck
Articulated dump truck
Articulated dump truck
Articulated dump truck
Generator

140E-5 Series

01 Specification

SEN00079-07

2. Outline of engine
(With EGR)
q

The 140E-5 engine is a high-performance and


high-efficiency engine, which passed strict
emission regulations (USA: EPA Regulations
for 2006, EU: Regulations for 2006, Japan:
Construction machinery regulations for 2006)
and attained low fuel consumption, low noise,
better exhaust gas color, and high acceleration
performance. Accordingly, this newly developed engine is suitable as a power source of
construction machinery and industrial machinery used for various purposes.

The 140E-5 engine is the successor to the


140E-3 engine. While it is an in-line 6-cylinder,
water-cooled, common rail direct injection, 4stroke diesel engine similar to 140E-3, it is
equipped with the cooled EGR system which is
a new technology.

1)

2)

3)

The main components of the cooled EGR system are the EGR cooler of corrugated tube
type made of newly developed special stainless steel and the EGR valve driven hydraulically and controlled electronically which
KOMATSU developed by itself. The cooled
EGR system secures the optimum EGR rate
from the low-speed range to the high-speed
range to attain both clean exhaust gas and low
fuel consumption with the bypass assist circuit
consisting of the venturi system and bypass
valve which has the same function and structure as those of the EGR valve.
The special EGR oil pump is employed to generate high oil pressure (1.47 MPa {15 kg/cm2})
as the drive power source of the EGR valve
driven hydraulically and controlled electronically. The engine oil pump has sufficient delivery for the EGR valve and increased output of
the engine. As a result, the reliability and durability of the engine are improved.
While the 140E-3 engine has only 1 combination filter of high performance and high efficiency, the 140E-5 engine has 2 of the same
filter to meet the requirements of the EGR system and high-dispersion oil and improve the
ability to capture the soot in the oil. In addition,
the recommended sub-materials for operation
(oil and fuel) are changed to improve the reliability and durability of the engine.

140E-5 Series

4)

To secure the high output of the engine, the


twin cooling nozzle to cool the piston employed
for 140E-3 and after models is improved to
increase the durability of the piston and lower
the back side temperature of the piston. As a
result, the lubricating oil on the piston is not
exposed to high temperature, thus it is not
deteriorated. Since the high-pressure fuel
injection system controlled electronically is
employed, less soot is produced and the draining interval of the oil is lengthened. (While the
capacity of the oil pan is not changed, the oil
replacement interval of 500 hours is secured.)

5)

The common rail high-pressure fuel injection


system controlled electronically is employed
for all of 140E-3 and after models. This system
can inject the fuel at high pressure of 120 MPa
{1,200 kg/cm2} from the low-speed range to the
high-speed range. In addition, this system can
control the form of injection most properly by
electronic control according to the speed and
load. The injection system of 140E-5 is further
improved to employ multiple injections and
increase the injection pressure up to 160 MPa
{1,600 kg/cm2}. As a result, exhaust gas of the
cleanest level in the world, good exhaust gas
color, low fuel consumption, and low noise are
realized simultaneously.

6)

As the injection pressure of the common rail


injection system employed for the 140E-3
engine and after models is increased (from
120 to 160 MPa {from 1,200 to 1,600 kg/cm2}),
the pressure resistance of the common rail,
injector, and supply pump is improved for
higher reliability.

7)

The main fuel filter of high efficiency and the


pre-fuel filter are installed as standard so that
the low grade fuel in the market (equivalent to
Class NAS13) can be used. In addition, the
delivery of the priming pump used to replace
the filters is increased for higher serviceability.

8)

The high-quality piston made of cast iron which


has been employed for the 140E-2 engine and
after models is employed. This piston has a
less coefficient of thermal expansion, a reentrant combustion chamber, and a shaker cooling gallery. As a result, clean exhaust gas,
good exhaust gas color, and low fuel consumption are attained simultaneously, and high
durability and reliability are also obtained.

SEN00079-07

9)

01 Specification

By using the above-mentioned high-pressure


fuel injection system controlled electronically,
the multiple injection and injection characteristics are set most properly to improve the startability and reduce the white exhaust smoke
when the temperature is low.

10) Since the controller is mounted on the engine


and equipped with the automatic high-altitude
compensation function, the engine can be
operated at high altitude without replacing the
controller. As a result, the serviceability is
improved.
11) The improved type of the KTR110 turbocharger manufactured by KOMATSU which
has been employed for the 140E-2 engine and
after models and which has high reliability and
high performance is mounted. Besides; the
efficiency of the blower impeller is heightened
and the strength of its material is improved to
obtain higher efficiency and pressure ratio.
Since the design of the shaft is improved to
increase the reliability, high performance is
obtained from the low-speed range to the highspeed range. As a result, the engine has high
performance and consumes less fuel and
attains high reliability.
12) The cylinder block is changed partly to add the
cooled EGR system. Since its overall length,
overall width, and overall height are the same
as before, however, its size is not increased.

140E-5 Series

01 Specification

SEN00079-07

(EGR-less)
q

The 140E-5 engine is a high-performance and


high-efficiency engine, which attained low fuel
consumption and low noise. Accordingly, this
newly developed engine is suitable as a power
source of construction machinery and industrial machinery used for various purposes.

4)

As the injection pressure of the common rail


injection system employed for the 140E-3
engine and after models is increased, the pressure resistance of the common rail, injector,
and supply pump is improved for higher reliability.

The 140E-5 engine is the successor to the


140E-3 engine. While it is an in-line 6-cylinder,
water-cooled, 4-stroke diesel engine, it is
equipped with the common rail direct injection
system.

5)

The main fuel filter of high efficiency and the


pre-fuel filter are installed as standard so that
the low grade fuel in the market can be used.
In addition, the delivery of the priming pump
used to replace the filters is increased for
higher serviceability.

1)

While the 140E-3 engine has only 1 combination filter of high performance and high efficiency, the 140E-5 engine has 2 of the same
filter to meet the requirements of the high-dispersion oil and improve the ability to capture
the soot in the oil. In addition, the recommended sub-materials for operation (oil and
fuel) are changed to improve the reliability and
durability of the engine.

6)

The high-quality piston made of cast iron which


has been employed for the 140E-2 engine and
after models is employed. This piston has a
less coefficient of thermal expansion, a reentrant combustion chamber, and a shaker cooling gallery. As a result, clean exhaust gas,
good exhaust gas color, and low fuel consumption are attained simultaneously, and high
durability and reliability are also obtained.

7)

By using the above-mentioned high-pressure


fuel injection system controlled electronically,
the multiple injection and injection characteristics are set most properly to improve the startability and reduce the white exhaust smoke
when the temperature is low.

8)

Since the controller is mounted on the engine


and equipped with the automatic high-altitude
compensation function, the engine can be
operated at high altitude without replacing the
controller. As a result, the serviceability is
improved.

9)

The improved type of the KTR110 turbocharger manufactured by KOMATSU which


has been employed for the 140E-2 engine and
after models and which has high reliability and
high performance is mounted. Besides; the
efficiency of the blower impeller is heightened
and the strength of its material is improved to
obtain higher efficiency and pressure ratio.
Since the design of the shaft is improved to
increase the reliability, high performance is
obtained from the low-speed range to the highspeed range. As a result, the engine has high
performance and consumes less fuel and
attains high reliability.

2)

3)

To secure the high output of the engine, the


twin cooling nozzle to cool the piston employed
for 140E-3 and after models is improved to
increase the durability of the piston and lower
the back side temperature of the piston. As a
result, the lubricating oil on the piston is not
exposed to high temperature, thus it is not
deteriorated. Since the high-pressure fuel
injection system controlled electronically is
employed, less soot is produced and the draining interval of the oil is lengthened. (While the
capacity of the oil pan is not changed, the oil
replacement interval of 500 hours is secured.)
The common rail high-pressure fuel injection
system controlled electronically is employed
for all of 140E-3 and after models. This system
can inject the fuel at high pressure of 120 MPa
{1,200 kg/cm2} from the low-speed range to the
high-speed range. In addition, this system can
control the form of injection most properly by
electronic control according to the speed and
load. The injection system of 140E-5 is further
improved to employ multiple injections and
increase the injection pressure. As a result,
exhaust gas of the cleanest level in the world,
good exhaust gas color, low fuel consumption,
and low noise are realized simultaneously.

140E-5 Series

SEN00079-07

01 Specification

Specifications

1
Engine name

SAA6D140E-5

Machine models

PC600-8, PC600LC-8
PC600-8E0, PC600LC-8E0
PC700-8E0, PC700LC-8E0

Number of cylinders Bore Stroke


Total displacement
Firing order

mm

Overall length

mm

1,494

Overall width

mm

1,151

Overall height (excluding exhaust pipe)

mm

1,467

Overall height (including exhaust pipe)

mm

1,863

Rated horsepower

kW{HP}/
min-1{rpm}

323 {433.3}/1,800 {1,800}


(Gross)

Max. torque

Nm{kgm}/
min-1{rpm}

1,944 {198.4}/1,400 {1,400}


(Gross)

Max. speed with no load


(High idle speed)

min-1{rpm}

1,950 50 {1,950 50}

Min. speed with no load


(Low idle speed)

min-1{rpm}

800 25 {800 25}

g/kWh
{g/HPh}

209 {156}

Dry weight

kg

1,845

Fuel supply pump


Governor

DENSO ECD-U2
Electronic control type

Quantity of lubricating oil (refill capacity)

48 (40)

Quantity of coolant

24

Alternator
Starting motor
Battery

24V, 60A, 90A


24V, 11kW
12V, 170Ah 2

Turbocharger
Air compressor
Others

KOMATSU KTR110L

With air-cooled aftercooler


With cooled EGR

Performance

Dimensions

6 140 165
15.2 {15,230}
153624

Fuel consumption ratio at rated point

l{cc}

140E-5 Series

01 Specification

SEN00079-07

1
Engine name

SAA6D140E-5

Machine models

PC600-8R, PC600LC-8R
PC600-8R1, PC600LC-8R1
PC700-8R, PC700LC-8R, PC700LC-8R1

Number of cylinders Bore Stroke


Total displacement
Firing order

mm

Overall length

mm

1,482

Overall width

mm

1,191

Overall height (excluding exhaust pipe)

mm

1,467

Overall height (including exhaust pipe)

mm

1,863

Rated horsepower

kW{HP}/
min-1{rpm}

323 {433.3}/1,800 {1,800}


(Gross)

Max. torque

Nm{kgm}/
min-1{rpm}

1,944 {198.4}/1,400 {1,400}


(Gross)

Max. speed with no load


(High idle speed)

min-1{rpm}

1,950 50 {1,950 50}

Min. speed with no load


(Low idle speed)

min-1{rpm}

800 25 {800 25}

g/kWh
{g/HPh}

205 {153}

Dry weight

kg

1,770

Fuel supply pump


Governor

DENSO ECD-U2
Electronic control type

Quantity of lubricating oil (refill capacity)

48 (40)

Quantity of coolant

24

Alternator
Starting motor
Battery

24V, 60A, 90A


24V, 11kW
12V, 170Ah 2

Turbocharger
Air compressor
Others

KOMATSU KTR110L

With air-cooled aftercooler

Performance

Dimensions

6 140 165
15.2 {15,230}
153624

Fuel consumption ratio at rated point

140E-5 Series

l{cc}

SEN00079-07

01 Specification

1
Engine name

SAA6D140E-5

Machine models

PC800-8, PC800SE-8, PC800LC-8,


PC850-8, PC850SE-8
PC800-8E0, PC800SE-8E0, PC800LC-8E0,
PC850-8E0, PC850SE-8E0

6 140 165
15.2 {15,230}
153624

Overall length

mm

1,762

Overall width

mm

1,176

Overall height (excluding exhaust pipe)

mm

1,686

Overall height (including exhaust pipe)

mm

1,902

Rated horsepower

kW{HP}/
min-1{rpm}

370 {496.4}/1,800 {1,800}


(Gross)

Max. torque

Nm{kgm}/
min-1{rpm}

2,195 {223.8}/1,350 {1,350}


(Gross)

Max. speed with no load


(High idle speed)

min-1{rpm}

1,980 50 {1,980 50}

Min. speed with no load


(Low idle speed)

min-1{rpm}

825 25 {825 25}

g/kWh
{g/HPh}

204 {152}

Dry weight

kg

1,920

Fuel supply pump


Governor

DENSO ECD-U2
Electronic control type

Quantity of lubricating oil (refill capacity)

58 (53)

Quantity of coolant

25 (In only engine)

Alternator
Starting motor
Battery

24V, 60A, 90A


24V, 11kW
12V, 170Ah 2

Turbocharger
Air compressor
Others

KOMATSU KTR110L

With air-cooled aftercooler


With cooled EGR

Performance

Dimensions

Number of cylinders Bore Stroke


Total displacement
Firing order

Fuel consumption ratio at rated point

mm
l{cc}

140E-5 Series

01 Specification

SEN00079-07

1
Engine name

SAA6D140E-5

Machine models

PC800-8R, PC800SE-8R, PC800LC-8R,


PC850-8R, PC850SE-8R
PC800-8R1, PC800SE-8R1, PC800LC-8R1
PC850-8R1, PC850SE-8R1

6 140 165
15.2 {15,230}
153624

Overall length

mm

1,718

Overall width

mm

1,176

Overall height (excluding exhaust pipe)

mm

1,686

Overall height (including exhaust pipe)

mm

1,902

Rated horsepower

kW{HP}/
min-1{rpm}

370 {496.4}/1,800 {1,800}


(Gross)

Max. torque

Nm{kgm}/
min-1{rpm}

2,195 {223.8}/1,350 {1,350}


(Gross)

Max. speed with no load


(High idle speed)

min-1{rpm}

1,980 50 {1,980 50}

Min. speed with no load


(Low idle speed)

min-1{rpm}

825 25 {825 25}

g/kWh
{g/HPh}

204 {152}

Dry weight

kg

1,850

Fuel supply pump


Governor

DENSO ECD-U2
Electronic control type

Quantity of lubricating oil (refill capacity)

58 (53)

Quantity of coolant

25 (In only engine)

Alternator
Starting motor
Battery

24V, 60A, 90A


24V, 11kW
12V, 170Ah 2

Turbocharger
Air compressor
Others

KOMATSU KTR110L

With air-cooled aftercooler

Performance

Dimensions

Number of cylinders Bore Stroke


Total displacement
Firing order

Fuel consumption ratio at rated point

140E-5 Series

mm
l{cc}

SEN00079-07

01 Specification

1
Engine name

SAA6D140E-5

Machine models

D155AX-6

6 140 165
15.2 {15,230}
153624

Overall length

mm

1,477

Overall width

mm

1,109

Overall height (excluding exhaust pipe)

mm

1,157

Overall height (including exhaust pipe)

mm

1,950

Rated horsepower

kW{HP}/
min-1{rpm}

268 {359.9}/1,900 {1,900}


(Gross)

Max. torque

Nm{kgm}/
min-1{rpm}

1,834 {187}/1,300 {1,300}


(Gross)

Max. speed with no load


(High idle speed)

min-1{rpm}

2,100 (0/50) {2,100 (0/50)}

Min. speed with no load


(Low idle speed)

min-1{rpm}

740 (+40/0) {740 (+40/0)}

g/kWh
{g/HPh}

215 {160}

Dry weight

kg

1,800

Fuel supply pump


Governor

DENSO ECD-U2
Electronic control type

Quantity of lubricating oil (refill capacity)

45 (37)

Quantity of coolant

25 (In only engine)

Alternator
Starting motor
Battery

24V, 60A, 75A, 90A


24V, 11kW
12V, 170Ah 2

Turbocharger
Air compressor
Others

KOMATSU KTR110L

With air-cooled aftercooler


With cooled EGR

Performance

Dimensions

Number of cylinders Bore Stroke


Total displacement
Firing order

Fuel consumption ratio at rated point

10

mm
l{cc}

140E-5 Series

01 Specification

SEN00079-07

1
Engine name

SAA6D140E-5

Machine models

D155A-6

6 140 165
15.2 {15,230}
153624

Overall length

mm

1,461

Overall width

mm

1,109

Overall height (excluding exhaust pipe)

mm

1,157

Overall height (including exhaust pipe)

mm

1,950

Rated horsepower

kW{HP}/
min-1{rpm}

268 {359.9}/1,900 {1,900}


(Gross)

Max. torque

Nm{kgm}/
min-1{rpm}

1,834 {187}/1,300 {1,300}


(Gross)

Max. speed with no load


(High idle speed)

min-1{rpm}

2,100 (0/50) {2,100 (0/50)}

Min. speed with no load


(Low idle speed)

min-1{rpm}

740 (+40/0) {740 (+40/0)}

g/kWh
{g/HPh}

215 {160}

Dry weight

kg

1,725

Fuel supply pump


Governor

DENSO ECD-U2
Electronic control type

Quantity of lubricating oil (refill capacity)

45 (37)

Quantity of coolant

25 (In only engine)

Alternator
Starting motor
Battery

24V, 60A, 75A, 90A


24V, 11kW
12V, 170Ah 2

Turbocharger
Air compressor
Others

KOMATSU KTR110L

With air-cooled aftercooler

Performance

Dimensions

Number of cylinders Bore Stroke


Total displacement
Firing order

Fuel consumption ratio at rated point

140E-5 Series

mm
l{cc}

11

SEN00079-07

01 Specification

1
Engine name

SAA6D140E-5

Machine models

D275AX-5E0

6 140 165
15.2 {15,230}
153624

Overall length

mm

1,477

Overall width

mm

966

Overall height (excluding exhaust pipe)

mm

2,020

Overall height (including exhaust pipe)

mm

Rated horsepower

kW{HP}/
min-1{rpm}

337 {451.6}/2,000 {2,000}


(Gross)

Max. torque

Nm{kgm}/
min-1{rpm}

2,030 {207}/1,400 {1,400}


(Gross)

Max. speed with no load


(High idle speed)

min-1{rpm}

2,200 50 {2,200 50}

Min. speed with no load


(Low idle speed)

min-1{rpm}

700 50 {700 50}

g/kWh
{g/HPh}

218 {162.3}

Dry weight

kg

1,869

Fuel supply pump


Governor

DENSO ECD-U2
Electronic control type

Quantity of lubricating oil (refill capacity)

58 (50)

Quantity of coolant

25 (In only engine)

Alternator
Starting motor
Battery

24V, 75A, 90A


24V, 11kW
12V, 170Ah 2

Turbocharger
Air compressor
Others

KOMATSU KTR110L

With air-cooled aftercooler


With cooled EGR

Performance

Dimensions

Number of cylinders Bore Stroke


Total displacement
Firing order

Fuel consumption ratio at rated point

12

mm
l{cc}

140E-5 Series

01 Specification

SEN00079-07

1
Engine name

SAA6D140E-5

Machine models

D275A-5R

6 140 165
15.2 {15,230}
153624

Overall length

mm

1,461

Overall width

mm

966

Overall height (excluding exhaust pipe)

mm

2,020

Overall height (including exhaust pipe)

mm

Rated horsepower

kW{HP}/
min-1{rpm}

337 {451.6}/2,000 {2,000}


(Gross)

Max. torque

Nm{kgm}/
min-1{rpm}

2,030 {207}/1,400 {1,400}


(Gross)

Max. speed with no load


(High idle speed)

min-1{rpm}

2,200 50 {2,200 50}

Min. speed with no load


(Low idle speed)

min-1{rpm}

700 50 {700 50}

g/kWh
{g/HPh}

215 {160}

Dry weight

kg

1,800

Fuel supply pump


Governor

DENSO ECD-U2
Electronic control type

Quantity of lubricating oil (refill capacity)

58 (50)

Quantity of coolant

25 (In only engine)

Alternator
Starting motor
Battery

24V, 75A, 90A


24V, 11kW
12V, 170Ah 2

Turbocharger
Air compressor
Others

KOMATSU KTR110L

With air-cooled aftercooler

Performance

Dimensions

Number of cylinders Bore Stroke


Total displacement
Firing order

Fuel consumption ratio at rated point

140E-5 Series

mm
l{cc}

13

SEN00079-07

01 Specification

1
Engine name

SAA6D140E-5

Machine models

WA500-6

6 140 165
15.2 {15,230}
153624

Overall length

mm

1,477

Overall width

mm

1,094

Overall height (excluding exhaust pipe)

mm

1,435

Overall height (including exhaust pipe)

mm

1,727

Rated horsepower

kW{HP}/
min-1{rpm}

266 {356.9}/1,900 {1,900}


(Gross)

Max. torque

Nm{kgm}/
min-1{rpm}

1,803 {184}/1,250 {1,250}


(Gross)

Max. speed with no load


(High idle speed)

min-1{rpm}

2,150 50 {2,150 50}

Min. speed with no load


(Low idle speed)

min-1{rpm}

700 25 {700 25}

g/kWh
{g/HPh}

216.2 {161.3}

Dry weight

kg

1,750

Fuel supply pump


Governor

DENSO ECD-U2
Electronic control type

Quantity of lubricating oil (refill capacity)

45 (37)

Quantity of coolant

25

Alternator
Starting motor
Battery

24V, 75A, 90A


24V, 11kW
12V, 170Ah 2

Turbocharger
Air compressor
Others

KOMATSU KTR110L

With air-cooled aftercooler


With cooled EGR

Performance

Dimensions

Number of cylinders Bore Stroke


Total displacement
Firing order

Fuel consumption ratio at rated point

14

mm
l{cc}

140E-5 Series

01 Specification

SEN00079-07

1
Engine name

SAA6D140E-5

Machine models

WA500-6R

6 140 165
15.2 {15,230}
153624

Overall length

mm

1,461

Overall width

mm

1,094

Overall height (excluding exhaust pipe)

mm

1,435

Overall height (including exhaust pipe)

mm

1,727

Rated horsepower

kW{HP}/
min-1{rpm}

266 {356.9}/1,900 {1,900}


(Gross)

Max. torque

Nm{kgm}/
min-1{rpm}

1,803 {184}/1,250 {1,250}


(Gross)

Max. speed with no load


(High idle speed)

min-1{rpm}

2,150 50 {2,150 50}

Min. speed with no load


(Low idle speed)

min-1{rpm}

700 25 {700 25}

g/kWh
{g/HPh}

211.4 {157.7}

Dry weight

kg

1,680

Fuel supply pump


Governor

DENSO ECD-U2
Electronic control type

Quantity of lubricating oil (refill capacity)

45 (37)

Quantity of coolant

25

Alternator
Starting motor
Battery

24V, 75A, 90A


24V, 11kW
12V, 170Ah 2

Turbocharger
Air compressor
Others

KOMATSU KTR110L

With air-cooled aftercooler

Performance

Dimensions

Number of cylinders Bore Stroke


Total displacement
Firing order

Fuel consumption ratio at rated point

140E-5 Series

mm
l{cc}

15

SEN00079-07

01 Specification

1
Engine name

SAA6D140E-5

Machine models

HD325-7, HD405-7

6 140 165
15.2 {15,230}
153624

Overall length

mm

1,775

Overall width

mm

1,009

Overall height (excluding exhaust pipe)

mm

1,604

Overall height (including exhaust pipe)

mm

Rated horsepower

kW{HP}/
min-1{rpm}

386 {517.7}/2,000 {2,000}


(Gross)

Max. torque

Nm{kgm}/
min-1{rpm}

2,170 {221.3}/1,400 {1,400}


(Gross)

Max. speed with no load


(High idle speed)

min-1{rpm}

2,300 25 {2,300 25}

Min. speed with no load


(Low idle speed)

min-1{rpm}

725 25 {725 25}

g/kWh
{g/HPh}

212 {158}

Dry weight

kg

1,810

Fuel supply pump


Governor

DENSO ECD-U2
Electronic control type

Quantity of lubricating oil (refill capacity)

58 (50)

Quantity of coolant

25 (In only engine)

Alternator
Starting motor
Battery

24V, 60A, 75A


24V, 11kW
12V, 170Ah 2

Turbocharger
Air compressor
Others

KOMATSU KTR110L

With air-cooled aftercooler


With cooled EGR

Performance

Dimensions

Number of cylinders Bore Stroke


Total displacement
Firing order

Fuel consumption ratio at rated point

16

mm
l{cc}

140E-5 Series

01 Specification

SEN00079-07

1
Engine name

SAA6D140E-5

Machine models

HD325-7R, HD405-7R

6 140 165
15.2 {15,230}
153624

Overall length

mm

1,775

Overall width

mm

1,009

Overall height (excluding exhaust pipe)

mm

1,604

Overall height (including exhaust pipe)

mm

Rated horsepower

kW{HP}/
min-1{rpm}

386 {517.7}/2,000 {2,000}


(Gross)

Max. torque

Nm{kgm}/
min-1{rpm}

2,170 {221.3}/1,400 {1,400}


(Gross)

Max. speed with no load


(High idle speed)

min-1{rpm}

2,300 25 {2,300 25}

Min. speed with no load


(Low idle speed)

min-1{rpm}

725 25 {725 25}

g/kWh
{g/HPh}

207 {154}

Dry weight

kg

1,740

Fuel supply pump


Governor

DENSO ECD-U2
Electronic control type

Quantity of lubricating oil (refill capacity)

58 (50)

Quantity of coolant

25 (In only engine)

Alternator
Starting motor
Battery

24V, 60A, 75A


24V, 11kW
12V, 170Ah 2

Turbocharger
Air compressor
Others

KOMATSU KTR110L

With air-cooled aftercooler

Performance

Dimensions

Number of cylinders Bore Stroke


Total displacement
Firing order

Fuel consumption ratio at rated point

140E-5 Series

mm
l{cc}

17

SEN00079-07

01 Specification

1
Engine name

SAA6D140E-5

Machine models

HM350-2

6 140 165
15.2 {15,230}
153624

Overall length

mm

1,724

Overall width

mm

1,250

Overall height (excluding exhaust pipe)

mm

1,496

Overall height (including exhaust pipe)

mm

Rated horsepower

kW{HP}/
min-1{rpm}

304 {407.2}/2,000 {2,000}


(Gross)

Max. torque

Nm{kgm}/
min-1{rpm}

1,991 {203}/1,400 {1,400}


(Gross)

Max. speed with no load


(High idle speed)

min-1{rpm}

2,200 (+50/0) {2,200 (+50/0)}

Min. speed with no load


(Low idle speed)

min-1{rpm}

725 25 {725 25}

g/kWh
{g/HPh}

223 {166}

Dry weight

kg

1,820

Fuel supply pump


Governor

DENSO ECD-U2
Electronic control type

Quantity of lubricating oil (refill capacity)

58 (50)

Quantity of coolant

25 (In only engine)

Alternator
Starting motor
Battery

24V, 60A, 75A


24V, 11kW
12V 170Ah 2

Turbocharger
Air compressor
Others

KOMATSU KTR110L

With air-cooled aftercooler


With cooled EGR

Performance

Dimensions

Number of cylinders Bore Stroke


Total displacement
Firing order

Fuel consumption ratio at rated point

18

mm
l{cc}

140E-5 Series

01 Specification

SEN00079-07

1
Engine name

SAA6D140E-5

Machine models

HM350-2R

6 140 165
15.2 {15,230}
153624

Overall length

mm

1,724

Overall width

mm

1,250

Overall height (excluding exhaust pipe)

mm

1,496

Overall height (including exhaust pipe)

mm

Rated horsepower

kW{HP}/
min-1{rpm}

304 {407.2}/2,000 {2,000}


(Gross)

Max. torque

Nm{kgm}/
min-1{rpm}

1,991 {203}/1,400 {1,400}


(Gross)

Max. speed with no load


(High idle speed)

min-1{rpm}

2,200 (+50/0) {2,200 (+50/0)}

Min. speed with no load


(Low idle speed)

min-1{rpm}

725 25 {725 25}

g/kWh
{g/HPh}

222 {165}

Dry weight

kg

1,750

Fuel supply pump


Governor

DENSO ECD-U2
Electronic control type

Quantity of lubricating oil (refill capacity)

58 (50)

Quantity of coolant

25 (In only engine)

Alternator
Starting motor
Battery

24V, 60A, 75A


24V, 11kW
12V 170Ah 2

Turbocharger
Air compressor
Others

KOMATSU KTR110L

With air-cooled aftercooler

Performance

Dimensions

Number of cylinders Bore Stroke


Total displacement
Firing order

Fuel consumption ratio at rated point

140E-5 Series

mm
l{cc}

19

SEN00079-07

01 Specification

1
Engine name

SAA6D140E-5

Machine models

HM400-2, HM400-3M0

6-140 165
15.2 {15,230}
153624

Overall length

mm

1,724

Overall width

mm

1,250

Overall height (excluding exhaust pipe)

mm

1,496

Overall height (including exhaust pipe)

mm

Rated horsepower

kW{HP}/
min-1{rpm}

338 {452.6}/2,000 {2,000}


(Gross)

Max. torque

Nm{kgm}/
min-1{rpm}

2,089 {213}/1,400 {1,400}


(Gross)

Max. speed with no load


(High idle speed)

min-1{rpm}

2,200 (+50/0) {2,200 (+50/0)}

Min. speed with no load


(Low idle speed)

min-1{rpm}

725 25 {725 25}

g/kWh
{g/HPh}

213 {159}

Dry weight

kg

1,820

Fuel supply pump


Governor

DENSO ECD-U2
Electronic control type

Quantity of lubricating oil (refill capacity)

58 (50)

Quantity of coolant

25 (In only engine)

Alternator
Starting motor
Battery

24V, 60A, 75A


24V, 11kW
12V, 170Ah 2

Turbocharger
Air compressor
Others

KOMATSU KTR110L

With air-cooled aftercooler


With cooled EGR

Performance

Dimensions

Number of cylinders Bore Stroke


Total displacement
Firing order

Fuel consumption ratio at rated point

20

mm
l{cc}

140E-5 Series

01 Specification

SEN00079-07

1
Engine name

SAA6D140E-5

Machine models

HM400-2R, HM400-3R

6-140 165
15.2 {15,230}
153624

Overall length

mm

1,724

Overall width

mm

1,250

Overall height (excluding exhaust pipe)

mm

1,496

Overall height (including exhaust pipe)

mm

Rated horsepower

kW{HP}/
min-1{rpm}

338 {452.6}/2,000 {2,000}


(Gross)

Max. torque

Nm{kgm}/
min-1{rpm}

2,089 {213}/1,400 {1,400}


(Gross)

Max. speed with no load


(High idle speed)

min-1{rpm}

2,200 (+50/0) {2,200 (+50/0)}

Min. speed with no load


(Low idle speed)

min-1{rpm}

725 25 {725 25}

g/kWh
{g/HPh}

218 {162}

Dry weight

kg

1,750

Fuel supply pump


Governor

DENSO ECD-U2
Electronic control type

Quantity of lubricating oil (refill capacity)

58 (50)

Quantity of coolant

25 (In only engine)

Alternator
Starting motor
Battery

24V, 60A, 75A


24V, 11kW
12V, 170Ah 2

Turbocharger
Air compressor
Others

KOMATSU KTR110L

With air-cooled aftercooler

Performance

Dimensions

Number of cylinders Bore Stroke


Total displacement
Firing order

Fuel consumption ratio at rated point

140E-5 Series

mm
l{cc}

21

SEN00079-07

01 Specification

1
Engine name

SAA6D140E-5

Machine models

SDG400S-6B1
(HOKUETSU INDUSTRIES GENERATOR)

6 140 165
15.2 {15,230}
153624

Overall length

mm

1,785

Overall width

mm

1,242

Overall height (excluding exhaust pipe)

mm

1,523

Overall height (including exhaust pipe)

mm

Rated horsepower

kW{HP}/
min-1{rpm}

357 {478}/1,800 {1,800}


(Net)

Max. torque

Nm{kgm}/
min-1{rpm}

Max. speed with no load


(High idle speed)

min-1{rpm}

Min. speed with no load


(Low idle speed)

min-1{rpm}

g/kWh
{g/HPh}

222 {163}

Dry weight

kg

1,950

Fuel supply pump


Governor

DENSO ECD-U2
Electronic control type

Quantity of lubricating oil (refill capacity)

82 (73)

Quantity of coolant (with radiator)

53

Alternator
Starting motor
Battery

24V, 35A
24V, 7.5kW

Turbocharger
Air compressor
Others

KOMATSU KTR110L

With air-cooled aftercooler


With cooled EGR

Performance

Dimensions

Number of cylinders Bore Stroke


Total displacement
Firing order

Fuel consumption ratio at rated point

22

mm
l{cc}

140E-5 Series

01 Specification

140E-5 Series

SEN00079-07

23

SEN00079-07

General view

01 Specification

SAA6D140E-5 (Left side view of engine)


Machine model: PC600-8, PC600LC-8

The shape is subject to machine models.

1.
2.

Center of crankshaft
Rear face of flywheel housing

24

140E-5 Series

01 Specification

SEN00079-07

SAA6D140E-5 (Front view of engine)


Machine model: PC600-8, PC600LC-8

The shape is subject to machine models.

1.
2.

Center of crankshaft
Center of cylinder liner

140E-5 Series

25

SEN00079-07

01 Specification

SAA6D140E-5 (Left side view of engine)


Machine model: PC600-8R, PC600LC-8R

a
a

The shape is subject to machine models.


Corrosion resistor-less, Single cartridge and Manual priming pump are set for some models. (See the
PC700-8R, PC700LC-8R.)

1.
2.

Center of crankshaft
Rear face of flywheel housing

26

140E-5 Series

01 Specification

SEN00079-07

SAA6D140E-5 (Front view of engine)


Machine model: PC600-8R, PC600LC-8R

a
a

The shape is subject to machine models.


Corrosion resistor-less, Single cartridge and Manual priming pump are set for some models. (See the
PC700-8R, PC700LC-8R.)

1.
2.

Center of crankshaft
Center of cylinder liner

140E-5 Series

27

SEN00079-07

01 Specification

SAA6D140E-5 (Left side view of engine)


Machine model: PC600-8E0, PC600LC-8E0, PC700-8E0, PC700LC-8E0

The shape is subject to machine models.

1.
2.

Center of crankshaft
Rear face of flywheel housing

28

140E-5 Series

01 Specification

SEN00079-07

SAA6D140E-5 (Front view of engine)


Machine model: PC600-8E0, PC600LC-8E0, PC700-8E0, PC700LC-8E0

The shape is subject to machine models.

1.
2.

Center of crankshaft
Center of cylinder liner

140E-5 Series

29

SEN00079-07

01 Specification

SAA6D140E-5 (Left side view of engine)


Machine model: PC600-8R1, PC600LC-8R1,
PC700-8R, PC700LC-8R, PC700LC-8R1

The shape is subject to machine models.

1.
2.

Center of crankshaft
Rear face of flywheel housing

30

140E-5 Series

01 Specification

SEN00079-07

SAA6D140E-5 (Front view of engine)


Machine model: PC600-8R1, PC600LC-8R1,
PC700-8R, PC700LC-8R, PC700LC-8R1

The shape is subject to machine models.

1.
2.

Center of crankshaft
Center of cylinder liner

140E-5 Series

31

SEN00079-07

01 Specification

SAA6D140E-5 (Left side view of engine)


Machine model: PC800-8, PC800SE-8, PC800LC-8, PC850-8, PC850SE-8
PC800-8E0, PC800SE-8E0, PC800LC-8E0, PC850-8E0, PC850SE-8E0

The shape is subject to machine models.

1.
2.

Center of crankshaft
Rear face of flywheel housing

32

140E-5 Series

01 Specification

SEN00079-07

SAA6D140E-5 (Front view of engine)


Machine model: PC800-8, PC800SE-8, PC800LC-8, PC850-8, PC850SE-8
PC800-8E0, PC800SE-8E0, PC800LC-8E0, PC850-8E0, PC850SE-8E0

The shape is subject to machine models.

1.
2.

Center of crankshaft
Center of cylinder liner

140E-5 Series

33

SEN00079-07

01 Specification

SAA6D140E-5 (Left side view of engine)


Machine model: PC800-8R, PC800SE-8R, PC800LC-8R, PC850-8R, PC850SE-8R

The shape is subject to machine models.

1.
2.

Center of crankshaft
Rear face of flywheel housing

34

140E-5 Series

01 Specification

SEN00079-07

SAA6D140E-5 (Front view of engine)


Machine model: PC800-8R, PC800SE-8R, PC800LC-8R, PC850-8R, PC850SE-8R

The shape is subject to machine models.

1.
2.

Center of crankshaft
Center of cylinder liner

140E-5 Series

35

SEN00079-07

01 Specification

SAA6D140E-5 (Left side view of engine)


Machine model: PC800-8R1, PC800SE-8R1, PC800LC-8R1, PC850-8R1,
PC850SE-8R1

The shape is subject to machine models.

1.
2.

Center of crankshaft
Rear face of flywheel housing

36

140E-5 Series

01 Specification

SEN00079-07

SAA6D140E-5 (Front view of engine)


Machine model: PC800-8R1, PC800SE-8R1, PC800LC-8R1, PC850-8R1,
PC850SE-8R1

The shape is subject to machine models.

1.
2.

Center of crankshaft
Center of cylinder liner

140E-5 Series

37

SEN00079-07

01 Specification

SAA6D140E-5 (Left side view of engine)


Machine model: D275AX-5E0

The shape is subject to machine models.

1.
2.

Center of crankshaft
Rear face of flywheel housing

38

140E-5 Series

01 Specification

SEN00079-07

SAA6D140E-5 (Front view of engine)


Machine model: D275AX-5E0

The shape is subject to machine models.

1.
2.

Center of crankshaft
Center of cylinder liner

140E-5 Series

39

SEN00079-07

01 Specification

SAA6D140E-5 (Left side view of engine)


Machine model: D275A-5R

The shape is subject to machine models.

1.
2.

Center of crankshaft
Rear face of flywheel housing

40

140E-5 Series

01 Specification

SEN00079-07

SAA6D140E-5 (Front view of engine)


Machine model: D275A-5R

The shape is subject to machine models.

1.
2.

Center of crankshaft
Center of cylinder liner

140E-5 Series

41

SEN00079-07

01 Specification

SAA6D140E-5 (Left side view of engine)


Machine model: WA500-6

The shape is subject to machine models.

1.
2.

Center of crankshaft
Rear face of flywheel housing

42

140E-5 Series

01 Specification

SEN00079-07

SAA6D140E-5 (Front view of engine)


Machine model: WA500-6

The shape is subject to machine models.

1.
2.

Center of crankshaft
Center of cylinder liner

140E-5 Series

43

SEN00079-07

01 Specification

SAA6D140E-5 (Left side view of engine)


Machine model: WA500-6R

The shape is subject to machine models.

1.
2.

Center of crankshaft
Rear face of flywheel housing

44

140E-5 Series

01 Specification

SEN00079-07

SAA6D140E-5 (Front view of engine)


Machine model: WA500-6R

The shape is subject to machine models.

1.
2.

Center of crankshaft
Center of cylinder liner

140E-5 Series

45

SEN00079-07

01 Specification

SAA6D140E-5 (Left side view of engine)


Machine model: HD325-7, HD405-7

The shape is subject to machine models.

1.
2.

Center of crankshaft
Rear face of flywheel housing

46

140E-5 Series

01 Specification

SEN00079-07

SAA6D140E-5 (Front view of engine)


Machine model: HD325-7, HD405-7

The shape is subject to machine models.

1.
2.

Center of crankshaft
Center of cylinder liner

140E-5 Series

47

SEN00079-07

01 Specification

SAA6D140E-5 (Left side view of engine)


Machine model: HD325-7R, HD405-7R

The shape is subject to machine models.

1.
2.

Center of crankshaft
Rear face of flywheel housing

48

140E-5 Series

01 Specification

SEN00079-07

SAA6D140E-5 (Front view of engine)


Machine model: HD325-7R, HD405-7R

The shape is subject to machine models.

1.
2.

Center of crankshaft
Center of cylinder liner

140E-5 Series

49

SEN00079-07

01 Specification

SAA6D140E-5 (Left side view of engine)


Machine model: HM350-2, HM400-2

The shape is subject to machine models.

1.
2.

Center of crankshaft
Rear face of flywheel housing

50

140E-5 Series

01 Specification

SEN00079-07

SAA6D140E-5 (Front view of engine)


Machine model: HM350-2, HM400-2

The shape is subject to machine models.

1.
2.

Center of crankshaft
Center of cylinder liner

140E-5 Series

51

SEN00079-07

01 Specification

SAA6D140E-5 (Left side view of engine)


Machine model: HM350-2R, HM400-2R

The shape is subject to machine models.

1.
2.

Center of crankshaft
Rear face of flywheel housing

52

140E-5 Series

01 Specification

SEN00079-07

SAA6D140E-5 (Front view of engine)


Machine model: HM350-2R, HM400-2R

The shape is subject to machine models.

1.
2.

Center of crankshaft
Center of cylinder liner

140E-5 Series

53

SEN00079-07

01 Specification

SAA6D140E-5 (Left side view of engine)


Machine model: HM400-3M0

The shape is subject to machine models.

1.
2.

Center of crankshaft
Rear face of flywheel housing

54

140E-5 Series

01 Specification

SEN00079-07

SAA6D140E-5 (Front view of engine)


Machine model: HM400-3M0

The shape is subject to machine models.

1.
2.

Center of crankshaft
Center of cylinder liner

140E-5 Series

55

SEN00079-07

01 Specification

SAA6D140E-5 (Left side view of engine)


Machine model: HM400-3R

The shape is subject to machine models.

1.
2.

Center of crankshaft
Rear face of flywheel housing

56

140E-5 Series

01 Specification

SEN00079-07

SAA6D140E-5 (Front view of engine)


Machine model: HM400-3R

The shape is subject to machine models.

1.
2.

Center of crankshaft
Center of cylinder liner

140E-5 Series

57

SEN00079-07

01 Specification

SAA6D140E-5 (Left side view of engine)


Machine model: SDG400S-6B1 (HOKUETSU INDUSTRIES GENERATOR)

The shape is subject to machine models.

1.
2.

Center of crankshaft
Rear face of flywheel housing

58

140E-5 Series

01 Specification

SEN00079-07

SAA6D140E-5 (Front view of engine)


Machine model: SDG400S-6B1 (HOKUETSU INDUSTRIES GENERATOR)

The shape is subject to machine models.

1.
2.

Center of crankshaft
Center of cylinder liner

140E-5 Series

59

SEN00079-07

01 Specification

Dimensions table

1
Unit: mm

Engine

Machine model

Dimension of each part


C

1,494 1,863

441

227

143

920

1,155 1,151

PC600-8E0, PC600LC-8E0
1,412 1,867
PC700-8E0, PC700LC-8E0

444

227

143

920

1,155 1,061

PC600-8R, PC600LC-8R
PC600-8R1, PC600LC-8R1,
1,482 1,863
PC700-8R, PC700LC-8R
PC700LC-8R1

411

227

143

920

1,155 1,151

PC800-8, PC800LC-8,
PC800SE-8,
PC850-8, PC850SE-8,
PC800-8E0,
PC800LC-8E0,
PC800SE-8E0,
PC850-8E0,
1,350 1,902
PC850SE-8E0,
PC800-8R, PC800LC-8R,
PC800SE-8R,
PC850-8R, PC850SE-8R
SAA6D140E-5 PC800-8R1, PC800LC-8R1,
PC800SE-8R1,
PC850-8R1, PC850SE-8R1

594

196

196

PC600-8, PC600LC-8

1,000 1,185 1,176

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,
HD325-7R, HD405-7R

1,775 1,604

542

80

80

875

HM350-2, HM350-2R,
HM400-2, HM400-2R

1,724 1,496

542

147

147

815

945

1,250

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 INDUSTRIES GENERATOR)

1,785 1,523

403

213

213

877

956

1,242

1,005 1,025

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

(With EGR)
No.

Unit: kg
Item

Main parts

SAA6D140E-5

Turbocharger

KOMATSU KTR110L

24 (Air-cooled) /
28 (Water-cooled)

Cylinder head assembly

Cylinder head, valve,


valve spring

23 6

Cylinder block assembly

Cylinder block, bearing, cap,


cylinder liner

Front cover

60

Oil pan

Flywheel assembly

480

Flywheel ring gear

PC800-8, PC800SE-8, PC800LC-8


PC850-8, PC850SE-8
PC800-8E0, PC800SE-8E0,
PC800LC-8E0
PC850-8E0, PC850SE-8E0

36

PC600-8, PC600LC-8
PC600-8E0, PC600LC-8E0
PC700-8E0, PC700LC-8E0
D155AX-6
WA500-6

30

D275AX-5E0
HD325-7, HD405-7
HM350-2, HM400-2
HM400-3M0

28

SDG400S-6B1 (HOKUETSU
INDUSTRIES GENERATOR)

62

PC600-8, PC600LC-8
PC800-8, PC800SE-8, PC800LC-8
PC850-8, PC850SE-8
PC800-8E0, PC800SE-8E0,
PC800LC-8E0
PC850-8E0, PC850SE-8E0
D155AX-6
D275AX-5E0
WA500-6

60

HD325-7, HD405-7
HM350-2, HM400-2
HM400-3M0

47

SDG400S-6B1 (HOKUETSU
INDUSTRIES GENERATOR)

123

65
7

Flywheel housing assembly

Crankshaft assembly

Crankshaft, crank gear

136

Camshaft assembly

Camshaft, cam gear, thrust


plate

20

10

Piston and connecting rod


assembly

Piston, piston ring, piston


pin, connecting rod

11

Oil pump

12

Fuel supply pump

13

13

Water pump

18

140E-5 Series

SDG400S-6B1 (HOKUETSU
INDUSTRIES GENERATOR)

63

11 6

61

SEN00079-07

01 Specification

Unit: kg
No.

14

Item

Alternator

Main parts

SAA6D140E-5

24V, 35A

24V, 50A

11

24V, 60A

11

24V, 75A

12.5

24V, 90A

19

24V, 7.5kW

15.5

24V, 11kW

18

15

Starting motor

16

EGR oil pump

17

EGR valve

10

18

Bypass valve

10

19

EGR cooler

10

62

140E-5 Series

01 Specification

SEN00079-07

(EGR-less)
No.

Unit: kg
Item

Main parts

SAA6D140E-5

Turbocharger

KOMATSU KTR110L

24 (Air-cooled) /
28 (Water-cooled)

Cylinder head assembly

Cylinder head, valve,


valve spring

23 6

Cylinder block assembly

Cylinder block, bearing, cap,


cylinder liner

Front cover

60

Oil pan

Flywheel assembly

480

Flywheel ring gear

PC800-8R, PC800SE-8R,
PC800LC-8R
PC850-8R, PC850SE-8R
PC800-8R1, PC800SE-8R1
PC800LC-8R1
PC850-8R1, PC850SE-8R1

36

PC600-8R, PC600LC-8R
PC600-8R1, PC600LC-8R1
PC700-8R, PC700LC-8R
PC700LC-8R1
D155A-6
WA500-6R

30

D275A-5R
HD325-7R, HD405-7R
HM350-2R, HM400-2R
HM400-3R

28

PC600-8R, PC600LC-8R
PC600-8R1, PC600LC-8R1
PC700LC-8R1
PC800-8R, PC800SE-8R,
PC800LC-8R
PC850-8R, PC850SE-8R
PC800-8R1, PC800SE-8R1
PC800LC-8R1
PC850-8R1, PC850SE-8R1
D155A-6
D275A-5R
WA500-6R

60

HD325-7R, HD405-7R
HM350-2R, HM400-2R
HM400-3R

47

Flywheel housing assembly

Crankshaft assembly

Crankshaft, crank gear

136

Camshaft assembly

Camshaft, cam gear,


thrust plate

20

10

Piston and connecting rod


assembly

Piston, piston ring, piston pin,


connecting rod

11

Oil pump

12

Fuel supply pump

13

13

Water pump

18

140E-5 Series

65

11 6

63

SEN00079-07

01 Specification

Unit: kg
No.

14

15

64

Item

Alternator

Starting motor

Main parts

SAA6D140E-5

24V, 35A

24V, 50A

11

24V, 60A

11

24V, 75A

12.5

24V, 90A

19

24V, 11kW

18

140E-5 Series

01 Specification

SEN00079-07

Engine performance curves


Engine

SAA6D140E-5

140E-5 Series

Engine serial No.

1
Machine model

Page

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

66

PC800-8, PC800LC-8,
PC800-8R, PC800LC-8R
PC800SE-8, PC800SE-8R
PC850-8, PC850-8R
PC850SE-8, PC850SE-8R
PC800-8E0, PC800SE-8E0,
PC800LC-8E0,
PC850-8E0, PC850SE-8E0
PC800-8R1, PC800SE-8R1
PC800LC-8R1
PC850-8R1, PC850SE-8R1

67

D155AX-6, D155A-6

68

D275AX-5E0, D275A-5R

69

WA500-6, WA500-6R

70

HD325-7, HD325-7R
HD405-7, HD405-7R

71

HM350-2, HM350-2R

72

HM400-2, HM400-2R
HM400-3M0, HM400-3R

73

65

SEN00079-07

01 Specification

SAA6D140E-5
(Machine model: PC600-8, PC600LC-8, PC600-8R, PC600LC-8R, PC6008E0, 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, PC8008R1, 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

SAA6D140E-5 (Machine model: D155AX-6, D155A-6)


Rated horsepower: 268 kW {359.9 HP}/1,900 min-1 {1,900 rpm} (Gross)
Max. torque: 1,834 Nm {187 kgm}/1,300 min-1 {1,300 rpm} (Gross)

68

140E-5 Series

01 Specification

SEN00079-07

SAA6D140E-5 (Machine model: D275AX-5E0, D275A-5R)


Rated horsepower: 337 kW {451.6 HP}/2,000 min-1 {2,000 rpm} (Gross)
Max. torque: 2,030 Nm {207 kgm}/1,400 min-1 {1,400 rpm} (Gross)

140E-5 Series

69

SEN00079-07

01 Specification

SAA6D140E-5 (Machine model: WA500-6, WA500-6R)


Rated horsepower: 266 kW {356.9 HP}/1,900 min-1 {1,900 rpm} (Gross)
Max. torque: 1,803 Nm {184 kgm}/1,250 min-1 {1,250 rpm} (Gross)

70

140E-5 Series

01 Specification

SEN00079-07

SAA6D140E-5 (Machine model: HD325-7, HD405-7, HD325-7R, HD405-7R)


Rated horsepower: 386 kW {517.7 HP}/2,000 min-1 {2,000 rpm} (Gross)
Max. torque: 2,170 Nm {221.3 kgm}/1,400 min-1 {1,400 rpm} (Gross)

140E-5 Series

71

SEN00079-07

01 Specification

SAA6D140E-5 (Machine model: HM350-2, HM350-2R)


Rated horsepower: 304 kW {407.2 HP}/2,000 min-1 {2,000 rpm} (Gross)
Max. torque: 1,991 Nm {203 kgm}/1,400 min-1 {1,400 rpm} (Gross)

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

KOMATSU 140E-5 Series engine


Form No. SEN00079-07

2012 KOMATSU
All Rights Reserved
Printed in Japan 12-12 (01)

74

SEN00081-08

ENGINE
1SHOP MANUAL

140E-5 Series

10 Structure, function and


maintenance standard

Structure, function and maintenance


standard, Part 1
Air intake and exhaust unit.............................................................................................................................. 3
Air cleaner....................................................................................................................................................... 5
Turbocharger................................................................................................................................................... 8
Aftercooler..................................................................................................................................................... 19
Muffler ........................................................................................................................................................... 20
EGR system.................................................................................................................................................. 25
Cylinder head................................................................................................................................................ 32
Cylinder block ............................................................................................................................................... 36
Cylinder liner ................................................................................................................................................. 39
Main moving parts......................................................................................................................................... 40
Crankshaft..................................................................................................................................................... 42

140E-5 Series

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

140E-5 Series

10 Structure, function and maintenance standard

Air intake and exhaust unit

SEN00081-08

SAA6D140E-5 (Left side view of engine)

The above illustration shows the engine for PC600-8.

A:

Air intake unit (Between air-cooled aftercooler and air intake manifold)

1.
2.
3.

Electrical intake air heater (ribbon heater)


Diffuser
Air intake manifold

140E-5 Series

SEN00081-08

10 Structure, function and maintenance standard

SAA6D140E-5 (Right side view of engine)

The above illustration shows the engine for PC600-8.

A:
B:
C:

To EGR cooler
To turbocharger
From bypass valve

1.
2.
3.

Exhaust manifold (rear)


Exhaust manifold (center)
Exhaust manifold (front)

140E-5 Series

10 Structure, function and maintenance standard

Air cleaner

SEN00081-08

ERB type
[Air cleaner of automatic exhaust gas discharge type (radial seal type)]

The shape is subject to machine models.

A:
B:
C:

Air inlet
To turbocharger (intake air)
To muffler (dust)

1.
2.
3.
4.

Pre-cleaner
Air cleaner casing
Outer element
Inner element

Engine

Machine
model

Type

D155AX-6,
D155A-6,
Komaclone, multi-cyclone
SAA6D140E-5
D275AX-5E0
(ERB type)
D275A-5R

140E-5 Series

Method of discharging
dust from pre-cleaner

Number of elements

Automatic discharge
(Exhaust ejector)

Inner cylinder: 1,
Outer cylinder: 1

SEN00081-08

10 Structure, function and maintenance standard

FRG type
[Air cleaner of cyclone pack type with evacuator valve (radial seal type)]

The shape is subject to machine models.

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

Inlet
Outlet
Guide vane
Primary element
Safety element
Evacuator valve
Dust pan
Guide plate (sleeve)
Body
Element

140E-5 Series

10 Structure, function and maintenance standard

Engine

Machine model

SEN00081-08

Type

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
FRG
PC850SE-8, PC850SE-8R
SAA6D140E-5
(radial seal type)
PC800-8E0, PC800LC-8E0,
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
q
The size of the body is reduced from the conventional type without changing the diameter
of the element.
q
Since the inlet is set in the tangential direction,
air is given sufficient centrifugal force by the
simple spiral guide vane, not by the guide
plate.

140E-5 Series

Evacuator valve

Number of
elements

Automatic
discharge

Inner cylinder: 1,
Outer cylinder: 1

Operation
q
Air containing dust is sucked in vertically
through inlet (1) and the dust is separated by
the centrifugal effect of guide vane (3).
q
More than 99.9% of the dust is removed by primary element (4) and clean air is sucked in the
engine through safety element (5) and outlet
(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 discharged out automatically.

SEN00081-08

Turbocharger

10 Structure, function and maintenance standard

(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)

140E-5 Series

10 Structure, function and maintenance standard

A:
B:
C:
D:
E:
F:

Intake air inlet


Intake air outlet
Exhaust gas inlet
Exhaust gas outlet
Oil inlet
Oil outlet

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.

Blower housing
V-band
Diffuser plate
Center housing
Shroud
Turbine housing
Blower impeller
Seal ring
Bearing metal
Journal bearing
Seal ring
Turbine impeller

SEN00081-08

Specifications
Model: KOMATSU KTR110L (air-cooled)
Overall length: 308 mm
Overall width: 305 mm
Overall height: 287 mm
Weight: 24 kg

140E-5 Series

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, HD3257R, HD405-7R, WA500-6R, HM350-2R, HM400-2R, HM400-3R

10

140E-5 Series

10 Structure, function and maintenance standard

A:
B:
C:
D:
E:
F:

Intake air inlet


Intake air outlet
Exhaust gas inlet
Exhaust gas outlet
Oil inlet
Oil outlet

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.

Blower housing
V-band
Diffuser plate
Center housing
Shroud
Turbine housing
Blower impeller
Seal ring
Bearing metal
Journal bearing
Seal ring
Turbine impeller

SEN00081-08

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

A:
B:
C:
D:
E:
F:
G:

SEN00081-08

Intake air inlet


Intake air outlet
Exhaust gas inlet
Exhaust gas outlet
Oil inlet
Oil outlet
Coolant

1.
2.
3.
4.

Blower housing
V-band
Diffuser plate
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, PC800SE8R1, PC850-8R1, PC850SE-8R1, D155A-6, D275A-5R

14

140E-5 Series

10 Structure, function and maintenance standard

A:
B:
C:
D:
E:
F:
G:

SEN00081-08

Intake air inlet


Intake air outlet
Exhaust gas inlet
Exhaust gas outlet
Oil inlet
Oil outlet
Coolant

1.
2.
3.
4.

Blower housing
V-band
Diffuser plate
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

The above illustration shows the air-cooled turbocharger.

140E-5 Series

10 Structure, function and maintenance standard

SEN00081-08

Unit: mm
No.

Check item

End play (play in axial direction)

Radial play (play in radial direction)

Clearance between blower housing and


impeller

140E-5 Series

Criteria

Remedy

Standard

Repair limit

0.08 to 0.13

0.18

0.43 to 0.68

0.84

Clearance limit (min.): 0.14

Replace thrust
parts
Replace bearing
parts
Replace bearing
parts

17

SEN00081-08

10 Structure, function and maintenance standard

Turbocharger mounting

a
a

The above illustration shows the engine for PC600-8.


The shape is subject to machine models.

A:
B:

Intake air inlet


Intake air (between turbocharger and air-cooled aftercooler)

1.
2.

Muffler
Turbocharger

18

140E-5 Series

10 Structure, function and maintenance standard

Aftercooler

SEN00081-08

Air-cooled type
SAA6D140E-5 (HD325-7, HD325-7R, HD405-7, HD405-7R)

The shape is subject to machine models.

a.

Inlet/Outlet of intake air


(between turbocharger and air intake manifold)

1.
2.
3.
4.

Tank
Side support
Tube
Fin

140E-5 Series

19

SEN00081-08

Muffler

10 Structure, function and maintenance standard

For PC600-8, PC600-8R, PC600LC-8, PC600LC-8R, PC600-8E0, PC600-8R1, PC600LC-8E0, PC600LC8R1, PC700-8E0, PC700-8R,PC700LC-8E0, PC700LC-8R, PC700LC-8R1

A:
B:
C:

20

Exhaust gas inlet (from turbocharger)


Exhaust gas outlet
Water drain

140E-5 Series

10 Structure, function and maintenance standard

SEN00081-08

For PC800-8, PC800SE-8, PC850-8, PC850SE-8, PC800LC-8, WA500-6,


PC800-8R, PC800SE-8R, PC850-8R, PC850SE-8R, PC800LC-8R, WA500-6R

A:
B:
C:

Exhaust gas inlet (from turbocharger)


Exhaust gas outlet
Water drain

140E-5 Series

21

SEN00081-08

10 Structure, function and maintenance standard

For PC800-8E0, PC800SE-8E0, PC800LC-8E0, PC850-8E0, PC850SE-8E0


PC800-8R1, PC800SE-8R1, PC800LC-8R1, PC850-8R1, PC850SE-8R1

A:
B:
C:

22

Exhaust gas inlet (from turbocharger)


Exhaust gas outlet
Water drain

140E-5 Series

10 Structure, function and maintenance standard

SEN00081-08

For D155AX-6, D155A-6

A:
B:
C:
D:

Exhaust gas inlet (from turbocharger)


Exhaust gas outlet
Water drain
From air cleaner (dust)

140E-5 Series

23

SEN00081-08

10 Structure, function and maintenance standard

For D275AX-5E0, D275A-5R

A:
B:
C:
D:

24

Exhaust gas inlet (from turbocharger)


Exhaust gas outlet
Water drain
From air cleaner (dust)

140E-5 Series

10 Structure, function and maintenance standard

EGR system

No.

SEN00081-08

Component part

Function

EGR valve
1 (driven hydraulically)

Controls the gas flow from the exhaust system to the air intake system.
Since the exhaust pressure (PEX) is higher than the boost pressure (PIN), the
exhaust gas flows to the air intake valve.

2 Bypass valve

Opens the bypass valve when the boost pressure (PIN) is higher than the
exhaust pressure (PEX).
Makes the intake air flow to the exhaust side to increase the exhaust pressure
so that the exhaust gas will be returned to the air intake side easily.

3 EGR cooler

Lowers the exhaust temperature and returns the exhaust gas to the air intake side.

4 Venturi system

Generates negative pressure with the venturi effect and takes in the exhaust gas.

5 Each sensor

Controls the EGR according to the operating condition.


Troubleshoots the system.

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 troubleshooted, a serious trouble is prevented.

140E-5 Series

25

SEN00081-08

26

10 Structure, function and maintenance standard

The above illustration shows the engine for D155AX-6.

140E-5 Series

10 Structure, function and maintenance standard

1.
2.
3.
4.
5.
6.
7.
8.
9.

SEN00081-08

EGR valve
Bypass valve
EGR cooler
Venturi system
EGR valve position sensor
Bypass valve position sensor
Bypass piping
EGR piping
EGR oil pump

Operation
q
The engine controller outputs signals for opening 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 manifold 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 pressure 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

EGR valve and bypass valve

A:
B:
C:
D:

Oil inlet
Oil outlet
EGR gas passage (EGR valve)
Boost air passage (bypass valve)

Function
q
The EGR valve controls the EGR gas.
q
This valve is driven hydraulically and its opening ratio is controlled electronically.
Operation
q
The oil pressure (engine oil) of 1.47 MPa {15
kg/cm2} supplied to oil inlet (A) is reduced by
oil pressure control valve (2).
q
Hydraulic piston (5) generates pressing force
from the reduced oil pressure.
q
The control oil pressure can be changed with
the drive current of solenoid (3).

28

1.
2.
3.
4.
5.
6.
7.

Stick prevention device


Oil pressure control valve
Solenoid
Position sensor
Hydraulic piston
Spring
Valve

Valve (7) is closed by spring (6) but pushed


open by hydraulic piston (5) to an opening ratio
in proportion to the control oil pressure.
The valve opening ratio is sensed with position
sensor (4) installed to hydraulic piston (5) and
set to the specified opening ratio by controlling
the solenoid current.
The bypass valve assists the EGR gas by
increasing the exhaust pressure.
The structure and operation of the EGR
bypass valve are the same as those of the
EGR valve.

q
q

140E-5 Series

10 Structure, function and maintenance standard

SEN00081-08

EGR cooler

A:
B:
C:

EGR gas inlet


EGR gas outlet
Coolant inlet

1.

Heat exchange tube (corrugated tube)

D:
E:

Coolant outlet
Air bleeder

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 efficiency.
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 corrosionresistant stainless steel and corrugated to
increase the cooling efficiency.

140E-5 Series

29

SEN00081-08

10 Structure, function and maintenance standard

Venturi system

A:
B:

Air inlet
EGR gas inlet

1.
2.
3.

Venturi nozzle
Throat
Diffuser

Structure
q
The EGR gas and intake air mix together in the
venturi system.
q
The venturi system consists of throat (2), venturi nozzle (1), and diffuser (3).
Operation
q
The boost pressure increased by the turbocharger 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

140E-5 Series

SEN00081-08

31

SEN00081-08

Cylinder head

32

10 Structure, function and maintenance standard

The shape is subject to machine models.

140E-5 Series

10 Structure, function and maintenance standard

A:
B:
C:
D:

Intake air
Exhaust gas
To fuel tank
To radiator

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

Rocker cover bolt


Cylinder head bolt
Air bleeding pipe from coolant
Fuel spill pipe
Rocker cover
Cylinder head
Injector connector
Injector assembly
Injector holder mounting bolt
Injector holder retainer

SEN00081-08

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
O-ring seal

Injector
q
Installation: Dry type (without sleeve)

140E-5 Series

33

SEN00081-08

10 Structure, function and maintenance standard

Tighten the cylinder head mounting bolts in the order of (1) to (7).

Unit: mm

No.

Check item

Strain of cylinder head mounting face

Projection of nozzle

Tightening torque for cylinder


head mounting bolt (Apply
molybdenum disulfide or
engine oil to threaded part)

Criteria

Remedy

Tolerance

Repair limit

0 to 0.06

0.09

Engine

Standard

SAA6D140E-5

2.3 to 2.9

Bolt No.

(1) to (6)

Target(Nm{kgm})

1st stage

137 to 157{14 to 16} Tighten in order


shown above. If
289{29.5}
284 to 294{29 to 30}
there are 5 punch
Retighten 90 deg.
90(+30/0) deg.
marks, replace bolt.

2nd stage
3rd stage

Range(Nm{kgm})

147{15}

68.6{7}

58.8 to 73.5{6 to 7.5}

Target(Nm{kgm})

Range(Nm{kgm})

Tightening torque for injector


holder mounting bolt

66.7{6.8}

58.8 to 73.5{6 to 7.5}

Tightening torque for fuel injection pipe

37.3{3.8}

34.3 to 40.2{3.5 to 4.1}

Tightening torque for head


cover mounting bolt

32.4{3.3}

29.4 to 34.3{3.0 to 3.5}

34

Replace nozzle or
gasket

Procedure

(7)

Correct by grinding
or replace

Retighten

Do not use a cylinder head mounting bolt more than 5 times.


Each time the bolt is used, make a punch mark on its head.

140E-5 Series

10 Structure, function and maintenance standard

140E-5 Series

SEN00081-08

35

SEN00081-08

Cylinder block

36

10 Structure, function and maintenance standard

140E-5 Series

10 Structure, function and maintenance standard

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.

SEN00081-08

Front cover
Cylinder block
Cylinder liner
Clevis seal
Liner O-ring (water)
Liner O-ring (oil)
Thrust bearing metal
Main bearing metal
Main bearing metal cap
Main bearing metal cap bolt
Front oil seal
Piston cooling nozzle (front side)
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
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
Upper: Clevis seal
q
Middle: O-ring (ethylene-propylene rubber)
q
Lower: O-ring (silicone rubber)
q

140E-5 Series

37

SEN00081-08

10 Structure, function and maintenance standard

Unit: mm

No.
1

Check item

Remedy

Tolerance

Repair limit

0 to 0.09

0.135

Standard dimension

Tolerance

127

+0.018
0.006

3.5

0.010
0.010

Strain of cylinder head mounting face


Diameter of main bearing metal
mounting hole

Criteria

Thickness of main bearing


metal
Roundness of mounting hole

Repair limit: 0.005


Standard dimension

Tolerance

Repair limit

120

+0.038
0.006

120.15

Diameter of cam bushing


mounting hole

69

+0.030
+0.030

Inside diameter of cam bushing

65

+0.040
+0.040

65.15

Level difference between


underside faces of cylinder
block and front cover

Tightening torque for main cap


mounting bolt (Apply engine oil
to threads)

Inside diameter of main bearing


metal

8
a

38

Tightening torque for crank pulley mounting bolt

Repair limit: 0.14

Correct by grinding
or replace
Replace main bearing metal cap

Replace bearing
metal

Replace bearing
metal
Correct or replace
block
Replace cam bushing
Reassemble

Procedure

Target(Nm{kgm})

Range(Nm{kgm})

1st stage

118{12}

108 to 127{11 to 13}

2nd stage

235{24}

230 to 240{23.5 to 24.5}

3rd stage

Retighten 90 deg.

90(+30/0) deg.

275{28}

245 to 309{25 to 31.5}

Retighten

Do not use a main cap mounting bolt more than 5 times.


Each time the bolt is used, make a punch mark on its head.
140E-5 Series

10 Structure, function and maintenance standard

Cylinder liner

SEN00081-08

Unit: mm

No.
1

Check item

Criteria

Projection of cylinder liner

Standard dimension

Tolerance

Repair limit

140

+0.020
+0.020

140.12

140

+0.040
+0.021

140.14

Roundness of inside of cylinder


liner

Repair limit: 0.02

Cylindricality of inside of cylinder


liner

Repair limit: 0.02

Outside diameter of cylinder liner

4
Interference of cylinder liner and
block

Outside diameter of cylinder liner


(at O-ring)
Clearance between cylinder liner
and block (at O-ring)

140E-5 Series

Replace cylinder liner

Standard dimension

Tolerance

170.2

0.10
0.10

Clearance between cylinder liner


and block
Outside diameter of cylinder liner

Replace cylinder liner or


cylinder block

Permissible range: 0.07 to 0.15


Rank

Inside diameter of cylinder liner

Remedy

Standard clearance: 0 to 0.163


Standard dimension

Tolerance

161.2

+0.090
+0.050

Standard interference

Interference limit

0.02 to 0.12

Min. 0.02

Standard size

Tolerance

158

0.073
0.103

Standard clearance: 0.024 to 0.089

Replace cylinder liner or


block
Replace cylinder liner

Replace or correct cylinder liner or block

Replace cylinder liner


Replace cylinder liner or
block

39

SEN00081-08

Main moving parts

The shape is subject to machine models.

1.
2.
3.
4.
5.
6.
7.
8.

Piston (FCD piston)


Piston pin
Connecting rod bushing
Top ring
Second ring
Oil ring
Connecting rod
Connecting rod cap

40

10 Structure, function and maintenance standard

9.
10.
11.
12.
13.
14.
15.
16.

Connecting rod cap bolt


Connecting rod bearing metal
Crank gear (number of teeth: 36)
Key (crank gear)
Crankshaft
Vibration damper
Pin (flange)
Flange

140E-5 Series

10 Structure, function and maintenance standard

Specifications
Crankshaft:

Piston:

SEN00081-08

Closed die forging


Journal, fillet
Induction hardening
Special thin ductile cast iron
(FCD piston)
Re-entrant piston

Connecting rod: Closed die forging


Cap bolt is screw type, installed
by plastic-region tightening, with
lubricating oil hole.
Piston rings

Top ring (1):

Double-side keystone, inner cut,


barrel face, hard chromium-plated

Second ring (2): Double-side keystone, inner cut,


taper face, hard chromium-plated
Oil ring (3):

140E-5 Series

M-shaped
steel,
with
expander, nitrided surface

coil

41

SEN00081-08

10 Structure, function and maintenance standard

Crankshaft

Unit: mm

No.
1

Check item

Criteria

End play

Standard value

Repair limit

0.140 to 0.315

0.50

Standard dimension

Outside diameter of main journal

0.25 US

119.75

0.50 US

119.50

0.75 US

119.25

119.13

1.00 US

119.00

118.88

Clearance of crank pin journal

42

Bend of crankshaft

119.88
119.63
0.050
0.068

119.38

Standard

Repair limit

0 to 0.009

0.020

Standard clearance

Allowable clearance

0.044 to 0.106

0.27
Tolerance

STD

90

89.88

89.75

89.63

0.50 US

89.50

0.75 US

89.25

0.050
0.068

89.38
89.13

89.00
Standard

Use undersize journal or


replace

Replace main bearing


metal

Repair limit

0.25 US

1.00 US
Roundness

Repair limit

120

Standard dimension

Outside diameter of crank pin


journal

Tolerance

Replace thrust bearing


metal or use oversize
metal

STD

Roundness

Clearance of main journal

Remedy

Use undersize journal or


replace

88.88
Repair limit

0 to 0.009

0.020

Standard clearance

Allowable clearance

0.042 to 0.110

0.24

Standard clearance

Repair limit

Coaxiallity of all main journals:


Max. 0.150

0.20

Coaxiallity of adjacent journals:


Max. 0.050

0.10

Replace connecting rod


bearing metal

Use undersize crankshaft


or replace

US: Undersize

140E-5 Series

10 Structure, function and maintenance standard

Camshaft

SEN00081-08

Unit: mm

No.
1

Check item

Criteria
Standard

Repair limit

0.1 to 0.25

0.36

Standard dimension

Tolerance

65

0.016
0.036

Standard clearance

Allowable clearance

0.016 to 0.096

0.15

End play

Outside diameter of camshaft


journal

2
Clearance of camshaft journal

3
4

Bend of camshaft

Height of cam

140E-5 Series

Remedy
Replace thrust plate

Replace camshaft

Replace cam bushing

Repair limit: 0.03 (Overall swing of indicator)


Cam

Standard dimension

Tolerance

Repair limit

Intake

55.48

0.1

55.08

Exhaust

55.75

0.1

55.35

Replace camshaft

43

SEN00081-08

10 Structure, function and maintenance standard

Cam follower and push rod

Unit: mm

No.

Check item

Repair limit

22

0.021
0.034

21.92

Diameter of cam follower shaft


hole

22

+0.021
+0.021

22.07

Outside diameter of cam roller

31.7

+0.05
+0.02

31.50

Inside diameter of cam roller

12.7

+0.038
+0.013

12.78

12.63

0.006

Remedy

Tolerance

Diameter of cam follower shaft

Criteria
Standard dimension

Diameter of cam roller pin

12.56

Standard dimension

Tolerance

12.7

0.20
0.20
0.20
0.20

Diameter of push rod ball end

Diameter of push rod socket


end

13.4

Bend of push rod

Repair limit: 0.3 (Overall swing of indicator)

44

Replace

140E-5 Series

10 Structure, function and maintenance standard

140E-5 Series

SEN00081-08

45

SEN00081-08

Piston, piston ring and piston pin

46

10 Structure, function and maintenance standard

140E-5 Series

10 Structure, function and maintenance standard

SEN00081-08

Unit: mm

No.

Check item

Criteria
Rank Standard dimension

Outside diameter of piston

Thickness of piston ring

Width of piston ring groove

2 to 4
Clearance between piston ring
and piston ring groove

Closed gap of piston ring

Outside diameter of piston pin

Diameter of piston pin hole


Clearance between piston pin
and piston

a
a

Remedy

Tolerance

Repair limit

140

0.120
0.135

139.830

140

0.105
0.120

139.845

No.

Measuring point

Standard dimension

Tolerance

No. 1 ring

2.9

0.015
0.035

No. 2 ring

2.41

0.010
0.035

Oil ring

0.010
0.030

No. 1 ring

Judge using groove wear gauge (*1)

No. 2 ring

Judge using groove wear gauge (*2)

Oil ring

No.

Measuring point

No. 1 ring

No. 2 ring

Oil ring

0.035 to 0.060

0.14

No. 1 ring

0.42 to 0.57
(Tension 16.5 to 23.5N
{1.68 to 2.40kg})

2.0

No. 2 ring
(Identification: 2RN
white mark)

1.15 to 1.30
(Tension 16.2 to 24.2N
{1.65 to 2.47kg})

1.8

Oil ring

0.30 to 0.50
(Tension 84.5 to 111.7N
{8.61 to 11.39kg})

1.0

Replace piston

Replace piston ring

Replace piston

+0.040
+0.025

Standard clearance Allowable clearance


Judge using groove wear gauge

Standard dimension

Tolerance

52

0.006
0.006

52

+0.045
+0.035

Standard clearance

Allowable clearance

0.035 to 0.051

0.10

Replace piston or
piston ring

Replace piston ring


or cylinder liner

Replace piston pin

Replace piston
Replace piston or
piston pin

*1: Part No. (groove wear gauge) 795-901-1150


*2: Part No. (groove wear gauge) 795-901-1130

140E-5 Series

47

SEN00081-08

10 Structure, function and maintenance standard

Connecting rod

Unit: mm

No.

Check item
Inside diameter of connecting
rod small end bushing
(Ream after press fitting)

Criteria

Remedy

Standard dimension

Tolerance

Repair limit

52

+0.049
+0.030

52.09

Clearance between connecting rod small end bushing and


piston pin

Standard clearance

Allowable clearance

0.030 to 0.055

0.11

Diameter of connecting rod


small end bushing mounting
hole

Standard dimension

Tolerance

57.4

+0.030
+0.030

Inside diameter of connecting


rod large end bearing metal

48

Replace bushing
(Spare is half
worked)
Replace bushing or
piston pin
Replace connecting
rod

Standard dimension

Tolerance

Repair limit

90

+0.042
0.008

90.15

Diameter of connecting rod


large end bearing metal
mounting hole
(Before measuring, tighten
connecting rod cap mounting
bolt to specified torque)

95

+0.026
0.004

Replace connecting
rod

Thickness of connecting rod


bearing metal

2.5

+0.002
0.008

Replace bearing
metal

Parallelism and twist of connecting rod

Tightening torque for connecting rod cap mounting bolt


(Apply engine oil to bolt
threads and nut seat)
Weight of connecting rod

Item

Standard

Repair limit

Parallelism a

0.20

0.25

Twist b

0.30

0.35

Dimension c

264

Procedure

Target(Nm{kgm})

Range(Nm{kgm})

1st stage

127.5{13}

117.7 to 132.4
{12.5 to 13.5}

2nd stage

Retighten 90 deg.

90(+30/0) deg.

Replace bearing
metal

Replace connecting
rod

Retighten

Permissible range: Dispersion of weight of connecting rods in one engine


Replace
must not exceed 154 g.

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.

140E-5 Series

10 Structure, function and maintenance standard

Flywheel and flywheel housing

The shape is subject to machine models.

1.
2.
3.
4.
5.
6.

Rear seal
Ring gear
Flywheel
Engine speed sensor (for monitor)
Flywheel housing
Engine speed sensor
(NE sensor for engine control)

140E-5 Series

SEN00081-08

49

SEN00081-08

Tighten the flywheel mounting bolts with an


impact wrench in the 1st stage and then
tighten them with a torque wrench in the 2nd
stage.

A:
B:

Tightening order of flywheel mounting bolts


Tightening order of flywheel housing mounting
bolts

50

10 Structure, function and maintenance standard

140E-5 Series

10 Structure, function and maintenance standard

SEN00081-08

Unit: mm

No.

Check item

Criteria

Facial runout of flywheel housing

Repair limit: 0.20

Radial runout of flywheel housing

Repair limit: 0.20

Facial runout of flywheel

Repair limit: 0.20

Radial runout of flywheel

Repair limit: 0.13


Target(Nm{kgm})

Range(Nm{kgm})

Tightening torque for flywheel


Procedure
housing mounting bolt
1st stage
(Apply engine oil to bolt threads
2nd stage
and seat surface)

191{19.5}

147 to 235{15 to 24}

275{28.0}

245 to 309{25 to 31.5}

Tightening torque for flywheel


Procedure
mounting bolt
1st stage
(Apply engine oil to bolt threads
2nd stage
and seat surface)

Target(Nm{kgm})

Range(Nm{kgm})

118{12}

113 to 123{11.5 to 12.5}

Retighten 90 deg.

90(+30/0) deg.

Remedy

Reassemble

Tighten in order
shown in above figure
Tighten and
retighten in order
shown in above figure

Do not use a flywheel mounting bolt more than


5 times.
Each time the bolt is used, make a punch mark
on its head.

140E-5 Series

51

SEN00081-08

Vibration damper

The shape is subject to machine models.

1.
2.
3.
4.
5.
6.

Adapter
Pin (between adapter and crankshaft pulley)
Vibration damper
Bolt (between adapter and vibration damper)
Bolt (between crankshaft and adapter)
Pin (between adapter and vibration damper)

52

10 Structure, function and maintenance standard

140E-5 Series

10 Structure, function and maintenance standard

140E-5 Series

SEN00081-08

53

SEN00081-08

Timing gear

10 Structure, function and maintenance standard

(With EGR)

54

The shape is subject to machine models.

140E-5 Series

10 Structure, function and maintenance standard

A:
B:
C:

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

SEN00081-08

Timing mark
[Between crank gear and main idler gear (large)]
Timing mark
[Between main idler gear (small) and fuel supply pump drive gear]
Timing mark
[Between main idler gear (small) and cam gear]
Water pump drive gear (Number of teeth: 23)
Sub idler gear (Number of teeth: 42)
Main idler gear (large) (Number of teeth: 60)
Main idler gear (small) (Number of teeth: 40)
Cam gear (Number of teeth: 48)
Air compressor pulley drive gear (Number of teeth: 14)
Fuel supply pump drive gear (Number of teeth: 48)
EGR oil pump drive gear (Number of teeth: 22)
Crank gear (Number of teeth: 36)
Oil pump drive gear (Number of teeth: 20)
Unit: mm

No.
11

Check item

Clearance between main idler


gear bushing and shaft

12

Clearance between sub idler


gear bushing and shaft

13

End play of main idler gear

14

End play of sub idler gear

Criteria
Standard
dimension

Position

Backlash of each gear

140E-5 Series

Tolerance

Remedy
Standard
clearance

Allowable
clearance

+0.034
+0.009

0.025 to 0.063

0.20

+0.055
+0.055

0.016 to 0.084

0.20

Shaft

Hole

56

0.016
0.029

56

0.016
0.029
Standard

Repair limit

0.06 to 0.24

0.4

0.11 to 0.23

0.4

Measuring point

Standard

15

Crank gear and main idler gear (large) 0.028 to 0.312

16

Main idler gear (small) and fuel supply


0.016 to 0.278
pump gear

17

Main idler gear (small) and cam gear

0.016 to 0.278

18

Main idler gear (large) and sub idler


gear

0.028 to 0.313

19

Sub idler gear and oil pump drive gear 0.080 to 0.417

20

Sub idler gear and water pump drive


gear

0.095 to 0.346

21

Cam gear and air conditioner drive


gear

0.118 to 0.369

22

Fuel supply pump gear and EGR oil


pump drive gear

0.118 to 0.369

Replace bushing

Replace thrust
bearing

Repair limit

Replace
0.6

55

SEN00081-08

10 Structure, function and maintenance standard

(EGR-less)

56

The shape is subject to machine models.

140E-5 Series

10 Structure, function and maintenance standard

A:
B:
C:

1.
2.
3.
4.
5.
6.
7.
8.
9.

SEN00081-08

Timing mark
[Between crank gear and main idler gear (large)]
Timing mark
[Between main idler gear (small) and fuel supply pump drive gear]
Timing mark
[Between main idler gear (small) and cam gear]
Water pump drive gear (Number of teeth: 23)
Sub idler gear (Number of teeth: 42)
Main idler gear (large) (Number of teeth: 60)
Main idler gear (small) (Number of teeth: 40)
Cam gear (Number of teeth: 48)
Air compressor pulley drive gear (Number of teeth: 14)
Fuel supply pump drive gear (Number of teeth: 48)
Crank gear (Number of teeth: 36)
Oil pump drive gear (Number of teeth: 20)
Unit: mm

No.
10

Check item

Clearance between main idler


gear bushing and shaft

11

Clearance between sub idler


gear bushing and shaft

12

End play of main idler gear

13

End play of sub idler gear

Criteria
Standard
dimension

Position

Backlash of each gear

140E-5 Series

Tolerance

Remedy
Standard
clearance

Allowable
clearance

+0.034
+0.009

0.025 to 0.063

0.20

+0.055
+0.055

0.016 to 0.084

0.20

Shaft

Hole

56

0.016
0.029

56

0.016
0.029
Standard

Repair limit

0.06 to 0.24

0.4

0.11 to 0.23

0.4

Measuring point

Standard

14

Crank gear and main idler gear (large) 0.141 to 0.425

15

Main idler gear (small) and fuel supply


0.129 to 0.391
pump gear

16

Main idler gear (small) and cam gear

0.129 to 0.391

17

Main idler gear (large) and sub idler


gear

0.141 to 0.425

18

Sub idler gear and oil pump drive gear 0.080 to 0.417

19

Sub idler gear and water pump drive


gear

0.095 to 0.346

20

Cam gear and air conditioner drive


gear

0.118 to 0.369

Replace bushing

Replace thrust
bearing

Repair limit

Replace
0.6

57

SEN00081-08

Valve system

58

10 Structure, function and maintenance standard

140E-5 Series

10 Structure, function and maintenance standard

A:

Lubricating oil inlet

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.

Cam gear (Number of teeth: 48)


Thrust plate
Camshaft
Cam roller
Cam roller pin
Cam follower shaft
Cam follower
Push rod
Rocker arm shaft
Locknut
Rocker arm adjustment screw
Rocker arm
Crosshead adjustment screw
Locknut
Crosshead
Valve retainer
Outer valve spring
Inner valve spring
Air intake valve
Valve guide
Spring seat
Exhaust valve

SEN00081-08

Valve timing

Specifications
Camshaft: Drawn steel bar (turning)
Journal and cam sections:
Induction hardening

140E-5 Series

59

SEN00081-08

Valve and valve guide

60

10 Structure, function and maintenance standard

140E-5 Series

10 Structure, function and maintenance standard

SEN00081-08

Unit: mm

No.
1

Check item

Sinking distance of valve

Criteria
Valve

Standard dimension

Tolerance

Repair limit

Intake

0.10

0.70

Exhaust

0.10

Valve

Remedy

Thickness of valve lip

0.70

Standard dimension

Repair limit

Intake

2.4

1.9

Exhaust

2.15

1.75

Valve

Standard dimension

Tolerance

Intake

30 deg.

15 min.

Exhaust

45 deg.

15 min.

Intake

10

0.045
0.060

Exhaust

10

0.074
0.089

Before head is press


fitted

10

+0.019
+0.001

Standard dimension

Tolerance

Valve seat angle

Diameter of valve stem

After head is press fitted

Clearance between valve guide


and stem
Bend of valve stem

+0.008
0.009
(Press fitted part)

Inside diameter of valve guide


10

+0.011
0.009
(Other than press
fitted part)

Valve

Standard clearance

Allowable clearance

Intake

0.036 to 0.068

0.22

Exhaust

0.065 to 0.097

0.24

Repair limit: 0.02 (Overall swing of indicator in 100)

Driving height of valve guide

Standard

Tolerance

22.0

0.2

Spring

Standard dimension

Repair limit

Outer

81.7

Inner

72.0

Spring Installed length

Standard installed
load(N{kg})

Allowable installed
load(N{kg})
377.3
{38.5}
192.1
{19.6}

Free length of valve spring

6
Installed load of valve spring

Perpendicularity of valve spring

140E-5 Series

Outer

51.0

424.321.6
{43.32.2}

Inner

46.0

215.610.8
{22.01.1}

Replace valve or valve


seat

Replace valve

Correct or replace valve


or valve seat

Replace valve

Replace valve guide

Replace valve or valve


guide
Replace valve
Correct

Replace valve spring

Repair limit: 2 deg. (both sides)

61

SEN00081-08

10 Structure, function and maintenance standard

Rocker arm and shaft

Unit: mm

No.

Check item
Diameter of rocker arm shaft

62

Valve clearance (when cold)

Tightening torque for locknut of


rocker arm adjustment screw

Remedy
Tolerance

32.0

0.0065

32.0

+0.087
+0.035

Standard clearance

Allowable clearance

0.0285 to 0.0935

0.13

Inside diameter of rocker arm


bushing
Clearance between rocker arm
shaft and rocker arm

Criteria
Standard dimension

Valve

Standard

Tolerance

Intake

0.35

0.02

Exhaust

0.57

0.02

Target(Nm{kgm})

Range(Nm{kgm})

58.8{6}

52.9 to 64.7{5.4 to 6.6}

Replace rocker arm shaft


Replace rocker arm
Replace rocker arm shaft
or rocker arm

Adjust

Tighten

140E-5 Series

10 Structure, function and maintenance standard

Crosshead and guide

SEN00081-08

Unit: mm

No.
1

Check item
Depth of crosshead stem
receiver
Inside diameter of crosshead

Criteria

Remedy

Standard dimension

Tolerance

Repair limit

6.2

+0.3
+0.3

6.61

11.04

0.02

11.17

Outside diameter of crosshead


guide

11

+0.011
+0.011

10.95

Projection of crosshead guide

49.0

0.25

140E-5 Series

Replace

Correct

63

SEN00081-08

KOMATSU 140E-5 Series engine


Form No. SEN00081-08

2012 KOMATSU
All Rights Reserved
Printed in Japan 12-12 (01)

64

SEN00082-06

ENGINE
1SHOP MANUAL

140E-5 Series

10 Structure, function and


maintenance standard

Structure, function and maintenance


standard, Part 2
Lubrication system .......................................................................................................................................... 4
Lubrication system diagram ................................................................................................................. 4
Oil pump............................................................................................................................................... 8
EGR oil pump....................................................................................................................................... 9
Oil filter ............................................................................................................................................... 10
Oil cooler ............................................................................................................................................ 12
Fuel system................................................................................................................................................... 14
CRI system diagram........................................................................................................................... 14
Outline of CRI system ........................................................................................................................ 16
Fuel piping.......................................................................................................................................... 38
Fuel cooler ......................................................................................................................................... 42

140E-5 Series

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

140E-5 Series

10 Structure, function and maintenance standard

140E-5 Series

SEN00082-06

SEN00082-06

10 Structure, function and maintenance standard

Lubrication system

Lubrication system diagram

(With EGR)

The layout of the oil filter, shapes of the oil pan and piping, etc. are subject to machine models.
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

SEN00082-06

10 Structure, function and maintenance standard

(EGR-less)

The layout of the oil filter, shapes of the oil pan and piping, etc. are subject to machine models.

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

SEN00082-06

10 Structure, function and maintenance standard

Oil pump

A: From oil pan


B: To oil cooler
C: Rotation direction
D: Pump mounting face

Specifications
Oil pump
Type: Gear pump
Revolving speed: Engine speed 1.8

1. Pump cover
2. Drive gear
3. Pump body
4. Pump drive gear (Number of teeth: 20)
5. Driven gear
6. Main relief valve
7. Main valve spring
8. Sub relief valve
9. Sub valve spring

Main relief valve


Cracking pressure:

600 50 kPa {6.0 0.5 kg/cm2}


Sub relief valve
Cracking pressure:
1,000 50 kPa {10.0 0.5 kg/cm2}

140E-5 Series

10 Structure, function and maintenance standard

SEN00082-06

EGR oil pump

A: From main gallery


B: To EGR valve and bypass valve
C: Rotation direction
1. Pump cover
2. Drive gear
3. Pump body
4. Driven gear
5. Pump drive gear (Number of teeth: 22)
6. Main relief valve
7. Main valve spring
8. Sub-relief valve
9. Sub-valve spring

140E-5 Series

Specifications
Oil pump
Type: Gear pump
Revolving speed: Engine speed 1.09
Main relief valve
Cracking pressure:
1,430 100 kPa {14.6 1.0 kg/cm2}
Sub-relief valve
Cracking pressure:
1,800 150 kPa {18.4 1.5 kg/cm2}

SEN00082-06

10 Structure, function and maintenance standard

Oil filter

Except SDG400S-6B1 (HOKUETSU INDUSTRIES GENERATOR)

The shape is subject to machine models.

A: Oil inlet
B: Oil outlet
1. Safety valve
2. Filter head
3. Cartridge

10

Specifications
Oil filter
Filtration area: 0.44 m2 (full flow)
Safety valve
Cracking pressure: 343 19.6 kPa {3.5 0.2 kg/cm2}

140E-5 Series

10 Structure, function and maintenance standard

SEN00082-06

For SDG400S-6B1 (HOKUETSU INDUSTRIES GENERATOR)

The shape is subject to machine models.

A: Oil inlet
B: Oil outlet
1. Safety valve
2. Filter head
3. Cartridge
4. Clogging switch

Specifications
Oil filter
Filtration area: 0.44 m2 (full flow)
Safety valve
Cracking pressure: 343 19.6 kPa {3.5 0.2 kg/cm2}
Clogging switch
q
Operating differential pressure:
+0.4
2
147 +39
+0 kPa {1.5 +0 kg/cm }
q
Contact type: NO (Normal Open)

140E-5 Series

11

SEN00082-06

10 Structure, function and maintenance standard

Oil cooler

12

The shape is subject to machine models.

140E-5 Series

10 Structure, function and maintenance standard

SEN00082-06

A: Oil inlet
B: Oil outlet
C: Coolant inlet
1. Oil cooler cover
2. Cooler element SAA6D140E-5: 15 layers
3. Thermo-valve
4. Thermo-valve spring
5. Thermo-valve cover
Specifications
Oil cooler thermo-valve
Opening temperature: 85 1.5C
Full opening temperature: 100C
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 100C for 4 to 5 minutes)

Opening/Closing of thermostat

140E-5 Series

Check that valve closes fully when its temperature is lowered from 100C Replace
for full opening to 85C. (Before checking valve, leave it in oil for 4 to 5
minutes)

13

SEN00082-06

10 Structure, function and maintenance standard

Fuel system

CRI system diagram

(With EGR)

CRI is an abbreviation for common rail injection.

1. NE speed sensor
2. Engine controller
3. Injector
4. Fuel cooler
5. Fuel tank
6. Pre-fuel filter
7. Main fuel filter
8. Overflow valve
9. Fuel supply pump
9A. PCV
9B. High-pressure pump

14

9C. Priming pump (sub)


9D. Feed pump
9E. Relief valve
9F. Bkup speed sensor (G sensor)
10. Common rail
11. High-pressure injection pipe
12. Flow damper
13. Pressure limiter
14. Priming pump (main)
15. Engine controller cooler

140E-5 Series

10 Structure, function and maintenance standard

SEN00082-06

(EGR-less)

CRI is an abbreviation for common rail injection.

1. NE speed sensor
2. Engine controller
3. Injector
4. Fuel cooler
5. Fuel tank
6. Pre-fuel filter
7. Main fuel filter (double cartridges)
a Single cartridge is set for some models.
8. Overflow valve
9. Fuel supply pump
9A. PCV
9B. High-pressure pump
140E-5 Series

9C. Priming pump


9D. Feed pump
9E. Relief valve
9F. Bkup speed sensor (G sensor)
10. Common rail
11. High-pressure injection pipe
12. Flow damper
13. Pressure limiter
14. Electric priming pump
a Manual priming pump is set for some models.
15. Engine controller cooler

15

SEN00082-06

10 Structure, function and maintenance standard

Outline of CRI system


Outline
q
The CRI system checks the condition of the
engine (engine speed, accelerator angle, coolant temperature, etc.) with sensors.
q
The microcomputer of the CRI system controls
the fuel injection rate, fuel injection timing, fuel
injection pressure, etc. totally to operate the
engine under the best condition.
q
The CRI system has a diagnosis function and
an alarm function, with which the computer of
the system checks the main component parts
and notifies the operator of detected failures.
q
In addition, the CRI system has a failsafe function which stops the engine when a certain
parts fail and a backup function which continues the operation by changing the control
method in such a case.
q
The CRI system has the same basic structure
as the current Tier 2 engine.
q
The maximum service pressure is heightened.
(120 MPa {1,200 kg/cm2} 160 MPa {1,600
kg/cm2})

1
1. Fuel system

Configuration
The CRI system is divided by the function into
the fuel system and control system.

16

The fuel system distributes the high-pressure


fuel supplied by the fuel supply pump to the
cylinders through the common rail.
The solenoid valve in the injector opens and
closes the nozzle needle valve to start and finish injection.

140E-5 Series

10 Structure, function and maintenance standard

SEN00082-06

2. Control system

Parts marked with * (2 places) are installed to only the engines with EGR.

The engine controller calculates and controls


the energizing timing and energizing period of
the injector with the signals from the sensors
installed to the machine to inject proper quantity of fuel in proper timing.
The control system is roughly divided by the
electric parts into the sensors, computer, and
actuators.

140E-5 Series

17

SEN00082-06

10 Structure, function and maintenance standard

Structure and operation of CRI system

18

The CRI system consists of the fuel supply


pump, common rail, injector, engine controller
to control them, and sensors.
The fuel supply pump generates fuel pressure
in the common rail. The fuel pressure is controlled by the fuel discharge rate of the supply
pump.
The discharge rate is controlled by turning on
and off the PCV (pressure control valve) of the
fuel supply pump according to the electric signals from the engine controller.
The common rail receives the pressurized fuel
from the fuel supply pump and distributes it to
the cylinders.
The fuel pressure is sensed by the common
rail fuel pressure sensor installed to the common rail.
A feedback control is applied so that the actual
fuel pressure will match to the command pressure set according to the engine speed and the
load on the engine.
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.
The injector controls the fuel injection rate and
fuel injection timing by turning on and off the
TWV (2-way solenoid valve).

If the TWV is turned on (energized), the fuel


circuit is so changed that the high-pressure
fuel in the control chamber will flow through the
orifice. As a result, the needle valve is raised
to start fuel injection by the nozzle cracking
pressure of the high-pressure fuel on the nozzle side.
If the TWV is turned off (de-energized), the fuel
circuit is so changed that the high-pressure
fuel will be applied to the control chamber
through the orifice. As a result, the needle
valve lowers and finishes fuel injection.
Accordingly, the fuel injection timing and fuel
injection rate are controlled respectively by the
timing to turn on the TWV and the length of the
turn-on time of the TWV.

140E-5 Series

10 Structure, function and maintenance standard

SEN00082-06

Structure and operation of component parts

1. Fuel supply pump

1. 3-head cam
2. Overflow valve
3. Drive gear
4. No. 1 high-pressure pump
5. PCV (pressure control valve)

6. No. 2 high-pressure pump


7. Priming pump
8. Feed pump
9. Gear for Bkup speed sensor (G sensor)

Outline
q
The fuel supply pump consists of priming
pump (7), feed pump (8), and high-pressure
pumps (4) and (6).
q
The function of the fuel supply pump is to generate common rail fuel pressure by controlling
the fuel delivery.

Structure
High-pressure pumps (4) and (6) have the
pressure feed systems similar to those of the
conventional in-line fuel injection pump and the
PCVs (pressure control valves) for each cylinder to control the fuel delivery.
q
By employing the 3-head cam, the necessary
number of the cylinders of high-pressure
pumps (4) and (6) is reduced to 1/3 of the
engine cylinders.
q

140E-5 Series

q
q

Since the number of the times of feeding fuel


to the common rail is the same as the number
of the times of fuel injection, the common rail
fuel pressure is smooth and stable.
The fuel fed by high-pressure pumps (4) and
(6) to the common rail is divided as follows.
No. 1 high-pressure pump (on the drive gear
side) (4) compensates for drop in the common
rail fuel pressure caused by fuel injection into
the No. 1, 3, and 5 cylinders.
No. 2 high-pressure pump (on the feed pump
side) (6) compensates for drop in the common
rail fuel pressure caused by fuel injection into
the No. 2, 4, and 6 cylinders.

19

SEN00082-06

10 Structure, function and maintenance standard

Operation

20

(A): During the lowering stroke of the plunger,


the PCV is open and the low-pressure fuel
is sucked in the plunger chamber through
the PCV.
(B): While the PCV is not energized and is
open after the plunger starts the rising
stroke, the sucked fuel is returned through
the PCV without being pressurized.
(C): If the PCV is energized and closed in the
timing for the necessary delivery, the
return passage is closed and the pressure
in the plunger chamber rises. Accordingly,
the fuel is fed through the delivery valve
(check valve) to the common rail. That is,
the quantity of the fuel corresponding to
the plunger lift after the PCV is closed is
the delivery. The delivery is changed and
the common rail fuel pressure is controlled
by changing the opening timing of the
PCV.
(D): After the cam passes the maximum lift
point, the plunger starts the lowering
stroke and the pressure in it lowers. At
this time, the delivery valve closes to stop
feeding the fuel. Since the PCV is deenergized, it opens and the low-pressure
fuel is sucked in the plunger chamber, or
the state of (A) starts again.

140E-5 Series

10 Structure, function and maintenance standard

1) PCV (pressure control valve)


q
The PCV adjusts the fuel delivery from the fuel
supply pump to adjust the common rail fuel
pressure. The delivery from the fuel supply
pump to the common rail is decided by the timing of energizing the PCV.

140E-5 Series

SEN00082-06

2) Feed pump
q
The feed pump built in the fuel supply pump
assembly draws the fuel from the fuel tank and
sends it through the fuel filter to the high-pressure pump chamber.
q
The outer and inner rotors of the feed pump
are rotated by the camshaft.
q
The fuel is sucked in on the suction side and
discharged on the delivery side according to
the increase and decrease of the spaces
between the outer and inner rotors.

21

SEN00082-06

10 Structure, function and maintenance standard

2. Common rail
Structure
q
Common rail (4) distributes the high-pressure
fuel from the high-pressure pump to the injectors of the cylinders.
q
Common rail (4) is equipped with common rail
fuel pressure sensor (2), flow dampers (1), and
pressure limiter (3).
q
The fuel injection pipes are connected to flow
dampers (1) to send the high-pressure fuel to
the injectors.
q
The piping of the pressure limiter (3) is
returned to the fuel tank.

When fuel is stopped


q
If the fuel flows out abnormally because of a
burst of the piping, etc., piston (2) moves to the
right stroke end.
q
The tip of piston (2) contacts seat (b) to stop
the fuel.
q
Once the fuel is stopped, piston (2) does not
return to the initial position until the engine is
stopped.

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.
When fuel is injected
The fuel pressure is applied to piston (2), which
compresses spring (3) and moves to the right.
q
The fuel for static leakage is supplied through
orifice (a) of piston (2) and clearance in the
sliding parts.
q

22

140E-5 Series

10 Structure, function and maintenance standard

2) Pressure limiter
q
If abnormally high pressure is generated, the
pressure limiter opens to release that pressure.
q
If the common rail fuel pressure reaches about
200 MPa {2,040 kg/cm2}, the pressure limiter
operates (opens).
q
If the common rail fuel pressure lowers to 30
MPa {310 kg/cm2}, the pressure limiter resets
itself (closes) to maintain the pressure.
q
Under the normal condition, the pressure limiter does not reset itself (close) until the engine
is stopped.

SEN00082-06

3) Common rail fuel pressure sensor


q
The common rail fuel pressure sensor is
installed to the common rail to sense the fuel
pressure.
q
This sensor is a semiconductor pressure sensor, which utilizes the phenomenon that the
electric resistance of silicon changes according
to pressure applied to it.

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 highpressure fuel from the common rail into each
combustion chamber of the engine in the optimum 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 nozzle and controls the fuel injection rate.
q
The hydraulic piston transmits the force generated 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

1. Inlet connector
2. Terminal
3. Upper body
4. Solenoid
5. Valve body
6. Orifice (out)
q

7. Orifice (in)
8. Pressure control chamber
9. Control piston
10. Spring
11. Pressure pin
12. Nozzle assembly

The injector consists of the nozzle section, orifice to control the fuel injection rate, hydraulic
piston section, and 2-way solenoid valve section.

140E-5 Series

25

SEN00082-06

10 Structure, function and maintenance standard

A: No fuel injection
B: Start of fuel injection

C: Finish of fuel injection


D: From common rail

1. Nozzle
2. Control piston
3. Orifice (in)
4. Orifice (out)

5. Valve body
6. Solenoid
7. Spring
8. Pressure control chamber

Operation
1) No fuel injection (A)
q
While solenoid (6) is not energized, valve body
(5) is pressed down by spring (7).
q
Since the high-pressure fuel is applied from
the common rail to pressure control chamber
(8), nozzle (1) is closed and the fuel is not
injected.

3) Finish of fuel injection (C)


q
If solenoid (6) is de-energized, valve body (5)
is lowered by spring (7) and the fuel passage is
closed.
q
At this time, the high-pressure fuel in the common rail is applied to pressure control chamber
(8) suddenly and nozzle (1) is closed quickly,
fuel injection is finished sharply.

2) Start of fuel injection (B)


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 injection rate is increased to the maximum.
q

26

140E-5 Series

10 Structure, function and maintenance standard

SEN00082-06

Electric circuit diagram

Since high voltage (65 V) is applied to the


wiring harnesses connected to the engine
controller, COMMON 1 and COMMON 2 of
the supply pump, and TWV #1 to #6 of the
injector, take care not get an electric shock.

140E-5 Series

27

SEN00082-06

28

10 Structure, function and maintenance standard

140E-5 Series

10 Structure, function and maintenance standard

SEN00082-06

Various controls

Parts marked with * (3 places) are installed to only the engines with EGR.

The CRI system controls the fuel injection rate


and fuel injection timing more properly than the
mechanical governor or timer of the conventional fuel injection pump.
For the control of the system, calculations necessary to the engine controller are performed
fr om th e si gn als se nt fr om the s en so rs
installed to the engine and machine.
The energizing timing and energizing period of
the injector are so controlled that the optimum
quantity of fuel will be injected in the optimum
timing.

2. Fuel injection timing control function


q

3. Fuel injection pressure control function (Common rail fuel pressure control
function)
q

1. Fuel injection rate control function


q

The fuel injection rate control function is


employed instead of the function of the conventional governor. It controls the fuel injection
according to the signals of engine speed and
accelerator angle so that the fuel injection rate
will be most proper.

140E-5 Series

The fuel injection timing control function is


employed instead of the function of the conventional timer. It controls the fuel injection
timing most properly from the engine speed
and fuel injection rate.

The fuel injection pressure control function


(common rail fuel pressure control function) is
a function of measuring the fuel pressure with
the common rail fuel pressure sensor and
feeding it back to the engine controller to control the delivery of the fuel supply pump.
This function performs pressure feedback control so that the fuel injection pressure will be
the same as the optimum value (command
value) set according to the engine speed and
fuel injection rate.

29

SEN00082-06

10 Structure, function and maintenance standard

4. Various sensors and relays

a
a
a

30

Nos. 1 to 13 in the above illustration correspond to title Nos. 1) to 13).


The above illustration shows the engine for HD325-7.
Parts *1, *3 and *4 are installed to only the engines with EGR.

140E-5 Series

10 Structure, function and maintenance standard

140E-5 Series

SEN00082-06

31

SEN00082-06

1) EGR inlet pressure sensor (with EGR)


q

This sensor is used to sense the EGR pressure.

10 Structure, function and maintenance standard

2) Fuel temperature sensor


q

32

The fuel temperature sensor senses the fuel


temperature and sends it to the engine controller. The sensor unit is a thermistor the resistance of which changes according to the
temperature.
The engine controller applies voltage to the
thermistor and senses the temperature by the
voltage divided by the resistance in the computer and the resistance of the thermistor.

The following graph shows the output characteristics of the EGR inlet pressure sensor.

140E-5 Series

10 Structure, function and maintenance standard

SEN00082-06

3) EGR valve position sensor (with EGR)


4) Bypass valve position sensor (with EGR)
q

These sensors sense the opening and closing positions of the EGR valve and bypass valve.

1. EGR and bypass valve position sensors


q

The following graph shows the output characteristics of the position sensor.

140E-5 Series

33

SEN00082-06

5) Engine controller

10 Structure, function and maintenance standard

7) Atmospheric pressure sensor


This sensor is used to correct altitude.
(with EGR)

6) NE speed sensor (crank angle sensor)


q
q

If the signal hole made on the flywheel passes


the sensor, the magnetic line of force changes.
If the magnetic line of force changes, the output of the Hall element sensor changes linearly
and it is converted into pulse of 0 to 5 V by the
wave form shaping circuit in the sensor, and
then output.

A: Pressure inlet
B: Mounting screw: M5
Tightening torque: 4.1 to 9.5 Nm {0.4 to 1.0 kgm}
q

34

The following graph shows the output characteristics of the atmospheric pressure sensor.

140E-5 Series

10 Structure, function and maintenance standard

SEN00082-06

(EGR-less)

10) Bkup speed sensor (G sensor)


(Cylinder No. sensor)
q

Similarly to the NE speed sensor, this sensor


utilizes the pulses of 0 5 V generated by the
change of the magnetic line of force crossing
the sensor unit.
The disc gear installed to the central part of the
camshaft of the high-pressure pump has teeth
(cut parts) around it at intervals of 120 degree.
In addition to the above teeth, one more tooth
is installed. Accordingly, 7 pulses are generated every 2 revolutions of the engine.
The standard pulse of the No. 1 cylinder is recognized by the combination of the NE speed
sensor pulse and Bkup speed sensor pulse.

A: Pressure inlet
B: Mounting screw: M5
Tightening torque: 4.5 0.5 Nm {0.46 0.05 kgm}
q

The following graph shows the output characteristics of the atmospheric pressure sensor.

8) Common rail pressure sensor


9) Oil pressure sensor

140E-5 Series

35

SEN00082-06

11) Charge pressure sensor

10 Structure, function and maintenance standard

(EGR-less)

This sensor is used to sense the charge pressure (boost pressure).


(with EGR)

1. Sensor
2. O-ring
q

The following graph shows the output characteristics of the charge pressure sensor.

A: Mounting screw: M6
Tightening torque: 5.5 0.5 Nm {0.56 0.05 kgm}
1. Sensor
2. O-ring
q

36

The following graph shows the output characteristics of the charge pressure sensor.

140E-5 Series

10 Structure, function and maintenance standard

12) Charge temperature sensor


q

The charge temperature sensor senses the


intake air temperature (boost temperature) and
sends it to the engine controller.
The sensor unit is a thermistor the resistance
of which changes according to the temperature. The engine controller applies voltage to
the thermistor and senses the temperature by
the voltage divided by the resistance in the
computer and the resistance of the thermistor.

140E-5 Series

SEN00082-06

13) Coolant temperature sensor


q

The coolant temperature sensor senses the


coolant temperature and sends it to the engine
controller.
The sensor unit is a thermistor the resistance
of which changes according to the temperature. The engine controller applies voltage to
the thermistor and senses the temperature by
the voltage divided by the resistance in the
computer and the resistance of the thermistor.

37

SEN00082-06

10 Structure, function and maintenance standard

Fuel piping

(with EGR)

a
a

The above illustration shows the engine for PC600-8.


The shape is subject to machine models.

Specifications
Fuel supply pump
Manufacturer: DENSO CORPORATION
Model: DENSO ECD-U2
Lubrication method:
Forced lubrication with engine oil

38

A: Fuel inlet
B: To engine controller cooler
C: To main fuel filter
D: From main fuel filter
E: To injector
F: Return fuel (between overflow valve and main
fuel tank)
G: Return fuel (between injector and main fuel tank)
H: Engine oil (to fuel supply pump)

140E-5 Series

10 Structure, function and maintenance standard

a
a

SEN00082-06

The above illustration shows the engine for PC600-8.


The shape is subject to machine models.

1. Fuel injection pipe (No. 1 cylinder)


2. Fuel injection pipe (No. 2 cylinder)
3. Fuel injection pipe (No. 3 cylinder)
4. Fuel injection pipe (No. 4 cylinder)
5. Fuel injection pipe (No. 5 cylinder)
6. Fuel injection pipe (No. 6 cylinder)
7. Common rail
8. Fuel return pipe
9. Priming pump (sub)
10. Feed pump

140E-5 Series

11. Oil inlet pipe (for pump lubricating oil)


12. Fuel supply pump
13. Drive gear (Number of teeth: 48)
14. Overflow valve
15. PCV
16. Priming pump (main)
17. Pre-fuel filter
18. Main fuel filter

39

SEN00082-06

10 Structure, function and maintenance standard

(EGR-less)

a
a

The above illustration shows the engine for D275A-5R.


The shape is subject to machine models.

Specifications
Fuel supply pump
Manufacturer: DENSO CORPORATION
Model: DENSO ECD-U2
Lubrication method:
Forced lubrication with engine oil

40

A: Fuel inlet
B: To engine controller cooler
C: To main fuel filter
D: From main fuel filter
E: To injector
F: Return fuel (between overflow valve and main
fuel tank)
G: Return fuel (between injector and main fuel tank)
H: Engine oil (to fuel supply pump)

140E-5 Series

10 Structure, function and maintenance standard

a
a

SEN00082-06

The above illustration shows the engine for D275A-5R.


The shape is subject to machine models.

1. Fuel injection pipe (No. 1 cylinder)


2. Fuel injection pipe (No. 2 cylinder)
3. Fuel injection pipe (No. 3 cylinder)
4. Fuel injection pipe (No. 4 cylinder)
5. Fuel injection pipe (No. 5 cylinder)
6. Fuel injection pipe (No. 6 cylinder)
7. Common rail
8. Fuel return pipe
9. Priming pump
10. Feed pump

140E-5 Series

11. Oil inlet pipe (for pump lubricating oil)


12. Fuel supply pump
13. Drive gear (Number of teeth: 48)
14. Overflow valve
15. PCV
16. Electric priming pump
a Manual priming pump is set for some models.
(See the "with EGR".)
17. Pre-fuel filter
18. Main fuel filter (double cartridges)
a Single cartridge is set for some models.
19. Air bleeding valve for electric priming pump

41

SEN00082-06

Fuel cooler

10 Structure, function and maintenance standard

(installed on the machine)

The shape is subject to machine models.

A: From fuel tank


B: To fuel supply pump
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

Fuel filter

SEN00082-06

Main fuel filter


(with EGR)

The shape is subject to machine models.

A: Fuel inlet
B: Fuel outlet
1. Air bleeding plug
2. Filter head
3. Cartridge (single cartridge)
Specifications
Filtration area: 1.06 m2

140E-5 Series

43

SEN00082-06

10 Structure, function and maintenance standard

(EGR-less)

The shape is subject to machine models.

A: Fuel inlet
B: Fuel outlet
1. Air bleeding plug
2. Filter head
3. Cartridge (double cartridges)
a Single cartridge is set for some models.
Specifications
Filtration area: 1.06 m2 x 2

44

140E-5 Series

10 Structure, function and maintenance standard

SEN00082-06

Pre-fuel filter

The shape is subject to machine models.

A: Fuel inlet
B: Fuel outlet
1. Air bleeding plug
2. Filter head
3. Cartridge
Specifications
Filtration area: 1.06 m2
with water separator

140E-5 Series

45

SEN00082-06

10 Structure, function and maintenance standard

Priming pump

(with EGR)

1. Spring
2. Cover
3. Shaft
4. Bushing
5. Diaphragm
6. Diaphragm cover
7. Body
8. Check valve

46

9. Valve stopper
10. Packing
11. Check valve body
12. Lever pin
13. E-ring
14. Washer
15. Bolt
16. Lever

140E-5 Series

10 Structure, function and maintenance standard

Electric priming pump

SEN00082-06

(EGR-less)
a

Manual priming pump is set for some models (see the"with EGR")

A: Fuel IN
B: Fuel OUT
1. Connector
2. Vibration prevention rubber

140E-5 Series

47

SEN00082-06

Engine controller cooler

10 Structure, function and maintenance standard

A: Fuel IN (from feed pump of fuel supply pump)


B: Fuel OUT (main fuel filter)
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

Cooling system diagram

SAA6D140E-5 (For construction machinery)


1. Hydraulic cooling fan (With EGR)
(PC600-8, PC600LC-8, PC600-8E0, PC600LC-8E0, PC700-8E0, PC700LC-8E0, PC8008, PC800SE-8, PC850-8, PC850SE-8, PC800LC-8, PC800-8E0, PC800SE-8E0, PC8508E0, PC850SE-8E0, PC800LC-8E0, D155AX-6, D275AX-5E0, WA500-6, HM400-3M0)

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

140E-5 Series

6. Corrosion resistor
a Corrosion resistor is not set for some models.
7. Hydraulic cooling fan
8. Hydraulic fan motor

49

SEN00082-06

10 Structure, function and maintenance standard

2. Hydraulic cooling fan (EGR-less)


(PC600-8R, PC600LC-8R, PC600-8R1, PC600LC-8R1, PC700-8R, PC700LC-8R,
PC700LC-8R1, PC800-8R, PC800LC-8R, PC800SE-8R, PC850-8R, PC850SE-8R,
PC800-8R1, PC800LC-8R1, PC800SE-8R1, PC850-8R1, PC850SE-8R1, D155A-6,
D275A-5R, WA500-6R, HM400-3R)

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

3. Engine-driven cooling fan (With EGR)


(HD325-7, HD405-7, HM350-2, HM400-2,
SDG400S-6B1 (HOKUETSU INDUSTRIES GENERATOR))

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

4. Engine-driven cooling fan (EGR-less)


(HD325-7R, HD405-7R, HM350-2R, HM400-2R)

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

140E-5 Series

SEN00082-06

53

SEN00082-06

Water pump

10 Structure, function and maintenance standard

SAA6D140E-5

54

The shape is subject to machine models.

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
1. Alternator drive pulley
2. Oil seal
3. Ball bearing
4. Pump shaft
5. Water pump drive gear (Number of teeth: 23)
6. Pump body
7. Water seal
8. Impeller
9. Pump cover
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.
10

Check item
Interference between impeller and
shaft

Criteria
Standard
dimension

Remedy

Tolerance

Standard interference

Shaft

Hole

16

0.082
0.095

0.120
0.150

0.025 to 0.068

11

Interference between drive gear and


shaft

28

+0.015
+0.002

0.023
0.055

0.025 to 0.070 Replace

12

Interference between flange and shaft

25

+0.015
+0.002

0.023
0.053

0.025 to 0.068

13
14

Clearance between impeller and body


Wear of water seal ring

140E-5 Series

Standard clearance: 0.6 to 0.9 (including end play)


Limits of size: 1.5

55

SEN00082-06

10 Structure, function and maintenance standard

Water pump mounting

SAA6D140E-5

a
a

The above illustration shows the engine for PC600-8.


The shape is subject to machine models.

A: To radiator inlet (coolant)


B: From thermostat (coolant)
C: From radiator outlet (coolant)
D: To each part of engine through oil cooler (coolant)
E: From oil pump (oil)
F: To each part of engine (oil)
1. Oil cooler
2. Thermostat housing
3. Water pump

56

140E-5 Series

10 Structure, function and maintenance standard

SEN00082-06

Thermostat

The shape is subject to machine models.

A: To radiator inlet
B: From radiator outlet
1. Thermostat housing
2. Thermostat

Specifications
Opening temperature: 76.5 2C
Full opening temperature: 90C
Lift at full opening: Min. 9 mm

Unit: mm

No.

Check item
Lift of thermostat at full opening

Criteria
Min. 9 mm (Before checking, leave valve in water of 90C for 4 to 5 minutes)
Check that valve closes fully when its temperature is lowered from 90C

Opening/Closing of thermostat

140E-5 Series

Remedy

Replace

for full opening to 76.5C. (Before checking valve, leave it in water for 4 to
5 minutes)

57

SEN00082-06

10 Structure, function and maintenance standard

Corrosion resistor

a
a

The shape is subject to machine models.


Corrosion resistor is not set for some models.

A: Coolant inlet
B: Coolant outlet
1. Head
2. Cartridge
3. Element
4. Inhibitor (solid anti-corrosion agent)
5. Spring
6. Stop valve

58

Specifications
Filtration area
Quantity of anti-corrosion
agent

0.13m2

0.19m2

0.37m2

400g

600g

1,000g

140E-5 Series

10 Structure, function and maintenance standard

SEN00082-06

Corrosion resistor mounting

a
a

The shape is subject to machine models.


Corrosion resistor is not set for some models.

1. Tube (return from corrosion resistor)


2. Corrosion resistor head
3. Corrosion resistor cartridge
4. Tube (to corrosion resistor)

140E-5 Series

59

SEN00082-06

10 Structure, function and maintenance standard

Cooling fan drive

Mounting (Adjustment bolt type)


SAA6D140E-5 [HD325-7, HD405-7, HM350-2, HM400-2, HD325-7R, HD405-7R,
HM350-2R, HM400-2R,
SDG400S-6B1 (HOKUETSU INDUSTRIES GENERATOR)]

The shape is subject to machine models.

1. Crankshaft pulley
2. Tension pulley
3. Adjustment bolt

4. Fan belt
5. Fan pulley

Outside diameter of pulley


Unit: mm
Engine

SAA6D140E-5

60

Machine model

Crankshaft pulley

Tension pulley

Fan pulley

HD325-7, HD405-7,
HD325-7R, HD405-7R

166

120

322

HM350-2, HM350-2R

166

120

262

HM400-2, HM400-2R

166

120

262

SDG400S-6B1
(HOKUETSU INDUSTRIES GENERATOR)

203

120

277

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)]

The shape is subject to machine models.

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

Fan mounting case


SAA6D140E-5 [HD325-7, HD405-7, HM350-2, HM400-2, HD325-7R, HD405-7R,
HM350-2R, HM400-2R,
SDG400S-6B1 (HOKUETSU INDUSTRIES GENERATOR)]

The shape is subject to machine models.

1. Fan pulley hub


2. Ball bearing
3. Shaft
4. Case

62

140E-5 Series

10 Structure, function and maintenance standard

SEN00082-06

Accessories

Front PTO

The shape is subject to machine models.

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

Front PTO mounting

The shape is subject to machine models.

1. Front PTO (for driving air conditioner compressor)


2. O-ring

64

140E-5 Series

10 Structure, function and maintenance standard

SEN00082-06

Electrical equipment

Alternator

1. Alternator with built-in regulator (open type, 35 A)

The shape is subject to machine models.

1. Alternator
2. Alternator pulley
3. Terminal B
4. Terminal E
5. Terminal R

140E-5 Series

6. Internal electric circuit diagram


6A. Field coil
6B. Regulator

65

SEN00082-06

10 Structure, function and maintenance standard

2. Alternator with built-in regulator (open type, 50 A)

The shape is subject to machine models.

1. Alternator
2. Alternator pulley
3. Terminal B
4. Terminal E
5. Terminal R

66

6. Internal electric circuit diagram


6A. Field coil
6B. Initial excitation resistor
6C. Regulator

140E-5 Series

10 Structure, function and maintenance standard

SEN00082-06

3. Alternator with built-in regulator (open type, 50 A)

The shape is subject to machine models.

1. Alternator
2. Alternator pulley
3. Terminal B
4. Terminal E
5. Terminal R

140E-5 Series

6. Internal electric circuit diagram


6A. Stator
6B. Regulator

67

SEN00082-06

10 Structure, function and maintenance standard

4. Alternator with built-in regulator (open type, 60 A)

The shape is subject to machine models.

1. Alternator
2. Alternator pulley
3. Terminal B
4. Terminal E
5. Terminal R

68

6. Internal electric circuit diagram


6A. Field coil
6B. Initial excitation resistor
6C. Regulator

140E-5 Series

10 Structure, function and maintenance standard

Engine

Machine model

Type

Specification

Open type (brushless)


manufactured by NIKKO DENKI

24V, 60A

PC800-8, PC800LC-8, PC800-8R,


PC800LC-8R, PC800SE-8,
PC800SE-8R
PC850-8, PC850-8R, PC850SE-8,
PC850SE-8R
Open type (brushless)
PC800-8E0, PC800SE-8E0,
manufactured by NIKKO DENKI
PC850-8E0, PC850SE-8E0,
PC800LC-8E0
PC800-8R1, PC800SE-8R1
PC850-8R1, PC850SE-8R1
PC800LC-8R1

24V, 60A

D155AX-6, D155A-6

Open type (brushless)


manufactured by NIKKO DENKI

24V, 60A

HD325-7, HD325-7R
HD405-7, HD405-7R

Open type (brushless)


manufactured by NIKKO DENKI

24V, 60A

HM350-2, HM350-2R
HM400-2, HM400-2R
HM400-3M0, HM400-3R

Open type (brushless)


manufactured by NIKKO DENKI

24V, 60A

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

SAA6D140E-5

SEN00082-06

140E-5 Series

Outside diameter
Weight (kg)
of pulley (mm)

69

SEN00082-06

10 Structure, function and maintenance standard

5. Alternator with built-in regulator (open type, 75 A)

The shape is subject to machine models.

1. Alternator
2. Alternator pulley
3. Terminal B
4. Terminal E
5. Terminal R
Engine

SAA6D140E-5

70

Machine model

6. Internal electric circuit diagram


6A. Stator
6B. Regulator

Type

Specification

D155AX-6, D155A-6
(If equipped)

Open type (brushless) manufactured


by SAWAFUJI DENKI

24V, 75A

D275AX-5E0,
D275A-5R

Open type (brushless) manufactured


by SAWAFUJI DENKI

24V, 75A

WA500-6, WA500-6R

Open type (brushless) manufactured


by SAWAFUJI DENKI

24V, 75A

HD325-7, HD325-7R
HD405-7, HD405-7R
(If equipped)

Open type (brushless) manufactured


by SAWAFUJI DENKI

24V, 75A

HM350-2, HM350-2R
Open type (brushless) manufactured
HM400-2, HM400-2R
HM400-3M0, HM400-3R by SAWAFUJI DENKI
(If equipped)

24V, 75A

Outside diameter of
pulley (mm)

Weight (kg)

140E-5 Series

10 Structure, function and maintenance standard

140E-5 Series

SEN00082-06

71

SEN00082-06

10 Structure, function and maintenance standard

6. Alternator with built-in regulator (open type, 90 A)

The shape is subject to machine models.

1. Alternator
2. Alternator pulley
3. Terminal B
4. Terminal E
5. Terminal R

72

6. Internal electric circuit diagram


6A. Field coil
6B. Initial excitation resistor
6C. Regulator

140E-5 Series

10 Structure, function and maintenance standard

Engine

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
(If equipped)
PC800-8, PC800LC-8, PC800-8R,
PC800LC-8R, PC800SE-8,
PC800SE-8R
PC850-8, PC850-8R
PC850SE-8, PC850SE-8R
PC800-8E0, PC800SE-8E0,
PC850-8E0, PC850SE-8E0,
PC800LC-8E0
PC800-8R1, PC800SE-8R1
PC850-8R1, PC850SE-8R1
PC800LC-8R1
(If equipped)
D155AX-6, D155A-6
(If equipped)
D275AX-5E0, D275A-5R
(If equipped)
WA500-6, WA500-6R
(If equipped)

140E-5 Series

SEN00082-06

Type

Specification

Open type (brushless)


manufactured by NIKKO DENKI

24V, 90A

Open type (brushless)


manufactured by NIKKO DENKI

24V, 90A

Open type (brushless)


manufactured by NIKKO DENKI
Open type (brushless)
manufactured by NIKKO DENKI
Open type (brushless)
manufactured by NIKKO DENKI

Outside diameter
Weight (kg)
of pulley (mm)

24V, 90A
24V, 90A
24V, 90A

73

SEN00082-06

10 Structure, function and maintenance standard

Alternator mounting

The shape is subject to machine models.

a: Outside diameter of alternator pulley: 85 mm


b: Outside diameter of alternator drive pulley: 132 mm
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

140E-5 Series

SEN00082-06

75

SEN00082-06

10 Structure, function and maintenance standard

Starting motor

For 7.5kW (for SDG400S-6B1 (HOKUETSU INDUSTRIES GENERATOR))

The shape is subject to machine models.

E: To chassis ground
R: To alternator terminal R
S: To starting switch terminal C

5. Terminal C
6. Safety relay
7. External connection diagram
(2-pole connector type)
7A. Safety relay section
7B. Starting motor section
8. Jump start prohibition label
9. Jump start prevention cover

1. Pinion gear
2. Starting motor assembly
3. Magnetic switch
4. Terminal B
Engine

Machine model

SDG400S-6B1
(HOKUETSU
SAA6D140E-5
INDUSTRIES
GENERATOR)

76

Type

Specification

Number of
pinion teeth

Weight (kg)

Type of
connector

Water-resistant, oil-resistant
type manufactured by
NIKKO DENKI

24V, 7.5kW

12

15.5

DT

140E-5 Series

10 Structure, function and maintenance standard

SEN00082-06

For 11kW (except SDG400S-6B1 (HOKUETSU INDUSTRIES GENERATOR))

The shape is subject to machine models.

E: To chassis ground
R: To alternator terminal R
S: To starting switch terminal C

5. Terminal C
6. Safety relay
7. External connection diagram
(2-pole connector type)
7A. Safety relay section
7B. Starting motor section
8. Jump start prohibition label
9. Jump start prevention cover

1. Pinion gear
2. Starting motor assembly
3. Magnetic switch
4. Terminal B
Engine
SAA6D140E-5

Machine model
All machines

140E-5 Series

Type

Specification

Number of
pinion teeth

Weight (kg)

Type of
connector

Water-resistant, oil-resistant
type manufactured by
NIKKO DENKI

24V, 11kW

12

18

DT

77

SEN00082-06

Starting aid

10 Structure, function and maintenance standard

Electric heater
For SAA6D140E-5

The shape is subject to machine models.

1. Body
2. Heater coil
3. Terminal
4. Connection diagram

78

Specifications
Type of heater: Electrical intake air heater
q
Rated voltage: 22 V (DC)
q
Load current: 175 A

140E-5 Series

10 Structure, function and maintenance standard

Engine controller

SEN00082-06

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.
Unified specifications of engine controller
Engine controller CM850 developed by the
cooperation between KOMATSU and CUMMINS is employed.

140E-5 Series

79

SEN00082-06

KOMATSU 140E-5 Series engine


Form No. SEN00082-06

2012 KOMATSU
All Rights Reserved
Printed in Japan 12-12 (01)

80

SEN00147-07

ENGINE
1SHOP MANUAL

140E-5 Series

20 Standard value table

Standard service value table


Standard service value table for testing, adjusting, and troubleshooting ........................................................ 2
Running-in standard and performance test standard.................................................................................... 19

140E-5 Series

SEN00147-07

20 Standard value table

Air intake and exhaust system

Performance Category

Standard service value table for testing, adjusting, and troubleshooting

Body
Lubrication system
Cooling system

SAA6D140E-5

Machine models

D155AX-6
Unit

Standard value for


new machine

Repair limit

Max. speed with no load

rpm

2,100(0/50)

2,100(0/50)

Min. speed with no load

rpm

740(+40/0)

740(+40/0)

Necessary speed for


starting

At 0C (without starting aid)

rpm

Min. 110

At 20C (with starting aid)

rpm

Min. 85

Air intake resistance

Whole speed range

kPa
{mmH2O}

Max. 3.73
{Max. 380}

7.47
{762}

Air boost pressure

At rated horsepower

kPa
{mmHg}

Min. 117
{Min. 880}

100
{750}

Exhaust pressure

At rated horsepower

kPa
{mmHg}

Min. 127
{Min. 950}

108
{810}

Exhaust temperature

Whole speed range (20C)

660

700

% (Bosch
index)

Max. 25
(Max. 2.5)

35
(3.5)

At rated horsepower

Bosch
index

Max. 1.5

2.5

At high idle

Bosch
index

Max. 1.0

2.0

Intake valve

mm

0.35

Exhaust valve

mm

0.57

At low idle

MPa
{kg/cm2}

Min. 1.18
{Min. 12}

Min. 1.18
{Min. 12}

At high idle

MPa
{kg/cm2}

Min. 1.43
{Min. 14.6}

Min. 1.43
{Min. 14.6}

Compression pressure

Engine oil temperature: 40 to 60C


Engine speed: 200 to 250 rpm

MPa
{kg/cm2}

Min. 4.1
{Min. 42}

2.8
{29}

Blow-by pressure

At rated horsepower
Engine coolant temperature: Min. 70C

kPa
{mmH2O}

Max. 2.94
{Max. 300}

3.92
{400}

Min. 0.34
{Min. 3.5}

0.21
{2.1}

Oil pressure

At rated horsepower
MPa
Engine oil temperature: SAE0W30EOS
2
}
{kg/cm
SAE5W40EOS
Min. 80C
SAE10W30DH
At low idle
SAE15W40DH
MPa
Engine oil temperature: SAE30DH
{kg/cm2}
Min. 80C

Min. 0.10
{Min. 1.0}

0.08
{0.8}

Item

Speed

Measurement conditions

At sudden acceleration (Low High)


Exhaust gas color

Valve clearance

EGR valve and bypass


valve drive oil pressure

Engine

Oil temperature

Whole speed range

90 to 110

120

Oil consumption

Ratio to fuel consumption at continuous


rated horsepower

Max. 0.15

0.3

Function of radiator
pressure valve

Cracking pressure
(Differential pressure)

kPa
{kg/cm2}

Fan speed

At rated speed

rpm

Hydraulically driven on machine side

Fan belt tension

Deflection under finger pressure of 98 N


{10 kg}

mm

Hydraulically driven on machine side

Alternator belt tension

Deflection under finger pressure of 98 N


{10 kg}

mm

13 to 16

13 to 16

140E-5 Series

Air intake and exhaust system

Performance Category

20 Standard value table

Body
Lubrication system

Engine

SAA6D140E-5

Machine models

D155A-6
Unit

Standard value for


new machine

Repair limit

Max. speed with no load

rpm

2,100(0/50)

2,100(0/50)

Min. speed with no load

rpm

740(+40/0)

740(+40/0)

Necessary speed for


starting

At 0C (without starting aid)

rpm

Min. 110

At 20C (with starting aid)

rpm

Min. 85

Air intake resistance

Whole speed range

kPa
{mmH2O}

Max. 3.73
{Max. 380}

7.47
{762}

Air boost pressure

At rated horsepower

kPa
{mmHg}

Min. 85
{Min. 640}

72
{540}

Exhaust pressure

At rated horsepower

kPa
{mmHg}

Min. 92
{Min. 690}

77
{580}

Exhaust temperature

Whole speed range (20C)

670

720

% (Bosch
index)

Max. 30
(Max. 3.0)

40
(4.0)

At rated horsepower

Bosch
index

Max. 1.5

2.5

At high idle

Bosch
index

Max. 1.0

2.0

Item

Speed

Measurement conditions

At sudden acceleration (Low High)


Exhaust gas color

Valve clearance

Cooling system

SEN00147-07

Intake valve

mm

0.35

Exhaust valve

mm

0.57

Compression pressure

Engine oil temperature: 40 to 60C


Engine speed: 200 to 250 rpm

MPa
{kg/cm2}

Min. 4.1
{Min. 42}

2.8
{29}

Blow-by pressure

At rated horsepower
Engine coolant temperature: Min. 70C

kPa
{mmH2O}

Max. 2.94
{Max. 300}

3.92
{400}

Min. 0.34
{Min. 3.5}

0.21
{2.1}

Oil pressure

At rated horsepower
MPa
Engine oil temperature: SAE0W30EOS
{kg/cm2}
SAE5W40EOS
Min. 80C
SAE10W30DH
At low idle
SAE15W40DH
MPa
Engine oil temperature: SAE30DH
{kg/cm2}
Min. 80C

Min. 0.10
{Min. 1.0}

0.08
{0.8}

Oil temperature

Whole speed range

90 to 110

120

Oil consumption

Ratio to fuel consumption at continuous


rated horsepower

Max. 0.15

0.3

Function of radiator
pressure valve

Cracking pressure
(Differential pressure)

kPa
{kg/cm2}

Fan speed

At rated speed

rpm

Hydraulically driven on machine side

Fan belt tension

Deflection under finger pressure of 98 N


{10 kg}

mm

Hydraulically driven on machine side

Alternator belt tension

Deflection under finger pressure of 98 N


{10 kg}

mm

140E-5 Series

13 to 16

13 to 16

Air intake and exhaust system

Performance Category

SEN00147-07

Body
Lubrication system
Cooling system

Engine

SAA6D140E-5

Machine models

D275AX-5E0
Unit

Standard value for


new machine

Repair limit

rpm

2,200 50

2,200 50

Min. speed with no load

rpm

700 50

700 50

Necessary speed for


starting

At 0C (without starting aid)

rpm

Min. 110

At 20C (with starting aid)

rpm

Min. 85

Air intake resistance

Whole speed range

kPa
{mmH2O}

Max. 3.73
{Max. 380}

7.47
{762}

Air boost pressure

At rated horsepower

kPa
{mmHg}

Min. 169
{Min. 1,270}

144
{1,080}

Exhaust pressure

At rated horsepower

kPa
{mmHg}

Min. 169
{Min. 1,270}

144
{1,080}

Exhaust temperature

Whole speed range (20C)

Item

Speed

Measurement conditions
Max. speed with no load

Max. 620

670

% (Bosch
index)

Max. 25
(Max. 2.5)

35
(3.5)

At rated horsepower

Bosch
index

Max. 1.5

2.5

At high idle

Bosch
index

Max. 1.0

2.0

Intake valve

mm

0.35

At sudden acceleration (Low High)


Exhaust gas color

Valve clearance

mm

0.57

At low idle

MPa
{kg/cm2}

Min. 1.18
{Min. 12}

Min. 1.18
{Min. 12}

At high idle

MPa
{kg/cm2}

Min. 1.43
{Min. 14.6}

Min. 1.43
{Min. 14.6}

Compression pressure

Engine oil temperature: 40 to 60C


Engine speed: 200 to 250 rpm

MPa
{kg/cm2}

Min. 4.1
{Min. 42}

2.8
{29}

Blow-by pressure

At rated horsepower
Engine coolant temperature: Min. 70C

kPa
{mmH2O}

Max. 2.94
{Max. 300}

3.92
{400}

Min. 0.34
{Min. 3.5}

0.21
{2.1}

Oil pressure

At rated horsepower
SAE0W30EOS
MPa
Engine oil temperature:
{kg/cm2}
SAE5W40EOS
Min. 80C
SAE10W30DH
At low idle
SAE15W40DH
MPa
Engine oil temperature:
SAE30DH
{kg/cm2}
Min. 80C

Min. 0.10
{Min. 1.0}

0.08
{0.8}

EGR valve and bypass


valve drive oil pressure

20 Standard value table

Exhaust valve

Oil temperature

Whole speed range

90 to 110

120

Oil consumption

Ratio to fuel consumption at continuous


rated horsepower

Max. 0.15

0.3

Function of radiator
pressure valve

Cracking pressure
(Differential pressure)

kPa
{kg/cm2}

Fan speed

At rated speed

rpm

Hydraulically driven on machine side

Fan belt tension

Deflection under finger pressure of 98 N


{10 kg}

mm

Hydraulically driven on machine side

Alternator belt tension

Deflection under finger pressure of 98 N


{10 kg}

mm

13 to 16

13 to 16

140E-5 Series

Air intake and exhaust system

Performance Category

20 Standard value table

Body
Lubrication system

Engine

SAA6D140E-5

Machine models

D275A-5R
Unit

Standard value for


new machine

Repair limit

Max. speed with no load

rpm

2,200 50

2,200 50

Min. speed with no load

rpm

700 50

700 50

Necessary speed for


starting

At 0C (without starting aid)

rpm

Min. 110

At 20C (with starting aid)

rpm

Min. 85

Air intake resistance

Whole speed range

kPa
{mmH2O}

Max. 3.73
{Max. 380}

7.47
{762}

Air boost pressure

At rated horsepower

kPa
{mmHg}

Min. 116
{Min. 870}

99
{740}

Exhaust pressure

At rated horsepower

kPa
{mmHg}

Min. 116
{Min. 870}

99
{740}

Exhaust temperature

Whole speed range (20C)

Max. 670

720

% (Bosch
index)

Max. 40
(Max. 4.0)

50
(5.0)

At rated horsepower

Bosch
index

Max. 1.5

2.5

At high idle

Bosch
index

Max. 1.0

2.0

Intake valve

mm

0.35

Exhaust valve

mm

0.57

Item

Speed

Measurement conditions

At sudden acceleration (Low High)


Exhaust gas color

Valve clearance

Cooling system

SEN00147-07

Compression pressure

Engine oil temperature: 40 to 60C


Engine speed: 200 to 250 rpm

MPa
{kg/cm2}

Min. 4.1
{Min. 42}

2.8
{29}

Blow-by pressure

At rated horsepower
Engine coolant temperature: Min. 70C

kPa
{mmH2O}

Max. 2.94
{Max. 300}

3.92
{400}

Min. 0.34
{Min. 3.5}

0.21
{2.1}

Oil pressure

At rated horsepower
SAE0W30EOS
MPa
Engine oil temperature:
{kg/cm2}
SAE5W40EOS
Min. 80C
SAE10W30DH
At low idle
SAE15W40DH
MPa
Engine oil temperature:
SAE30DH
{kg/cm2}
Min. 80C

Min. 0.10
{Min. 1.0}

0.08
{0.8}

Oil temperature

Whole speed range

90 to 110

120

Oil consumption

Ratio to fuel consumption at continuous


rated horsepower

Max. 0.15

0.3

Function of radiator
pressure valve

Cracking pressure
(Differential pressure)

kPa
{kg/cm2}

Fan speed

At rated speed

rpm

Hydraulically driven on machine side

Fan belt tension

Deflection under finger pressure of 98 N


{10 kg}

mm

Hydraulically driven on machine side

Alternator belt tension

Deflection under finger pressure of 98 N


{10 kg}

mm

140E-5 Series

13 to 16

13 to 16

Air intake and exhaust system

Performance Category

SEN00147-07

Item

Speed
Necessary speed for
starting

Body
Lubrication system
Cooling system

Engine

SAA6D140E-5

Machine models

PC600-8, PC600LC-8
PC600-8E0, PC600LC-8E0
PC700-8E0, PC700LC-8E0
Unit

Standard value for


new machine

Repair limit

Max. speed with no load

rpm

1,950 50

1,950 50

Min. speed with no load

rpm

800 25

800 25

At 0C (without starting aid)

rpm

Min. 110

Measurement conditions

At 20C (with starting aid)

rpm

Min. 85

Max. 3.73
{Max. 380}

7.47
{762}

Air intake resistance

Whole speed range

kPa
{mmH2O}

Air boost pressure

At rated horsepower

kPa
{mmHg}

Min. 147
{Min. 1,100}

125
{940}

Exhaust pressure

At rated horsepower

kPa
{mmHg}

Min. 145
{Min. 1,090}

128
{930}

Exhaust temperature

Whole speed range (20C)

Max. 650

700

% (Bosch
index)

Max. 25
(Max. 2.5)

35
(3.5)

At rated horsepower

Bosch
index

Max. 1.5

2.5

At high idle

Bosch
index

Max. 1.0

2.0

Intake valve

mm

0.35

Exhaust valve

mm

0.57

At low idle

MPa
{kg/cm2}

Min. 1.18
{Min. 12}

Min. 1.18
{Min. 12}

At high idle

MPa
{kg/cm2}

Min. 1.43
{Min. 14.6}

Min. 1.43
{Min. 14.6}

Compression pressure

Engine oil temperature: 40 to 60C


Engine speed: 200 to 250 rpm

MPa
{kg/cm2}

Min. 4.1
{Min. 42}

2.8
{29}

Blow-by pressure

At rated horsepower
Engine coolant temperature: Min. 70C

kPa
{mmH2O}

Max. 2.94
{Max. 300}

3.92
{400}

Min. 0.34
{Min. 3.5}

0.21
{2.1}

Oil pressure

At rated horsepower
SAE0W30EOS
MPa
Engine oil temperature:
{kg/cm2}
SAE5W40EOS
Min. 80C
SAE10W30DH
At low idle
SAE15W40DH
MPa
Engine oil temperature:
{kg/cm2}
SAE30DH
Min. 80C

Min. 0.10
{Min. 1.0}

0.08
{0.8}

At sudden acceleration (Low High)


Exhaust gas color

Valve clearance

EGR valve and bypass


valve drive oil pressure

20 Standard value table

Oil temperature

Whole speed range

90 to 110

120

Oil consumption

Ratio to fuel consumption at continuous


rated horsepower

Max. 0.15

0.3

Function of radiator
pressure valve

Cracking pressure
(Differential pressure)

kPa
{kg/cm2}

Fan speed

At rated speed

rpm

Hydraulically driven on machine side

Fan belt tension

Deflection under finger pressure of 98 N


{10 kg}

mm

Hydraulically driven on machine side

Alternator belt tension

Deflection under finger pressure of 98 N


{10 kg}

mm

13 to 16

13 to 16

140E-5 Series

Air intake and exhaust system

Performance Category

20 Standard value table

Body
Lubrication system

Engine

SAA6D140E-5

Machine models

PC600-8R, PC600LC-8R,
PC600-8R1, PC600LC-8R1,
PC700-8R, PC700LC-8R,
PC700LC-8R1
Unit

Standard value for


new machine

Repair limit

rpm

1,950 50

1,950 50

Min. speed with no load

rpm

800 25

800 25

Necessary speed for


starting

At 0C (without starting aid)

rpm

Min. 110

At 20C (with starting aid)

rpm

Min. 85

Air intake resistance

Whole speed range

kPa
{mmH2O}

Max. 3.73
{Max. 380}

7.47
{762}

Air boost pressure

At rated horsepower

kPa
{mmHg}

Min. 120
{Min. 900}

102
{760}

Exhaust pressure

At rated horsepower

kPa
{mmHg}

Min. 116
{Min. 870}

99
{740}

Exhaust temperature

Whole speed range (20C)

Max. 700

750

% (Bosch
index)

Max. 30
(Max. 3.0)

40
(4.0)

At rated horsepower

Bosch
index

Max. 1.5

2.5

At high idle

Bosch
index

Max. 1.0

2.0

Item

Speed

Measurement conditions
Max. speed with no load

At sudden acceleration (Low High)


Exhaust gas color

Valve clearance

Cooling system

SEN00147-07

Intake valve

mm

0.35

Exhaust valve

mm

0.57

Compression pressure

Engine oil temperature: 40 to 60C


Engine speed: 200 to 250 rpm

MPa
{kg/cm2}

Min. 4.1
{Min. 42}

2.8
{29}

Blow-by pressure

At rated horsepower
Engine coolant temperature: Min. 70C

kPa
{mmH2O}

Max. 2.94
{Max. 300}

3.92
{400}

Min. 0.34
{Min. 3.5}

0.21
{2.1}

Oil pressure

At rated horsepower
SAE0W30EOS
MPa
Engine oil temperature:
{kg/cm2}
SAE5W40EOS
Min. 80C
SAE10W30DH
At low idle
SAE15W40DH
MPa
Engine oil temperature:
SAE30DH
{kg/cm2}
Min. 80C

Min. 0.10
{Min. 1.0}

0.08
{0.8}

Oil temperature

Whole speed range

90 to 110

120

Oil consumption

Ratio to fuel consumption at continuous


rated horsepower

Max. 0.15

0.3

Function of radiator
pressure valve

Cracking pressure
(Differential pressure)

kPa
{kg/cm2}

Fan speed

At rated speed

rpm

Hydraulically driven on machine side

Fan belt tension

Deflection under finger pressure of 98 N


{10 kg}

mm

Hydraulically driven on machine side

Alternator belt tension

Deflection under finger pressure of 98 N


{10 kg}

mm

140E-5 Series

13 to 16

13 to 16

Air intake and exhaust system

Performance Category

SEN00147-07

Body
Lubrication system
Cooling system

Engine

SAA6D140E-5

Machine models

PC800-8, PC800SE-8, PC800LC-8


PC850-8, PC850SE-8
PC800-8E0, PC800SE-8E0,
PC800LC-8E0
PC850-8E0, PC850SE-8E0
Unit

Standard value for


new machine

Repair limit

rpm

1,980 50

1,980 50

Min. speed with no load

rpm

825 25

825 25

Necessary speed for


starting

At 0C (without starting aid)

rpm

Min. 110

At 20C (with starting aid)

rpm

Min. 85

Air intake resistance

Whole speed range

kPa
{mmH2O}

Max. 3.73
{Max. 380}

7.47
{762}

Air boost pressure

At rated horsepower

kPa
{mmHg}

Min. 184
{Min. 1,380}

157
{1,180}

Exhaust pressure

At rated horsepower

kPa
{mmHg}

Min. 172
{Min. 1,290}

147
{1,100}

Exhaust temperature

Whole speed range (20C)

Max. 650

700

% (Bosch
index)

Max. 25
(Max. 2.5)

35
(3.5)

At rated horsepower

Bosch
index

Max. 1.5

2.5

At high idle

Bosch
index

Max. 1.0

2.0

Intake valve

mm

0.35

Exhaust valve

mm

0.57

At low idle

MPa
{kg/cm2}

Min. 1.18
{Min. 12}

Min. 1.18
{Min. 12}

At high idle

MPa
{kg/cm2}

Min. 1.43
{Min. 14.6}

Min. 1.43
{Min. 14.6}

Compression pressure

Engine oil temperature: 40 to 60C


Engine speed: 200 to 250 rpm

MPa
{kg/cm2}

Min. 4.1
{Min. 42}

2.8
{29}

Blow-by pressure

At rated horsepower
kPa
Engine coolant temperature: Min. 70C {mmH2O}

Max. 2.94
{Max. 300}

3.92
{400}

Min. 0.34
{Min. 3.5}

0.21
{2.1}

Oil pressure

At rated horsepower
SAE0W30EOS
MPa
Engine oil temperature:
SAE5W40EOS {kg/cm2}
Min. 80C
SAE10W30DH
At low idle
SAE15W40DH
MPa
Engine oil temperature:
2
}
{kg/cm
SAE30DH
Min. 80C

Min. 0.10
{Min. 1.0}

0.08
{0.8}

Item

Speed

Measurement conditions
Max. speed with no load

At sudden acceleration (Low High)


Exhaust gas color

Valve clearance

EGR valve and bypass


valve drive oil pressure

20 Standard value table

Oil temperature

Whole speed range

90 to 110

120

Oil consumption

Ratio to fuel consumption at continuous


rated horsepower

Max. 0.15

Max. 0.3

Function of radiator
pressure valve

Cracking pressure
(Differential pressure)

kPa
{kg/cm2}

Fan speed

At rated speed

rpm

Hydraulically driven on machine side

Fan belt tension

Deflection under finger pressure of 98 N


{10 kg}

mm

Hydraulically driven on machine side

Alternator belt tension

Deflection under finger pressure of 98 N


{10 kg}

mm

13 to 16

13 to 6

140E-5 Series

Air intake and exhaust system

Performance Category

20 Standard value table

Body
Lubrication system

Engine

SAA6D140E-5

Machine models

PC800-8R, PC800SE-8R,
PC800LC-8R
PC850-8R, PC850SE-8R
PC800-8R1, PC800SE-8R1,
PC800LC-8R1, PC850-8R1,
PC850SE-8R1
Unit

Standard value for


new machine

Repair limit

Max. speed with no load

rpm

1,980 50

1,980 50

Min. speed with no load

rpm

825 25

825 25

Necessary speed for


starting

At 0C (without starting aid)

rpm

Min. 110

At 20C (with starting aid)

rpm

Min. 85

Air intake resistance

Whole speed range

kPa
{mmH2O}

Max. 3.73
{Max. 380}

7.47
{762}

Air boost pressure

At rated horsepower

kPa
{mmHg}

Min. 128
{Min. 960}

108
{810}

Exhaust pressure

At rated horsepower

kPa
{mmHg}

Min. 113
{Min. 850}

96
{720}

Exhaust temperature

Whole speed range (20C)

Max. 700

750

% (Bosch
index)

Max. 30
(Max. 3.0)

40
(4.0)

At rated horsepower

Bosch
index

Max. 1.5

2.5

At high idle

Bosch
index

Max. 1.0

2.0

Item

Speed

Measurement conditions

At sudden acceleration (Low High)


Exhaust gas color

Valve clearance

Cooling system

SEN00147-07

Intake valve

mm

0.35

Exhaust valve

mm

0.57

MPa
{kg/cm2}

Min. 4.1
{Min. 42}

2.8
{29}

Max. 2.94
{Max. 300}

3.92
{400}

Min. 0.34
{Min. 3.5}

0.21
{2.1}

Min. 0.10
{Min. 1.0}

0.08
{0.8}

Compression pressure

Engine oil temperature: 40 to 60C


Engine speed: 200 to 250 rpm

Blow-by pressure

At rated horsepower
kPa
Engine coolant temperature: Min. 70C {mmH2O}

Oil pressure

At rated horsepower
SAE0W30EOS
MPa
Engine oil temperature:
SAE5W40EOS {kg/cm2}
Min. 80C
SAE10W30DH
At low idle
SAE15W40DH
MPa
Engine oil temperature:
{kg/cm2}
SAE30DH
Min. 80C

Oil temperature

Whole speed range

90 to 110

120

Oil consumption

Ratio to fuel consumption at continuous


rated horsepower

Max. 0.15

Max. 0.3

Function of radiator
pressure valve

Cracking pressure
(Differential pressure)

kPa
{kg/cm2}

Fan speed

At rated speed

rpm

Hydraulically driven on machine side

Fan belt tension

Deflection under finger pressure of 98 N


{10 kg}

mm

Hydraulically driven on machine side

Alternator belt tension

Deflection under finger pressure of 98 N


{10 kg}

mm

140E-5 Series

13 to 16

13 to 6

Air intake and exhaust system

Performance Category

SEN00147-07

Body
Lubrication system
Cooling system

Engine

SAA6D140E-5

Machine models

WA500-6
Unit

Standard value for


new machine

Repair limit

Max. speed with no load

rpm

2,150 50

2,150 50

Min. speed with no load

rpm

700 25

700 25

Necessary speed for


starting

At 0C (without starting aid)

rpm

Min. 110

At 20C (with starting aid)

rpm

Min. 85

Air intake resistance

Whole speed range

kPa
{mmH2O}

Max. 3.73
{Max. 380}

7.47
{762}

Air boost pressure

At rated horsepower

kPa
{mmHg}

Min. 116
{Min. 870}

89
{670}

Exhaust pressure

At rated horsepower

kPa
{mmHg}

Min. 121
{Min. 910}

91
{680}

Exhaust temperature

Whole speed range (20C)

Max. 650

700

% (Bosch
index)

Max. 25
(Max. 2.5)

35
(3.5)

At rated horsepower

Bosch
index

Max. 1.5

2.5

At high idle

Bosch
index

Max. 1.0

2.0

Intake valve

mm

0.35

Exhaust valve

mm

0.57

At low idle

MPa
{kg/cm2}

Min. 1.18
{Min. 12}

Min. 1.18
{Min. 12}

At high idle

MPa
{kg/cm2}

Min. 1.43
{Min. 14.6}

Min. 1.43
{Min. 14.6}

Compression pressure

Engine oil temperature: 40 to 60C


Engine speed: 200 to 250 rpm

MPa
{kg/cm2}

Min. 4.1
{Min. 42}

2.8
{29}

Blow-by pressure

At rated horsepower
kPa
Engine coolant temperature: Min. 70C {mmH2O}

Max. 2.94
{Max. 300}

3.92
{400}

Min. 0.34
{Min. 3.5}

0.21
{2.1}

Oil pressure

At rated horsepower
MPa
Engine oil temperature: SAE0W30EOS
{kg/cm2}
SAE5W40EOS
Min. 80C
SAE10W30DH
At low idle
SAE15W40DH
MPa
Engine oil temperature: SAE30DH
{kg/cm2}
Min. 80C

Min. 0.10
{Min. 1.0}

0.08
{0.8}

Item

Speed

Measurement conditions

At sudden acceleration (Low High)


Exhaust gas color

Valve clearance

EGR valve and bypass


valve drive oil pressure

10

20 Standard value table

Oil temperature

Whole speed range

90 to 110

120

Oil consumption

Ratio to fuel consumption at continuous


rated horsepower

Max. 0.15

0.3

Function of radiator
pressure valve

Cracking pressure
(Differential pressure)

kPa
{kg/cm2}

Fan speed

At rated speed

rpm

Hydraulically driven on machine side

Fan belt tension

Deflection under finger pressure of 98 N


{10 kg}

mm

Hydraulically driven on machine side

Alternator belt tension

Deflection under finger pressure of 98 N


{10 kg}

mm

13 to 16

13 to 16

140E-5 Series

Air intake and exhaust system

Performance Category

20 Standard value table

Item

Speed
Necessary speed for
starting

Body
Lubrication system

Engine

SAA6D140E-5

Machine models

WA500-6R
Unit

Standard value for


new machine

Repair limit

Max. speed with no load

rpm

2,150 50

2,150 50

Min. speed with no load

rpm

700 25

700 25

At 0C (without starting aid)

rpm

Min. 110

At 20C (with starting aid)

rpm

Min. 85

Measurement conditions

Air intake
resistance

Whole speed range

kPa
{mmH2O}

Max. 3.73
{Max. 380}

7.47
{762}

Air boost
pressure

At rated horsepower

kPa
{mmHg}

Min. 89
{Min. 670}

76
{570}

Exhaust
pressure

At rated horsepower

kPa
{mmHg}

Min. 101
{Min. 760}

85
{640}

Exhaust
temperature

Whole speed range (20C)

Max. 670

720

% (Bosch
index)

Max. 40
(Max. 4.0)

50
(5.0)

At rated horsepower

Bosch
index

Max. 1.5

2.5

At high idle

Bosch
index

Max. 1.0

2.0

Intake valve

mm

0.35

Exhaust valve

mm

0.57

At sudden acceleration (Low High)


Exhaust gas color

Valve clearance

Cooling system

SEN00147-07

Compression pressure

Engine oil temperature: 40 to 60C


Engine speed: 200 to 250 rpm

MPa
{kg/cm2}

Min. 4.1
{Min. 42}

2.8
{29}

Blow-by
pressure

At rated horsepower
Engine coolant temperature: Min. 70C

kPa
{mmH2O}

Max. 2.94
{Max. 300}

3.92
{400}

Min. 0.34
{Min. 3.5}

0.21
{2.1}

Oil pressure

At rated horsepower
MPa
Engine oil temperature: SAE0W30EOS
2
}
{kg/cm
SAE5W40EOS
Min. 80C
SAE10W30DH
At low idle
SAE15W40DH
MPa
Engine oil temperature: SAE30DH
{kg/cm2}
Min. 80C

Min. 0.10
{Min. 1.0}

0.08
{0.8}

Oil temperature

Whole speed range

90 to 110

120

Oil consumption

Ratio to fuel consumption at continuous


rated horsepower

Max. 0.15

0.3

Function of
radiator
pressure valve

Cracking pressure
(Differential pressure)

kPa
{kg/cm2}

Fan speed

At rated speed

rpm

Hydraulically driven on machine side

Fan belt tension

Deflection under finger pressure of 98 N


{10 kg}

mm

Hydraulically driven on machine side

Alternator belt tension

Deflection under finger pressure of 98 N


{10 kg}

mm

140E-5 Series

13 to 16

13 to 16

11

Air intake and exhaust system

Performance Category

SEN00147-07

Item

Speed
Necessary speed for
starting

Body
Lubrication system
Cooling system

Engine

SAA6D140E-5

Machine models

HD325-7
HD405-7
Unit

Standard value for


new machine

Repair limit

Max. speed with no load

rpm

2,300 25

2,300 25

Min. speed with no load

rpm

725 25

725 25

At 0C (without starting aid)

rpm

Min. 110

At 20C (with starting aid)

rpm

Min. 85

Max. 3.73
{Max. 380}

7.47
{762}

Measurement conditions

Air intake resistance

Whole speed range

kPa
{mmH2O}

Air boost pressure

At rated horsepower

kPa
{mmHg}

Min. 183
{Min. 1,370}

156
{1,170}

Exhaust pressure

At rated horsepower

kPa
{mmHg}

Min. 163
{Min. 1,220}

139
{1,040}

Exhaust temperature

Whole speed range (20C)

Max. 650

700

% (Bosch
index)

Max. 25
(Max. 2.5)

35
(3.5)

At rated horsepower

Bosch
index

Max. 1.5

2.5

At high idle

Bosch
index

Max. 1.0

2.0

Intake valve

mm

0.35

Exhaust valve

mm

0.57

At low idle

MPa
{kg/cm2}

Min. 1.18
{Min. 12}

Min. 1.18
{Min. 12}

At high idle

MPa
{kg/cm2}

Min. 1.43
{Min. 14.6}

Min. 1.43
{Min. 14.6}

Compression pressure

Engine oil temperature: 40 to 60C


Engine speed: 200 to 250 rpm

MPa
{kg/cm2}

Min. 4.1
{Min. 42}

2.8
{29}

Blow-by pressure

At rated horsepower
kPa
Engine coolant temperature: Min. 70C {mmH2O}

Max. 2.94
{Max. 300}

3.92
{400}

Min. 0.34
{Min. 3.5}

0.21
{2.1}

Oil pressure

At rated horsepower
SAE0W30EOS
MPa
Engine oil temperature:
SAE5W40EOS {kg/cm2}
Min. 80C
SAE10W30DH
At low idle
SAE15W40DH
MPa
Engine oil temperature:
{kg/cm2}
SAE30DH
Min. 80C

Min. 0.10
{Min. 1.0}

0.08
{0.8}

At sudden acceleration (Low High)


Exhaust gas color

Valve clearance

EGR valve and bypass


valve drive oil pressure

12

20 Standard value table

Oil temperature

Whole speed range

90 to 110

120

Oil consumption

Ratio to fuel consumption at continuous


rated horsepower

Max. 0.15

0.3

Function of radiator
pressure valve

Cracking pressure
(Differential pressure)

kPa
{kg/cm2}

Fan speed

At rated speed

rpm

1,020 30

1,020 30

Fan belt tension

Deflection under finger pressure of 98 N


{10 kg}

mm

13 to 15
(when new)

17 to 19
(when retightened)

Alternator belt tension

Deflection under finger pressure of 98 N


{10 kg}

mm

13 to 16

13 to 16

140E-5 Series

Air intake and exhaust system

Performance Category

20 Standard value table

Item

Speed
Necessary speed for
starting

Body
Lubrication system

Engine

SAA6D140E-5

Machine models

HD325-7R
HD405-7R
Unit

Standard value for


new machine

Repair limit

Max. speed with no load

rpm

2,300 25

2,300 25

Min. speed with no load

rpm

725 25

725 25

At 0C (without starting aid)

rpm

Min. 110

At 20C (with starting aid)

rpm

Min. 85

Max. 3.73
{Max. 380}

7.47
{762}

Measurement conditions

Air intake resistance

Whole speed range

kPa
{mmH2O}

Air boost pressure

At rated horsepower

kPa
{mmHg}

Min. 135
{Min. 1,010}

115
{860}

Exhaust pressure

At rated horsepower

kPa
{mmHg}

Min. 121
{Min. 910}

103
{770}

Exhaust temperature

Whole speed range (20C)

Max. 680

730

% (Bosch
index)

Max. 40
(Max. 4.0)

50
(5.0)

At rated horsepower

Bosch
index

Max. 1.5

2.5

At high idle

Bosch
index

Max. 1.0

2.0

Intake valve

mm

0.35

Exhaust valve

mm

0.57

At sudden acceleration (Low High)


Exhaust gas color

Valve clearance

Cooling system

SEN00147-07

Compression pressure

Engine oil temperature: 40 to 60C


Engine speed: 200 to 250 rpm

MPa
{kg/cm2}

Min. 4.1
{Min. 42}

2.8
{29}

Blow-by pressure

At rated horsepower
Engine coolant temperature: Min. 70C

kPa
{mmH2O}

Max. 2.94
{Max. 300}

3.92
{400}

Min. 0.34
{Min. 3.5}

0.21
{2.1}

Oil pressure

At rated horsepower
SAE0W30EOS
MPa
Engine oil temperature:
SAE5W40EOS {kg/cm2}
Min. 80C
SAE10W30DH
At low idle
SAE15W40DH
MPa
Engine oil temperature:
2
}
{kg/cm
SAE30DH
Min. 80C

Min. 0.10
{Min. 1.0}

0.08
{0.8}

Oil temperature

Whole speed range

90 to 110

120

Oil consumption

Ratio to fuel consumption at continuous


rated horsepower

Max. 0.15

0.3

Function of radiator
pressure valve

Cracking pressure
(Differential pressure)

kPa
{kg/cm2}

Fan speed

At rated speed

rpm

1,020 30

1,020 30

Fan belt tension

Deflection under finger pressure of 98 N


{10 kg}

mm

13 to 15
(when new)

17 to 19
(when retightened)

Alternator belt tension

Deflection under finger pressure of 98 N


{10 kg}

mm

13 to 16

13 to 16

140E-5 Series

13

Air intake and exhaust system

Performance Category

SEN00147-07

Body
Lubrication system
Cooling system

Engine

SAA6D140E-5

Machine models

HM350-2
Unit

Standard value for


new machine

Repair limit

Max. speed with no load

rpm

2,200(+50/0)

2,200(+50/0)

Min. speed with no load

rpm

725 25

725 25

Necessary speed for


starting

At 0C (without starting aid)

rpm

Min. 110

At 20C (with starting aid)

rpm

Min. 85

Air intake resistance

Whole speed range

kPa
{mmH2O}

Max. 3.73
{Max. 380}

7.47
{762}

Air boost pressure

At rated horsepower

kPa
{mmHg}

Min. 145
{Min. 1,090}

124
{930}

Exhaust pressure

At rated horsepower

kPa
{mmHg}

Min. 148
{Min. 1,110}

127
{950}

Exhaust temperature

Whole speed range (20C)

Max. 620

670

% (Bosch
index)

Max. 25
(Max. 2.5)

35
(3.5)

At rated horsepower

Bosch
index

Max. 1.5

2.5

At high idle

Bosch
index

Max. 1.0

2.0

Intake valve

mm

0.35

Exhaust valve

mm

0.57

At low idle

MPa
{kg/cm2}

Min. 1.18
{Min. 12}

Min. 1.18
{Min. 12}

At high idle

MPa
{kg/cm2}

Min. 1.43
{Min. 14.6}

Min. 1.43
{Min. 14.6}

Compression pressure

Engine oil temperature: 40 to 60C


Engine speed: 200 to 250 rpm

MPa
{kg/cm2}

Min. 4.1
{Min. 42}

2.8
{29}

Blow-by pressure

At rated horsepower
kPa
Engine coolant temperature: Min. 70C {mmH2O}

Max. 2.94
{Max. 300}

3.92
{400}

Min. 0.34
{Min. 3.5}

0.21
{2.1}

Oil pressure

At rated horsepower
SAE0W30EOS
MPa
Engine oil temperature:
SAE5W40EOS {kg/cm2}
Min. 80C
SAE10W30DH
At low idle
SAE15W40DH
MPa
Engine oil temperature:
{kg/cm2}
SAE30DH
Min. 80C

Min. 0.10
{Min. 1.0}

0.08
{0.8}

Item

Speed

Measurement conditions

At sudden acceleration (Low High)


Exhaust gas color

Valve clearance

EGR valve and bypass


valve drive oil pressure

14

20 Standard value table

Oil temperature

Whole speed range

90 to 110

120

Oil consumption

Ratio to fuel consumption at continuous


rated horsepower

Max. 0.15

0.3

Function of radiator
pressure valve

Cracking pressure
(Differential pressure)

kPa
{kg/cm2}

Fan speed

At rated speed

rpm

1,256 38

1,256 38

Fan belt tension

Deflection under finger pressure of 98 N


{10 kg}

mm

13 to 15
(when new)

17 to 19
(when retightened)

Alternator belt tension

Deflection under finger pressure of 98 N


{10 kg}

mm

13 to 16

13 to 16

140E-5 Series

Air intake and exhaust system

Performance Category

20 Standard value table

Body
Lubrication system

Engine

SAA6D140E-5

Machine models

HM350-2R
Unit

Standard value for


new machine

Repair limit

Max. speed with no load

rpm

2,200(+50/0)

2,200(+50/0)

Min. speed with no load

rpm

725 25

725 25

Necessary speed for


starting

At 0C (without starting aid)

rpm

Min. 110

At 20C (with starting aid)

rpm

Min. 85

Air intake resistance

Whole speed range

kPa
{mmH2O}

Max. 3.73
{Max. 380}

7.47
{762}

Air boost pressure

At rated horsepower

kPa
{mmHg}

Min. 98
{Min. 730}

83
{620}

Exhaust pressure

At rated horsepower

kPa
{mmHg}

Min. 104
{Min. 780}

88
{660}

Exhaust temperature

Whole speed range (20C)

Max. 670

720

% (Bosch
index)

Max. 40
(Max. 4.0)

50
(5.0)

At rated horsepower

Bosch
index

Max. 1.5

2.5

At high idle

Bosch
index

Max. 1.0

2.0

Intake valve

mm

0.35

Exhaust valve

mm

0.57

Item

Speed

Measurement conditions

At sudden acceleration (Low High)


Exhaust gas color

Valve clearance

Cooling system

SEN00147-07

Compression pressure

Engine oil temperature: 40 to 60C


Engine speed: 200 to 250 rpm

MPa
{kg/cm2}

Min. 4.1
{Min. 42}

2.8
{29}

Blow-by pressure

At rated horsepower
Engine coolant temperature: Min. 70C

kPa
{mmH2O}

Max. 2.94
{Max. 300}

3.92
{400}

Min. 0.34
{Min. 3.5}

0.21
{2.1}

Oil pressure

At rated horsepower
SAE0W30EOS
MPa
Engine oil temperature:
{kg/cm2}
SAE5W40EOS
Min. 80C
SAE10W30DH
At low idle
SAE15W40DH
MPa
Engine oil temperature:
{kg/cm2}
SAE30DH
Min. 80C

Min. 0.10
{Min. 1.0}

0.08
{0.8}

Oil temperature

Whole speed range

90 to 110

120

Oil consumption

Ratio to fuel consumption at continuous


rated horsepower

Max. 0.15

0.3

Function of radiator
pressure valve

Cracking pressure
(Differential pressure)

kPa
{kg/cm2}

Fan speed

At rated speed

rpm

1,256 38

1,256 38

Fan belt tension

Deflection under finger pressure of 98 N


{10 kg}

mm

13 to 15
(when new)

17 to 19
(when retightened)

Alternator belt tension

Deflection under finger pressure of 98 N


{10 kg}

mm

13 to 16

13 to 16

140E-5 Series

15

Air intake and exhaust system

Performance Category

SEN00147-07

Body
Lubrication system
Cooling system

Engine

SAA6D140E-5

Machine models

HM400-2, HM400-3M0
Unit

Standard value for


new machine

Repair limit

Max. speed with no load

rpm

2,200(+50/0)

2,200(+50/0)

Min. speed with no load

rpm

725 25

725 25

Necessary speed for


starting

At 0C (without starting aid)

rpm

Min. 110

At 20C (with starting aid)

rpm

Min. 85

Air intake resistance

Air intake resistance

kPa
{mmH2O}

Max. 3.73
{Max. 380}

7.47
{762}

Air boost pressure

At rated horsepower

kPa
{mmHg}

Min. 160
{Min. 1,200}

136
{1,020}

Exhaust pressure

At rated horsepower

kPa
{mmHg}

Min. 163
{Min. 1,220}

139
{1,040}

Exhaust temperature

Whole speed range (20C)

Max. 650

700

% (Bosch
index)

Max. 25
(Max. 2.5)

35
(3.5)

At rated horsepower

Bosch
index

Max. 1.5

2.5

At high idle

Bosch
index

Max. 1.0

2.0

Intake valve

mm

0.35

Exhaust valve

mm

0.57

At low idle

MPa
{kg/cm2}

Min. 1.18
{Min. 12}

Min. 1.18
{Min. 12}

At high idle

MPa
{kg/cm2}

Min. 1.43
{Min. 14.6}

Min. 1.43
{Min. 14.6}

Compression pressure

Engine oil temperature: 40 to 60C


Engine speed: 200 to 250 rpm

MPa
{kg/cm2}

Min. 4.1
{Min. 42}

2.8
{29}

Blow-by pressure

At rated horsepower
kPa
Engine coolant temperature: Min. 70C {mmH2O}

Max. 2.94
{Max. 300}

3.92
{400}

Min. 0.34
{Min. 3.5}

0.21
{2.1}

Oil pressure

At rated horsepower
SAE0W30EOS
MPa
Engine oil temperature:
SAE5W40EOS {kg/cm2}
Min. 80C
SAE10W30DH
At low idle
MPa
SAE15W40DH
Engine oil temperature:
{kg/cm2}
SAE30DH
Min. 80C

Min. 0.10
{Min. 1.0}

0.08
{0.8}

Item

Speed

Measurement conditions

At sudden acceleration (Low High)


Exhaust gas color

Valve clearance

EGR valve and bypass


valve drive oil pressure

16

20 Standard value table

Oil temperature

Whole speed range

90 to 110

120

Oil consumption

Ratio to fuel consumption at continuous


rated horsepower

Max. 0.15

0.3

Function of radiator
pressure valve

Cracking pressure
(Differential pressure)

kPa
{kg/cm2}

Fan speed

At rated speed

rpm

Hydraulically driven on machine side

Fan belt tension

Deflection under finger pressure of 98 N


{10 kg}

mm

Hydraulically driven on machine side

Alternator belt tension

Deflection under finger pressure of 98 N


{10 kg}

mm

13 to 16

13 to 16

140E-5 Series

Air intake and exhaust system

Performance Category

20 Standard value table

Body
Lubrication system

Engine

SAA6D140E-5

Machine models

HM400-2R, HM400-3R
Unit

Standard value for


new machine

Repair limit

Max. speed with no load

rpm

2,200(+50/0)

2,200(+50/0)

Min. speed with no load

rpm

725 25

725 25

Necessary speed for


starting

At 0C (without starting aid)

rpm

Min. 110

At 20C (with starting aid)

rpm

Min. 85

Air intake resistance

Air intake resistance

kPa
{mmH2O}

Max. 3.73
{Max. 380}

7.47
{762}

Air boost pressure

At rated horsepower

kPa
{mmHg}

Min. 111
{Min. 830}

94
{700}

Exhaust pressure

At rated horsepower

kPa
{mmHg}

Min. 115
{Min. 860}

98
{730}

Exhaust temperature

Whole speed range (20C)

Max. 670

720

% (Bosch
index)

Max. 40
(Max. 4.0)

50
(5.0)

At rated horsepower

Bosch
index

Max. 1.5

2.5

At high idle

Bosch
index

Max. 1.0

2.0

Intake valve

mm

0.35

Exhaust valve

mm

0.57

Item

Speed

Measurement conditions

At sudden acceleration (Low High)


Exhaust gas color

Valve clearance

Cooling system

SEN00147-07

Compression pressure

Engine oil temperature: 40 to 60C


Engine speed: 200 to 250 rpm

MPa
{kg/cm2}

Min. 4.1
{Min. 42}

2.8
{29}

Blow-by pressure

At rated horsepower
Engine coolant temperature: Min. 70C

kPa
{mmH2O}

Max. 2.94
{Max. 300}

3.92
{400}

Min. 0.34
{Min. 3.5}

0.21
{2.1}

Oil pressure

At rated horsepower
SAE0W30EOS
MPa
Engine oil temperature:
SAE5W40EOS {kg/cm2}
Min. 80C
SAE10W30DH
At low idle
MPa
SAE15W40DH
Engine oil temperature:
{kg/cm2}
SAE30DH
Min. 80C

Min. 0.10
{Min. 1.0}

0.08
{0.8}

Oil temperature

Whole speed range

90 to 110

120

Oil consumption

Ratio to fuel consumption at continuous


rated horsepower

Max. 0.15

0.3

Function of radiator
pressure valve

Cracking pressure
(Differential pressure)

kPa
{kg/cm2}

Fan speed

At rated speed

rpm

Hydraulically driven on machine side

Fan belt tension

Deflection under finger pressure of 98 N


{10 kg}

mm

Hydraulically driven on machine side

Alternator belt tension

Deflection under finger pressure of 98 N


{10 kg}

mm

140E-5 Series

13 to 16

13 to 16

17

SEN00147-07

20 Standard value table

Engine

SAA6D140E-5
SDG400S-6B1

Air intake and exhaust system

Performance Category

Machine models

Item

Speed

Body
Lubrication system
Cooling system

Unit

Standard value for


new machine

Repair limit

Max. speed with no load

rpm

1,890 50

1,890 50

Min. speed with no load

rpm

875 25

875 25

Measurement conditions

Necessary speed for


starting

At 0C (without starting aid)

rpm

Min. 110

At 20C (with starting aid)

rpm

Min. 85

Air intake resistance

Whole speed range

kPa
{mmH2O}

Max. 3.73
{Max. 380}

7.47
{762}

Air boost pressure

At rated horsepower

kPa
{mmHg}

Min. 207
{Min. 1,550}

171
{1,280}

Exhaust pressure

At rated horsepower

kPa
{mmHg}

Min. 185
{Min. 1,390}

153
{1,150}

Exhaust temperature

Whole speed range (20C)

Max. 670

700

% (Bosch
index)

()

()

At rated horsepower

Bosch
index

Max. 1.5

2.5

At high idle

Bosch
index

Max. 1.0

2.0

Intake valve

mm

0.35

Exhaust valve

mm

0.57

At low idle

MPa
{kg/cm2}

Min. 1.18
{Min. 12}

Min. 1.18
{Min. 12}

At high idle

MPa
{kg/cm2}

Min. 1.43
{Min. 14.6}

Min. 1.43
{Min. 14.6}

Compression pressure

Engine oil temperature: 40 to 60C


Engine speed: 200 to 250 rpm

MPa
{kg/cm2}

Min. 4.1
{Min. 42}

2.8
{29}

Blow-by pressure

At rated horsepower
Engine coolant temperature: Min. 70C

kPa
{mmH2O}

Max. 2.94
{Max. 300}

3.92
{400}

Min. 0.34
{Min. 3.5}

0.21
{2.1}

Oil pressure

At rated horsepower
MPa
Engine oil temperature: SAE0W30EOS
2
}
{kg/cm
SAE5W40EOS
Min. 80C
SAE10W30DH
At low idle
SAE15W40DH
MPa
Engine oil temperature: SAE30DH
{kg/cm2}
Min. 80C

Min. 0.10
{Min. 1.0}

0.08
{0.8}

At sudden acceleration (Low High)


Exhaust gas color

Valve clearance

EGR valve and bypass


valve drive oil pressure

18

(HOKUETSU INDUSTRIES GENERATOR)

Oil temperature

Whole speed range

90 to 110

120

Oil consumption

Ratio to fuel consumption at continuous


rated horsepower

Max. 0.15

0.3

Function of radiator
pressure valve

Cracking pressure
(Differential pressure)

kPa
{kg/cm2}

Fan speed

At rated speed

rpm

1,329 40

1,329 40

Fan belt tension

Deflection under finger pressure of 98 N


{10 kg}

mm

13 to 15
(When new)

17 to 19

Alternator belt tension

Deflection under finger pressure of 98 N


{10 kg}

mm

13 to 16

13 to 16

140E-5 Series

20 Standard value table

SEN00147-07

Running-in standard and performance test standard

Running-in standard
Engine

SAA6D140E-5

Machine models

D155AX-6
Procedure

Item

Running time

min.

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
a

This table shows the values when the fan is not installed.
The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.

Performance test standard


Engine

SAA6D140E-5

Machine models

D155AX-6

Test item

Rated horsepower

Max. torque

High idle speed

Low idle speed

Specification value
(Gross value)

Speed

rpm

1,900

1,300

2,100(0/50)

740(+40/0)

Dynamometer load

N
{kg}

1,823 to 1,940
{186 to 198}

2,460 to 2,607
{251 to 266}

Output (Gross value)

kW
{HP}

260 to 277
{349 to 371}

Torque (Gross value)

Nm
{kgm}

1,758 to 1,868
{179.4 to 190.6}

Fuel consumption

sec/300cc

Min. 16.0

Coolant temperature

70 to 90

70 to 90

70 to 90

70 to 90

Lubricating oil
temperature

90 to 110

90 to 110

90 to 110

80 to 110

Lubricating oil
pressure

kPa
{kg/cm2}

340 to 490
{3.5 to 5.0}

340 to 490
{3.5 to 5.0}

340 to 490
{3.5 to 5.0}

Min. 120
{Min. 1.2}

Exhaust temperature

Max. 650

Max. 650

a
a
a
a
a
a

268 kW/1,900 rpm 1,834 Nm/1,300 rpm


2,100(0/50) rpm
{359.9 HP/1,900 rpm} {187 kgm/1,300 rpm}

740(+40/0) rpm

This table shows the standard values obtained by using the JIS correction coefficients.
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.
This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Use ASTM No.1 or No. 2 diesel fuel as fuel.
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

Running time

min.

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
a

This table shows the values when the fan is not installed.
The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.

Performance test standard


Engine

SAA6D140E-5

Machine models

D155A-6

Test item

Rated horsepower

Max. torque

High idle speed

Specification value
(Gross value)

Speed

rpm

1,900

1,300

2,100(0/50)

740(+40/0)

Dynamometer load

N
{kg}

1,823 to 1,940
{186 to 198}

2,482 to 2,635
{253 to 269}

Output (Gross value)

kW
{HP}

260 to 277
{349 to 371}

Torque (Gross value)

Nm
{kgm}

1,778 to 1,888
{181.4 to 192.6}

Fuel consumption

sec/300cc

Min. 16.0

Coolant temperature

70 to 90

70 to 90

70 to 90

70 to 90

Lubricating oil
temperature

90 to 110

90 to 110

90 to 110

80 to 110

Lubricating oil
pressure

kPa
{kg/cm2}

340 to 490
{3.5 to 5.0}

340 to 490
{3.5 to 5.0}

340 to 490
{3.5 to 5.0}

Min. 120
{Min. 1.2}

Exhaust temperature

Max. 670

Max. 670

a
a
a
a
a
a

20

268 kW/1,900 rpm 1,834 Nm/1,300 rpm


2,100(0/50) rpm
{359.9 HP/1,900 rpm} {187 kgm/1,300 rpm}

Low idle speed


740(+40/0) rpm

This table shows the standard values obtained by using the JIS correction coefficients.
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.
This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Use ASTM No.1 or No. 2 diesel fuel as fuel.
Use SAE15W-40 as lubricating oil.

140E-5 Series

20 Standard value table

SEN00147-07

Running-in standard
Engine

SAA6D140E-5

Machine models

D275AX-5E0
Procedure

Item

Running time

min.

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
a

This table shows the values when the fan is not installed.
The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.

Performance test standard


Engine

SAA6D140E-5

Machine models

D275AX-5E0

Test item

Rated horsepower

Max. torque

Low idle speed

2,200 50 rpm

700 50 rpm

Specification value
(Gross value)

Speed

rpm

2,000

1,400

2,200 50

700 50

Dynamometer load

N
{kg}

2,177 to 2,314
{222.0 to 236.0}

2,753 to 2,917
{280.7 to 297.5}

Output
(Gross value)

kW
{HP}

327 to 347
{438 to 465}

Torque (Gross value)

Nm
{kgm}

1,970 to 2,087
{201 to 213}

Fuel consumption

sec/300cc

Min. 12.8

Coolant temperature

70 to 90

70 to 90

70 to 90

70 to 90

Lubricating oil
temperature

90 to 110

90 to 110

90 to 110

90 to 110

Lubricating oil
pressure

kPa
{kg/cm2}

340 to 490
{3.5 to 5.0}

340 to 490
{3.5 to 5.0}

340 to 490
{3.5 to 5.0}

Min. 120
{Min. 1.2}

Exhaust temperature

Max. 650

Max. 650

a
a
a
a
a
a

337 kW/2,000 rpm 2,030 Nm/1,400 rpm


{451.6 HP/2,000 rpm} {207 kgm/1,400 rpm}

High idle speed

This table shows the standard values obtained by using the JIS correction coefficients.
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.
This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Use ASTM No.1 or No. 2 diesel fuel as fuel.
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

Running time

min.

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
a

This table shows the values when the fan is not installed.
The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.

Performance test standard


Engine

SAA6D140E-5

Machine models

D275A-5R

Test item

Rated horsepower

Max. torque

Low idle speed

2,200 50 rpm

700 50 rpm

Specification value
(Gross value)

Speed

rpm

2,000

1,400

2,200 50

700 50

Dynamometer load

N
{kg}

2,177 to 2,314
{222.0 to 236.0}

2,753 to 2,917
{280.7 to 297.5}

Output
(Gross value)

kW
{HP}

327 to 347
{438 to 465}

Torque (Gross value)

Nm
{kgm}

1,970 to 2,087
{201 to 213}

Fuel consumption

sec/300cc

Min. 12.8

Coolant temperature

70 to 90

70 to 90

70 to 90

70 to 90

Lubricating oil
temperature

90 to 110

90 to 110

90 to 110

90 to 110

Lubricating oil
pressure

kPa
{kg/cm2}

340 to 490
{3.5 to 5.0}

340 to 490
{3.5 to 5.0}

340 to 490
{3.5 to 5.0}

Min. 120
{Min. 1.2}

Exhaust temperature

Max. 670

Max. 670

a
a
a
a
a
a

22

337 kW/2,000 rpm 2,030 Nm/1,400 rpm


{451.6 HP/2,000 rpm} {207 kgm/1,400 rpm}

High idle speed

This table shows the standard values obtained by using the JIS correction coefficients.
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.
This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Use ASTM No.1 or No. 2 diesel fuel as fuel.
Use SAE15W-40 as lubricating oil.

140E-5 Series

20 Standard value table

SEN00147-07

Running-in standard
Engine

SAA6D140E-5

Machine models

PC600-8, PC600LC-8, PC600-8E0, PC600LC-8E0


PC700-8E0, PC700LC-8E0
Procedure

Item

Running time

min.

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
a

This table shows the values when the fan is not installed.
The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.

Performance test standard


Engine

SAA6D140E-5

Machine models

PC600-8, PC600LC-8, PC600-8E0, PC600LC-8E0


PC700-8E0, PC700LC-8E0

Test item

Rated horsepower

Max. torque

High idle speed

Low idle speed

Specification value
(Gross value)

323 kW/1,800 rpm


{433.3 HP/
1,800 rpm}

1,944Nm/1,400rpm
{198.4 kgm/
1,400 rpm}

1,950 50 rpm

800 25 rpm

Speed

rpm

1,800

1,400

1,950 50

800 25

Dynamometer load

N
{kg}

2,323 to 2,470
{237 to 252}

2,626 to 2,793
{268 to 285}

Output (Gross value)

kW
{HP}

313 to 333
{420 to 447}

Torque (Gross value)

Nm
{kgm}

1,882 to 1,999
{192 to 204}

Fuel consumption

sec/300cc

Min. 13.8

Coolant temperature

70 to 90

70 to 90

70 to 90

70 to 90

Lubricating oil
temperature

90 to 110

90 to 110

90 to 110

80 to 110

Lubricating oil
pressure

kPa
{kg/cm2}

340 to 490
{3.5 to 5.0}

340 to 490
{3.5 to 5.0}

340 to 490
{3.5 to 5.0}

Min. 120
{Min. 1.2}

Exhaust temperature

Max. 650

Max. 650

a
a
a
a
a
a

This table shows the standard values obtained by using the JIS correction coefficients.
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.
This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Use ASTM No.1 or No. 2 diesel fuel as fuel.
Use SAE15W-40 as lubricating oil.

140E-5 Series

23

SEN00147-07

20 Standard value table

Running-in standard
Engine

SAA6D140E-5

Machine models

PC600-8R, PC600LC-8R,
PC600-8R1, PC600LC-8R1,
PC700-8R, PC700LC-8R, PC700LC-8R1
Procedure

Item

Running time

min.

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
a

This table shows the values when the fan is not installed.
The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.

Performance test standard


Engine

SAA6D140E-5

Machine models

PC600-8R, PC600LC-8R,
PC600-8R1, PC600LC-8R1,
PC700-8R, PC700LC-8R, PC700LC-8R1

Test item

Rated horsepower

Max. torque

High idle speed

Low idle speed

Specification value
(Gross value)

323 kW/1,800 rpm


{433.3 HP/
1,800 rpm}

1,944Nm/1,400rpm
{198.4 kgm/
1,400 rpm}

1,950 50 rpm

800 25 rpm

Speed

rpm

1,800

1,400

1,950 50

800 25

Dynamometer load

N
{kg}

2,323 to 2,470
{237 to 252}

2,626 to 2,793
{268 to 285}

Output (Gross value)

kW
{HP}

313 to 333
{420 to 447}

Torque (Gross value)

Nm
{kgm}

1,882 to 1,999
{192 to 204}

Fuel consumption

sec/300cc

Min. 13.8

Coolant temperature

70 to 90

70 to 90

70 to 90

70 to 90

Lubricating oil
temperature

90 to 110

90 to 110

90 to 110

80 to 110

Lubricating oil
pressure

kPa
{kg/cm2}

340 to 490
{3.5 to 5.0}

340 to 490
{3.5 to 5.0}

340 to 490
{3.5 to 5.0}

Min. 120
{Min. 1.2}

Exhaust temperature

Max. 700

Max. 700

a
a
a
a
a
a

24

This table shows the standard values obtained by using the JIS correction coefficients.
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.
This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Use ASTM No.1 or No. 2 diesel fuel as fuel.
Use SAE15W-40 as lubricating oil.

140E-5 Series

20 Standard value table

SEN00147-07

Running-in standard
Engine

SAA6D140E-5

Machine models

PC800-8, PC800SE-8, PC800LC-8, PC850-8, PC850SE-8


PC800-8E0, PC800SE-8E0, PC800LC-8E0, PC850-8E0, PC850SE-8E0
Procedure

Item

Running time

min.

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
a

This table shows the values when the fan is not installed.
The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.

Performance test standard


Engine

SAA6D140E-5

Machine models

PC800-8, PC800SE-8, PC800LC-8, PC850-8, PC850SE-8


PC800-8E0, PC800SE-8E0, PC800LC-8E0, PC850-8E0, PC850SE-8E0

Test item

Rated horsepower

Max. torque

High idle speed

Low idle speed

Specification value
(Gross value)

370 kW/1,800 rpm


{496.4 HP/
1,800 rpm}

2,195 Nm/1,350 rpm


{223.8 kgm/
1,350 rpm}

1,980 50 rpm

825 25 rpm

Speed

rpm

1,800

1,350

1,980 50

825 25

Dynamometer load

N
{kg}

2,550 to 2,690
{260 to 274}

2,930 to 3,100
{299 to 316}

Output (Gross value)

kW
{HP}

359 to 381
{481 to 512}

Torque (Gross value)

Nm
{kgm}

2,126 to 2,264
{217 to 231}

Fuel consumption

sec/300cc

Min. 12.3

Coolant temperature

70 to 90

70 to 90

70 to 90

70 to 90

Lubricating oil
temperature

90 to 110

90 to 110

90 to 110

80 to 110

Lubricating oil
pressure

kPa
{kg/cm2}

340 to 490
{3.5 to 5.0}

340 to 490
{3.5 to 5.0}

340 to 490
{3.5 to 5.0}

Min. 120
{Min. 1.2}

Exhaust temperature

Max. 650

Max. 650

a
a
a
a
a
a

This table shows the standard values obtained by using the JIS correction coefficients.
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.
This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Use ASTM No.1 or No. 2 diesel fuel as fuel.
Use SAE15W-40 as lubricating oil.

140E-5 Series

25

SEN00147-07

20 Standard value table

Running-in standard
Engine

SAA6D140E-5

Machine models

PC800-8R, PC800SE-8R, PC800LC-8R, PC850-8R, PC850SE-8R


PC800-8R1, PC800SE-8R1, PC800LC-8R1, PC850-8R1, PC850SE-8R1
Procedure

Item

Running time

min.

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
a

This table shows the values when the fan is not installed.
The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.

Performance test standard


Engine

SAA6D140E-5

Machine models

PC800-8R, PC800SE-8R, PC800LC-8R, PC850-8R, PC850SE-8R


PC800-8R1, PC800SE-8R1, PC800LC-8R1, PC850-8R1, PC850SE-8R1

Test item

Rated horsepower

Max. torque

High idle speed

Low idle speed

Specification value
(Gross value)

370 kW/1,800 rpm


{496.4 HP/
1,800 rpm}

2,195 Nm/1,350 rpm


{223.8 kgm/
1,350 rpm}

1,980 50 rpm

825 25 rpm

Speed

rpm

1,800

1,350

1,980 50

825 25

Dynamometer load

N
{kg}

2,550 to 2,690
{260 to 274}

2,969 to 3,162
{303 to 323}

Output (Gross value)

kW
{HP}

359 to 381
{481 to 512}

Torque (Gross value)

Nm
{kgm}

2,126 to 2,264
{217 to 231}

Fuel consumption

sec/300cc

Min. 12.3

Coolant temperature

70 to 90

70 to 90

70 to 90

70 to 90

Lubricating oil
temperature

90 to 110

90 to 110

90 to 110

80 to 110

Lubricating oil
pressure

kPa
{kg/cm2}

340 to 490
{3.5 to 5.0}

340 to 490
{3.5 to 5.0}

340 to 490
{3.5 to 5.0}

Min. 120
{Min. 1.2}

Exhaust temperature

Max. 700

Max. 700

a
a
a
a
a
a

26

This table shows the standard values obtained by using the JIS correction coefficients.
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.
This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Use ASTM No.1 or No. 2 diesel fuel as fuel.
Use SAE15W-40 as lubricating oil.

140E-5 Series

20 Standard value table

SEN00147-07

Running-in standard
Engine

SAA6D140E-5

Machine models

WA500-6
Procedure

Item

Running time

min.

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
a

This table shows the values when the fan is not installed.
The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.

Performance test standard


Engine

SAA6D140E-5

Machine models

WA500-6

Test item

Rated horsepower

Max. torque

Low idle speed

2,150 50 rpm

700 25 rpm

Specification value
(Gross value)

Speed

rpm

1,900

1,250

2,150 50

700 25

Dynamometer load

N
{kg}

1,744 to 1,852
{178 to 189}

2,440 to 2,597
{249 to 265}

Output (Gross value)

kW
{HP}

248 to 263
{333 to 353}

Torque (Gross value)

Nm
{kgm}

1,744 to 1,862
{178 to 190}

Fuel consumption

sec/300cc

Min. 16.8

Coolant temperature

70 to 90

70 to 90

70 to 90

70 to 90

Lubricating oil
temperature

90 to 110

90 to 110

90 to 110

80 to 110

Lubricating oil
pressure

kPa
{kg/cm2}

340 to 490
{3.5 to 5.0}

340 to 490
{3.5 to 5.0}

340 to 490
{3.5 to 5.0}

Min. 120
{Min. 1.2}

Exhaust temperature

Max. 650

Max. 650

a
a
a
a
a
a

266 kW/1,900 rpm 1,803 Nm/1,250 rpm


{357 HP/1,900 rpm} {184 kgm/1,250 rpm}

High idle speed

This table shows the standard values obtained by using the JIS correction coefficients.
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.
This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Use ASTM No.1 or No. 2 diesel fuel as fuel.
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

Running time

min.

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
a

This table shows the values when the fan is not installed.
The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.

Performance test standard


Engine

SAA6D140E-5

Machine models

WA500-6R

Test item

Rated horsepower

Max. torque

Low idle speed

2,150 50 rpm

700 25 rpm

Specification value
(Gross value)

Speed

rpm

1,900

1,250

2,150 50

700 25

Dynamometer load

N
{kg}

1,814 to 1,922
{185 to 196}

2,440 to 2,597
{249 to 265}

Output (Gross value)

kW
{HP}

258 to 274
{346 to 368}

Torque (Gross value)

Nm
{kgm}

1,744 to 1,862
{178 to 190}

Fuel consumption

sec/300cc

Min. 16.8

Coolant temperature

70 to 90

70 to 90

70 to 90

70 to 90

Lubricating oil
temperature

90 to 110

90 to 110

90 to 110

80 to 110

Lubricating oil
pressure

kPa
{kg/cm2}

340 to 490
{3.5 to 5.0}

340 to 490
{3.5 to 5.0}

340 to 490
{3.5 to 5.0}

Min. 120
{Min. 1.2}

Exhaust temperature

Max. 670

Max. 670

a
a
a
a
a
a

28

266 kW/1,900 rpm 1,803 Nm/1,250 rpm


{357 HP/1,900 rpm} {184 kgm/1,250 rpm}

High idle speed

This table shows the standard values obtained by using the JIS correction coefficients.
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.
This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Use ASTM No.1 or No. 2 diesel fuel as fuel.
Use SAE15W-40 as lubricating oil.

140E-5 Series

20 Standard value table

SEN00147-07

Running-in standard
Engine

SAA6D140E-5

Machine models

HD325-7
HD405-7
Procedure

Item

Running time

min.

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
a

This table shows the values when the fan is not installed.
The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.

Performance test standard


Engine

SAA6D140E-5

Machine models

HD325-7
HD405-7

Test item

Rated horsepower

Max. torque

High idle speed

Low idle speed

2,300 25 rpm

725 25 rpm

Specification value
(Gross value)

Speed

rpm

2,000

1,400

2,300 25

725 25

Dynamometer load

N
{kg}

2,499 to 2,646
{255 to 270}

2,930 to 3,120
{299 to 318}

Output (Gross value)

kW
{HP}

374 to 398
{502 to 533}

Torque (Gross value)

Nm
{kgm}

2,100 to 2,230
{214 to 228}

Fuel consumption

sec/300cc

Min. 11.4

Coolant temperature

70 to 90

70 to 90

70 to 90

70 to 90

Lubricating oil
temperature

90 to 110

90 to 110

90 to 110

80 to 110

Lubricating oil
pressure

kPa
{kg/cm2}

340 to 490
{3.5 to 5.0}

340 to 490
{3.5 to 5.0}

340 to 490
{3.5 to 5.0}

Min. 120
{Min. 1.2}

Exhaust temperature

Max. 650

Max. 650

a
a
a
a
a

386 kW/2,000 rpm


2,170 Nm/1,400 rpm
{517.7 HP/2,000 rpm} {221.3 kgm/1,400 rpm}

This table shows the standard values obtained by using the JIS correction coefficients.
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.
This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
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

Machine models

HD325-7R
HD405-7R
Procedure

Item

Running time

min.

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
a

This table shows the values when the fan is not installed.
The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.

Performance test standard


Engine

SAA6D140E-5

Machine models

HD325-7R
HD405-7R

Test item

Rated horsepower

Max. torque

High idle speed

Low idle speed

2,300 25 rpm

725 25 rpm

Specification value
(Gross value)

Speed

rpm

2,000

1,400

2,300 25

725 25

Dynamometer load

N
{kg}

2,499 to 2,646
{255 to 270}

2,930 to 3,120
{299 to 318}

Output (Gross value)

kW
{HP}

374 to 398
{502 to 533}

Torque (Gross value)

Nm
{kgm}

2,100 to 2,230
{214 to 228}

Fuel consumption

sec/300cc

Min. 11.4

Coolant temperature

70 to 90

70 to 90

70 to 90

70 to 90

Lubricating oil
temperature

90 to 110

90 to 110

90 to 110

80 to 110

Lubricating oil
pressure

kPa
{kg/cm2}

340 to 490
{3.5 to 5.0}

340 to 490
{3.5 to 5.0}

340 to 490
{3.5 to 5.0}

Min. 120
{Min. 1.2}

Exhaust temperature

Max. 680

Max. 680

a
a
a
a
a
a

30

386 kW/2,000 rpm 2,170 Nm/1,400 rpm


{517.7 HP/2,000 rpm} {221.3 kgm/1,400 rpm}

This table shows the standard values obtained by using the JIS correction coefficients.
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.
This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Use ASTM No.1 or No. 2 diesel fuel as fuel.
Use SAE15W-40 as lubricating oil.

140E-5 Series

20 Standard value table

SEN00147-07

Running-in standard
Engine

SAA6D140E-5

Machine models

HM350-2
Procedure

Item

Running time

min.

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
a

This table shows the values when the fan is not installed.
The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.

Performance test standard


Engine

SAA6D140E-5

Machine models

HM350-2

Test item

Rated horsepower

Max. torque

High idle speed

Specification value
(Gross value)

Speed

rpm

2,000

1,400

2,200(+50/0)

725 25

Dynamometer load

N
{kg}

1,960 to 2,087
{200 to 213}

2,695 to 2,862
{275 to 292}

Output (Gross value)

kW
{HP}

295 to 315
{395 to 419}

Torque (Gross value)

Nm
{kgm}

1,931 to 2,048
{197 to 209}

Fuel consumption

sec/300cc

Min. 13.8

Coolant temperature

70 to 90

70 to 90

70 to 90

70 to 90

Lubricating oil temperature

90 to 110

90 to 110

90 to 110

80 to 110

Lubricating oil pressure

kPa
{kg/cm2}

340 to 490
{3.5 to 5.0}

340 to 490
{3.5 to 5.0}

340 to 490
{3.5 to 5.0}

Min. 120
{Min. 1.2}

Exhaust temperature

Max. 650

Max. 650

a
a
a
a
a
a

304 kW/2,000 rpm 1,990 Nm/1,400 rpm


2,200(+50/0) rpm
{407.2 HP/2,000 rpm} {203 kgm/1,400 rpm}

Low idle speed


725 25 rpm

This table shows the standard values obtained by using the JIS correction coefficients.
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.
This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Use ASTM No.1 or No. 2 diesel fuel as fuel.
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

Running time

min.

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
a

This table shows the values when the fan is not installed.
The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.

Performance test standard


Engine

SAA6D140E-5

Machine models

HM350-2R

Test item

Rated horsepower

Max. torque

High idle speed

Specification value
(Gross value)

Speed

rpm

2,000

1,400

2,200(+50/0)

725 25

Dynamometer load

N
{kg}

1,960 to 2,087
{200 to 213}

2,695 to 2,862
{275 to 292}

Output (Gross value)

kW
{HP}

295 to 315
{395 to 419}

Torque (Gross value)

Nm
{kgm}

1,931 to 2,048
{197 to 209}

Fuel consumption

sec/300cc

Min. 13.8

Coolant temperature

70 to 90

70 to 90

70 to 90

70 to 90

Lubricating oil temperature

90 to 110

90 to 110

90 to 110

80 to 110

Lubricating oil pressure

kPa
{kg/cm2}

340 to 490
{3.5 to 5.0}

340 to 490
{3.5 to 5.0}

340 to 490
{3.5 to 5.0}

Min. 120
{Min. 1.2}

Exhaust temperature

Max. 670

Max. 670

a
a
a
a
a
a

32

304 kW/2,000 rpm 1,991 Nm/1,400 rpm


2,200(+50/0) rpm
{407.2 HP/2,000 rpm} {203 kgm/1,400 rpm}

Low idle speed


725 25 rpm

This table shows the standard values obtained by using the JIS correction coefficients.
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.
This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Use ASTM No.1 or No. 2 diesel fuel as fuel.
Use SAE15W-40 as lubricating oil.

140E-5 Series

20 Standard value table

SEN00147-07

Running-in standard
Engine

SAA6D140E-5

Machine models

HM400-2, HM400-3M0
Procedure

Item

Running time

min.

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
a

This table shows the values when the fan is not installed.
The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.

Performance test standard


Engine

SAA6D140E-5

Machine models

HM400-2, HM400-3M0

Test item

Rated horsepower

Max. torque

High idle speed

Specification value
(Gross value)

Speed

rpm

2,000

1,400

2,200(+50/0)

725 25

Dynamometer load

N
{kg}

2,185 to 2,313
{223 to 236}

2,832 to 2,999
{289 to 306}

Output (Gross value)

kW
{HP}

327 to 348
{439 to 466}

Torque (Gross value)

Nm
{kgm}

2,029 to 2,146
{207 to 219}

Fuel consumption

sec/300cc

Min. 13.0

Coolant temperature

70 to 90

70 to 90

70 to 90

70 to 90

Lubricating oil
temperature

90 to 110

90 to 110

90 to 110

80 to 110

Lubricating oil
pressure

kPa
{kg/cm2}

340 to 490
{3.5 to 5.0}

340 to 490
{3.5 to 5.0}

340 to 490
{3.5 to 5.0}

Min. 120
{Min. 1.2}

Exhaust temperature

Max. 650

Max. 650

a
a
a
a
a
a

338 kW/2,000 rpm 2,090 Nm/1,400 rpm


2,200(+50/0) rpm
{452.6 HP/2,000 rpm} {213 kgm/1,400 rpm}

Low idle speed


725 25 rpm

This table shows the standard values obtained by using the JIS correction coefficients.
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.
This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Use ASTM No.1 or No. 2 diesel fuel as fuel.
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

Running time

min.

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
a

This table shows the values when the fan is not installed.
The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.

Performance test standard


Engine

SAA6D140E-5

Machine models

HM400-2R, HM400-3R

Test item

Rated horsepower

Max. torque

High idle speed

Specification value
(Gross value)

Speed

rpm

2,000

1,400

2,200(+50/0)

725 25

Dynamometer load

N
{kg}

2,185 to 2,313
{223 to 236}

2,832 to 2,999
{289 to 306}

Output (Gross value)

kW
{HP}

327 to 348
{439 to 466}

Torque (Gross value)

Nm
{kgm}

2,029 to 2,146
{207 to 219}

Fuel consumption

sec/300cc

Min. 13.0

Coolant temperature

70 to 90

70 to 90

70 to 90

70 to 90

Lubricating oil
temperature

90 to 110

90 to 110

90 to 110

80 to 110

Lubricating oil
pressure

kPa
{kg/cm2}

340 to 490
{3.5 to 5.0}

340 to 490
{3.5 to 5.0}

340 to 490
{3.5 to 5.0}

Min. 120
{Min. 1.2}

Exhaust temperature

Max. 670

Max. 670

a
a
a
a
a
a

34

338 kW/2,000 rpm 2,090 Nm/1,400 rpm


2,200(+50/0) rpm
{452.6 HP/2,000 rpm} {213 kgm/1,400 rpm}

Low idle speed


725 25 rpm

This table shows the standard values obtained by using the JIS correction coefficients.
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.
This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Use ASTM No.1 or No. 2 diesel fuel as fuel.
Use SAE15W-40 as lubricating oil.

140E-5 Series

20 Standard value table

SEN00147-07

Running-in standard
Engine

SAA6D140E-5

Machine models

SDG400S-6B1 (HOKUETSU INDUSTRIES GENERATOR)


Procedure

Item

Running time

min.

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
a

This table shows the values when the fan is not installed.
The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.

Performance test standard


Engine

SAA6D140E-5

Machine models

SDG400S-6B1 (HOKUETSU INDUSTRIES GENERATOR)

Test item

Rated horsepower

Max. torque

High idle speed

Low idle speed

Specification value
(Gross value)

371 kW/1,800 rpm


{498 HP/1,800 rpm}

1,890 50 rpm

875 25 rpm

Speed

rpm

1,800

1,890 50

875 25

Dynamometer load

N
{kg}

2,695 to 2,813
{275 to 287}

Output (Gross value)

kW
{HP}

360 to 382
{483 to 512}

Torque (Gross value)

Nm
{kgm}

Fuel consumption

sec/300cc

Min. 10.8

Coolant temperature

70 to 90

70 to 90

70 to 90

Lubricating oil
temperature

90 to 110

90 to 110

80 to 110

Lubricating oil
pressure

kPa
{kg/cm2}

340 to 490
{3.5 to 5.0}

{}

340 to 490
{3.5 to 5.0}

Min. 120
{Min. 1.2}

Exhaust temperature

Max. 670

a
a
a
a
a
a

This table shows the standard values obtained by using the JIS correction coefficients.
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.
This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Use ASTM No.1 or No. 2 diesel fuel as fuel.
Use SAE15W-40 as lubricating oil.

140E-5 Series

35

SEN00147-07

KOMATSU 140E-5 Series engine


Form No. SEN00147-07

2012 KOMATSU
All Rights Reserved
Printed in Japan 12-12 (01)

36

SEN00149-05

ENGINE
1SHOP MANUAL

140E-5 Series

30 Testing and adjusting

Testing and adjusting


Testing and adjusting (with EGR).................................................................................................................... 3
Testing and adjusting tools list ............................................................................................................. 3
Sketches of special tools...................................................................................................................... 5
Testing air boost pressure .................................................................................................................... 6
Testing exhaust temperature................................................................................................................ 7
Adjusting valve clearance .................................................................................................................... 8
Testing compression pressure ............................................................................................................. 9
Testing blow-by pressure ....................................................................................................................11
Testing engine oil pressure ................................................................................................................ 12
Testing EGR valve and bypass valve drive oil pressure .................................................................... 13
Handling fuel system parts ................................................................................................................. 14
Releasing residual pressure in fuel system........................................................................................ 14
Testing fuel pressure .......................................................................................................................... 15
Reduced cylinder mode operation ..................................................................................................... 16
No-injection cranking.......................................................................................................................... 16
Testing fuel return rate and leakage................................................................................................... 17

140E-5 Series

SEN00149-05

30 Testing and adjusting

Bleeding air from fuel circuit ............................................................................................................... 20


Testing fuel system for leakage .......................................................................................................... 22
Testing and adjusting alternator belt tension ...................................................................................... 23
Testing and adjusting fan belt tension ................................................................................................ 24
Handling controller high-voltage circuit .............................................................................................. 25
Testing and adjusting (EGR-less).................................................................................................................. 26
Testing and adjusting tools list............................................................................................................ 26
Sketches of special tools.................................................................................................................... 28
Testing air boost pressure .................................................................................................................. 29
Testing exhaust temperature .............................................................................................................. 30
Adjusting valve clearance................................................................................................................... 31
Testing compression pressure............................................................................................................ 32
Testing blow-by pressure.................................................................................................................... 34
Testing engine oil pressure................................................................................................................. 35
Handling fuel system parts ................................................................................................................. 36
Releasing residual pressure in fuel system........................................................................................ 36
Testing fuel pressure .......................................................................................................................... 37
Reduced cylinder mode operation...................................................................................................... 38
No-injection cranking.......................................................................................................................... 38
Testing fuel return rate and leakage ................................................................................................... 39
Bleeding air from fuel circuit ............................................................................................................... 42
Testing fuel system for leakage .......................................................................................................... 44
Testing and adjusting alternator belt tension ...................................................................................... 45
Testing and adjusting fan belt tension ................................................................................................ 46
Handling controller high-voltage circuit .............................................................................................. 47

140E-5 Series

30 Testing and adjusting

SEN00149-05

Testing and adjusting (with EGR)


Testing and adjusting tools list
Testing and
adjusting item

Symbol

Part No.

Part name

Q'ty

Remarks

799-201-2202 Boost gauge kit

101 200 kPa {760 1,500 mmHg}

799-401-2220 Hose

I-coupler type (if necessary)

Testing air boost


pressure

Testing exhaust
temperature

799-101-1502 Digital thermometer

99.9 1,299C

Adjusting valve
clearance

Commercially
Clearance gauge
available

Intake: 0.35 mm
Exhaust: 0.57 mm

1 795-502-1590 Compression gauge

0 7 MPa {0 70 kg/cm2}

Testing compression
pressure

795-471-1330 Adapter

6261-71-6150 Gasket

799-201-1504 Blow-by checker

0 5 kPa {0 500 mmH2O}

799-101-5002 Hydraulic tester

Pressure gauge:
2.5, 6, 40, 60 MPa
{25, 60, 400, 600 kg/cm2}

790-261-1204 Digital hydraulic tester

Pressure gauge: 60 MPa {600 kg/cm2}

2 799-401-2320 Hydraulic tester

Pressure gauge: 1 MPa {10 kg/cm2}

799-101-5002 Hydraulic tester

Pressure gauge:
2.5, 6, 40, 60 MPa
{25, 60, 400, 600 kg/cm2}

790-261-1204 Digital hydraulic tester

Pressure gauge: 60 MPa {600 kg/cm2}

Pressure gauge: 1 MPa {10 kg/cm2}

795-471-1450 Adapter

8 1.25 mm o R1/8

07005-00812 Gasket

1 6151-51-8490 Spacer

Inside diameter: 14 mm

2 6206-71-1770 Joint

Inside diameter of joint: 10 mm

Commercially
Hose
available

5mm 2 3 m

H 4

Commercially
Hose
available

15mm 2 3 m

Commercially
Measuring cylinder
available

Commercially
Stopwatch
available

Testing blow-by
pressure
Testing engine oil pressure
Testing EGR valve and
bypass valve drive oil
pressure

2
E

1
Testing fuel pressure

2 799-401-2320 Gauge
3

Testing fuel return rate


and leakage

140E-5 Series

For 140E-5

SEN00149-05

Testing and
adjusting item

Troubleshooting for
controllers, sensors,
and actuators

30 Testing and adjusting

Symbol

Part No.

Part name

Q'ty

799-601-4130 T-adapter

For Ne sensor

799-601-4330 Socket

For Bkup sensor

799-601-4240 Socket

For atmospheric pressure sensor

799-601-4250 Socket

For boost pressure sensor

799-601-4180 T-adapter

For EGR gas sensor

799-601-9420 T-adapter

For common rail pressure

799-601-4150 T-adapter

For oil pressure sensor

795-799-5540 T-adapter

For boost temperature sensor

795-799-5530 T-adapter

For coolant temperature sensor


For fuel temperature sensor

799-601-9020 T-adapter

For EGR valve solenoid


For bypass valve solenoid

799-601-9030 T-adapter

For EGR valve stroke sensor


For bypass valve stroke sensor

799-601-9430 T-adapter

For supply pump PCV

799-601-9020 T-adapter

For injector

799-601-4260 T-adapter

For controller (4-pole)

799-601-4210 T-adapter

For controller (50-pole)

799-601-4220 T-adapter

For controller (60-pole)

799-601-9320 T-box

799-601-9310 Plate

799-601-4350 T-box

For 60-pole type

Checking coolant temperature and oil temperature

799-101-1502 Digital thermometer

Checking voltage and


resistance

Commercially
Tester
available

Removal and installation of engine coolant


temperature sensor

Commercially
Socket
available

For 24-pole type

99.9 1,299C

21 mm deep socket
(MITOLOY 4ML 21 or equivalent)
Applicable engine serial No.:
530056-534132

19 mm deep socket
(MITOLOY 4ML 19 or equivalent)
Applicable engine serial No.:
534133 and up

795T-981-1010 Socket

Remarks

140E-5 Series

30 Testing and adjusting

Sketches of special tools

SEN00149-05

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
Socket

140E-5 Series

SEN00149-05

30 Testing and adjusting

Testing air boost pressure


a

Testing tools for air boost pressure

Symbol
A
k

a
1.

Part No.

Part name

799-201-2202

Boost gauge kit

799-401-2220

Hose

Be careful not to touch any hot part when


removing or installing the testing tools.
The test point is subject to machine models.
Remove air boost pressure pickup plug (1)
from the bottom of the air intake connector.
4.

2.

Install nipple [1] of boost gauge kit A and connect it to gauge [2].

3.

Run the engine at the rated output and test the


air boost pressure.
a When testing with the engine mounted on
the machine, test on the condition
described in the shop manual for the
machine.

After finishing testing, remove the testing tools


and return the removed parts.
q
Remove the gasket sealant remaining on
the threads of the removed plug with a
wire brush and apply new adhesive or
gasket sealant to the plug before installing.
2 Plug: Adhesive (LT2) or gasket
sealant (LG-5)
3 Plug:
6.9 14.7 Nm {0.7 1.5 kgm} (*1)
9.8 19.6 Nm {1.0 2.0 kgm} (*2)
(*1): When air intake connector is made of
iron.
(*2): When air intake connector is made of
aluminum.

140E-5 Series

30 Testing and adjusting

SEN00149-05

Testing exhaust temperature


a

Testing tool for exhaust temperature

Symbol

Part No.

799-101-1502

a
1.

Part name
Digital thermometer

Remove and install the testing tools after


the exhaust manifold temperature has lowered.
The test point is subject to machine models.
Remove exhaust temperature pickup plug (1)
from the bottom of the exhaust manifold.
a You may measure at either front or rear
plug.

2.

Install sensor [1] of digital thermometer B and


connect it to thermometer [2].

3.

Run the engine and test the exhaust temperature in the whole speed range.
a When testing with the engine mounted on
the machine, test on the condition
described in the shop manual for the
machine.

140E-5 Series

4.

After finishing testing, remove the testing tools


and return the removed parts.
q
Clean the thread of the removed plug and
apply seizure prevention compound to the
plug before installing.
2 Plug: Seizure prevention compound (LC-G)
(NEVER-SEEZ (NEVER-SEEZ COMPOUND CO, LTD) or equivalent).
3 Plug: 2.9 5.9 Nm {0.3 0.6 kgm}

SEN00149-05

30 Testing and adjusting

Adjusting valve clearance


a

Part No.

Commercially
available

2.

3.

While fixing adjustment screw (3), loosen locknut (4).


a After setting the No. 1 cylinder to the compression top dead center, adjust the valve
clearance of the No. 1 cylinder.

4.

Insert clearance gauge C in the clearance


between rocker arm (5) and crosshead (6) and
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

5.

While fixing adjustment screw (3), tighten locknut (4).


3 Locknut: 45.1 51.0 Nm {4.6 5.2 kgm}
a After tightening the locknut, check the
valve clearance again.

6.

After adjusting the No. 1 cylinder, rotate the


crankshaft forward by 120 and adjust the
clearance of each cylinder according the firing
order.
a Firing order: 1 5 3 6 2 4

7.

After finishing adjustment, return the removed


parts.
3 Cylinder head cover mounting bolt:
29.4 34.3 Nm {3.0 3.5 kgm}

Adjusting tool for valve clearance

Symbol

1.

Part name
Clearance gauge

Remove 6 cylinder head covers (1).

Rotate the crankshaft forward to bring the


stamped 1.6TOP line (a) of the damper to
pointer (2) and set the No. 1 cylinder to the
compression top dead center.
a Rotate the crankshaft with the hexagonal
part at the end of the water pump drive
shaft.
a When the No. 1 cylinder is at the compression top dead center, the rocker arm of the
No. 1 cylinder can be moved by the valve
clearance with the hand. If the rocker arm
cannot be moved, rotate the crankshaft
one more turn.

140E-5 Series

30 Testing and adjusting

SEN00149-05

Testing compression pressure


a

Testing tools for compression pressure

Symbol
1
D

1.

Part No.

Part name

795-502-1590

Compression gauge

795-471-1330

Adapter

6261-71-6150

Gasket

When measuring the compression pressure, take care not to burn yourself on the
exhaust manifold, muffler, etc. or get
caught in a rotating part.
Measure the compression pressure after the
engine is warmed up (Engine oil temperature:
40 60C).

4.

Install adapter D2 to the mounting hole on the


injector and the compression gauge D1.
a Fit the gasket to the adapter end without
fail.
a Fix the adapter with the injector holder.
3 Holder mounting bolt:
58.8 73.5 Nm {6.0 7.5 kgm}
a Apply a little amount of engine oil to the
connecting parts of the adapter and gauge
so that air will not leak easily.

5.

Install rocker arm assembly (2) and adjust the


valve clearance.
3 Rocker arm mounting bolt:
93 103 Nm {9.5 10.5 kgm}
a See Adjusting valve clearance.

6.

Connect the INSITE (bench test tool) to the


engine and set the engine in the no-injection
cranking mode.
a When inspecting with the engine mounted
on the machine, set the engine in the noinjection cranking mode by operating the
monitor panel.
k If the engine is not set in the no-injection cranking mode, it will start and will
be dangerous. Accordingly, be sure to
set the engine in this mode.

Remove cylinder head cover (1) of the cylinder


to be tested for compression pressure.

2.

Bring the cylinder to be tested to the compression top dead center and remove rocker arm
assembly (2).
a See Adjusting valve clearance.

3.

Disconnect fuel high-pressure tube (3) and


injector wiring harness and remove injector (4).
a Disconnect the terminal of the injector wiring harness on the injector side and the
bracket on the rocker housing side and
r e m o v e t h e i n j e c t o r w ir i n g h a r n e s s
(Loosen the 2 terminal nuts alternately).
a Pass a wire, etc. under the fuel path projected sideways and pull up the injector
(Do not pry the injector top up).

140E-5 Series

SEN00149-05

7.

Rotate the engine with the starting motor and


measure the compression pressure.
a Read the pressure gauge pointer when it
is stabilized.

8.

After finishing testing, remove the testing tools


and return the removed parts.
a Install the injector and fuel high-pressure
tube according to the following procedure.
1) Push in injector (11) with the hand to
assemble holder (12) temporarily.
a Change the copper gasket and the O-ring
for a new part.
2) Tighten bolt (13) and washer (14) temporarily.
2 Spherical part of washer: Engine oil
3) Tighten sleeve nut (15) of the fuel highpressure tube temporarily.
4) Tighten bolt (13) permanently.
3 Bolt: 58.8 73.5 Nm {6.0 7.5 kgm}
5) Tighten sleeve nut (15) permanently.
3 Sleeve nut: 39.2 49.0 Nm {4 5 kgm}

30 Testing and adjusting

Install the injector wiring harness according to the following procedure.


1) Install the injector wiring harness to the
rocker arm housing and fix the connector
side with the plate.
2) Fix the intermediate clamp with the clip.
3) Tighten the nut on the injector side.
3 Nut: 2 0.2 Nm {0.2 0.02 kgm}
4) Secure the clamp and spacer with the
bolt.
3

Adjust the valve clearance. For details, see


Adjusting valve clearance.

10

Rocker arm assembly mounting bolt:


93 103 Nm {9.5 10.5 kgm}

Cylinder head cover mounting bolt:


29.4 34.3 Nm {3.0 3.5 kgm}

140E-5 Series

30 Testing and adjusting

SEN00149-05

Testing blow-by pressure


a

Testing tool for blow-by pressure

Symbol

Part No.

799-201-1504

Part name
Blow-by checker

The test point is subject to machine models.

1.

Install nozzle [1] of blow-by checker E to the


end of blow-by hose (1).

2.

Connect hose [2], and then connect it to gauge


[3].

3.

Run the engine at the rated output and test the


blow-by pressure.
a When testing with the engine mounted on
the machine, test on the condition
described in the shop manual for the
machine.

4.

After finishing testing, remove the testing tools


and return the removed parts.

140E-5 Series

11

SEN00149-05

30 Testing and adjusting

Testing engine oil pressure


a

Testing tools for engine oil pressure

Symbol
F

1
2

Part No.

Part name

799-101-5002

Hydraulic tester

790-261-1204

Digital hydraulic tester

799-401-2320

Hydraulic tester

The test point is subject to machine models.

1.

Remove oil pressure pickup plug (1) from the


cylinder block.

4.

2.

Install nipples [1] and [2] of hydraulic tester F1


and connect them to hydraulic tester F2.
a Since the size of the plug hole is R1/4,
quick nipple (799-101-5210) may be used.

3.

Run the engine at the rated output and low idle


and test the oil pressure.
a When testing with the engine mounted on
the machine, test on the condition
described in the shop manual for the
machine.

12

After finishing testing, remove the testing tools


and return the removed parts.
q
Remove the gasket sealant remaining on
the threads of the removed plug with a
wire brush and apply new adhesive or
gasket sealant to the plug before installing.
2 Plug: Adhesive (LT2) or gasket
sealant (LG-5)
3 Plug:
16.7 37.2 Nm {1.7 3.8 kgm}

140E-5 Series

30 Testing and adjusting

SEN00149-05

Testing EGR valve and bypass


valve drive oil pressure
a

Connect hydraulic tester [2] (Component part


of tool F1) to the nipple.

4.

Start the engine and measure the oil pressure


at low idle and high idle.

5.

After finishing measurement, remove the measuring instruments and return the removed
parts.
Remove the gasket sealant remaining on the
threads of the removed plug with a wire brush
and apply new adhesive or gasket sealant to
the plug before installing.
2 Plug: Adhesive (LT2) or gasket sealant (LG-5)
3 Plug: 9.8 19.6 Nm {1.0 2.0 kgm}

Testing instrument for EGR valve and bypass


valve drive oil pressure

Symbol
F

3.

Part No.

Part name

799-101-5002

Hydraulic tester

790-261-1204

Digital hydraulic tester

The measuring point may be different from the


following explanation, depending on each
applicable machine.

1.

Remove oil pressure pickup plug (2) from the


left side of timing gear cover (1).

2.

Install nipple [1] (Component part of tool F1:


PT 1/8) to the hole from which the oil pressure
pickup plug was removed.

140E-5 Series

13

SEN00149-05

Handling fuel system parts


a

14

30 Testing and adjusting

Precautions for testing and maintaining fuel


system
The common rail fuel injection system (CRI)
consists of more precise parts than the conventional fuel injection pump and nozzle. If foreign matter enters this system, it can cause a
trouble.
When testing and maintaining the fuel system,
take care more than the past. If dust, etc.
sticks to any part, wash that part thoroughly
with clean fuel.
Precautions for replacing fuel filter cartridge
Be sure to use the Komatsu genuine fuel filter
cartridge.
Since the common rail fuel injection system
(CRI) consists of more precise parts than the
conventional fuel injection pump and nozzle, it
employs a high-efficiency special filter to prevent foreign matter from entering it. If a filter
other than the genuine one is used, the fuel
system may have a trouble. Accordingly,
never use such a filter.

Releasing residual pressure in


fuel system
a

Pressure is generated in the low-pressure circuit and high-pressure circuit of the fuel system while the engine is running.
Low-pressure circuit:
Feed pump Fuel filter Supply pump
High-pressure circuit:
Supply pump Common rail Injector
The pressure in both low-pressure circuit and
high-pressure circuit lowers to a safety level
automatically 30 seconds after the engine is
stopped.
Before the fuel circuit is tested and its parts are
removed, the residual pressure in the fuel circuit must be released completely. Accordingly,
observe the following.
Before testing the fuel system or removing
its parts, wait at least 30 seconds after stopping the engine until the residual pressure
in the fuel circuit is released. (Do not start
the work just after stopping the engine
since there is residual pressure.)

140E-5 Series

30 Testing and adjusting

SEN00149-05

Testing fuel pressure


a

1
2
3

a
k

1.

3.

Testing tools for fuel pressure

Symbol

Part No.

Part name

799-101-5002

Hydraulic tester

790-261-1204

Digital hydraulic tester

799-401-2320

Gauge

795-471-1450

Adapter

07005-00812

Gasket

Engine speed

Fuel pressure

High idle

0.15 0.3 MPa


{1.5 3 kg/cm2}

Check the fuel pressure in only the low-pressure circuit from the feed pump via the fuel filter to the supply pump.
Since the pressure in the high-pressure circuit from the supply pump through the
common rail to the injector is very high, it
cannot be measured.
Remove fuel pressure pickup plug (1) from the
fuel filter head.

4.

2.

Run the engine at high idle and measure the


fuel pressure.
a If the fuel pressure is in the following
range, it is normal.

After finishing testing, remove the testing tools


and return the removed parts.
3 Plug: 7.8 9.8 Nm {0.8 1.0 kgm}

Install adapter G3, 90 elbow [1] of hydraulic


tester G1, and nipple [2] and connect them to
gauge G2.

140E-5 Series

15

SEN00149-05

Reduced cylinder mode


operation

30 Testing and adjusting

No-injection cranking
a

1.

2.

3.

16

Reduced cylinder mode operation means to


run the engine with the fuel injectors of 1 or
more cylinders disabled electrically to reduce
the number of effective cylinders. The purposes and effects of this operation are as follows.
This operation is used to find out a cylinder
which does not output power normally (or,
combustion in it is abnormal).
When a cylinder is selected for the reduced
cylinder mode operation, if the engine speed
and output do not change from the normal
operation (all-cylinder operation), that cylinder
has 1 or more defects. The possible defects
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
Since the common rail fuel injection system
controls the injector of each cylinder electronically, the operator can perform the reduced cylinder mode operation easily with switches to
find out a defective cylinder.
a Perform the reduced cylinder mode operation 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).

No-injection cranking means to crank the


engine with the starting motor while all the
injections are stopped electrically. The purpose and effect of this operation are as follows.
Before the engine is started after it or the
machine has been stored for a long period, the
no-injection cranking is performed to lubricate
the engine parts and protect them from seizure.
Perform the no-injection operation 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).

140E-5 Series

30 Testing and adjusting

SEN00149-05

Testing fuel return rate and leakage

Type of engine having intake manifold equipped with return block

If the engine has the intake manifold equipped


with the return block on it to return the fuel
spilling from the injector to the fuel tank, test
the fuel return rate and fuel leakage according
to the following procedure (The figure shows
the engine for D155AX-6).

Testing tools for fuel return rate and leakage

Symbol

Part No.

Part name

6151-51-8490

Spacer

6206-71-1770

Joint

Commercially available Hose

Commercially available Hose

Commercially available Measuring cylinder

Commercially available Stopwatch

1.

Preparation work
1) Remove tube (3) between common rail (1)
and supply pump (2).
2) Insert spacer H1 on supply pump (2) side
and tighten the removed joint bolt again.
a Connect the return pipe to the fuel
tank again, too.
a Be sure to fit the gaskets to both ends
of the spacer.

Prepare a receiving pan of about 20 l to


receive the fuel flowing out during the test.

140E-5 Series

17

SEN00149-05

30 Testing and adjusting

3)

4)

2.

18

Insert joint H2 on common rail (1) side and


tighten the removed joint bolt again.
a Be sure to fit the gaskets to both ends
of the joint.
Connect test hose H3 to the end of joint
H2.
a Bind the connecting part of the test
hose with a wire, etc. to prevent it
from coming off.
a The above is the preparation work for
testing the leakage from the pressure
limiter.

Testing leakage from pressure limiter


1) Lay test hose H3 so that it will not slacken
and put its end in the receiving pan.
2) Connect INSITE (bench test tool) to the
engine and set it so that it can check the
engine speed.
q
Or set on the machine so that it can
check the engine speed.
3) Start the engine and keep its speed to
rated output.
4) After the engine speed is stabilized, test
the leakage in 1 minute with measuring
cylinder H5.
a You may test for 20 seconds and
judge by multiplying the result by 3.

5)
3.

If the leakage from the pressure limiter is in the following range, it is normal.
Engine speed

Leakage
(cc/min)

At rated output

Max. 10

After finishing testing, stop the engine.

Testing return rate from injector


a Keep the hose on the pressure limiter side
connected and keep its end in the receiving pan while testing the return rate from
the injector.
1) Disconnect return hose (5) of return block
(4) and connect test hose H4.
a Stop the return hose with a plug, etc.
and fix it to the fuel tank.
Plug: 07376-70315
a Bind the connecting part of the test
hose with a wire, etc. to prevent it
from coming off.
2) Lay test hose H4 so that it will not slacken
and put its end in the receiving pan.

3)

Connect INSITE (bench test tool) to the


engine and set it so that it can check the
engine speed.
q
Or set on the machine so that it can
check the engine speed.

140E-5 Series

30 Testing and adjusting

4)
5)

6)
4.

SEN00149-05

Run the engine at the rated output.


After the engine speed is stabilized, test
the return rate in 1 minute with measuring
cylinder H5.
a You may test for 20 seconds and
judge by multiplying the result by 3.
a If the supply pump is not supplying
fuel, the engine speed may not rise.
In this case, record the engine speed,
too, during the test.
a If the return rate (spill) from the injector is in the following range, it is normal.
Rated output
speed (rpm)

Limit of return rate


(spill) (cc/min)

1,600

960

1,700

1,020

1,800

1,080

1,900

1,140

2,000

1,200

After finishing testing, stop the engine.

Work after finishing testing


After finishing all testing, remove the testing
tools and return the removed parts.
3 Common rail pressure limiter joint bolt:
17.7 22.6 Nm {1.8 2.3 kgm}
3 Supply pump overflow joint bolt:
14.8 19.6 Nm {1.5 2.0 kgm}

140E-5 Series

19

SEN00149-05

Bleeding air from fuel circuit

a
a

1.

20

30 Testing and adjusting

If fuel is used up or if a fuel circuit part is


removed and installed, bleed air from the fuel
circuit according to the following procedure.
The locations of the fuel circuit parts are subject to machine models (The figure shows the
engine for D155AX-6).
Remove fuel pre-filter (1) and fill it with fuel.
a Fill the fuel filter with clean fuel and take
care that dirt will not enter it.
a Check that the cap is fitted to part (a)
(central hole) of the fuel pre-filter, and then
add fuel through part (b) (holes around the
central hole).
a After filling the fuel pre-filter with fuel,
remove the cap from part (a).
a If clean fuel is not available, do not
remove the fuel pre-filter but fill it with the
fuel by operating priming pump (4).
a Do not add fuel to fuel main filter (2) from
outside.

2.

Install fuel pre-filter (1) to the filter head.


a Apply engine oil thinly over the packing on
the fuel pre-filter side.
a After the packing of the fuel pre-filter
touches the sealing face of the filter head,
tighten the fuel pre-filter 3/4 turns.

140E-5 Series

30 Testing and adjusting

SEN00149-05

6.

3.

Remove air bleed plug (3) of the fuel main filter


(2) and operate priming pump (4).
a Operate the priming pump until the fuel
flows out of the plug hole and install the
plug.
3 Air bleed plug:
7.8 9.8 Nm {0.8 1.0 kgm}

4.

Remove air bleed plug (5) of the fuel main filter


(2) and operate priming pump (4).
a Operate the priming pump until the fuel
flows out of the plug hole and install the
plug.
3 Air bleed plug:
7.8 9.8 Nm {0.8 1.0 kgm}

5.

Loosen air bleeder (6) of the fuel supply pump


and operate priming pump (4) 90 100 times.
a Operate the priming pump until the fuel
flows out of the air bleeder and tighten the
air bleeder. Then, operate the priming
pump several times more until it becomes
heavy.
3 Air bleeder:
4.9 6.9 Nm {0.5 0.7 kgm}

140E-5 Series

Start the engine with the starting motor.


a The air in the high-pressure circuit is bled
automatically if the engine is cranked.
a If the engine does not start, there may be
still air in the low-pressure circuit. In this
case, repeat the above procedure from
step 3.

21

SEN00149-05

30 Testing and adjusting

Testing fuel system for leakage 1


k

9.
Very high pressure is generated in the highpressure circuit of the fuel system. If fuel
leaks while the engine is running, it is dangerous since it can catch fire.
After testing the fuel system or removing
its parts, test it for fuel leakage according
to the following procedure.
Clean and degrease the engine and the parts
around it in advance so that you can test it easily for fuel leakage.

1.

Spray color checker (developer) over the fuel


supply pump, common rail, fuel injector, and
joints of the high-pressure piping.

2.

Run the engine at speed below 1,000 rpm and


stop it after its speed is stabilized.

3.

Inspect the fuel piping and devices for fuel


leakage.
a Inspect mainly around the high-pressure
circuit parts coated with the color checker
for fuel leakage.
a If any fuel leakage is detected, repair it
and inspect again from step 1.

4.

Run the engine at low idle.

5.

Inspect the fuel piping and devices for fuel


leakage.
a Inspect mainly around the high-pressure
circuit parts coated with the color checker
for fuel leakage.
a If any fuel leakage is detected, repair it
and inspect again from step 1.

6.

Run the engine at high idle.

7.

Inspect the fuel piping and devices for fuel


leakage.
a Inspect mainly around the high-pressure
circuit parts coated with the color checker
for fuel leakage.
a If any fuel leakage is detected, repair it
and inspect again from step 1.

8.

Run the engine at high idle and load it.


a When testing the engine mounted on the
machine, stall the torque converter or
relieve the oil from the hydraulic pump.

22

Inspect the fuel piping and devices for fuel


leakage.
a Inspect mainly around the high-pressure
circuit parts coated with the color checker
for fuel leakage.
a If any fuel leakage is detected, repair it
and inspect again from step 1.
a If no fuel leakage is detected, inspection is
completed.

140E-5 Series

30 Testing and adjusting

SEN00149-05

Testing and adjusting alternator


belt tension
1
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.
1.

Loosen mounting bolts (2), (3) and (4) of alternator (1), and then loosen locknut (5).

2.

Move alternator (1) with adjustment nut (6) to


adjust the tension of belt (7).

3.

Tighten locknut (5), and then tighten mounting


bolts (3), (2) and (1).
a After adjusting, test the belt tension again.

140E-5 Series

23

SEN00149-05

Testing and adjusting fan belt tension

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.
1.

Loosen lock bolt of tension pulley (3).

2.

Move tension pulley (3) with adjustment bolt


(2) to adjust the belt tension.
a After adjusting, test the belt tension again.

3.

Tighten lock bolt of tension pulley (3).

24

140E-5 Series

30 Testing and adjusting

Handling controller high-voltage circuit


1.

Before disconnecting or connecting the connector between the engine controller and
engine, be sure to turn the starting switch OFF.

2.

If the T-adapter is inserted in or connected to


the connector between the engine controller
and engine for troubleshooting, do not start the
engine.
a You may turn the starting switch to the
OFF or ON position but must not turn it to
the START position.

140E-5 Series

SEN00149-05

25

SEN00149-05

30 Testing and adjusting

Testing and adjusting (EGR-less)

Testing and adjusting tools list

Testing and
adjusting item

Symbol

799-401-2220 Hose

I-coupler type (if necessary)

799-101-1502 Digital thermometer

99.9 1,299C

Commercially
Clearance gauge
available

Intake: 0.35 mm
Exhaust: 0.57 mm

1 795-502-1590 Compression gauge

0 7 MPa {0 70 kg/cm2}

Adjusting valve
clearance

795-471-1330 Adapter

6261-71-6150 Gasket

799-201-1504 Blow-by checker

0 5 kPa {0 500 mmH2O}

799-101-5002 Hydraulic tester

Pressure gauge:
2.5, 6, 40, 60 MPa
{25, 60, 400, 600 kg/cm2}

790-261-1204 Digital hydraulic tester

Pressure gauge: 60 MPa {600 kg/cm2}

2 799-401-2320 Hydraulic tester

Pressure gauge: 1 MPa {10 kg/cm2}

799-101-5002 Hydraulic tester

Pressure gauge:
2.5, 6, 40, 60 MPa
{25, 60, 400, 600 kg/cm2}

790-261-1204 Digital hydraulic tester

Pressure gauge: 60 MPa {600 kg/cm2}

Pressure gauge: 1 MPa {10 kg/cm2}

795-471-1450 Adapter

8 1.25 mm o R1/8

07005-00812 Gasket

1 6151-51-8490 Spacer

Inside diameter: 14 mm

2 6206-71-1770 Joint

Inside diameter of joint: 10 mm

Commercially
Hose
available

5mm 2 3 m

H 4

Commercially
Hose
available

15mm 2 3 m

Commercially
Measuring cylinder
available

Commercially
Stopwatch
available

Testing blow-by
pressure

2
E

1
G

2 799-401-2320 Gauge
3

Testing fuel return rate


and leakage

26

Remarks
101 200 kPa {760 1,500 mmHg}

Testing exhaust
temperature

Testing fuel pressure

Q'ty
1

Testing engine oil pressure

Part name

799-201-2202 Boost gauge kit

Testing air boost


pressure

Testing compression
pressure

Part No.

For 140E-5

140E-5 Series

30 Testing and adjusting

Testing and
adjusting item

Troubleshooting for
controllers, sensors,
and actuators

Symbol

SEN00149-05

Part No.

Part name

Q'ty

799-601-4130 T-adapter

For Ne sensor

799-601-4330 Socket

For Bkup sensor

799-601-4240 Socket

For atmospheric pressure sensor

799-601-4250 Socket

For boost pressure sensor

799-601-9420 T-adapter

For common rail pressure

799-601-4150 T-adapter

For oil pressure sensor

795-799-5540 T-adapter

For boost temperature sensor

795-799-5530 T-adapter

799-601-9430 T-adapter

For supply pump PCV

799-601-9020 T-adapter

For injector

799-601-4260 T-adapter

For controller (4-pole)

799-601-4210 T-adapter

For controller (50-pole)

799-601-4220 T-adapter

For controller (60-pole)

799-601-9320 T-box

799-601-9310 Plate

799-601-4350 T-box

For 60-pole type

Checking coolant temperature and oil temperature

799-101-1502 Digital thermometer

Checking voltage and


resistance

Commercially
Tester
available

Removal and installation of engine coolant


temperature sensor

Commercially
Socket
available

For coolant temperature sensor


For fuel temperature sensor

For 24-pole type

99.9 1,299C

21 mm deep socket
(MITOLOY 4ML 21 or equivalent)
Applicable engine serial No.:
530056-534132

19 mm deep socket
(MITOLOY 4ML 19 or equivalent)
Applicable engine serial No.:
534133 and up

795T-981-1010 Socket

140E-5 Series

Remarks

27

SEN00149-05

Sketches of special tools

30 Testing and adjusting

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
Socket

28

140E-5 Series

30 Testing and adjusting

SEN00149-05

Testing air boost pressure


a

Testing tools for air boost pressure

Symbol
A
k

a
1.

Part No.

Part name

799-201-2202

Boost gauge kit

799-401-2220

Hose

Be careful not to touch any hot part when


removing or installing the testing tools.
The test point is subject to machine models.
Remove air boost pressure pickup plug (1)
from the bottom of the air intake connector.
4.

2.

Install nipple [1] of boost gauge kit A and connect it to gauge [2].

3.

Run the engine at the rated output and test the


air boost pressure.
a When testing with the engine mounted on
the machine, test on the condition
described in the shop manual for the
machine.

140E-5 Series

After finishing testing, remove the testing tools


and return the removed parts.
q
Remove the gasket sealant remaining on
the threads of the removed plug with a
wire brush and apply new adhesive or
gasket sealant to the plug before installing.
2 Plug: Adhesive (LT2) or gasket
sealant (LG-5)
3 Plug:
6.9 14.7 Nm {0.7 1.5 kgm} (*1)
9.8 19.6 Nm {1.0 2.0 kgm} (*2)
(*1): When air intake connector is made of
iron.
(*2): When air intake connector is made of
aluminum.

29

SEN00149-05

30 Testing and adjusting

Testing exhaust temperature


a

Testing tool for exhaust temperature

Symbol

Part No.

799-101-1502

Part name
Digital thermometer

Remove and install the testing tools after


the exhaust manifold temperature has lowered.
The test point is subject to machine models.

1.

Remove the heat insulation cover.

2.

Remove exhaust temperature pickup plug (1)


from the bottom of the exhaust manifold.

3.

Install sensor [1] of digital thermometer B and


connect it to thermometer [2].

4.

Run the engine and test the exhaust temperature in the whole speed range.
a When testing with the engine mounted on
the machine, test on the condition
described in the shop manual for the
machine.

30

5.

After finishing testing, remove the testing tools


and return the removed parts.
q
Clean the thread of the removed plug and
apply seizure prevention compound to the
plug before installing.
2 Plug: Seizure prevention compound (LC-G)
(NEVER-SEEZ (NEVER-SEEZ COMPOUND CO, LTD) or equivalent).
3 Plug: 2.9 5.9 Nm {0.3 0.6 kgm}

140E-5 Series

30 Testing and adjusting

SEN00149-05

Adjusting valve clearance


a

Part No.

Commercially
available

2.

3.

While fixing adjustment screw (3), loosen locknut (4).


a After setting the No. 1 cylinder to the compression top dead center, adjust the valve
clearance of the No. 1 cylinder.

4.

Insert clearance gauge C in the clearance


between rocker arm (5) and crosshead (6) and
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

5.

While fixing adjustment screw (3), tighten locknut (4).


3 Locknut: 45.1 51.0 Nm {4.6 5.2 kgm}
a After tightening the locknut, check the
valve clearance again.

6.

After adjusting the No. 1 cylinder, rotate the


crankshaft forward by 120 and adjust the
clearance of each cylinder according the firing
order.
a Firing order: 1 5 3 6 2 4

7.

After finishing adjustment, return the removed


parts.
3 Cylinder head cover mounting bolt:
29.4 34.3 Nm {3.0 3.5 kgm}

Adjusting tool for valve clearance

Symbol

1.

Part name
Clearance gauge

Remove 6 cylinder head covers (1).

Rotate the crankshaft forward to bring the


stamped 1.6TOP line (a) of the damper to
pointer (2) and set the No. 1 cylinder to the
compression top dead center.
a Rotate the crankshaft with the hexagonal
part at the end of the water pump drive
shaft.
a When the No. 1 cylinder is at the compression top dead center, the rocker arm of the
No. 1 cylinder can be moved by the valve
clearance with the hand. If the rocker arm
cannot be moved, rotate the crankshaft
one more turn.

140E-5 Series

31

SEN00149-05

30 Testing and adjusting

Testing compression pressure


a

Testing tools for compression pressure

Symbol
1
D

1.

Part No.

Part name

795-502-1590

Compression gauge

795-471-1330

Adapter

6261-71-6150

Gasket

When measuring the compression pressure, take care not to burn yourself on the
exhaust manifold, muffler, etc. or get
caught in a rotating part.
Measure the compression pressure after the
engine is warmed up (Engine oil temperature:
40 60C).

Install adapter D2 to the mounting hole on the


injector and the compression gauge D1.
a Fit the gasket to the adapter end without
fail.
a Fix the adapter with the injector holder.
3 Holder mounting bolt:
58.8 73.5 Nm {6.0 7.5 kgm}
a Apply a little amount of engine oil to the
connecting parts of the adapter and gauge
so that air will not leak easily.

5.

Install rocker arm assembly (2) and adjust the


valve clearance.
3 Rocker arm mounting bolt:
93 103 Nm {9.5 10.5 kgm}
a See Adjusting valve clearance.

6.

Connect the INSITE (bench test tool) to the


engine and set the engine in the no-injection
cranking mode.
a When inspecting with the engine mounted
on the machine, set the engine in the noinjection cranking mode by operating the
monitor panel.
k If the engine is not set in the no-injection cranking mode, it will start and will
be dangerous. Accordingly, be sure to
set the engine in this mode.

Remove cylinder head cover (1) of the cylinder


to be tested for compression pressure.

2.

Bring the cylinder to be tested to the compression top dead center and remove rocker arm
assembly (2).
a See Adjusting valve clearance.

3.

Disconnect fuel high-pressure tube (3) and


injector wiring harness and remove injector (4).
a Disconnect the terminal of the injector wiring harness on the injector side and the
bracket on the rocker housing side and
r e m o v e t h e i n j e c t o r w ir i n g h a r n e s s
(Loosen the 2 terminal nuts alternately).
a Pass a wire, etc. under the fuel path projected sideways and pull up the injector
(Do not pry the injector top up).

32

4.

140E-5 Series

30 Testing and adjusting

7.

Rotate the engine with the starting motor and


measure the compression pressure.
a Read the pressure gauge pointer when it
is stabilized.

8.

After finishing testing, remove the testing tools


and return the removed parts.
a Install the injector and fuel high-pressure
tube according to the following procedure.
1) Push in injector (11) with the hand to
assemble holder (12) temporarily.
a Change the copper gasket and the O-ring
for a new part.
2) Tighten bolt (13) and washer (14) temporarily.
2 Spherical part of washer: Engine oil
3) Tighten sleeve nut (15) of the fuel highpressure tube temporarily.
4) Tighten bolt (13) permanently.
3 Bolt: 58.8 73.5 Nm {6.0 7.5 kgm}
5) Tighten sleeve nut (15) permanently.
3 Sleeve nut: 39.2 49.0 Nm {4 5 kgm}

SEN00149-05

Install the injector wiring harness according to the following procedure.


1) Install the injector wiring harness to the
rocker arm housing and fix the connector
side with the plate.
2) Fix the intermediate clamp with the clip.
3) Tighten the nut on the injector side.
3 Nut: 2 0.2 Nm {0.2 0.02 kgm}
4) Secure the clamp and spacer with the
bolt.
3

Rocker arm assembly mounting bolt:


93 103 Nm {9.5 10.5 kgm}

Adjust the valve clearance. For details, see


Adjusting valve clearance.

Cylinder head cover mounting bolt:


29.4 34.3 Nm {3.0 3.5 kgm}

140E-5 Series

33

SEN00149-05

30 Testing and adjusting

Testing blow-by pressure


a

Testing tool for blow-by pressure

Symbol

Part No.

799-201-1504

Part name
Blow-by checker

The test point is subject to machine models.

1.

Install nozzle [1] of blow-by checker E to the


end of blow-by hose (1).

2.

Connect hose [2], and then connect it to gauge


[3].

3.

Run the engine at the rated output and test the


blow-by pressure.
a When testing with the engine mounted on
the machine, test on the condition
described in the shop manual for the
machine.

4.

After finishing testing, remove the testing tools


and return the removed parts.

34

140E-5 Series

30 Testing and adjusting

SEN00149-05

Testing engine oil pressure


a

Testing tools for engine oil pressure

Symbol
F

1
2

Part No.

Part name

799-101-5002

Hydraulic tester

790-261-1204

Digital hydraulic tester

799-401-2320

Hydraulic tester

The test point is subject to machine models.

1.

Remove oil pressure pickup plug (1) from the


cylinder block.

4.

2.

Install nipples [1] and [2] of hydraulic tester F1


and connect them to hydraulic tester F2.
a Since the size of the plug hole is R1/4,
quick nipple (799-101-5210) may be used.

3.

Run the engine at the rated output and low idle


and test the oil pressure.
a When testing with the engine mounted on
the machine, test on the condition
described in the shop manual for the
machine.

140E-5 Series

After finishing testing, remove the testing tools


and return the removed parts.
q
Remove the gasket sealant remaining on
the threads of the removed plug with a
wire brush and apply new adhesive or
gasket sealant to the plug before installing.
2 Plug: Adhesive (LT2) or gasket
sealant (LG-5)
3 Plug:
16.7 37.2 Nm {1.7 3.8 kgm}

35

SEN00149-05

Handling fuel system parts


a

36

30 Testing and adjusting

Precautions for testing and maintaining fuel


system
The common rail fuel injection system (CRI)
consists of more precise parts than the conventional fuel injection pump and nozzle. If foreign matter enters this system, it can cause a
trouble.
When testing and maintaining the fuel system,
take care more than the past. If dust, etc.
sticks to any part, wash that part thoroughly
with clean fuel.
Precautions for replacing fuel filter cartridge
Be sure to use the Komatsu genuine fuel filter
cartridge.
Since the common rail fuel injection system
(CRI) consists of more precise parts than the
conventional fuel injection pump and nozzle, it
employs a high-efficiency special filter to prevent foreign matter from entering it. If a filter
other than the genuine one is used, the fuel
system may have a trouble. Accordingly,
never use such a filter.

Releasing residual pressure in


fuel system
a

Pressure is generated in the low-pressure circuit and high-pressure circuit of the fuel system while the engine is running.
Low-pressure circuit:
Feed pump Fuel filter Supply pump
High-pressure circuit:
Supply pump Common rail Injector
The pressure in both low-pressure circuit and
high-pressure circuit lowers to a safety level
automatically 30 seconds after the engine is
stopped.
Before the fuel circuit is tested and its parts are
removed, the residual pressure in the fuel circuit must be released completely. Accordingly,
observe the following.
Before testing the fuel system or removing
its parts, wait at least 30 seconds after stopping the engine until the residual pressure
in the fuel circuit is released. (Do not start
the work just after stopping the engine
since there is residual pressure.)

140E-5 Series

30 Testing and adjusting

SEN00149-05

Testing fuel pressure


a

1
2
3

a
k

1.

3.

Testing tools for fuel pressure

Symbol

Part No.

Part name

799-101-5002

Hydraulic tester

790-261-1204

Digital hydraulic tester

799-401-2320

Gauge

795-471-1450

Adapter

07005-00812

Gasket

Engine speed

Fuel pressure

High idle

0.15 0.3 MPa


{1.5 3 kg/cm2}

Check the fuel pressure in only the low-pressure circuit from the feed pump via the fuel filter to the supply pump.
Since the pressure in the high-pressure circuit from the supply pump through the
common rail to the injector is very high, it
cannot be measured.
Remove fuel pressure pickup plug (1) from the
fuel filter head.
a Single cartridge is set for some models.
4.

2.

Run the engine at high idle and measure the


fuel pressure.
a If the fuel pressure is in the following
range, it is normal.

After finishing testing, remove the testing tools


and return the removed parts.
3 Plug: 7.8 9.8 Nm {0.8 1.0 kgm}

Install adapter G3, nipple [1] of hydraulic tester


G1, and connect them to gauge G2.

140E-5 Series

37

SEN00149-05

30 Testing and adjusting

Reduced cylinder mode operation1

No-injection cranking

1.

2.

3.

38

Reduced cylinder mode operation means to


run the engine with the fuel injectors of 1 or
more cylinders disabled electrically to reduce
the number of effective cylinders. The purposes and effects of this operation are as follows.
This operation is used to find out a cylinder
which does not output power normally (or,
combustion in it is abnormal).
When a cylinder is selected for the reduced
cylinder mode operation, if the engine speed
and output do not change from the normal
operation (all-cylinder operation), that cylinder
has 1 or more defects. The possible defects
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
Since the common rail fuel injection system
controls the injector of each cylinder electronically, the operator can perform the reduced cylinder mode operation easily with switches to
find out a defective cylinder.
a Perform the reduced cylinder mode operation 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).

No-injection cranking means to crank the


engine with the starting motor while all the
injections are stopped electrically. The purpose and effect of this operation are as follows.
Before the engine is started after it or the
machine has been stored for a long period, the
no-injection cranking is performed to lubricate
the engine parts and protect them from seizure.
Perform the no-injection operation 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).

140E-5 Series

30 Testing and adjusting

SEN00149-05

Testing fuel return rate and leakage

Type of engine having intake manifold equipped with return block

If the engine has the intake manifold equipped


with the return block on it to return the fuel
spilling from the injector to the fuel tank, test
the fuel return rate and fuel leakage according
to the following procedure (The figure shows
the engine for WA500-6R).

Testing tools for fuel return rate and leakage

Symbol

1
2
H

Part No.

Part name

6151-51-8490

Spacer

6206-71-1770

Joint

Commercially available Hose

Commercially available Hose

Commercially available Measuring cylinder

Commercially available Stopwatch

1.

Preparation work
1) Remove tube (3) between common rail (1)
and supply pump (2).
2) Insert spacer H1 on supply pump (2) side
and tighten the removed joint bolt again.
a Connect the return pipe to the fuel
tank again, too.
a Be sure to fit the gaskets to both ends
of the spacer.

Prepare a receiving pan of about 20 l to


receive the fuel flowing out during the test.

140E-5 Series

39

SEN00149-05

30 Testing and adjusting

3)

4)

2.

40

Insert joint H2 on common rail (1) side and


tighten the removed joint bolt again.
a Be sure to fit the gaskets to both ends
of the joint.
Connect test hose H3 to the end of joint
H2.
a Bind the connecting part of the test
hose with a wire, etc. to prevent it
from coming off.
a The above is the preparation work for
testing the leakage from the pressure
limiter.

Testing leakage from pressure limiter


1) Lay test hose H3 so that it will not slacken
and put its end in the receiving pan.
2) Connect INSITE (bench test tool) to the
engine and set it so that it can check the
engine speed.
q
Or set on the machine so that it can
check the engine speed.
3) Start the engine and keep its speed to
rated output.
4) After the engine speed is stabilized, test
the leakage in 1 minute with measuring
cylinder H5.
a You may test for 20 seconds and
judge by multiplying the result by 3.

5)
3.

If the leakage from the pressure limiter is in the following range, it is normal.
Engine speed

Leakage
(cc/min)

At rated output

Max. 10

After finishing testing, stop the engine.

Testing return rate from injector


a Keep the hose on the pressure limiter side
connected and keep its end in the receiving pan while testing the return rate from
the injector.
1) Disconnect return hose (5) of return block
(4) and connect test hose H4.
a Stop the return hose with a plug, etc.
and fix it to the fuel tank.
Plug: 07376-70315
a Bind the connecting part of the test
hose with a wire, etc. to prevent it
from coming off.
2) Lay test hose H4 so that it will not slacken
and put its end in the receiving pan.

3)

Connect INSITE (bench test tool) to the


engine and set it so that it can check the
engine speed.
q
Or set on the machine so that it can
check the engine speed.

140E-5 Series

30 Testing and adjusting

4)
5)

6)
4.

SEN00149-05

Run the engine at the rated output.


After the engine speed is stabilized, test
the return rate in 1 minute with measuring
cylinder H5.
a You may test for 20 seconds and
judge by multiplying the result by 3.
a If the supply pump is not supplying
fuel, the engine speed may not rise.
In this case, record the engine speed,
too, during the test.
a If the return rate (spill) from the injector is in the following range, it is normal.
Rated output
speed (rpm)

Limit of return rate


(spill) (cc/min)

1,600

960

1,700

1,020

1,800

1,080

1,900

1,140

2,000

1,200

After finishing testing, stop the engine.

Work after finishing testing


After finishing all testing, remove the testing
tools and return the removed parts.
3 Common rail pressure limiter joint bolt:
17.7 22.6 Nm {1.8 2.3 kgm}
3 Supply pump overflow joint bolt:
14.8 19.6 Nm {1.5 2.0 kgm}

140E-5 Series

41

SEN00149-05

Bleeding air from fuel circuit

30 Testing and adjusting

4.

Reference: The electric priming pump switch is


installed to the chassis.
a
a

Turn ON switch (3) of electric priming pump


(2) installed to the chassis.
a The electric priming pump operates and
lamp (4) blinks.

Manual priming pump is set for some models.


(See the "with EGR".)
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
If the fuel filter was replaced, do not fill the
main filter and prefilter with the fuel.

1.

Turn the starting switch to the OFF position.

2.

Check that the fuel valve on the fuel tank side


is open.

3.

Turn lever (1) of the air bleeding piping to the


parallel position with the piping to open the circuit valve.

a
a
k

The electric priming pump has a timer in it


to start and stop itself automatically (See
the following figure).
The electric priming pump stops while the
lamp is blinking. This phenomenon is not
abnormal, however.
If the switch is turned to the OFF position
while the lamp is blinking, the lamp goes
off and the electric priming pump stops.
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.

Reference: The operating procedure sticker is


stuck near the air bleeding piping lever.

42

5.

After the specified time (approx. 7 minutes),


lamp (4) goes off and the electric priming pump
stops automatically.
a If only the fuel filter was replaced, the air
bleeding work is completed now.

6.

If the fuel was used up or the fuel piping or


supply pump was replaced and there is not fuel
in the fuel circuit, turn switch (3) ON after the
electric priming pump stops automatically.

140E-5 Series

30 Testing and adjusting

7.

When lamp (4) goes off, the air bleeding work


is completed.

8.

Turn lever (1) of the air bleeding piping to the


cross position with the piping to close the circuit valve.

SEN00149-05

9.

Start the engine with the starting motor.


a Do not operate the starting motor continuously for more than 20 seconds.
q
After starting the engine, run it at low
idle for about 5 minutes to bleed all air
from the fuel circuit.
q
Stop the engine and check that the air
bleeding valve is closed.
10. If the engine does not start, try to start it again
according to the following procedure.
k When starting the engine, check that there
is no person around it.
a Carry out the work with the air bleeding
valve closed. (Do not open the air bleeding valve after step 7.)
a After the engine fails to start, wait for
about 2 minutes before trying to start
again.
1) Turn the electric priming pump switch ON.
2) While the electric priming pump is operating, crank the engine.
q
If the engine does not start, repeat the
above operation.
a Do not operate the starting motor continuously for more than 20 seconds.
a If the engine fails to start, wait for about 2
minutes and try to start again.
3) After starting the engine, run it at low idle
for about 5 minutes to bleed all air from
the fuel circuit.
4) Stop the engine and check that the air
bleeding valve is closed.
5) After the above operation, start the engine
normally.

140E-5 Series

43

SEN00149-05

30 Testing and adjusting

Testing fuel system for leakage 1


k

9.
Very high pressure is generated in the highpressure circuit of the fuel system. If fuel
leaks while the engine is running, it is dangerous since it can catch fire.
After testing the fuel system or removing
its parts, test it for fuel leakage according
to the following procedure.
Clean and degrease the engine and the parts
around it in advance so that you can test it easily for fuel leakage.

1.

Spray color checker (developer) over the fuel


supply pump, common rail, fuel injector, and
joints of the high-pressure piping.

2.

Run the engine at speed below 1,000 rpm and


stop it after its speed is stabilized.

3.

Inspect the fuel piping and devices for fuel


leakage.
a Inspect mainly around the high-pressure
circuit parts coated with the color checker
for fuel leakage.
a If any fuel leakage is detected, repair it
and inspect again from step 1.

4.

Run the engine at low idle.

5.

Inspect the fuel piping and devices for fuel


leakage.
a Inspect mainly around the high-pressure
circuit parts coated with the color checker
for fuel leakage.
a If any fuel leakage is detected, repair it
and inspect again from step 1.

6.

Run the engine at high idle.

7.

Inspect the fuel piping and devices for fuel


leakage.
a Inspect mainly around the high-pressure
circuit parts coated with the color checker
for fuel leakage.
a If any fuel leakage is detected, repair it
and inspect again from step 1.

8.

Run the engine at high idle and load it.


a When testing the engine mounted on the
machine, stall the torque converter or
relieve the oil from the hydraulic pump.

44

Inspect the fuel piping and devices for fuel


leakage.
a Inspect mainly around the high-pressure
circuit parts coated with the color checker
for fuel leakage.
a If any fuel leakage is detected, repair it
and inspect again from step 1.
a If no fuel leakage is detected, inspection is
completed.

140E-5 Series

30 Testing and adjusting

SEN00149-05

Testing and adjusting alternator


belt tension
1
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.
1.

Loosen mounting bolts (2), (3) and (4) of alternator (1), and then loosen locknut (5).

2.

Move alternator (1) with adjustment nut (6) to


adjust the tension of belt (7).

3.

Tighten locknut (5), and then tighten mounting


bolts (3), (2) and (1).
a After adjusting, test the belt tension again.

140E-5 Series

45

SEN00149-05

Testing and adjusting fan belt tension

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.
1.

Loosen lock bolt of tension pulley (3).

2.

Move tension pulley (3) with adjustment bolt


(2) to adjust the belt tension.
a After adjusting, test the belt tension again.

3.

Tighten lock bolt of tension pulley (3).

46

140E-5 Series

30 Testing and adjusting

SEN00149-05

Handling controller high-voltage


circuit
1
1.

Before disconnecting or connecting the connector between the engine controller and
engine, be sure to turn the starting switch OFF.

2.

If the T-adapter is inserted in or connected to


the connector between the engine controller
and engine for troubleshooting, do not start the
engine.
a You may turn the starting switch to the
OFF or ON position but must not turn it to
the START position.

140E-5 Series

47

SEN00149-05

KOMATSU 140E-5 Series engine


Form No. SEN00149-05

2010 KOMATSU
All Rights Reserved
Printed in Japan 04-10

48

SEN00151-04

ENGINE
1SHOP MANUAL

140E-5 Series

40 Troubleshooting

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

SEN00151-04

40 Troubleshooting

Points to remember when troubleshooting


k
k
k
k
k
k

When troubleshooting a machine, stop it in a level ground, and check that the lock pin, chocks,
and parking brake are securely fitted.
When carrying out the operation with two or more workers, keep strictly to the agreed signals,
and do not allow any unauthorized person to come near.
If the radiator cap is removed when the engine is hot, hot coolant may spurt out and cause
burns, so be sure to wait for the engine to cool down before starting troubleshooting.
Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
When disconnecting wiring, always disconnect the negative (-) terminal of the battery first.
When removing the plug or cap from a location which is under pressure from oil, water, or air,
always release the internal pressure first. When installing measuring equipment, be sure to connect it properly.

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 questions to form some idea of possible causes of the failure that would produce the reported symptoms.
1.

2.

3.

When carrying out troubleshooting, do not


hurry to disassemble the components.
If components are disassembled immediately
after any failure occurs:
q
Parts that have no connection with the failure or other unnecessary parts will be disassembled.
q
It will become impossible to find the cause
of the failure.
It will also cause a waste of manhours, parts,
or oil or grease, and at the same time, will also
lose the confidence of the user or operator.
For this reason, when carrying out troubleshooting, it is necessary to carry out thorough prior
investigation and to carry out troubleshooting in
accordance with the fixed procedure.
Points to ask user or operator
1) Have any other problems occurred apart
from the problem that has been reported?
2) Was there anything strange about the
machine before the failure occurred?
3) Did the failure occur suddenly, or were
there problems with the machine condition
before this?
4) Under what conditions did the failure
occur?
5) Had any repairs been carried out before
the failure? When were these repairs carried out?
6) Has the same kind of failure occurred
before?
Check before troubleshooting
1) Check for symptoms of any abnormality in
the machine and engine.
2) Be sure to check the CHECKS BEFORE
STARTING items.

3)
4)

5)

Check other inspection items, if necessary.


Some other maintenance items can be
checked externally, so check any item that
is considered to be necessary.
Check the controller for display of an error.

4.

Confirming failure
Confirm the extent of the failure yourself, and
judge whether to handle it as a real failure or
as a problem with the method of operation, etc.
a When operating the machine or engine to
reenact the troubleshooting symptoms, do
not carry out any investigation or measurement that may make the problem
worse.

5.

Troubleshooting
Use the results of the investigation and inspection in Items 2 4 to narrow down the causes
of failure, then use the troubleshooting matrix
to locate the position of the failure exactly.
a The basic procedure for troubleshooting is
as follows.
1) Start from the simple points.
2) Start from the most likely points.
3) Investigate other related parts or information.

6.

Measures to remove root cause of failure


Even if the failure is repaired, if the root cause
of the failure is not repaired, the same failure
will occur again. To prevent this, always investigate why the problem occurred. Then,
remove the root cause.

140E-5 Series

40 Troubleshooting

SEN00151-04

Method of displaying trouble diagnosis lamps (Method of displaying


error code)

For generator
If the trouble diagnosis lamps and diagnosis lamp indication selector switch are installed on the applicable
machine side, the trouble diagnosis lamps indicate as follows.
When the starting switch is turned ON, the trouble diagnosis lamps indicate as follows in the normal display
mode and error code display mode.
Combination of trouble diagnosis lamps and diagnosis lamp indication selector switch
Item

Normal display mode


Error code display mode
(While starting switch is ON or engine is running) (While starting switch is ON and engine is stopped)
When normal

Diagnosis lamp
indication selector
switch
R
Y

When error occurs


OFF

Lamp off

Either lamp lights up

When error occurs


ON
Error code is indicated by number of flashes.
Lamp off

Indication when starting switch is turned ON (Initial indication)


q
The following is displayed once whenever the starting switch is turned ON, regardless of the position of
the diagnosis lamp indication selector switch.
q
If the starting switch is turned ON, the red lamp and yellow lamp indicate as follows.

140E-5 Series

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)
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 diagnosis lamp indication selector switch ON while the engine is running.
q

140E-5 Series

40 Troubleshooting

SEN00151-04

Error codes and failure codes list

For construction equipment


INSITE error code

Machine failure
code

Failure phenomenon

111

CA111

Engine Controller Internal Failure

115

CA115

Eng. Ne and Bkup Speed Sensor Error

122

CA122

Charge (boost) Air Press Sensor High Error

123

CA123

Charge (boost) Air Press Sensor Low Error

131

CA131

Throttle Sensor High Error

132

CA132

Throttle Sensor Low Error

135

CA135

Oil Press. Sensor High Error

141

CA141

Oil Press. Sensor Low Error

144

CA144

Coolant Temp. Sensor High Error

145

CA145

Coolant Temp. Sensor Low Error

153

CA153

Charge (boost) Air Temp. Sensor High Error

154

CA154

Charge (boost) Air Temp. Sensor Low Error

187

CA187

Sensor Sup. 2 Volt. Low Error

221

CA221

Ambient Air Press. Sensor High Error

222

CA222

Ambient Air Press. Sensor Low Error

227

CA227

Sensor Sup. 2 Volt. High Error

234

CA234

Eng. Overspeed

238

CA238

Ne Speed Sensor Sup. Volt. Error

263

CA263

Fuel Temp. Sensor High Error

265

CA265

Fuel Temp. Sensor Low Error

271

CA271

PCV1 Short Error

272

CA272

PCV1 Open Error

273

CA273

PCV2 Short Error

274

CA274

PCV2 Open Error

322

CA322

Injector #1 System Open/Short Error

323

CA323

Injector #5 System Open/Short Error

324

CA324

Injector #3 System Open/Short Error

325

CA325

Injector #6 System Open/Short Error

331

CA331

Injector #2 System Open/Short Error

332

CA332

Injector #4 System Open/Short Error

342

CA342

Engine Controller Data Matching Error

351

CA351

INJ. Drive Circuit Error

352

CA352

Sensor Sup. 1 Volt. Low Error

386

CA386

Sensor Sup. 1 Volt. High Error

431

CA431

Idle Validation Switch Error

432

CA432

Idle Validation Process Error

441

CA441

Supply Voltage Low Error

442

CA442

Supply Voltage High Error

140E-5 Series

Reference document No.

Troubleshooting of
electrical system
(E-mode), Part 1
SEN00153-02

SEN00151-04

40 Troubleshooting

INSITE error code

Machine failure
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

1631

CA1631

Bypass Valve Lift Sensor High Error

1632

CA1632

Bypass Valve Lift Sensor Low Error

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

Failure phenomenon

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

Reference document No.

Troubleshooting of
electrical system
(E-mode), Part 2
SEN00154-02

INSITE error code:


An error code of 3 or 4 digits displayed on the INSITE (bench test tool) when the occurrence condition of
the failure is confirmed with the INSITE.
Machine failure code:
An error code of 5 or 6 digits displayed on the machine monitor when the occurrence condition of the
failure is confirmed with the machine monitor, etc. on the machine side.

140E-5 Series

40 Troubleshooting

SEN00151-04

For generator
Machine failure
code

Failure phenomenon

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

CA222

Ambient Air Press. Sensor Low Error

CA227

Sensor Sup. 2 Volt. High Error

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

Reference document No.

Troubleshooting of
electrical system
(E-mode), Part 1
SEN00153-02

SEN00151-04

40 Troubleshooting

Machine failure
code

Failure phenomenon

CA331

Injector #2 System Open/Short Error

CA332

Injector #4 System Open/Short Error

CA342

Engine Controller Data Matching Error

CA351

INJ. Drive Circuit Error

CA352

Sensor Sup. 1 Volt. Low Error

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

CA1633

KOMNET Error

CA2185

Throttle Sens. Sup. Volt. High Error

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

Reference document No.

Troubleshooting of
electrical system
(E-mode), Part 1
SEN00153-02

Troubleshooting of
electrical system
(E-mode), Part 2
SEN00154-02

140E-5 Series

40 Troubleshooting

140E-5 Series

SEN00151-04

SEN00151-04

40 Troubleshooting

Information in troubleshooting table


a

The following information is summarized in the troubleshooting table and the related electrical circuit
diagram. Before carrying out troubleshooting, understand that information fully.
Error code

Failure code

Display on INSITE

Display on
applicable machine

Contents of trouble

Contents of trouble detected by engine controller

Action of controller

Action taken by engine controller to protect system or devices when engine controller
detects trouble

Trouble

Trouble in engine

Problem that appears


Problem that appears on engine as a result of action taken by engine controller (shown above)
on machine
Related information Information related to detected trouble or troubleshooting
Cause

Standard value in normal state/Remarks on troubleshooting


<Contents of description>
Standard value in normal state to judge possible causes
Remarks on judgment

Possible causes and


standard value in
normal state

10

<Troubles in wiring harness>


Disconnection
Connector is connected imperfectly or wiring harness is
broken.
Ground fault
Wiring harness which is not connected to chassis
ground circuit is in contact with chassis ground circuit.
Hot short
Wiring harness which is not connected to power source
(24 V) circuit is in contact with power source (24 V) circuit.
Short circuit
Independent wiring harnesses are in contact with each
other abnormally.

Possible causes of trouble


(Given numbers are reference numbers, which do not <Precautions for troubleshooting>
indicate priority)
1) Method of indicating connector No. and handling of Tadapter
Insert or connect T-adapter as explained below for troubleshooting, unless otherwise specified.
3
If connector No. has no marks of male and
female, disconnect connector and insert T-adapters
in both male side and female side.
If connector No. has marks of male and female,
disconnect connector and connect T-adapter to only
male side or female side.
2) Entry order of pin Nos. and handling of tester leads
Connect positive (+) lead and negative () lead of tester
as explained below for troubleshooting, unless otherwise specified.
4
Connect positive (+) lead to pin No. or wiring harness
entered on front side.
Connect negative () lead to pin No. or harness entered
on rear side.

140E-5 Series

40 Troubleshooting

SEN00151-04

Related circuit diagram

This drawing is a part of the electric circuit diagram related to troubleshooting.


Connector No.: Indicates (Model Number of pins) and (Color).
Connector No. and pin No. from each branching/merging point:
Shows the ends of branch or source of merging within the parts of the
same wiring harness.
Arrow
: Roughly shows the location on the machine.

140E-5 Series

11

SEN00151-04

Connection table for connector pin numbers


a

12

40 Troubleshooting

(Rev. 2009.04)

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.

140E-5 Series

40 Troubleshooting

140E-5 Series

SEN00151-04

13

SEN00151-04

14

40 Troubleshooting

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SEN00151-04

40 Troubleshooting

T- branch box and T- branch adapter table


a

(Rev. 2009.03)
1

q q

Out of kit

799-601-4201

799-601-4101

799-601-9300

799-601-9200

799-601-9100

799-601-9000

799-601-8000

799-601-7500

799-601-7400

799-601-7100

799-601-7000

799-601-2800

Identification
symbol

799-601-2700

Part name

T-adapter kit
799-601-2500

Part No.

Number of pins

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.

799-601-2600 T-box (for ECONO)

21

799-601-3100 T-box (for MS)

37

799-601-3200 T-box (for MS)

37

q
q

799-601-3380 Plate for MS (14-pin)


799-601-3410 Adapter for BENDIX (MS)

24

MS-24P

799-601-3420 Adapter for BENDIX (MS)

24

MS-24P

799-601-3430 Adapter for BENDIX (MS)

17

MS-17P

799-601-3440 Adapter for BENDIX (MS)

17

MS-17P

799-601-3450 Adapter for BENDIX (MS)

MS-5P

799-601-3460 Adapter for BENDIX (MS)

10

MS-10P

799-601-3510 Adapter for BENDIX (MS)

MS-5P

799-601-3520 Adapter for BENDIX (MS)

17

MS-17P

799-601-3530 Adapter for BENDIX (MS)

19

MS-19P

799-601-2910 Adapter for BENDIX (MS)

14

MS-14P

q
q

799-601-3470 Case
799-601-2710 Adapter for MIC

MIC-5P

q q

799-601-2720 Adapter for MIC

13

MIC-13P

q q

799-601-2730 Adapter for MIC

17

MIC-17P

q q q

799-601-2740 Adapter for MIC

21

MIC-21P

q q q

799-601-2950 Adapter for MIC

MIC-9P

799-601-2750 Adapter for ECONO

ECONO2P

q q

799-601-2760 Adapter for ECONO

ECONO3P

q q

799-601-2770 Adapter for ECONO

ECONO4P

q q

799-601-2780 Adapter for ECONO

ECONO8P

q q

799-601-2790 Adapter for ECONO

12 ECONO12P q q

799-601-2810 Adapter for DLI

DLI-8P

q q

799-601-2820 Adapter for DLI

12

DLI-12P

q q

799-601-2830 Adapter for DLI

16

DLI-16P

q q

799-601-2840 Extension cable (ECONO type)

12 ECONO12P q q

q
q q

q q

q q q

799-601-2850 Case
799-601-4350 T-box (for DRC 60, ECONO)

60

799-601-4360 Case
799-601-7010 Adapter for X (T-adapter)

799-601-7020 Adapter for X

X2P

q q q

799-601-7030 Adapter for X

X3P

q q q

799-601-7040 Adapter for X

X4P

q q q

799-601-7050 Adapter for SWP

SW6P

q q q

799-601-7060 Adapter for SWP

SW8P

q q q

799-601-7310 Adapter for SWP

12

SW12P

799-601-7070 Adapter for SWP

14

SW14P

799-601-7320 Adapter for SWP

16

SW16P

799-601-7080 Adapter for M (T-adapter)

799-601-7090 Adapter for M

799-601-7110 Adapter for M

48

q
q

M2P

q q q

M3P

q q q

140E-5 Series

40 Troubleshooting

SEN00151-04

799-601-7150 Adapter for S (White)

10

S10P

q q q

799-601-7160 Adapter for S (Blue)

12

S12P

q q q

799-601-7170 Adapter for S (Blue)

16

S16P

q q q

Out of kit

799-601-4201

q q q

799-601-4101

S8P

799-601-9300

799-601-9200

799-601-7140 Adapter for S

799-601-9100

M8P

799-601-9000

799-601-8000
q

799-601-7340 Adapter for M

799-601-7500

q q q

799-601-7400

q q q

M6P

799-601-7100

M4P

799-601-7000

799-601-7130 Adapter for M

799-601-2800

799-601-7120 Adapter for M

Part name

799-601-2700

Identification
symbol

Part No.

799-601-2500

Number of pins

T-adapter kit

q
q

799-601-7330 Adapter for S (White)

16

S16PW

799-601-7350 Adapter for S (White)

12

S12PW

799-601-7180 Adapter for AMP040

A8P

799-601-7190 Adapter for AMP040

12

A12P

799-601-7210 Adapter for AMP040

16

A16P

q q q

799-601-7220 Adapter for AMP040

20

A20P

q q q

799-601-7230 Short connector for X

q q q

q q

799-601-7240 Case

799-601-7270 Case
799-601-7510 Adapter for 070

10

07-10

799-601-7520 Adapter for 070

12

07-12

799-601-7530 Adapter for 070

14

07-14

799-601-7540 Adapter for 070

18

07-18

799-601-7550 Adapter for 070

20

07-20

799-601-7360 Adapter for relay

REL-5P

799-601-7370 Adapter for relay

REL-6P

799-601-7380 Adapter for JFC

799-601-9010 Adapter for DTM

DTM2

799-601-9020 Adapter for DT

DT2

799-601-9030 Adapter for DT

DT3

799-601-9040 Adapter for DT

DT4

799-601-9050 Adapter for DT

DT6

799-601-9060 Adapter for DT (Gray)

DT8GR

799-601-9070 Adapter for DT (Black)

DT8B

799-601-9080 Adapter for DT (Green)

DT8G

799-601-9090 Adapter for DT (Brown)

DT8BR

799-601-9110 Adapter for DT (Gray)

12

DT12GR

799-601-9120 Adapter for DT (Black)

12

DT12B

799-601-9130 Adapter for DT (Green)

12

DT12G

799-601-9140 Adapter for DT (Brown)

12

DT12BR

799-601-9210 Adapter for HD30-18

D18-8

q q

799-601-9220 Adapter for HD30-18

14

D18-14

q q

799-601-9230 Adapter for HD30-18

20

D18-20

q q

799-601-9240 Adapter for HD30-18

21

D18-21

q q

799-601-9250 Adapter for HD30-24

D24-9

q q

799-601-9260 Adapter for HD30-24

16

D24-16

q q

799-601-9270 Adapter for HD30-24

21

D24-21

q q

799-601-9280 Adapter for HD30-24

23

D24-23

q q

799-601-9290 Adapter for HD30-24

31

D24-31

q q

799-601-9310 Plate for HD30 (24-pin)


799-601-9320 T-box (for ECONO)

140E-5 Series

24

q q
q q

q q

q q

49

Out of kit

799-601-4201

799-601-4101

799-601-9300

799-601-9200

799-601-9100

799-601-9000

799-601-8000

799-601-7500

799-601-7400

799-601-7100

799-601-7000

799-601-2800

Identification
symbol

799-601-2700

Part name

T-adapter kit
799-601-2500

Part No.

40 Troubleshooting

Number of pins

SEN00151-04

799-601-9330 Case

799-601-9340 Case
799-601-9350 Adapter for DRC

40

DRC-40

799-601-9360 Adapter for DRC

24

DRC-24

799-601-9410* Socket for engine (CRI-T2)

Adapter for engine (CRI-T2)


799-601-9420 Adapter for engine (CRI-T3) PFUEL
Oil pressure sensor

A3

q q

q q

799-601-9440* Socket for engine (CRI-T2)

1,2,3

795-799-5520* Socket for engine (HPI-T2)

Socket for engine (HPI-T2)


795-799-5530* Socket for engine (CRI-T3)
Temperature sensor

q q

q q

795-799-5460 Cable for engine (HPI-T2)

795-799-5470 Cable for engine (HPI-T2)

799-601-9430*

795-799-5540*

Socket for engine (CRI-T2)


Socket for engine (CRI-T3) PCV

Socket for engine (HPI-T2)


Socket for engine (CRI-T3) TIM

795-799-5480 Cable for engine (HPI-T2)

799-601-4110 Adapter for engine (140-T3) PIM

ITT3N

q q

799-601-4130 Adapter for engine (CRI-T3) NE, CAM

FCIN

q q

FCIG

q q

799-601-4150 Adapter for engine (CRI-T3) POIL

FCIB

q q

Adapter for engine (CRI-T3)


799-601-4160
Oil pressure switch

4160

q q

799-601-4180 Adapter for engine (CRI-T3) PEVA

4180

q q

Socket for engine (CRI-T3)


799-601-4190*
Commonrail pressure

1,2,3L

q q

1,2,3,4C

q q

799-601-4240* Socket for engine (CRI-T3) PAMB

1,2,3A

q q

799-601-4250* Socket for engine (CRI-T3) PIM

1,2,3B

q q

799-601-4330* Socket for engine (CRI-T3) G

1,2,3,G

q q

Socket for engine (CRI-T3)


799-601-4340*
Pump actuator

2,PA

q q

1,2,3,4T

799-601-4260 Adapter for controller (ENG)

DTP4

799-601-4140

799-601-4230*

799-601-4380*

Adapter for engine (CRI-T3)


Atomosphere pressure

Socket for engine (CRI-T3)


Air intake pressure/temperature

Socket for engine (CRI-T3)(95)


Air intake pressure/temperature

q
q q

799-601-4211 Adapter for controller (ENG)

50

DRC50

799-601-4220 Adapter for controller (ENG)

60

DRC60

799-601-4390* Socket for controller (95 ENG)

60

799-601-4280* Box for controller (PUMP)

121

799-601-9720 Adapter for controller (HST)

16

HST16A

799-601-9710 Adapter for controller (HST)

16

HST16B

799-601-9730 Adapter for controller (HST)

26

HST26A

2,
3,
4,

799-601-9890

Multi-adapter for
DT2 4 and DTM2

* Shows not T-adapter but socket.

50

140E-5 Series

40 Troubleshooting

140E-5 Series

SEN00151-04

51

SEN00151-04

KOMATSU 140E-5 Series engine


Form No. SEN00151-04

2009 KOMATSU
All Rights Reserved
Printed in Japan 09-09 (01)

52

SEN00152-03

ENGINE
1SHOP MANUAL

140E-5 Series

40 Troubleshooting

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

SEN00152-03

40 Troubleshooting

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

140E-5 Series

40 Troubleshooting

140E-5 Series

SEN00152-03

SEN00152-03

40 Troubleshooting

Troubleshooting of mechanical system (S-mode)

Method of using troubleshooting charts

The troubleshooting chart consists of the questions, check items, causes, and troubleshooting blocks.
The questions and check items are used to pinpoint high probability causes by simple inspection or from
phenomena without using troubleshooting tools.
Next, troubleshooting tools or direct inspection are applied to check the narrowed causes in order from the
most probable one to make final confirmation according to the troubleshooting procedure.
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.)

140E-5 Series

40 Troubleshooting

140E-5 Series

SEN00152-03

SEN00152-03

40 Troubleshooting

<Example of troubleshooting> Exhaust gas color is black (incomplete combustion)


Let us assume that a trouble of Exhaust gas color is black occurred and we checked the [Questions] and
[Check items] and found the following 3 items to be the causal symptoms; [Color of exhaust gas gradually
became black], [Power was lost gradually], and [Dust indicator is red].

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

SEN00152-03

40 Troubleshooting

S-1 Starting performance is poor

General causes why starting performance is poor

Causes

Clogged air cleaner element


Cracked EGR cooler (Coolant in exhaust pipe)
["with EGR" only]
Defective contact of valve, vale seat
Worn piston ring, cylinder
Clogged air breather hole of fuel tank cap
Leaking or clogged fuel piping, entry of air
Clogged fuel filter, element
Clogged feed pump gauze filter
Stuck, seized supply pump plunger
Defective injector
Defective intake air heater system
Defective alternator (regulator section)
Defective alternator (generator section)
Defective, deteriorated battery

Defective electrical system

Coolant in exhaust pipe ("with EGR" only)

Troubleshooting

Check items

Questions

a The common rail fuel injection system (CRI) controls the fuel
injection timing electrically. Accordingly, even if the starting
operation is carried out, the engine may not start until the crankshaft revolves 2 turns at maximum. This phenomenon does not
indicate a trouble, however.
Confirm recent repair history
Degree of use of
Operated for long period
machine
Became worse gradually
Starting performance
Engine starts easily when warm
Non-specified fuel is being used
Replacement of filters has not been carried out according to Operation and Maintenance Manual
Engine oil must be added more frequently
When engine is preheated or when temperature is low, preheating monitor does
not indicate normally (if monitor is installed)
During operation, charge level monitor indicates abnormal charge (if monitor is
installed)
Dust indicator is red (if indicator is installed)
Air breather hole of fuel tank cap is clogged
Fuel is leaking from fuel piping
When priming pump is operated, it makes no reaction or it is heavy
Starting motor cranks engine slowly
If air bleeding plug of fuel filter is removed, fuel does not
While engine is
flow out
cranked with starting
motor
If spill hose from injector is disconnected, little fuel spills
When exhaust manifold is touched immediately after starting engine, temperature
of some cylinders is low
Engine does not pick up smoothly and combustion is irregular
There is hunting from engine (rotation is irregular)
Blow-by gas is excessive
Inspect air cleaner directly
When EGR cooler outlet gas piping is removed, coolant containing antifreeze
flows out (*1) ["with EGR" only]
When compression pressure is measured, it is found to be low
When air is bled from fuel system, air comes out
Inspect fuel filter, element directly
Inspect feed pump gauze filter directly
Carry out troubleshooting according to No-pressure feed by supply pump (*2) in
E-mode
When a cylinder is cut out for reduced cylinder mode operation, engine speed
does not change
When starting switch is turned to HEAT, intake air heater mount does not become
warm
Is voltage 20 30 V between alternator terminal B and terminal E with Yes
engine at low idle?
No
When specific gravity of electrolyte and voltage of battery are measured, they are
low
Remedy

E E
Q Q ww

EE
QQ

QQQQ
wwQQ

w
w
ww
w

w
Q

w
Q
wQQ

ww
w
QQ
w

w
w

QwQQ

q
q
qq

q
q
q
q
q

q
q

Correct
Replace
Clean
Correct
Clean
Clean
Replace
Replace
Replace
Replace
Replace
Replace

Improper selection of fuel

Replace

Insufficient intake of air

Clean

Insufficient supply of fuel

140E-5 Series

40 Troubleshooting

SEN00152-03

*1: EGR cooler outlet gas piping


Loosen 4 mounting bolts (1) of the EGR cooler outlet gas piping and check that the coolant flows out. A
little condensate produced from cooled exhaust gas may flow out. If it is colorless and transparent, however, it is not a problem.

*2: Code [559/CA559] and code [2249/CA2249] in E-mode

140E-5 Series

SEN00152-03

40 Troubleshooting

S-2 Engine does not start

a) Engine does not turn

Defective starting circuit wiring

Defective starting motor (motor section)

Defective starting motor (safety relay section)

Problem in drive devices on applicable machine side


Carry out troubleshooting for devices on applicable machine

Defective starting switch

Defective electrical system

Defective battery relay

Water hammer caused by coolant which entered cylinder

Defective connection of battery terminal

Internal parts of engine seized


See S-4 Engine stops during operations.

Defective or deteriorated battery

General causes why engine does not turn

Broken flywheel ring gear

Cracked EGR cooler (Coolant in exhaust pipe)


["with EGR" only]

Causes

E EE

Operated for long period

Condition of horn when Horn does not sound


starting switch is turned
Horn volume is low
ON

Battery electrolyte is low

w
Q
Q
w

When starting switch is turned ON, there is no operating sound from battery relay
Check items

When starting switch is turned to START, starting pinion does not move out

Speed of rotation is low

w
w
w
Q w

Soon disengages again

Makes rattling noise and does not turn

q
q

Inspect flywheel ring gear directly

Troubleshooting

Makes grating noise

When EGR cooler outlet gas piping is removed, coolant containing antifreeze flows out (*1).
["with EGR" only]

When specific gravity of electrolyte and voltage of battery are measured, they are low
There is not voltage (20 30 V) between battery relay terminal B and
terminal E
Turn starting switch
OFF, connect cord, and
carry out troubleshooting at ON

Battery terminal is loose

When starting switch is


turned to START, starting pinion moves out,
but

When terminal B and terminal C of starting switch are connected,


engine starts

When terminal B and terminal C at safety relay outlet are connected,


engine starts

Even if terminal B and terminal C at safety relay outlet are connected,


engine does not start

10

Replace

Replace

Replace

Correct

Replace

Replace

Replace

Remedy

Carry out troubleshooting on applicable machine side

Degree of use of
machine

Replace

Questions

Confirm recent repair history

140E-5 Series

40 Troubleshooting

SEN00152-03

*1: EGR cooler outlet gas piping


Loosen 4 mounting bolts (1) of the EGR cooler outlet gas piping and check that the coolant flows out. A
little condensate produced from cooled exhaust gas may flow out. If it is colorless and transparent, however, it is not a problem.

140E-5 Series

11

SEN00152-03

40 Troubleshooting

b) Engine turns but no exhaust smoke comes out

Supply of fuel is extremely small

Use of improper fuel


Insufficient fuel in tank

Improper selection of fuel (particularly in winter)

Defective fuel injector

Fuel is not being supplied

Clogged air breather hole of fuel tank cap


Leaking or clogged fuel piping, entry of air
Clogged fuel filter element
Clogged feed pump gauze filter
Seized, abnormally worn feed pump

General causes why engine turns but no exhaust smoke comes out

Broken supply pump shaft, key


Stuck, seized supply pump plunger
Defective supply pump PCV
Wrong connection of supply pump PCV
Defective operation of overflow valve (Does not close)
Defective operation of flow damper

Causes

EEE

Operated for long period

wQwww

Exhaust smoke suddenly stopped coming out (when starting again)


Replacement of filters has not been carried out according to Operation and Maintenance Manual

QQQ

QQ

Air breather hole of fuel tank cap is clogged


Rust and water are found when fuel tank is drained

Fuel is leaking from fuel piping

w
w

When priming pump is operated, it makes no reaction or it is heavy [with EGR


only]

wQQ

When fuel filter is removed, there is not fuel in it


Check items

When fuel tank is inspected, it is found to be empty

If air bleeding plug of fuel filter is removed, fuel does not flow
While engine is
cranked with start- out
ing motor
If spill hose from injector is disconnected, little fuel spills

wQ

wwww

qq

When air is bled from fuel system, air comes out

Inspect fuel filter directly


Troubleshooting

ww

EE

Inspect feed pump gauze filter directly

Inspect feed pump directly


Carry out troubleshooting according to No-pressure feed by supply pump (*1) in
E-mode
Carry out troubleshooting according to Abnormality in PCV1 (*2) or Abnormality in
PCV2 (*3) in E-mode

q
q
q

Inspect overflow valve directly

qq
Clean
Correct
Replace
Clean
Replace

Remedy

Replace
Add

Engine can be started in reduced cylinder mode

Replace

Degree of use of
machine

Replace
Replace
Replace
Correct
Replace
Replace

Questions

Confirm recent repair history

*1: Code [559/CA559] and code [2249/CA2249] in E-mode


*2: Code [271/CA271] and code [272/CA272] in E-mode
*3: Code [273/CA273] and code [274/CA274] in E-mode

12

140E-5 Series

40 Troubleshooting

SEN00152-03

c) Exhaust smoke comes out but engine does not start (fuel is being injected)

Clogged air cleaner element


Worn dynamic valve system (Valve, rocker lever, etc.)
Worn piston ring, cylinder liner
Use of improper fuel
Clogged air breather hole of fuel tank cap
Leaking or clogged fuel system, entry of air
Clogged fuel filter, strainer
Clogged feed pump gauze filter
Stuck, seized supply pump plunger
Clogged injector, defective spray
Defective, deteriorated battery
Defective coolant temperature sensor, wiring harness
Defective intake air heater system

Causes

General causes why exhaust smoke comes out but engine does not start
Lack of rotating force due to defective electrical system
Insufficient supply of fuel
Insufficient intake of air
Improper selection of fuel

Confirm recent repair history

Questions

Degree of use of machine Operated for long period

EE E
w
QQ

Suddenly failed to start


Non-specified fuel is being used
Replacement of filters has not been carried out according to Operation and Maintenance
Manual

ww
w

Engine oil must be added more frequently


When engine is preheated or when temperature is low, preheating monitor does not indicate
normally (if monitor is installed)

w
w

Dust indicator is red (if indicator is installed)

Air breather hole of fuel tank cap is clogged

ww

Rust and water are found when fuel tank is drained

When fuel filter is removed, there is not fuel in it

w
wQQ

Fuel is leaking from fuel piping


When priming pump is operated, it makes no reaction or it is heavy

w
w

When engine is cranked, abnormal sound is generated around cylinder head


While engine is cranked
with starting motor,

ww
w

If spill hose from injector is disconnected, little fuel spills

When exhaust manifold is touched immediately after starting engine, temperature of some
cylinders is low

w
q

Inspect air cleaner directly

Inspect dynamic valve system directly

When compression pressure is measured, it is found to be low


Troubleshooting

If air bleeding plug of fuel filter is removed, fuel does not flow out

When air is bled from fuel system, air comes out

Inspect fuel filter, strainer directly

Inspect feed pump gauze filter directly


Carry out troubleshooting according to No-pressure feed by supply pump (*1) in E-mode

q
q

When injector unit is tested, spray condition is bad


When specific gravity of electrolyte and voltage of battery are measured, they are low
Coolant temperature gauge does not indicate normally (if coolant temperature gauge is
installed)
When starting switch is turned to HEAT, intake air heater mount does not become warm
Remedy

q
q
q
Clean
Replace
Replace
Replace
Clean
Correct
Clean
Clean
Replace
Clean
Replace
Replace
Replace

Check items

Starting motor cranks engine slowly

*1: Code [559/CA559] and code [2249/CA2249] in E-mode

140E-5 Series

13

SEN00152-03

40 Troubleshooting

S-3 Engine does not pick up smoothly

Clogged injector, defective spray

Defective operation of flow damper


(Large leakage from injector)

Defective EGR valve or bypass valve


["with EGR" only]

Defective contact of valve and valve seat


Improper valve clearance
Seized turbocharger, interference of turbocharger
Worn piston ring, cylinder liner
Clogged air breather hole of fuel tank cap
Leaking or clogged fuel piping, entry of air
Clogged fuel filter, strainer
Clogged feed pump gauze filter
Stuck, seized supply pump plunger

Clogged air cleaner element

Causes

General causes why engine does not pick up smoothly


q
Insufficient intake of air
q
Insufficient supply of fuel
q
Defective condition of fuel spray
q
Improper selection of fuel
q
Controller is controlling in derate mode
(limiting injection rate (output) because of an error in
electrical system)
q
EGR valve is stuck open ["with EGR" only]
(There is much EGR gas and intake of air is insufficient)

Operated for long period

Engine pick-up suddenly became worse

E E
Q Q

Q
w w w

Non-specified fuel is being used


Replacement of filters has not been carried out according to Operation and
Maintenance Manual

w w
w

Oil must be added more frequently


w

Dust indicator is red (if indicator is installed)

Air breather hole of fuel tank cap is clogged

w w

Rust and water are found when fuel tank is drained


Fuel is leaking from fuel piping

When priming pump is operated, it makes no reaction or it is heavy

w Q Q

Check items

When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low
Color of exhaust gas

Blue under light load


w

Black

When engine is cranked, abnormal sound is generated around cylinder head

When engine is cranked, interference sound is generated around turbocharger


High idle speed under no load is normal, but speed suddenly drops when load is
applied
There is hunting from engine (rotation is irregular)

w w

Q w

w w

Blow-by gas is excessive


q

Inspect air cleaner directly


Carry out troubleshooting according to Abnormality in EGR valve servo (*1) in
E-mode or Abnormality in bypass valve servo (*1) in E-mode ["with EGR" only]
Troubleshooting

q
q

When compression pressure is measured, it is found to be low

q
q

Inspect valve clearance directly

When turbocharger is rotated by hand, it is found to be heavy

When air is bled from fuel system, air comes out

Inspect fuel filter, strainer directly

Inspect feed pump gauze filter directly


Carry out troubleshooting according to No-pressure feed by supply pump (*2)
in E-mode

Replace
Adjust
Replace
Replace
Clean
Correct
Clean
Clean
Replace

Replace

Remedy

Clean

When a cylinder is cut out for reduced cylinder mode operation, engine speed
does not change

q
Replace

Degree of use of machine

Replace

Questions

Confirm recent repair history

*1: Code [1228/CA1228] and code [1625/CA1625] or code [1628/CA1628] and code [1629/CA1629] in Emode
*2: Code [559/CA559] and code [2249/CA2249] in E-mode

14

140E-5 Series

40 Troubleshooting

SEN00152-03

S-4 Engine stops during operations

1
Broken dynamic valve system (valve, rocker arm, etc.)
Broken, seized piston, connecting rod
Broken, seized crankshaft bearing
Broken, seized gear train
Insufficient fuel in tank
Clogged air breather hole of fuel tank cap
Leaking, clogged fuel piping
Clogged fuel filter, strainer
Clogged feed pump gauze filter
Broken, seized feed pump
Broken supply pump shaft, key
Stuck, seized supply pump plunger
Broken auxiliary equipment (pump, compressor, etc.)
Defective engine controller power supply wiring
Defective starting switch wiring

Problem in drive devices on applicable machine side

Causes

General causes why engine stops during operations


q
Seized parts inside engine
q
Insufficient supply of fuel
q
There is overheating
q
Problem in drive devices on applicable machine
side
o Requires troubleshooting on applicable
machine side.

Confirm recent repair history


E E

Degree of use of machine Operated for long period

Questions

Abnormal noise was heard and engine


stopped suddenly
Condition when engine
stopped

w w w w
w Q

Engine overheated and stopped

Q
w

Q Q

Q Q

There was hunting and engine stopped

w Q

Q Q Q

Q Q

Non-specified fuel is being used

Q Q Q

Replacement of filters has not been carried out according to Operation


and Maintenance Manual

w w

Fuel level monitor indicates low level (if monitor is installed)

When fuel tank is inspected, it is found to be empty

Fuel is leaking from fuel piping

When priming pump is operated, it makes no reaction or it is heavy

w Q Q
w w

Rust and water are found when fuel tank is drained


w w w

Metal particles are found when oil is drained

w w

Does not turn at all


When engine is cranked
by hand

Engine stopped slowly

Air breather hole of fuel tank cap is clogged

Check items

Q w Q w

Turns in opposite direction

Moves by amount of gear backlash

w
w

Supply pump shaft does not turn

Engine turns, but stops when load is applied to machine


q

Inspect dynamic valve system directly

Inspect piston, connecting rod directly

Inspect gear train directly

Inspect fuel filter, strainer directly

Inspect feed pump gauze filter directly

Inspect feed pump directly


Carry out troubleshooting according to No-pressure feed by supply
pump (*1) in E-mode
Engine rotates when pump auxiliary equipment (pump, compressor, etc.)
is removed

q q
q
q

Inspect controller power supply wiring

Inspect starting switch wiring


Remedy

Replace
Replace
Replace
Replace
Add
Clean
Correct
Clean
Clean
Replace
Replace
Replace
Replace
Correct
Correct

Troubleshooting

Carry out troubleshooting


on applicable machine side

Inspect crankshaft bearing directly

*1: Code [559/CA559] and code [2249/CA2249] in E-mode


140E-5 Series

15

SEN00152-03

40 Troubleshooting

S-5 Engine does not rotate smoothly

Defective Bkup speed sensor, wiring harness

Defective Ne speed sensor, wiring harness

Clogged injector, defective spray (dirt in injector)

Defective operation of flow damper (Large leakage from injector)

Clogged fuel filter, strainer

Clogged feed pump gauze filter

Leaking or clogged fuel piping, entry of air

Clogged air breather hole of fuel tank cap

Insufficient fuel in tank

Defective operation of bypass valve ["with EGR" only]

Low setting of low idle speed

Defective operation of EGR valve ["with EGR" only]

Causes

General causes why engine does not rotate smoothly


q
Air in fuel system
q
Defective speed sensor
(Error at degree that it is not indicated)
q
Defective EGR valve ["with EGR" only]
q
Defective bypass valve ["with EGR" only]

Confirm recent repair history

Condition of hunting

E E

Operated for long period


Occurs at a certain speed range

Q Q Q

Occurs at low idle

E E
Q Q
Q Q Q Q Q Q Q

Q Q

Occurs even when speed is raised

Q Q

Occurs on slopes

Q Q

Replacement of filters has not been carried out according to Operation and Maintenance Manual

w w
w

Check items

When fuel tank is inspected, it is found to be empty

Air breather hole of fuel tank cap is clogged

Q Q

Rust and water are found when fuel tank is drained


Fuel is leaking from fuel piping

When priming pump is operated, it makes no reaction or it is heavy

w Q Q

Troubleshooting

Carry out troubleshooting according to Abnormality in EGR valve servo (*1) in E-mode
["with EGR" only]

Carry out troubleshooting according to Abnormality in bypass valve servo (*2) in Emode ["with EGR" only]

q
q

When air is bled from fuel system, air comes out

Inspect feed pump gauze filter directly

Inspect fuel filter, strainer directly


When a cylinder is cut out for reduced cylinder mode operation, engine speed does not
change

q q

Carry out troubleshooting according to Abnormality in engine Ne speed sensor (*3) in


E-mode

Carry out troubleshooting according to Abnormality in engine Bkup speed sensor (*4)
in E-mode

*1:
*2:
*3:
*4:

16

Code
Code
Code
Code

Correct

Replace

Replace

Replace

Replace

Correct

Clean

Add

Replace

Replace

Correct

Remedy

q
Correct

Questions

Degree of use of machine

[1228/CA1228] and code [1625/CA1625] in E-mode


[1628/CA1628] and code [1629/CA1629] in E-mode
[689/CA689] in E-mode
[778/CA778] in E-mode

140E-5 Series

40 Troubleshooting

SEN00152-03

S-6 Engine lacks output (or lacks power)

General causes why engine lacks output

Defective drive of injector (signal, solenoid)

Q Q Q
Q

Defective fuel temperature sensor, wiring harness

Clogged injector, defective spray (dirt in injector)

Stuck, seized supply pump plunger

Clogged feed pump gauze filter

Clogged fuel filter, strainer

Leaking, clogged fuel piping

Clogged air breather hole of fuel tank cap

Worn piston ring, cylinder liner

Improper valve clearance

Controller is controlling in derate mode (limiting injection rate (output) because of an error in electrical system)

Clogged air cleaner element

There is overheating
See S-14 Coolant temperature becomes too high (Overheating)

Air leakage from air intake piping

Improper selection of fuel

Defective contact of valve and valve seat

Defective spray condition of fuel

Seized turbocharger, interference of turbocharger

Insufficient supply of fuel

Defective charge (boost) pressure sensor, wiring harness

Insufficient intake of air

Defective installation of charge (boost) pressure sensor (air leakage)

Causes

Confirm recent repair history

Power was lost

Operated for long period

E E

Q Q
Q Q

Suddenly

Gradually

Non-specified fuel is being used


Replacement of filters has not been carried out according to Operation and Maintenance Manual

w
Q Q Q

Engine oil must be added more frequently

Dust indicator is red (if indicator is installed)

Air breather hole of fuel tank cap is clogged

Fuel is leaking from fuel piping

Output becomes insufficient after short stop of operation

Blue under light load

Check items

When exhaust manifold is touched immediately after starting engine, temperature of


some cylinders is low

w
w

When engine is cranked, interference sound is generated around turbocharger

When engine is cranked, abnormal sound is generated around cylinder head

High idle speed is too low


High idle speed under no load is normal, but speed suddenly drops when load is
applied

w w Q
w

Engine does not pick up smoothly and combustion is irregular

Q Q
Q Q Q Q

There is hunting from engine (rotation is irregular)

Blow-by gas is excessive


Inspect air cleaner directly

Inspect air intake piping directly

q
q q q

When boost pressure is measured, it is found to be low

When compression pressure is measured, it is found to be low

q
q

Inspect valve clearance directly


Troubleshooting

Inspect fuel filter, strainer directly

Inspect feed pump gauze filter directly


Carry out troubleshooting according to No-pressure feed by supply pump (*1) in Emode
When a cylinder is cut out for reduced cylinder mode operation, engine speed does
not change

q
q q
q

Inspect charge (boost) pressure sensor mount directly


Carry out troubleshooting according to Abnormality in charge pressure sensor (*2) in
E-mode
Carry out troubleshooting according to Abnormality in fuel temperature sensor (*3) in
E-mode

140E-5 Series

Correct

Replace

Replace

Replace

Clean

Replace

Correct

Clean

Replace

Adjust

Replace

Replace

Correct

Remedy

Clean

*1: Code [559/CA559] and code [2249/CA2249] in E-mode


*2: Code [122/CA122] and code [123/CA123] in E-mode
*3: Code [263/CA263] and code [265/CA265] in E-mode

Replace

Color of exhaust gas

w w w

Black

Replace

Questions

Degree of use of
machine

17

SEN00152-03

40 Troubleshooting

S-7 Exhaust smoke is black (incomplete combustion)

Defective coolant temperature sensor, wiring harness

Improper fuel injection pressure

Improper injection timing

Clogged fuel spill piping (on cylinder head side)

Abnormally worn injector

Clogged, seized injector

Stuck, seized supply pump plunger

Worn piston ring, cylinder liner

Crushed, clogged muffler

Leakage of air between turbocharger and cylinder head

Improper valve clearance

Defective contact of valve and valve seat

EGR gas piping is clogged ["with EGR" only]

Defective EGR valve or bypass valve ["with EGR" only]

Seized turbocharger, interference of turbocharger

Causes

Clogged air cleaner element

General causes why exhaust smoke is black


q
Insufficient intake of air
q
Excessive injection of fuel
q
Defective condition of fuel injection
q
Improper selection of fuel
q
There is overheating
o See S-14 Coolant temperature becomes too high
(Overheating)
q
Controller is controlling in derate mode (limiting
injection rate (output) because of an error in electrical system)
q
EGR valve is stuck open ["with EGR" only] (There is
much EGR gas and intake of air is insufficient)
q
EGR gas piping is clogged ["with EGR" only] (Entry
of exhaust gas into air intake at acceleration or
deceleration) (*2)

Confirm recent repair history


Operated for long period

Suddenly became black


Color of exhaust gas
Gradually became black
color
Blue under light load

w Q Q

Q Q

Q Q
w
Q Q

Non-specified fuel is being used


w

Oil must be added more frequently


Power was lost

Suddenly

Gradually

Q Q
Q

Dust indicator is red (if indicator is installed)

Muffler is crushed
w

Air leaks between turbocharger and cylinder head, clamp is loosened

Q Q Q

Engine is operated in low-temperature mode at normal temperature

Check items

When exhaust manifold is touched immediately after starting engine, temperature of


some cylinders is low

Q w
w

When engine is cranked, interference sound is generated around turbocharger

When engine is cranked, abnormal sound is generated around cylinder head


Torque converter stall speed or pump relief speed is high (Fuel is injected excessively)

Q Q

Exhaust noise is abnormal

Engine does not pick up smoothly and combustion is irregular

Q Q

Blow-by gas is excessive

Q Q Q

Q w
w
w

If spill hose from injector is disconnected, abnormally much fuel spills


q

Inspect air cleaner directly

When turbocharger is rotated by hand, it is fount to be heavy

Troubleshooting

Carry out troubleshooting according to Abnormality in EGR valve servo (*1) in Emode or Abnormality in bypass valve servo (*1) in E-mode ["with EGR" only]

q
q

Inspect EGR gas piping directly (*2) ["with EGR" only]

When compression pressure is measured, it is found to be low

q
q

Inspect valve clearance directly

When muffler is removed, exhaust color improves


Carry out troubleshooting according to No-pressure feed by supply pump (*3) in Emode

When a cylinder is cut out for reduced cylinder mode operation, engine speed does
not change

q
q
q

Inspect fuel spill piping (on cylinder head side) directly


Carry out troubleshooting according to Abnormality in coolant temperature sensor
(*4) in E-mode

18

Adjust

Adjust

Correct

Replace

Replace

Replace

Replace

Replace

Adjust

Correct

Replace

Replace

Replace

Clean

Replace

Remedy

q
Replace

Questions

Degree of use of
machine

140E-5 Series

40 Troubleshooting

SEN00152-03

*1: Code [1228/CA1228] and code [1625/CA1625] or code [1628/CA1628] and code [1629/CA1629] in Emode
*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.

*3: Code [559/CA559] and code [2249/CA2249] in E-mode


*4: Code [144/CA144] and code [145/CA145] in E-mode

140E-5 Series

19

SEN00152-03

40 Troubleshooting

S-8 Oil consumption is excessive (or exhaust smoke is blue)


General causes why oil consumption is excessive

Long-time operation of engine at low idle or high idle (Do not run engine
at idle for more than 20 minutes continuously)
External leakage of oil
Wear of parts in lubrication system

Dust sucked in from intake system


Worn, damaged valve (stem, guide, seal)
Worn seal at turbocharger end
Turbocharger
Worn seal at blower end
Oil leakage from EGR valve stem ["with EGR" only]
Clogged breather, breather hose
Broken piston ring
Worn piston ring, cylinder liner
Worn, damaged rear oil seal
Broken oil cooler
Oil leakage from oil cooler
Oil leakage from oil filter
Oil leakage from oil piping
Oil leakage from oil drain plug
Oil leakage from oil pan, cylinder head, etc.

Causes

Abnormal consumption of oil

Questions

Confirm recent repair history


Degree of use of
Operated for long period
machine
Oil consumption suddenly increased

EEEE

E
w

Oil must be added more frequently


Oil becomes contaminated quickly

Q
Q

w
Q Q w

w w w w w

Outside of engine is dirty with oil

There are loose piping clamps in intake system

w
Q w

Inside of turbocharger exhaust outlet pipe is dirty with oil

There is oil in coolant

Oil level in clutch chamber or damper chamber is high

Exhaust smoke is blue under light load


Amount of blow-by
gas

Excessive

Troubleshooting

Q
w

None

When intake manifold is removed, dust is found inside


When intake manifold is removed, inside is found to be dirty abnormally
Excessive play of turbocharger shaft
When EGR valve is removed, exhaust port is found to be dirty with oil
["with EGR" only]
Check breather and breather hose directly
When compression pressure is measured, it is found to be low

q
q
q q
q
q
q q
q

Inspect rear oil seal directly

q q

Pressure-tightness test of oil cooler shows there is leakage

q q q

There is external leakage of oil from engine


Remedy

20

w w
w w

Correct
Replace
Replace
Replace
Replace
Clean
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct

Check items

Inside of turbocharger intake outlet pipe is dirty with oil

140E-5 Series

40 Troubleshooting

SEN00152-03

S-9 Oil becomes contaminated quickly

General causes why oil becomes contaminated quickly

Defective turbocharger turbine side seal


Worn EGR valve guide ["with EGR" only]
Worn valve, valve guide
Worn piston ring, cylinder liner
Clogged breather, breather hose
Clogged oil cooler
Clogged oil filter
Defective oil filter safety valve
Clogged turbocharger lubrication drain tube
Exhaust smoke is bad

Causes

Entry of exhaust gas into oil due to internal wear


Clogging of lubrication passage
Use of improper fuel
Use of improper oil

Confirm recent repair history


Degree of use of
Operated for long period
machine

EEEE
Q

Non-specified fuel is being used

Engine oil must be added more frequently


Even when engine oil temperature rises, oil filter clogging monitor indicates clogging (if monitor is installed)
Metal particles are found when oil is drained

w
w Q
Q Q
w

Inside of exhaust pipe is dirty with oil

Color of exhaust gas


color
Amount of blow-by gas

Blue under light load

Black

Excessive

None

Excessive play of turbocharger shaft


When EGR valve is removed, exhaust port is found to be dirty with oil
["with EGR" only]
When compression pressure is measured, it is found to be low

q
q
q q
q

Inspect breather and breather hose directly

Inspect oil cooler directly

Inspect oil filter directly

Spring of oil filter safety valve is hitched or broken

Inspect turbocharger lubrication drain tube directly


Remedy

140E-5 Series

Q w

Replace
Replace
Replace
Replace
Clean
Replace
Replace
Replace
Clean

Troubleshooting

Check items

Engine oil temperature rises quickly

See S-7

Questions

Operation under excessive load

21

SEN00152-03

40 Troubleshooting

S-10 Fuel consumption is excessive

General causes why fuel consumption is excessive

Fuel leakage inside head cover


Fuel leakage from fuel filter, piping, etc.
Defective feed pump oil seal
Defective supply pump plunger
Defective common rail pressure
Defective spray by injector
Defective operation of injector
Improper fuel injection timing
Defective coolant temperature sensor, wiring harness

Causes

Leakage of fuel
Defective condition of fuel injection (fuel pressure, injection timing)

Questions

Excessive injection of fuel

Confirm recent repair history


Degree of use of
Operated for long period
machine
More than for other machines of same model
Condition of fuel
Gradually increased
consumption
Suddenly increased

EE

E
Q

Q
Q Q
w

There is external leakage of fuel from engine

Engine oil level rises and oil smells of diesel fuel


w
When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low
Low idle speed is high

w
w
Q
Q

Torque converter stall speed or pump relief speed is high


Exhaust smoke
color

Q Q

Black
White

Remove and inspect head cover directly

Inspect feed pump oil seal directly


Carry out troubleshooting according to No-pressure feed by supply pump (*2)
in E-mode
When a cylinder is cut out for reduced cylinder mode operation, engine speed
does not change
If spill hose from injector is disconnected, much fuel spills
Carry out troubleshooting according to Abnormality in coolant temperature
sensor (*2) in E-mode
Confirm with INSITE or with monitoring function on applicable machine side
Remedy

Q Q

q
q
q
q
q
q

Correct
Correct
Replace
Replace
Correct
Replace
Replace
Correct
Correct

Check items

Combustion is irregular

Troubleshooting

Q Q Q
Q

*1: Code [559/CA559] and code [2249/CA2249] in E-mode


*2: Code [144/CA144] and code [145/CA145] in E-mode

22

140E-5 Series

40 Troubleshooting

SEN00152-03

S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)1
Causes

Internal leakage in lubrication system

Broken oil cooler core, O-ring

Insufficient protrusion of cylinder liner

Damaged cylinder liner O-ring, holes caused by pitting

Internal cracks in cylinder block

Broken cylinder head, head gasket

Internal leakage in cooling system

Broken hydraulic oil cooler or power train oil cooler on applicable machine side

General causes why oil is in coolant

Degree of use of machine Operated for long period


Oil level

Q Q
Q
Q Q

Gradually increased

Hard water is being used as coolant

There are excessive air bubbles in radiator, coolant spurts back

Q
w
w

Hydraulic oil or power train oil on applicable machine side is milky

When hydraulic oil or power train oil is drained, water is found

w
q

Pressure-tightness test of cylinder head shows there is leakage

q q

Inspect cylinder block, liner directly

Inspect cylinder liner directly

140E-5 Series

Replace

Replace

Replace

Remedy

Replace

Pressure-tightness test of oil cooler shows there is leakage

Carry out troubleshooting on


applicable machine side

Check items

Oil level has risen and oil is milky

Troubleshooting

E
Q Q

Suddenly increased

Replace

Questions

Confirm recent repair history

23

SEN00152-03

40 Troubleshooting

S-12 Oil pressure drops

General causes why oil pressure drops


Leakage, clogging, wear in lubrication system
Defective oil pressure control
Selection of oil by the temperature etc. specified in the Operation and Maintenance Manual is not observed.

Confirm recent repair history


Degree of use of
Operated for long period
E
E
E
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
Oil is milky or smells of diesel oil
w
Metal particles are found when oil pan is drained
w
w

Remedy

q q
q
See S-13

Metal particles are found in oil filter


q
Inspect oil pan strainer, pipe directly
Oil pump rotation is heavy, there is play in oil pump
Valve and spring of oil pump relief valve are fatigued, damaged
Inspect oil filter directly
Relief valve of EGR oil pump is damaged, oil leaks from it ["with EGR" only]
Inspect EGR hydraulic piping directly ["with EGR" only]
Carry out troubleshooting according to Abnormality in oil pressure sensor
(*1) in E-mode
If oil level sensor is replaced, oil pressure monitor indicates normally

q
q
q
q
q
q

Clean
Clean
Replace
Adjust
Replace
Correct
Replace
Replace
Replace
Replace

Metal particles are found when oil filter is drained

Replace
Add

Troubleshooting

Check items

Questions

Deterioration of oil due to overheating

Worn journal of bearing


Lack of oil in oil pan
Coolant, fuel in oil
Clogged strainer in oil pan
Clogged, broken pipe in oil pan
Defective oil pump
Defective oil pump relief valve
Clogged oil filter
Leaking, crushed, clogged hydraulic piping
Defective EGR oil pump ["with EGR" only]
Leaking EGR hydraulic piping ["with EGR" only]
Defective oil pressure sensor, wiring harness
Defective oil level sensor, wiring harness

Causes

*1: Code [135/CA135] and code [141/CA141] in E-mode

24

140E-5 Series

40 Troubleshooting

SEN00152-03

S-13 Oil level rises (Entry of coolant/fuel)

General causes why oil level rises

Cracked EGR cooler (Entry of coolant) ["with EGR" only]


Broken cylinder head, head gasket
Fuel leakage inside head cover
Cracks inside cylinder block
Damaged cylinder liner O-ring, holes caused by pitting
Worn, damaged rear oil seal
Broken oil cooler core, O-ring
Clogged water pump drain hole (breather hole), defective seal
Defects in supply pump
Defective seal of auxiliary equipment (pump, compressor)

Causes

Coolant in oil (milky)


Fuel in oil (smells diluted diesel fuel)

Confirm recent repair history


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
Exhaust smoke is white
Q
Water pump drain hole (breather hole) is clogged
w
When water pump drain hole (breather hole) is cleaned, coolant comes out
w
Oil level in clutch or damper chamber of machine is low
w
Oil level in hydraulic tank of machine is low
w
When EGR cooler outlet gas piping is removed, coolant containing antifreeze flows
q
out (*1) ["with EGR" only]
When compression pressure is measured, it is found to be low
q
Remove and inspect head cover directly
q
Inspect cylinder block, liner directly
q q
Inspect rear oil seal directly
q
Pressure-tightness test of oil cooler shows there is leakage
q
Remove and inspect water pump directly
q
Remove and inspect supply pump directly
q
Inspect seal of auxiliary equipment directly
q
Remedy

140E-5 Series

Replace
Replace
Correct
Replace
Replace
Correct
Replace
Replace
Replace
Replace

Troubleshooting

Check items

Questions

a If oil is in coolant, carry out troubleshooting for S-11 Oil is in coolant

25

SEN00152-03

40 Troubleshooting

*1: EGR cooler outlet gas piping


Loosen 4 mounting bolts (1) of the EGR cooler outlet gas piping and check that the coolant flows out. A
little condensate produced from cooled exhaust gas may flow out. If it is colorless and transparent, however, it is not a problem.

26

140E-5 Series

40 Troubleshooting

SEN00152-03

S-14 Coolant temperature becomes too high (overheating)


General causes why coolant temperature becomes too high

1
Rise in power train oil temperature on applicable machine side

Defective coolant temperature gauge

Slipping fan belt, worn fan pulley

Defective radiator cap (pressure valve)

Clogged radiator core

Clogged, crushed radiator fins

Defective operation of thermostat

Broken water pump

Rise in oil temperature in power train


Carry out troubleshooting for machine

Lack of coolant

Problem in coolant circulation system

Clogged, broken oil cooler

Drop in heat dissipation efficiency

Damaged cylinder liner O-ring, hole caused by pitting

Lack of cooling air (deformation, damage of fan)

Broken cylinder head, head gasket

External leakage of coolant from EGR cooler ["with EGR" only]

Causes

Degree of use of
machine
Condition of
overheating

Operated for long period

E E E

Sudden overheated

E E
Q w

Coolant temperature Rises quickly


gauge (if installed)
Does not go down from red range

Radiator coolant level monitor indicates drop of coolant level (if monitor is installed) Q

w
w

w Q

Engine oil level has risen, oil is milky

Fan belt tension is low


When fan pulley is turned, it has play

w
w

Milky oil is floating on coolant


w

There are excessive air bubbles in radiator, coolant spurts back


Check items

Q
Q w w

Always tends to overheat

When light bulb is held behind radiator core, no light passes through

Radiator shroud, inside of underguard on applicable machine side are clogged with
dirt or mud

Coolant is leaking because of cracks in hose or loose clamps

Coolant flows out from radiator overflow hose

Fan belt whines under sudden acceleration


Power train oil temperature enters red range faster than engine coolant temperature
(if oil temperature gauge and coolant temperature gauge are installed)

w
q

Inspect EGR cooler for coolant leakage ["with EGR" only]

When compression pressure is measured, it is found to be low

Inspect cylinder liner directly

q
q

Temperature difference between upper and lower tanks of radiator is large


When operation of thermostat is carried out, it does not open at cracking temperature

q
q

Temperature difference between upper and lower tanks of radiator is slight

Inspect radiator core directly

When operation of radiator cap is carried out, its cracking pressure is low

Inspect fan belt, pulley directly

140E-5 Series

Replace

Replace

Correct

Correct

Replace

Replace

Add

Replace

Replace

Replace

Remedy

Replace

When coolant temperature is measured, it is fount to be normal

Replace

Troubleshooting

Inspect oil cooler directly

Carry out troubleshooting on applicable machine

Questions

Confirm recent repair history

27

SEN00152-03

40 Troubleshooting

S-15 Abnormal noise is made

General causes why abnormal noise is made

Improper fuel injection timing


(abnormality in coolant temperature sensor)

Dirt caught in injector

Clogged, seized injector

Deformed cooling fan, loose fan belt, interference of fan


belt

Removed, seized gear train bushing

Improper gear train backlash

Excessive wear of piston ring, cylinder liner

a When the engine is accelerated, it is operated in the acceleration


mode and its sound becomes a little larger for up to about 5 seconds. This does not indicate abnormality, however.

Improper valve clearance

a The engine is operated in the low-temperature mode while it is not


warmed up sufficiently. Accordingly, the engine sound becomes a
little larger. This does not indicate abnormality, however.

Defective inside of muffler (dividing board out of position)

a Judge if the noise is an internal noise or an external noise before


starting troubleshooting.

Broken dynamic valve system (valve, rocker lever)

Air sucked in from intake system

Cracked, leaking EGR gas piping ["with EGR" only]

Abnormal combustion

Interference of turbocharger, seized turbocharger

Abnormality due to defective parts

Leakage of air between turbocharger and cylinder head

Causes

Degree of use of
machine
Condition of
abnormal noise

Operated for long period

Gradually occurred

Q Q Q

Sudden occurred

Q
Q

Non-specified fuel is being used

w
w

Oil must be added more frequently


Metal particles are found when oil filter is drained

When engine is cranked, interference sound is generated around turbocharger


When engine is cranked, abnormal sound is generated around EGR gas piping
["with EGR" only]

w
w

When engine is cranked, abnormal sound is generated around cylinder head


Check items

Air leaks between turbocharger and cylinder head

w
w

When engine is cranked, beat noise is generated around muffler


When exhaust manifold is touched immediately after starting engine, temperature
of some cylinders is low
Color of exhaust
gas

w Q
w

Blue under light load

Q w

Black

Engine does not pick up smoothly and combustion is irregular

Abnormal noise is loud when engine is accelerated

w
Q

Blow-by gas is excessive

When turbocharger is rotated by hand, it is fount to be heavy

Inspect EGR gas piping directly ["with EGR" only]

Inspect dynamic valve system directly


Troubleshooting

When muffler is removed, abnormal noise disappears

Inspect valve clearance directly

When compression pressure is measured, it is found to be low

q q

Inspect gear train directly

Inspect fan and fan belt directly


When a cylinder is cut out for reduced cylinder mode operation, engine speed
does not change

q q
q

Abnormal noise is heard only when engine is started

28

Replace

Replace

Correct

Replace

Replace

Replace

Adjust

Replace

Replace

Replace

Replace

Remedy

Replace

Confirm with INSITE or with monitoring function on applicable machine side

Correct

Questions

Confirm recent repair history

140E-5 Series

40 Troubleshooting

SEN00152-03

S-16 Vibration is excessive

General causes why vibration is excessive

Stuck dynamic valve system (valve, rocker lever)


Worn main bearing, connecting rod bearing
Improper gear train backlash
Worn camshaft bushing
Loose engine mounting bolts, broken cushions
Misalignment between engine and devices on applicable machine side
Worn front support spigot joint portion
Broken output shaft, parts in damper on applicable machine side

Causes

Defective parts (abnormal wear, breakage)


Misalignment between engine and chassis
Abnormal combustion

Confirm recent repair history


Degree of use of
Operated for long period
machine
Suddenly increased
Condition of
vibration
Gradually increased
Non-specified fuel is being used
Metal particles are found when oil filter is drained
Metal particles are found when oil pan is drained
Oil pressure is low at low idle
Vibration occurs at mid-range speed
Vibration follows engine speed

EE
Q

Q
Q
Q
w
w
Q

Exhaust smoke is black

Inspect dynamic valve system directly


Inspect main bearing and connecting rod bearing directly
Inspect gear train directly
Inspect camshaft bushing directly
Inspect engine mounting bolts and cushions directly
When alignment is checked, radial runout or facial runout is detected
Inspect front support spigot joint portion directly
Inspect output shaft or inside of damper directly

Remedy

140E-5 Series

Q Q
Q
Q
w
w
Q
Q
Q
Q
Q Q Q Q

q
q
q
q
q
q
Q
Replace
Replace
Replace
Replace
Replace
Adjust
Replace
Replace

Troubleshooting

Check items

Questions

a If abnormal noise is made and vibration is excessive, carry out troubleshooting for S-15 Abnormal noise is made, too.

29

SEN00152-03

KOMATSU 140E-5 Series engine


Form No. SEN00152-03

2009 KOMATSU
All Rights Reserved
Printed in Japan 01-09 (01)

30

SEN00153-03

ENGINE
1SHOP MANUAL

140E-5 Series

40 Troubleshooting

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

SEN00153-03

40 Troubleshooting

E-13 Code [187/CA187] Sensor Sup. 2 Volt. Low Error..................................................................... 34


E-14 Code [221/CA221] Ambient Air Press. Sensor High Error......................................................... 38
E-15 Code [222/CA222] Ambient Air Press. Sensor Low Error ......................................................... 40
E-16 Code [227/CA227] Sensor Sup. 2 Volt. High Error .................................................................... 42
E-17 Code [234/CA234] Eng. Overspeed .......................................................................................... 42
E-18 Code [238/CA238] Ne Speed Sensor Sup. Volt. Error............................................................... 44
E-19 Code [263/CA263] Fuel Temp. Sensor High Error..................................................................... 46
E-20 Code [265/CA265] Fuel Temp. Sensor Low Error ..................................................................... 48
E-21 Code [271/CA271] PCV1 Short Error ........................................................................................ 50
E-22 Code [272/CA272] PCV1 Open Error ........................................................................................ 52
E-23 Code [273/CA273] PCV2 Short Error ........................................................................................ 54
E-24 Code [274/CA274] PCV2 Open Error ........................................................................................ 56
E-25 Code [322/CA322] Injector #1 System Open/Short Error .......................................................... 58
E-26 Code [323/CA323] Injector #5 System Open/Short Error .......................................................... 60
E-27 Code [324/CA324] Injector #3 System Open/Short Error .......................................................... 62
E-28 Code [325/CA325] Injector #6 System Open/Short Error .......................................................... 64
E-29 Code [331/CA331] Injector #2 System Open/Short Error .......................................................... 66
E-30 Code [332/CA332] Injector #4 System Open/Short Error .......................................................... 68
E-31 Code [342/CA342] Engine Controller Data Matching Error ....................................................... 70
E-32 Code [351/CA351] INJ. Drive Circuit Error ................................................................................ 72
E-33 Code [352/CA352] Sensor Sup. 1 Volt. Low Error..................................................................... 74
E-34 Code [386/CA386] Sensor Sup. 1 Volt. High Error .................................................................... 75
E-35 Code [431/CA431] Idle Validation Switch Error ......................................................................... 78
E-36 Code [432/CA432] Idle Validation Process Error ....................................................................... 80
E-37 Code [441/CA441] Supply Voltage Low Error............................................................................ 81
E-38 Code [442/CA442] Supply Voltage High Error........................................................................... 81

140E-5 Series

40 Troubleshooting

Troubleshooting of electrical system (E-mode), Part 1

SEN00153-03

Troubleshooting method for disconnecting wiring harness of pressure


sensor system
1
a

Since pressure sensor consists not only of resistors but also electronic circuits such as amplifiers, it may
have the deferences among the registances measured and its own polarities. So troubleshooting must
be performed carefully.

Failure codes applicable to this diagnosis


CA123: Charge air pressure sensor low error (for "EGR-less" only)
q CA222: Ambient pressure sensor low error
q

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 other 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 measurement 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'.
3. Judging open circuit
If there is an "apparent difference" between resistances R1 and R2 measured in step 1 and resistances
R1' and R2' measured in step 2, "wiring harness is disconnected".
140E-5 Series

SEN00153-03

40 Troubleshooting

a "Apparent difference" means a difference of 10 or more times.

List of pressure sensor measuring locations and reference values


Sensor
Charge pressure
sensor

Ambient pressure
sensor

Measuring location at
sensor pin

Internal resistance of measured


sensor
(Reference value)

R2: Between (1) and (3)

Approx. 2.9kz

R1: Between (2) and (3)

Approx. 4.3kz

R2: Between (1) and (3)

Approx. 3.2kz

R1: Between (2) (+) and


(1) (-)
R1: Between (1) (+) and
(2) (-)

Approx. 4.6kz
Approx. 2.9kz

Remarks
Sensor is common to engine models 140 for EGR-less, 125, 170 and
12V140
Sensor is common to engine models 95, 125, 140, 170 and 12V140
If polarities are reversed, resistance value changes.

*: 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 sensor (CA222)
Connectors of charge pressure sensor, resistance RES, engine oil pressure sensor, and G sensor

140E-5 Series

40 Troubleshooting

SEN00153-03

Measurement record (For measuring locations, see circuit diagram related to each code)
Sensor

Charge pressure
sensor

Sensor unit (Measuring


location on sensor pin
side)
R2: Between (1) and (3)
R1: Between (2) and (3)
R2: Between (1) and (3)

Ambient pressure
sensor

140E-5 Series

R1: Between (2) (+) and


(1) (-)
R1: Between (1) (+) and
(2) (-)

Measured value

Sensor + Wiring harness


(Measuring location on
wiring harness side of
engine controller)
R1: Between (1) (+) and
(2) (-)
R1': Between (44) and
(47)
R2': Between (37) and
(38) (*)
R1': Between (3) (+)
and (38) (-)
R1': Between (38) (+)
and (3) (-)

Measured value

SEN00153-03

40 Troubleshooting

E-1 Code [111/CA111] Engine Controller Internal Failure


Error code

Failure code

111

CA111

Trouble

Abnormality in engine controller

Contents of trouble

Abnormality occurred in controller.

Action of controller

None in particular.

Problem that appears


Engine runs normally but it may stop during operation or may not be able to start.
on machine
Related information

Different machine models may have different connector Nos.


Cause

1 Defective fuse

Possible causes and


standard value in
normal state

Standard value in normal state/Remarks on troubleshooting


Check fuse or circuit breaker on machine side directly for
defect.
(If fuse is broken or circuit breaker is turned OFF, circuit probably has ground fault.)

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wir- Wiring harness between E03 (female)
2
Resistance Max. 1 z
ing or defective contact in
(3), (4) battery (+)
connector)
Wiring harness between E03 (female)
Resistance Max. 1 z
(1), (2) chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring har- Wiring harness between E03 (female)
Resistance Min. 1 Mz
3 ness (Short circuit with GND (3), (4) battery (+) and chassis ground
circuit)
Wiring harness between E03 (female)
(1), (2) chassis ground and chassis Resistance Min. 1 Mz
ground
a Prepare with starting switch OFF, then turn starting switch
ON and carry out troubleshooting.
4 Defective engine controller

E03

Voltage

Between (3), (4) (1), (2)

20 30V

Circuit diagram related to controller power supply

140E-5 Series

40 Troubleshooting

SEN00153-03

E-2 Code [115/CA115] Eng. Ne and Bkup Speed Sensor Error


Error code

Failure code

115

CA115

Trouble

Abnormality in engine Ne and Bkup sensors

Contents of trouble

Abnormality occurred in Ne speed sensor circuit and Bkup speed sensor circuit simultaneously.

Action of controller

None in particular.

Problem that appears Engine cannot be started (if engine has been stopped).
on machine
Engine stops (if engine has been running).
Related information
Cause

Possible causes and


standard value in
normal state

Defective Ne speed sensor


Carry out troubleshooting for code [689/CA689].
system

Defective Bkup speed senCarry out troubleshooting for code [778/CA778].


sor system

Defective mount of Ne
speed sensor

Check mount of Ne speed sensor directly for defect (defective


installation of sensor, internal trouble of flywheel, etc.)

Defective mount of Bkup


speed sensor

Check mount of Bkup speed sensor directly for defect (defective installation of sensor, internal trouble of supply pump, etc.)

Defective connection
(Wrong connection)

Check Ne speed sensor and Bkup speed sensor directly for


defective connection (wrong connection).

6 Defective engine controller

140E-5 Series

Standard value in normal state/Remarks on troubleshooting

If causes 1 5 are not detected, engine controller may be


defective. (Since trouble is in system, troubleshooting cannot
be carried out.)

SEN00153-03

40 Troubleshooting

E-3 Code [122/CA122] Charge (boost) Air Press Sensor High Error
a

For with EGR


Error code

Failure code

122

CA122

Trouble

Abnormally high level in charge (boost) pressure sensor

Contents of trouble

Signal voltage in charge (boost) pressure sensor circuit is abnormally high.

Action of controller

Fixes charge (boost) pressure (400 kPa {4.08 kg/cm2}) and continues operation.

Problem that appears


Acceleration performance of engine drops.
on machine
Related information

If sensor connector is disconnected, code [123/CA123] for "Low Error" is displayed, even in
normal condition.
Cause
1

Possible causes and


standard value in
normal state

Defective sensor power


supply system

Defective charge boost


pressure sensor

Standard value in normal state/Remarks on troubleshooting


If code [187/CA187] or [227/CA227] is indicated, carry out troubleshooting for it first.
1. Turn starting switch to OFF position.
2. Disconnect connector PIM.
3. Turn starting switch to ON position.
If code changes from [122/CA122] to [123/CA123], charge
(boost) pressure sensor is defective.

1. Turn starting switch to OFF position, then perform troubleshooting.


Short circuit in wiring har- 2. Disconnect connectors ENG and PIM, and connect T-adapter
3
ness
to female side of ENG.
Between ENG (female) (37) and (44)

Resistance Min. 1 Mz

1. Turn starting switch to OFF position.


2. Disconnect connector PIM, and connect T-adapter to female
side or insert T-adapter into connector ENG.
Hot short circuit in wiring
3. Turn starting switch to ON position (with connector PIM
4 harness
disconnected).
(contact with 24 V circuit)
Between PIM (female) (3) and (2), or
Voltage
Max. 1 V
between ENG (44) and (47)
5

If no failure is found by above checks, engine controller is defecDefective engine controltive. (Since this is an internal failure, troubleshooting cannot be
ler
performed.)

140E-5 Series

40 Troubleshooting

SEN00153-03

Circuit diagram related to charge (boost) pressure sensor


a For with EGR

140E-5 Series

SEN00153-03
a

40 Troubleshooting

For EGR-less
Error code

Failure code

122

CA122

Trouble

Abnormally high level in charge (boost) pressure sensor

Contents of trouble

Signal voltage in charge (boost) pressure sensor circuit is abnormally high.

Action of controller

Fixes charge (boost) pressure (400 kPa {4.08 kg/cm2}) and continues operation.

Problem that appears


Acceleration performance of engine drops.
on machine
Related information

If sensor connector is disconnected, code [123/CA123] for "Low Error" is displayed, even in
normal condition.
Cause
1

Possible causes and


standard value in
normal state

Defective sensor power


supply system

Defective charge boost


pressure sensor

Standard value in normal state/Remarks on troubleshooting


If code [187/CA187] or [227/CA227] is indicated, carry out troubleshooting for it first.
1. Turn starting switch to OFF position.
2. Disconnect connector PIM.
3. Turn starting switch to ON position.
If code changes from [122/CA122] to [123/CA123], charge
(boost) pressure sensor is defective.

1. Turn starting switch to OFF position, then perform troubleshooting.


Short circuit in wiring har- 2. Disconnect connectors ENG and PIM, and connect T-adapter
3
ness
to female side of ENG.
Between ENG (female) (37) and (44)

Resistance Min. 1 Mz

1. Turn starting switch to OFF position.


2. Disconnect connector PIM, and insert T-adapter into
Hot short circuit in wiring
connector ENG.
4 harness
3. Turn starting switch to ON position (with connector PIM
(contact with 24 V circuit)
disconnected).
Between ENG (44) and (47)
5

10

Voltage

Max. 1 V

If no failure is found by above checks, engine controller is defecDefective engine controltive. (Since this is an internal failure, troubleshooting cannot be
ler
performed.)

140E-5 Series

40 Troubleshooting

SEN00153-03

Circuit diagram related to charge (boost) pressure sensor


a For EGR-less

140E-5 Series

11

SEN00153-03

40 Troubleshooting

E-4 Code [123/CA123] Charge (boost) Air Press Sensor Low Error
Error code

Failure code

123

CA123

Trouble

Abnormally low level in charge (boost) pressure sensor

Contents of trouble

Signal voltage in charge (boost) pressure sensor circuit is abnormally low.

Action of controller

Fixes charge (boost) pressure (400 kPa {4.08 kg/cm2}) and continues operation.

Problem that appears


Acceleration performance of engine drops.
on machine
Related information

If sensor connector is disconnected, this code is displayed.

For with EGR


Cause

Standard value in normal state/Remarks on troubleshooting


If code [187/CA187] or [227/CA227] is displayed, perform
troubleshooting for it first.

Defective power supply sys- 1. Turn starting switch to OFF position.


tem of charge pressure sen- 2. Disconnect connectors PIM and connect T-adapter to
1
sor (boost pressure sensor)
female side.
3. Turn starting switch to ON position.
Between PIM (female) (1) and
(2)

Power
input

Voltage

4.75
5.25 V

1. Turn starting switch to OFF position.


2. Disconnect connectors ENG and PIM and connect Tadapters to each female side.

Possible causes and


standard value in
normal state

Open circuit in wiring harBetween ENG (female) (37) and PIM


ness
(female) (1)
2
(wire breakage or defective
Between ENG (female) (44) and PIM
contact of connector)
(female) (3)

Resistance

Max.
1z

Resistance

Max.
1z

Between ENG (female) (47) and PIM


(female) (2)

Resistance

Max.
1z

Short circuit in wiring harness

1. Turn starting switch to OFF position.


2. Disconnect connectors ENG and PIM.
3. Connect T-adapter to female side of ENG.
Between ENG (female) (44) and (47)

Ground fault in wiring har4 ness


(contact with ground circuit)

Defective boost pressure


sensor

12

Min.
1 Mz

1. Turn starting switch to OFF position, then perform troubleshooting.


2. Disconnect connectors ENG and PIM, and connect Tadapters to either female side.
Between ENG (female) (44) or PIM
(female) (3) and ground

Resistance

Min.
1 Mz

a If no failure is found by checks on causes 1 to 4, and check


result of checks on cause 5 is abnormal, sensor is defective.
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector ENG or PIM.
3. Turn starting switch to ON position.
Between ENG (44) and (47), or
between PIM (3) and (2)

6 Defective engine controller

Resistance

Sensor
output

Voltage

0.3 4.7
V

If no failure is found by above checks, engine controller is


defective. (Since this is an internal failure, troubleshooting
cannot be performed.)

140E-5 Series

40 Troubleshooting

SEN00153-03

Circuit diagram related to charge (boost) pressure sensor


a For "with EGR"

140E-5 Series

13

SEN00153-03

40 Troubleshooting

For "EGR-less"
Cause

Standard value in normal state/Remarks on troubleshooting

Defective power supply sysIf code [187/CA187] or [227/CA227] is indicated, carry out
1 tem of charge pressure sentroubleshooting for it first.
sor (boost pressure sensor)

Short circuit in wiring harness

1. Turn starting switch to OFF position.


2. Disconnect connectors ENG and PIM.
3. Connect T-adapter to female side of ENG.
Between ENG (female) (44) and (47)

Possible causes and


standard value in
normal state

Ground fault in wiring har3 ness


(contact with ground circuit)

Min.
1 Mz

1. Turn starting switch to OFF position, then carry out troubleshooting.


2. Disconnect connectors ENG and PIM, and connect Tadapter to female side of ENG.
Between ENG (female) (44) and ground

Resistance

Resistance

Min.
1 Mz

Disconnection in wiring har- If cause is not found by the above checks, wiring harness may
ness
be disconnected. (*)

Defective charge pressure


(boost pressure) sensor
5
(lmproper input voltage of
engine controller)

a If causes 1 - 4 are not the cause for the trouble and check
result of cause 5 is abnormal, sensor is defective.
1. Turn starting switch to OFF position.
2. Connect T-adapter to connector ENG.
3. Turn starting switch to ON position.
Between ENG (44) and (47)

6 Defective engine controller

Sensor
output

Voltage

0.3 4.7
V

If no abnormality is found by the above checks, the engine


controller is defective.
(Since the failure is in it, troubleshooting cannot be performed.)

*: Refer to "Troubleshooting method for disconnected wiring harness of pressure sensor system."

14

140E-5 Series

40 Troubleshooting

SEN00153-03

Circuit diagram related to charge (boost) pressure sensor


a For "EGR-less"

140E-5 Series

15

SEN00153-03

40 Troubleshooting

E-5 Code [131/CA131] Throttle Sensor High Error

Throttle sensor of accelerator pedal type (Case of HD325/405-7)


Error code
131
Contents of trouble
Action of controller

Failure code
Trouble Abnormally high level in throttle sensor
CA131
Signal voltage in throttle sensor circuit is abnormally high.
Sets throttle angle with signal other than throttle signal and continues operation (depending on
each model).

Problem that appears


Different problems occur on different machine models.
on machine
Related information Different machine models may have different connector Nos.
Cause
Defective sensor power
1
supply system

Possible causes and


standard value in
normal state

Defective accelerator pedal


(Internal trouble)

Disconnection in wiring harness (Disconnection in wir3


ing or defective contact in
connector)

Ground fault in wiring har4 ness (Short circuit with GND


circuit)

5 Defective engine controller

16

Standard value in normal state/Remarks on troubleshooting


If code [2185/CA2185] or [2186/CA2186] is indicated, carry
out troubleshooting for it first.
a Prepare with starting switch OFF, then turn starting switch
ON and carry out troubleshooting.
Accelerator
WAS1
Voltage
pedal
All range
Between (1) (3)
4.75 5.25 V
(Power supply)
(9 2% of source
Released
voltage)
Between (2) (3)
(73 2% of source
Pressed
voltage)
Sensor voltage is measured with wiring harness connected.
Accordingly, if voltage is abnormal, check wiring harness and
controller, too, for another cause of trouble, and then judge.
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between E02 (female)
Resistance Max. 1 z
(22) WAS1 (female) (1)
Wiring harness between E02 (female)
Resistance Max. 1 z
(9) WAS1 (female) (2)
Wiring harness between E02 (female)
Resistance Max. 1 z
(23) WAS1 (female) (3)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between E02 (female)
(22) WAS1 (female) (1) and chassis Resistance Min. 1 Mz
ground
Wiring harness between E02 (female)
(9) WAS1 (female) (2) and chassis Resistance Min. 1 Mz
ground
Wiring harness between E02 (female)
(23) WAS1 (female) (3) and chassis Resistance Min. 1 Mz
ground
a Prepare with starting switch OFF, then turn starting switch
ON and carry out troubleshooting.
Accelerator
Voltage
E02
pedal
All range
4.75 5.25 V
Between (22) (23)
(Power supply)
(9 2% of source
Released
voltage)
Between (9) (23)
(73 2% of source
Pressed
voltage)

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)
Error code

Failure code

131

CA131

Trouble

Abnormally high level in throttle sensor

Contents of trouble

Signal voltage in throttle sensor circuit is abnormally high.

Action of controller

Sets throttle angle with signal other than throttle signal and continues operation (depending on
each model).

Problem that appears


Different problems occur on different machine models.
on machine
Related information

Different machine models may have different connector Nos.


Cause
Defective sensor power
1
supply system

Standard value in normal state/Remarks on troubleshooting


If code [2185/CA2185] or [2186/CA2186] is indicated, carry
out troubleshooting for it first.
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Defective fuel control dial


(Internal trouble)

P20 (male)

Resistance

Between (1) (3)

4.0 6.0 kz

Between (2) (1)

0.25 5.0 kz

Between (2) (3)

0.25 5.0 kz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wir3
ing or defective contact in
connector)
Possible causes and
standard value in
normal state

Wiring harness between E02 (female)


Resistance Max. 1 z
(22) P20 (female) (1)
Wiring harness between E02 (female)
Resistance Max. 1 z
(9) P20 (female) (2)
Wiring harness between E02 (female)
Resistance Max. 1 z
(23) P20 (female) (3)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between E02 (female)
(22) P20 (female) (1) and chassis
Resistance Min. 1 Mz
ground

Ground fault in wiring har4 ness (Short circuit with GND Wiring harness between E02 (female)
circuit)
(9) P20 (female) (2) and chassis
Resistance Min. 1 Mz
ground
Wiring harness between E02 (female)
(23) P20 (female) (3) and chassis
Resistance Min. 1 Mz
ground
a Prepare with starting switch OFF, then turn starting switch
ON and carry out troubleshooting.
5 Defective engine controller

18

E02

Voltage

Between (22) (23)

Power supply

4.75 5.25 V

Between (9) (23)

Signal

0.5 4.5 V

140E-5 Series

40 Troubleshooting

SEN00153-03

Circuit diagram related to throttle sensor of fuel control dial type


(Case of PC800/800SE/850/850SE/850LC-8)

140E-5 Series

19

SEN00153-03

40 Troubleshooting

E-6 Code [132/CA132] Throttle Sensor Low Error


Error code

Failure code

132

CA132

Trouble

Abnormally low level in throttle sensor

Contents of trouble

Signal voltage in throttle sensor circuit is abnormally low.

Action of controller

Sets throttle angle with signal other than throttle signal and continues operation (depending on
each model).

Problem that appears


Different problems occur on different machine models.
on machine
Related information
Possible causes and
standard value in
normal state

20

Cause

Standard value in normal state/Remarks on troubleshooting


Carry out troubleshooting for E-5 Code [131/CA131].

140E-5 Series

40 Troubleshooting

140E-5 Series

SEN00153-03

21

SEN00153-03

40 Troubleshooting

E-7 Code [135/CA135] Oil Press. Sensor High Error


Error code

Failure code

135

CA135

Trouble Abnormally high level in oil pressure sensor

Contents of trouble

Signal voltage in oil pressure sensor circuit is abnormally high.

Action of controller

Sets oil pressure to default value (250 kPa {2.55 kg/cm2}) and continues operation.

Problem that appears


on machine
Related information
Cause
1

Defective sensor power


supply system

Standard value in normal state/Remarks on troubleshooting


If code [187/CA187] or [227/CA227] is indicated, carry out troubleshooting for it first.

1. Turn starting switch to OFF position.


2. Disconnect connector POIL.
Defective engine oil pres- 3. Turn starting switch to ON position.
2
sure sensor
If code changes from [135/CA135] to [141/CA141] , engine oil
pressure sensor is defective.

Possible causes and


standard value in
normal state

1. Turn starting switch to OFF position.


2. Disconnect connectors ENG and POIL, and connect TShort circuit in wiring haradapters to either female side.
3
ness
Between ENG (female) (13) and (37), or
Resistance Min. 1 Mz
between POIL (female) (1) and (3)
1. Turn starting switch to OFF position.
2. Disconnect connector POIL.
3. Connect T-adapter to female side of connector POIL or insert
Hot short circuit in wiring
T-adapter into connector ENG.
4 harness
4. Turn starting switch to ON position (with connector POIL
(contact with 24 V circuit)
disconnected).
Between ENG (female) (13) and (47), or
between POIL (female) (3) and (2)
5

22

Voltage

Max. 1 V

If no failure is found by above checks, engine controller is defecDefective engine controltive. (Since this is an internal failure, troubleshooting cannot be
ler
performed.)

140E-5 Series

40 Troubleshooting

SEN00153-03

Circuit diagram related to oil pressure sensor


a For with EGR
a There is connector PEVA only for serial No. up to 530896.

For EGR-less

140E-5 Series

23

SEN00153-03

40 Troubleshooting

E-8 Code [141/CA141] Oil Press. Sensor Low Error


Error code

Failure code

141

CA141

Trouble

Abnormally low level in oil pressure sensor

Contents of trouble

Signal voltage in oil pressure sensor circuit is abnormally low.

Action of controller

Sets oil pressure to default value (250 kPa {2.55 kg/cm2}) and continues operation.

Problem that appears


on machine
Related information
Cause

Standard value in normal state/Remarks on troubleshooting


If code [187/CA187] or [227/CA227] is displayed, carry out
troubleshooting for it first.

1. Turn starting switch to OFF position.


Defective power supply sys2. Disconnect connector POIL and connect T-adapter to
1 tem of engine oil pressure
female side.
sensor
3. Turn starting switch to ON position.
Between POIL (female) (1) and
(2)

Power
input

Voltage

4.75
5.25V

1. Turn starting switch to OFF position.


2. Disconnect connectors ENG and POIL and connect Tadapters to each female side.
a If power supply input in checks on
cause 1 is normal, this check is not required.
Between ENG (female) (37) and POIL
(female) (1)

Possible causes and


standard value in
normal state

Open circuit in wiring harness


2
(wire breakage or defective
a If power supply input in checks on
contact of connector)
cause 1 is normal, this check is not required.
Between ENG (female) (47) and POIL
(female) (2)
Between ENG (female) (13) and POIL
(female) (3) (Sensor output)

Resistance

Max. 1 z

Resistance

Max. 1 z

Resistance

Max. 1 z

1. Turn starting switch to OFF position.


2. Disconnect connectors ENG and POIL, and connect Tadapters to either female side.

Ground fault of wiring har3 ness


(contact with ground circuit) Between ENG (female) (13) or POIL
(female) (3) and ground

Short circuit in wiring harness

Resistance

Min.
1 Mz

1. Turn starting switch to OFF position.


2. Disconnect connectors ENG and POIL, and connect Tadapters to either female side.
Between ENG (female) (13) and (47), or
between POIL (female) (2) and (3)

Resistance

Min.
1 Mz

a If no failure is found by checks on causes 1 to 4 and check


result of checks on cause 5, sensor is defective.
1. Turn starting switch to OFF position.
Defective engine oil pres5 sure sensor (improper input 2. Insert T-adapter into connector ENG or POIL.
voltage to engine controller) 3. Turn starting switch to ON position.
0.3 4.7
Between ENG (13) and (47), or Sensor
Voltage
V
output
between POIL (3) and (2)
6 Defective engine controller

24

If no failure is found by above checks, engine controller is


defective. (Since this is an internal failure, troubleshooting cannot be performed.)

140E-5 Series

40 Troubleshooting

SEN00153-03

Circuit diagram related to oil pressure sensor


a For "with EGR"
a There is connector PEVA only ofr serial No. up to 530896.

For "EGR-less"

140E-5 Series

25

SEN00153-03

40 Troubleshooting

E-9 Code [144/CA144] Coolant Temp. Sensor High Error


Error code

Failure code

144

CA144

Trouble

Abnormally high level in coolant temperature sensor

Contents of trouble

Signal voltage in coolant temperature sensor circuit is abnormally high.

Action of controller

Fixes coolant temperature (90C) and continues operation.

Problem that appears


Engine starting performance decreases during low temperature.
on machine

Related information

This failure code is generated if temperature sensor connector is disconnected.


Because troubleshooting "socket" for this sensor features female connector alone, it is not
connectable to female connector of sensor wiring harness, and thus not usable for checking
open circuit (not designed as a T-adapter).
Cause

Standard value in normal state/Remarks on troubleshooting


1. Turn starting switch to OFF position.
2. Disconnect connector TWTR and connect T-adapter to
male side.
a If coolant temperature sensor has resistance of 700 z
37 kz with coolant temperature above 0 C, regard coolant
temperature sensor as normal.
0 C

Defective coolant temperature sensor

Resistance

25 C Resistance
Between TWTR (male) (A)
and (B)
50 C Resistance
a Coolant temperature -Resistaure characteristics
80 C Resistance

Possible causes and


standard value in
normal state

95 C Resistance

30
37 kz
9.3
10.7 kz
3.2
3.8 kz
1.0
1.3 kz
700
800 z

1. Turn starting switch to OFF position.


2. Disconnect connector ENG and connect T-adapter to
female side.
2

Open or short circuit in wir- Between ENG (female) (15) and (38)
(Coolant temperature: Min. 0 C)
ing harness
a The resistance is the same as that
Resistance
shown in the resistance characteristics table of the coolant temperature sensor of cause 1.

3 Defective engine controller

26

700 z
37 kz

If no failure is found by above checks, engine controller is


defective. (Since this is an internal failure, troubleshooting
cannot be performed.)

140E-5 Series

40 Troubleshooting

SEN00153-03

Circuit diagram related to coolant temperature sensor


a For with EGR

There are not connector SBP and line to the SBP for EGR-less in above figure.

140E-5 Series

27

SEN00153-03

40 Troubleshooting

E-10 Code [145/CA145] Coolant Temp. Sensor Low Error


Error code

Failure code

145

CA145

Trouble

Abnormally low level in coolant temperature sensor

Contents of trouble

Signal voltage in coolant temperature sensor circuit is abnormally low.

Action of controller

Fixes coolant temperature (90C) and continues operation.

Problem that appears


Engine starting performance decreases during low temperature.
on machine
Related information

If temperature sensor connector is disconnected, this failure code is not generated but code
[144/CA144] for "High Error" is generated.
Cause

Standard value in normal state/Remarks on troubleshooting


1. Turn starting switch to OFF position.
2. Disconnect connector TWTR and connect T-adapter to
male side.
a If coolant temperature sensor has resistance of 700 z
37 kz with coolant temperature above 0 C, regard coolant
temperature sensor as normal.

Between TWTR (male) (A) and


Defective coolant tempera(B)
ture sensor
a Coolant temperature-Resistaure characteristics

Possible causes and


standard value in
normal state

Between (B) and ground

0 C

Resistance

30
37 kz

25 C

Resistance

9.3
10.7 kz

50 C

Resistance

3.2
3.8 kz

80 C

Resistance

1.0
1.3 kz

95 C

Resistance

700
800 z

Whole
coolant
temperature
range

Resistance

Min.
1 Mz

1. Turn starting switch to OFF position.


2. Disconnect connector ENG and connect T-adapter to
female side.
2

Short circuit in wiring harness

Ground fault of wiring har3 ness


(contact with ground circuit)

4 Defective engine controller

28

Between ENG (female) (15) and (38)


(Coolant temperature: Min. 0 C)
a The resistance is the same as that
shown in the resistance characteristics
table of the coolant temperature sensor of cause 1.

Resistance

700 z
37 kz

1. Turn starting switch to OFF position.


2. Disconnect connectors ENG and TWTR, and connect Tadapter to female side of ENG.
Between ENG (female) (15) and ground

Resistance

Min.
1 Mz

If no failure is found by above checks, engine controller is


defective. (Since this is an internal failure, troubleshooting cannot be performed.)

140E-5 Series

40 Troubleshooting

SEN00153-03

Circuit diagram related to coolant temperature sensor


a For "with EGR"

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
Error code

Failure code

153

CA153

Trouble

Abnormally high level in charge (boost) temperature sensor

Contents of trouble

Signal voltage in charge (boost) temperature sensor circuit is abnormally high.

Action of controller

Fixes charge (boost) temperature (intake air temperature) (70C) and continues operation.

Problem that appears


Engine starting performance decreases during low temperature.
on machine

Related information

Because troubleshooting "socket" for this sensor features female connector alone, it is not connectable to female connector of sensor wiring harness, and thus not usable for checking open
circuit (not designed as a T-adapter).
This failure code is generated if temperature sensor connector is disconnected.
Cause

Standard value in normal state/Remarks on troubleshooting


1. Turn starting switch to OFF position.
2. Disconnect connector TIM and connect socket to male side.
a If temperature sensor has resistance of 280 z - 382 kz, regard boost temperature sensor as normal.

Defective boost temperature sensor

Possible causes and


standard value in
normal state

-40 C Resistance

291
382 kz

-20 C Resistance

85
109 kz

Resistance

29
36 kz

30 C Resistance

7.3
8.8 kz

60 C Resistance

2.3
2.7 kz

90 C Resistance

860
970 z

130 C Resistance

280
320 z

0 C
Between TIM (male) (A) and
(B)
a Boost temperature-Resistance characteristic

1. Turn starting switch to OFF position.


2. Disconnect connector ENG and connect T-adapter to
female side.
2

Open or short circuit in wir- Between ENG (female) (23) and (47)
ing harness
a The resistance is the same as that
shown in the resistance character- Resistance
istics table of the coolant temperature sensor of cause 1.

3 Defective engine controller

30

280 z
382 kz

If no failure is found by above checks, engine controller is


defective. (Since this is an internal failure, troubleshooting cannot be performed.)

140E-5 Series

40 Troubleshooting

SEN00153-03

Circuit diagram related to charge (boost) temperature sensor


a For with EGR

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
Error code

Failure code

154

CA154

Trouble

Abnormally low level in charge (boost) temperature sensor

Contents of trouble

Signal voltage in charge (boost) temperature sensor circuit is abnormally low.

Action of controller

Fixes charge (boost) temperature (intake air temperature) (70C) and continues operation.

Problem that appears


Engine starting performance decreases during low temperature.
on machine
Related information

If temperature sensor connector is disconnected, this failure code is not generated but code
[153/CA153] for "High Error" is generated.
Cause

Standard value in normal state/Remarks on troubleshooting


1. Turn starting switch to OFF position.
2. Disconnect connector TIM and connect socket to male side
of.
a If temperature sensor has resistance of 280 z - 382 kz, regard boost temperature sensor as normal.

Defective boost temperature sensor

Possible causes and


standard value in
normal state

Between TIM (male) (A) and


(B)
a Boost temperature-Resistance characteristic

-40 C

Resistance

291
382 kz

-20 C

Resistance

85
109 kz

0 C

Resistance

29
36 kz

30 C

Resistance

7.3
8.8 kz

60 C

Resistance

2.3
2.7 kz

90 C

Resistance

860
970 z

130 C

Resistance

280
320 z

1. Turn starting switch to OFF position.


2. Disconnect connector ENG and connect T-adapter to
female side.
2

Short circuit in wiring harness

Between ENG (female) (23) and (47)


a The resistance is the same as that
shown in the resistance characteristics
table of the coolant temperature sensor of cause 1.

Resistance

280 z
382 kz

1. Turn starting switch to OFF position.


Ground fault of wiring har- 2. Disconnect connectors ENG and TIM and connect Tadapter to female side of ENG.
3 ness
(contact with ground circuit)
ResisMin.
Between ENG (female) (23) and ground
tance
1 Mz
4 Defective engine controller

32

If no failure is found by above checks, engine controller is


defective. (Since this is an internal failure, troubleshooting cannot be performed.)

140E-5 Series

40 Troubleshooting

SEN00153-03

Circuit diagram related to charge (boost) temperature sensor


a For "with EGR"

Pin number of connector PIM is not "2" but "3" for "EGR-less" in above figure.

140E-5 Series

33

SEN00153-03

40 Troubleshooting

E-13 Code [187/CA187] Sensor Sup. 2 Volt. Low Error


Error code

Failure code

187

CA187

Trouble

Abnormally low level in sensor power supply 2 circuit

Contents of trouble

Signal voltage in sensor power supply 2 (5 V) circuit is abnormally low.

Action of controller

Operates Bkup speed sensor with signals of Ne speed sensor.


Sets oil pressure sensor to default value (250 kPa {2.55 kg/cm2}) and continues operation.
Sets ambient pressure sensor to default value (52.44 kPa {0.53 kg/cm2}) and continues operation.
Fixes charge (boost) pressure sensor value (400 kPa {4.08 kg/cm2}) and continues operation.
Sets EGR inlet pressure sensor to default value (102 kPa {1.04 kg/cm2}) and continues operation. ["serial No. up to 530896 with EGR" only]
Limits output of EGR valve lift sensor and closes EGR valve and bypass valve. ["with EGR"
only]
Limits output of bypass valve lift sensor and closes EGR valve and bypass valve. ["with EGR"
only]

Problem that appears


Output drops.
on machine
Related information
Cause

Standard value in normal state/Remarks on troubleshooting


1. Turn starting switch to OFF position.
2. Disconnect following connectors one by one and turn
starting switch to ON position each time.
3. After each troubleshooting, turn starting switch to OFF position.
If this failure code is not displayed when a connector is disconnected, that sensor or engine wiring harness is defective.
a Other failure codes are displayed, too. This is because the
connector is disconnected. Ignore codes other than [187/
CA187].

Defective sensor or wiring


harness

Possible causes and


standard value in
normal state

2 Defect in related system

3 Defective engine controller

Sensor or harness

Connector

Bkup speed sensor

G connector

Oil pressure sensor

POIL connector

Boost pressure sensor

PIM connector

Ambient pressure sensor

PAMB connector

EGR valve lift sensor *

SEGR connector *

Bypass valve lift sensor *

SBP connector *

EGR inlet pressure sensor **

PEVA connector **

Engine wiring harness

ENG

If another failure code is displayed, perform troubleshooting for


it.
1. Turn starting switch to OFF position.
2. Disconnect connector ENG and connect T-adapter to male
side.
3. Turn starting switch to ON position with connector ENG
disconnected.
Between ENG (male) (37) and (47)

Voltage

4.75
5.25 V

*: "with EGR" only


**: "only early model of "with EGR", serial No. up to 530896.

34

140E-5 Series

40 Troubleshooting

SEN00153-03

Circuit diagram related to sensor power supply 2 (5 V)


a For serial No. up to 530896 "with EGR"

140E-5 Series

35

SEN00153-03

40 Troubleshooting

Circuit diagram related to sensor power supply 2 (5 V)


a For serial No. and up 530897 "with EGR"

36

140E-5 Series

40 Troubleshooting

SEN00153-03

Circuit diagram related to sensor power supply 2 (5 V)


a For "EGR-less"

140E-5 Series

37

SEN00153-03

40 Troubleshooting

E-14 Code [221/CA221] Ambient Air Press. Sensor High Error


a

For with EGR


Error code

Failure code

221

CA221

Trouble

Abnormally high level in atmospheric pressure sensor

Contents of trouble

Signal voltage in atmospheric pressure sensor circuit is abnormally high.

Action of controller

Sets atmospheric pressure to default value (52.44 kPa {0.53 kg/cm2}) and continues operation.

Problem that appears


Output drops.
on machine
Related information
Cause
1

Possible causes and


standard value in
normal state

Defective sensor power


supply system

Defective ambient pressure sensor

Standard value in normal state/Remarks on troubleshooting


If code [187/CA187] or [227/CA227] is indicated, carry out troubleshooting for it first.
1. Turn starting switch to OFF position.
2. Disconnect connector PAMB.
3. Turn starting switch to ON position.
If code changes from [221/CA221] to [222/CA222], sensor is
defective.

1. Turn starting switch to OFF position.


Short circuit in wiring har- 2. Disconnect connector ENG and PAMB, and connect T3
adapter to female side of ENG.
ness
Between ENG (female) (37) and (3)
1.
2.
Hot short circuit in wiring 3.
4 harness
4.
(contact with 24 V circuit)

Turn starting switch to OFF position.


Disconnect connector PAMB.
Insert T-adapter into connector ENG.
Turn starting switch to ON position (with connector PAMB
disconnected).

Between ENG (3) and (38)


5

38

Resistance Min. 1 Mz

Voltage

Max. 1 V

If no failure is found by above checks, engine controller is defecDefective engine controltive. (Since this is an internal failure, troubleshooting cannot be
ler
performed.)

140E-5 Series

40 Troubleshooting

SEN00153-03

Circuit diagram related to atmospheric pressure sensor


a For with EGR

There are not connector SBP and line to the SBP for "EGR-less" in above figure.

140E-5 Series

39

SEN00153-03

40 Troubleshooting

E-15 Code [222/CA222] Ambient Air Press. Sensor Low Error


Error code

Failure code

222

CA222

Trouble

Abnormally low level in atmospheric pressure sensor

Contents of trouble

Signal voltage in atmospheric pressure sensor circuit is abnormally low.

Action of controller

Sets atmospheric pressure to default value (52.44 kPa {0.53 kg/cm2}) and continues operation.

Problem that appears


Output drops.
on machine

Related information

Since troubleshooting "socket" for this sensor features female connector alone, it is not usable
for checking open circuit in wiring harness and voltage at sensor connector (not designed as a
T-adapter).
If sensor connector is disconnected, this failure code is generated.
Cause

Standard value in normal state/Remarks on troubleshooting

Defective power supply line If failure code [187/CA187] or [227/CA227] is displayed, per1
of ambient pressure sensor form troubleshooting for it first.

Short circuit in wiring harness

1. Turn starting switch to OFF position.


2. Disconnect connectors PAMB and ENG.
3. Connect T-adapter to female side of ENG.
Between ENG (female) (3) and (38)

Possible causes and


standard value in
normal state

Resistance

Min.
1 Mz

1. Turn starting switch to OFF position.


Ground fault in wiring har- 2. Disconnect connectors PAMB and ENG and connect Tadapter to female side of ENG.
3 ness
(contact with ground circuit)
ResisMin.
Between ENG (female) (3) and ground
tance
1 Mz
4

Open circuit in wiring harness

If no failure is found by above checks, wiring harness may have


open circuit. (*)

a If no failure is found by checks on causes 1 to 4 and check


result of checks on cause 5 is abnormal, sensor is defective.
Defective ambient pressure 1. Turn starting switch to OFF position.
5 sensor (defective input volt- 2. Insert T-adapter into connector ENG.
3. Turn starting switch to ON position.
age to engine controller)
Sensor
0.3 4.7
Between ENG (3) and (38)
Voltage
output
V
6 Defective engine controller

If no failure is found by above checks, engine controller is


defective. (Since this is an internal failure, troubleshooting cannot be performed.)

*: Refer to "Troubleshooting method for open circuit in wiring harness of pressure sensor system".

40

140E-5 Series

40 Troubleshooting

SEN00153-03

Circuit diagram related to atmospheric pressure sensor


a For "with EGR"

There are not connector SBP and line to the SBP for "EGR-less" in above figure.

140E-5 Series

41

SEN00153-03

40 Troubleshooting

E-16 Code [227/CA227] Sensor Sup. 2 Volt. High Error


Error code
227
Contents of trouble

Action of controller

Failure code
Trouble Abnormally high level in sensor power supply 2 circuit
CA227
Signal voltage in sensor power supply 2 (5 V) circuit is abnormally high.
Operates Bkup speed sensor with signals of Ne speed sensor.
Sets oil pressure sensor to default value (250 kPa {2.55 kg/cm2}) and continues operation.
Sets ambient pressure sensor to default value (52.44 kPa {0.53 kg/cm2}) and continues operation.
Fixes charge (boost) pressure sensor value (400 kPa {4.08 kg/cm2}) and continues operation.
Sets EGR inlet pressure sensor to default value (102 kPa {1.04 kg/cm2}) and continues operation. ["serial No. up to 530896 with EGR" only]
Limits output of EGR valve lift sensor and closes EGR valve and bypass valve. ["with EGR"
only]
Limits output of bypass valve lift sensor and closes EGR valve and bypass valve. ["with EGR"
only]

Problem that appears


Output drops.
on machine
Related information Different machine models may have different connector Nos.
Possible causes and
standard value in
normal state

Cause

Standard value in normal state/Remarks on troubleshooting

1 Carry out troubleshooting for code [187/CA187].

E-17 Code [234/CA234] Eng. Overspeed


Error code

Failure code

234

CA234

Trouble

Engine overspeed

Contents of trouble

Engine speed is above operating range.

Action of controller

Limits fuel injection rate until engine speed lowers to operating range.

Problem that appears


Engine speed fluctuates.
on machine
Related information
Cause
Possible causes and
standard value in
normal state

42

Standard value in normal state/Remarks on troubleshooting

1 Defective related system

If another failure code is indicated, carry out troubleshooting for it.

2 Improper way of use

Way of use may be improper. Teach proper way of use to operator.

3 Defective engine controller

If causes 1 2 are not detected, engine controller may be


defective. (Since trouble is in system, troubleshooting cannot
be carried out.)

140E-5 Series

40 Troubleshooting

140E-5 Series

SEN00153-03

43

SEN00153-03

40 Troubleshooting

E-18 Code [238/CA238] Ne Speed Sensor Sup. Volt. Error


Error code

Failure code

238

CA238

Trouble

Abnormality in Ne speed sensor power supply

Contents of trouble

Abnormality occurred in Ne speed sensor power supply (5 V) circuit.

Action of controller

Controls Ne speed sensor with signals of Bkup speed sensor.

Problem that appears Running engine stops (when Bkup speed sensor is also abnormal).
on machine
Stopped engine cannot be started (when Bkup speed sensor is also abnormal).
Related information

Different machine models may have different connector Nos.


Cause

Standard value in normal state/Remarks on troubleshooting


a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.

Defective Ne speed sen- Disconnect devices at right


in order. If error code disapsor (Internal trouble)
Ne speed
pears when a device is dissensor
connected, that device has
a defect in it.

NE connector

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Possible causes and


standard value in
normal state

Disconnection in wiring
harness (Disconnection Wiring harness between ENG (female)
2
in wiring or defective con- (16) NE (female) (1)
tact in connector)
Wiring harness between ENG (female)
(48) NE (female) (2)

Resistance Max. 1 z
Resistance Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring
3 harness (Short circuit
with GND circuit)

Wiring harness between ENG (female)


Resistance Min. 1 Mz
(16) NE (female) (1) and chassis ground
Wiring harness between ENG (female)
Resistance Min. 1 Mz
(48) NE (female) (2) and chassis ground

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Short circuit in wiring har4 ness (with another wiring Wiring harness between ENG (female)
harness)
(16) NE (female) (1) and between ENG Resistance Min. 1 Mz
(female) (48) NE (female) (2)
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
Defective engine control5
ler
ENG
Voltage
Between (16) (48)

44

4.75 5.25 V

140E-5 Series

40 Troubleshooting

SEN00153-03

Circuit diagram related to Ne speed sensor power supply

140E-5 Series

45

SEN00153-03

40 Troubleshooting

E-19 Code [263/CA263] Fuel Temp. Sensor High Error


Error code

Failure code

263

CA263

Trouble

Abnormally high level in fuel temperature sensor

Contents of trouble

Signal voltage in fuel temperature sensor circuit is abnormally high.

Action of controller

Uses signals from coolant temperature sensor to perform fuel injection rate correction based
on fuel temperature.
Fixes fuel temperature (90C) and continues operation.

Problem that appears


on machine

Related information

This failure code is generated if temperature sensor connector is disconnected.


Because troubleshooting "socket" for this sensor features female connector alone, it is not
connectable to female connector of sensor wiring harness, and thus not usable for checking
open circuit (not designed as a T-adapter).
Cause

Standard value in normal state/Remarks on troubleshooting


1. Turn starting switch to OFF position.
2. Disconnect connector TFUEL and connect socket to male
side.
a If coolant temperature sensor resistance is 700 z to 37 kz
with coolant temperature above 0 C, regard coolant temperature sensor as normal.
0 C

Defective fuel temperature


sensor
Between TFUEL (male)(A)
and (B)
a Fuel temperature-Resistance characteristics

Possible causes and


standard value in
normal state

Resistance

30
37 kz

25 C Resistance

9.3
10.7 kz

50 C Resistance

3.2
3.8 kz

80 C Resistance

1.0
1.3 kz

95 C Resistance

700
800 z

1. Turn starting switch to OFF position.


2. Disconnect connector ENG and connect T-adapter to
female side.
2

Open or short circuit in wir- Between ENG (female) (30) and (47)
(Fuel temperature: Min. 0 C)
ing harness
a The resistance is the same as that
Resistance
shown in the resistance characteristics table of the coolant temperature sensor of cause 1.

3 Defective engine controller

46

700 z
37 kz

If no failure is found by above checks, engine controller is


defective. (Since this is an internal failure, troubleshooting
cannot be performed.)

140E-5 Series

40 Troubleshooting

SEN00153-03

Circuit diagram related to fuel temperature sensor


a For with EGR

Pin number of connector PIM is not "2" but "3" for EGR-less in above figure.

140E-5 Series

47

SEN00153-03

40 Troubleshooting

E-20 Code [265/CA265] Fuel Temp. Sensor Low Error


Error code

Failure code

265

CA265

Trouble

Abnormally low level in fuel temperature sensor

Contents of trouble

Signal voltage in fuel temperature sensor circuit is abnormally low.

Action of controller

Uses signals from coolant temperature sensor to perform fuel injection rate correction based
on fuel temperature.
Fixes fuel temperature (90C) and continues operation.

Problem that appears


on machine
Related information

If temperature sensor connector is disconnected, this code is not generated but code [263/
CA263] for "High Error" is generated.
Cause

Standard value in normal state/Remarks on troubleshooting


1. Turn starting switch to OFF position.
2. Disconnect connector TFUEL and connect socket to male
side.
a If coolant temperature sensor resistance is 700 z to 37 kz
with coolant temperature above 0 C, regard coolant temperature sensor as normal.

Defective fuel temperature


sensor

Possible causes and


standard value in
normal state

Between TFUEL (male)(A) and


(B)
a Fuel temperature-Resistance characteristic

Between (B) and ground

0 C

Resistance

30
37 kz

25 C

Resistance

9.3
10.7 kz

50 C

Resistance

3.2
3.8 kz

80 C

Resistance

1.0
1.3 kz

95 C

Resistance

700
800 z

All fuel
temperature
range

Resistance

Min.
1 Mz

1. Turn starting switch to OFF position.


2. Disconnect connector ENG and connect T-adapter to
female side.
2

Short circuit in wiring harness

Between ENG (female) (30) and (47)


(Fuel temperature: Min. 0 C)
a The resistance is the same as that
shown in the resistance characteristics
table of the coolant temperature sensor of cause 1.

Resistance

700 z
37 kz

1. Turn starting switch to OFF position.


Ground fault in wiring har- 2. Disconnect connector TFUEL, and connect T-adapter to
female side of ENG.
3 ness
(contact with ground circuit)
ResisMin.
Between ENG (female) (30) and ground
tance
1 Mz
4 Defective engine controller

48

If no failure is found by above checks, engine controller is


defective. (Since this is an internal failure, troubleshooting cannot be performed.)

140E-5 Series

40 Troubleshooting

SEN00153-03

Circuit diagram related to fuel temperature sensor


a For "with EGR"

Pin number of connector PIM is not "2" but "3" for "EGR-less" in above figure.

140E-5 Series

49

SEN00153-03

40 Troubleshooting

E-21 Code [271/CA271] PCV1 Short Error


Error code

Failure code

271

CA271

Trouble

Short circuit in PCV1

Contents of trouble

There is short circuit in PCV1 circuit of supply pump.

Action of controller

None in particular.

Problem that appears


on machine
Related information

Different machine models may have different connector Nos.


Cause

Standard value in normal state/Remarks on troubleshooting


a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Defective supply pump


PCV1 (Internal trouble)

PCV1 (male)

Resistance

Between (1) (2)

2.3 5.3 z

Between (1), (2)


chassis ground

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Possible causes and


standard value in
normal state

Wiring harness between ENG


Ground fault in wiring har(female) (4) PCV1 (female) (1) and Resistance Min. 1 Mz
2 ness (Short circuit with GND
chassis ground
circuit)
Wiring harness between ENG
(female) (5) PCV1 (female) (2) and Resistance Min. 1 Mz
chassis ground
a Prepare with starting switch OFF, then turn starting switch
ON and carry out troubleshooting.
Wiring harness between ENG
Hot short (Short circuit with
(female) (4) PCV1 (female) (1) and
3 24V circuit) in wiring harchassis ground
ness
Wiring harness between ENG
(female) (5) PCV1 (female) (2) and
chassis ground

Voltage

Max. 1 V

Voltage

Max. 1 V

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
4 Defective engine controller

50

ENG (female)

Resistance

Between (4) (5)

2.3 5.3 z

Between (4), (5)


chassis ground

Min. 1 Mz

140E-5 Series

40 Troubleshooting

SEN00153-03

Circuit diagram related to supply pump PCV1

140E-5 Series

51

SEN00153-03

40 Troubleshooting

E-22 Code [272/CA272] PCV1 Open Error


Error code

Failure code

272

CA272

Trouble

Disconnection in PCV1

Contents of trouble

There is disconnection in PCV1 circuit of supply pump.

Action of controller

None in particular.

Problem that appears


on machine
Related information

Different machine models may have different connector Nos.


Cause

Standard value in normal state/Remarks on troubleshooting


a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Defective supply pump


1 PCV1 (Internal disconnection)

Possible causes and


standard value in
normal state

PCV1 (male)

Resistance

Between (1) (2)

2.3 5.3 z

Between (1), (2)


chassis ground

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wir- Wiring harness between ENG
2
Resistance Max. 1 z
ing or defective contact in
(female) (4) PCV1 (female) (1)
connector)
Wiring harness between ENG
Resistance Max. 1 z
(female) (5) PCV1 (female) (2)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between ENG
Ground fault in wiring har(female) (4) PCV1 (female) (1) and Resistance Min. 1 Mz
3 ness (Short circuit with GND
chassis ground
circuit)
Wiring harness between ENG
(female) (5) PCV1 (female) (2) and Resistance Min. 1 Mz
chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
4 Defective engine controller

52

ENG (female)

Resistance

Between (4) (5)

2.3 5.3 z

Between (4), (5)


chassis ground

Min. 1 Mz

140E-5 Series

40 Troubleshooting

SEN00153-03

Circuit diagram related to supply pump PCV1

140E-5 Series

53

SEN00153-03

40 Troubleshooting

E-23 Code [273/CA273] PCV2 Short Error


Error code

Failure code

273

CA273

Trouble

Short circuit in PCV2

Contents of trouble

There is short circuit in PCV2 circuit of supply pump.

Action of controller

None in particular.

Problem that appears


on machine
Related information

Different machine models may have different connector Nos.


Cause

Standard value in normal state/Remarks on troubleshooting


a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Defective supply pump


PCV2 (Internal trouble)

PCV2 (male)

Resistance

Between (1) (2)

2.3 5.3 z

Between (1), (2)


chassis ground

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Possible causes and


standard value in
normal state

Wiring harness between ENG


Ground fault in wiring har(female) (9) PCV2 (female) (1) and Resistance Min. 1 Mz
2 ness (Short circuit with GND
chassis ground
circuit)
Wiring harness between ENG
(female) (10) PCV2 (female) (2) and Resistance Min. 1 Mz
chassis ground
a Prepare with starting switch OFF, then turn starting switch
ON and carry out troubleshooting.
Wiring harness between ENG
Hot short (Short circuit with
(female) (9) PCV2 (female) (1) and
3 24V circuit) in wiring harchassis ground
ness
Wiring harness between ENG
(female) (10) PCV2 (female) (2) and
chassis ground

Voltage

Max. 1 V

Voltage

Max. 1 V

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
4 Defective engine controller

54

ENG (female)

Resistance

Between (9) (10)

2.3 5.3 z

Between (9), (10)


chassis ground

Min. 1 Mz

140E-5 Series

40 Troubleshooting

SEN00153-03

Circuit diagram related to supply pump PCV2

140E-5 Series

55

SEN00153-03

40 Troubleshooting

E-24 Code [274/CA274] PCV2 Open Error


Error code

Failure code

274

CA274

Trouble

Disconnection in PCV2

Contents of trouble

There is disconnection in PCV2 circuit of supply pump.

Action of controller

None in particular.

Problem that appears


on machine
Related information

Different machine models may have different connector Nos.


Cause
Defective supply pump
1 PCV2 (Internal disconnection)

Standard value in normal state/Remarks on troubleshooting


a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
PCV2 (male)

Resistance

Between (1) (2)

2.3 5.3 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wir- Wiring harness between ENG
2
Resistance Max. 1 z
ing or defective contact in
(female) (9) PCV2 (female) (1)
connector)
Wiring harness between ENG
Resistance Max. 1 z
(female) (10) PCV2 (female) (2)
Possible causes and
standard value in
normal state

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between ENG
Ground fault in wiring har(female) (9) PCV2 (female) (1) and Resistance Min. 1 Mz
3 ness (Short circuit with GND
chassis ground
circuit)
Wiring harness between ENG
(female) (10) PCV2 (female) (2) and Resistance Min. 1 Mz
chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
4 Defective engine controller

56

ENG (female)

Resistance

Between (9) (10)

2.3 5.3 z

Between (9), (10)


chassis ground

Min. 1 Mz

140E-5 Series

40 Troubleshooting

SEN00153-03

Circuit diagram related to supply pump PCV2

140E-5 Series

57

SEN00153-03

40 Troubleshooting

E-25 Code [322/CA322] Injector #1 System Open/Short Error


Error code

Failure code

322

CA322

Trouble

Disconnection or short circuit in injector #1 system

Contents of trouble

There is disconnection or short circuit in injector #1 circuit.

Action of controller

None in particular.

Problem that appears Output drops.


on machine
Rotation is unstable.
Related information

While engine is running normally, pulse voltage of about 70 V is applied to positive (+) side of
injector. This pulse voltage cannot be measured with circuit tester.
Different machine models may have different connector Nos.
Cause

Standard value in normal state/Remarks on troubleshooting


a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Defective injector #1 (Internal trouble)

CN1 (male)

Resistance

Between (1) (2)

0.4 1.1 z

Between (1), (2)


chassis ground

Min. 1M z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wir- Wiring harness between ENG
2
Resistance Max. 1 z
ing or defective contact in
(female) (45) CN1 (female) (1)
connector)
Wiring harness between ENG
Resistance Max. 1 z
(female) (53) CN1 (female) (2)
Possible causes and
standard value in
normal state

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between ENG
Ground fault in wiring har(female) (45) CN1 (female) (1) and
3 ness (Short circuit with GND
chassis ground
circuit)
Wiring harness between ENG
(female) (53) CN1 (female) (2) and
chassis ground
4

Resistance Min. 1 Mz

Resistance Min. 1 Mz

Defective injector or wiring If failure code of another cylinder is displayed, carry out trouharness of another cylinder bleshooting for it, too.
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

5 Defective engine controller

58

ENG (female)

Resistance

Between (45) (53)

0.4 1.1 z

Between (45), (53)


chassis ground

Min. 1 Mz

140E-5 Series

40 Troubleshooting

SEN00153-03

Circuit diagram related to injector #1


a For with EGR

For EGR-less

Improper installation of injector wiring harness


(H)

Q: Injector wiring harness (H) is in good condition


being laid close to injector (N)

140E-5 Series

x: Injector wiring harness (H) is in bad condition


without being laid close to injector (N)
a: Injector wiring harness (H) may interfere with
rocker arm.

59

SEN00153-03

40 Troubleshooting

E-26 Code [323/CA323] Injector #5 System Open/Short Error


Error code

Failure code

323

CA323

Trouble

Disconnection or short circuit in injector #5 system

Contents of trouble

There is disconnection or short circuit in injector #5 circuit.

Action of controller

None in particular.

Problem that appears Output drops.


on machine
Rotation is unstable.
Related information

While engine is running normally, pulse voltage of about 70 V is applied to positive (+) side of
injector. This pulse voltage cannot be measured with circuit tester.
Different machine models may have different connector Nos.
Cause

Standard value in normal state/Remarks on troubleshooting


a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Defective injector #5 (Internal trouble)

CN5 (male)

Resistance

Between (1) (2)

0.4 1.1 z

Between (1), (2)


chassis ground

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wir- Wiring harness between ENG
2
Resistance Max. 1 z
ing or defective contact in
(female) (46) CN5 (female) (1)
connector)
Wiring harness between ENG
Resistance Max. 1 z
(female) (60) CN5 (female) (2)
Possible causes and
standard value in
normal state

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between ENG
Ground fault in wiring har(female) (46) CN5 (female) (1) and
3 ness (Short circuit with GND
chassis ground
circuit)
Wiring harness between ENG
(female) (60) CN5 (female) (2) and
chassis ground
4

Resistance Min. 1 Mz

Resistance Min. 1 Mz

Defective injector or wiring If failure code of another cylinder is displayed, carry out trouharness of another cylinder bleshooting for it, too.
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

5 Defective engine controller

60

ENG (female)

Resistance

Between (46) (60)

0.4 1.1 z

Between (46), (60)


chassis ground

Min. 1 Mz

140E-5 Series

40 Troubleshooting

SEN00153-03

Circuit diagram related to injector #5


a For with EGR

For EGR-less

Improper installation of injector wiring harness


(H)

Q: Injector wiring harness (H) is in good condition


being laid close to injector (N)

140E-5 Series

x: Injector wiring harness (H) is in bad condition


without being laid close to injector (N)
a: Injector wiring harness (H) may interfere with
rocker arm.

61

SEN00153-03

40 Troubleshooting

E-27 Code [324/CA324] Injector #3 System Open/Short Error


Error code

Failure code

324

CA324

Trouble

Disconnection or short circuit in injector #3 system

Contents of trouble

There is disconnection or short circuit in injector #3 circuit.

Action of controller

None in particular.

Problem that appears Output drops.


on machine
Rotation is unstable.
Related information

While engine is running normally, pulse voltage of about 70 V is applied to positive (+) side of
injector. This pulse voltage cannot be measured with circuit tester.
Different machine models may have different connector Nos.
Cause

Standard value in normal state/Remarks on troubleshooting


a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Defective injector #3 (Internal trouble)

CN3 (male)

Resistance

Between (1) (2)

0.4 1.1 z

Between (1), (2) chassis


ground

Min. 1M z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wir- Wiring harness between ENG
2
Resistance Max. 1 z
ing or defective contact in
(female) (55) CN3 (female) (1)
connector)
Wiring harness between ENG
Resistance Max. 1 z
(female) (52) CN3 (female) (2)
Possible causes and
standard value in
normal state

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between ENG
Ground fault in wiring har(female) (55) CN3 (female) (1) and
3 ness (Short circuit with GND
chassis ground
circuit)
Wiring harness between ENG
(female) (52) CN3 (female) (2) and
chassis ground
4

Resistance Min. 1 Mz

Resistance Min. 1 Mz

Defective injector or wiring If failure code of another cylinder is displayed, carry out trouharness of another cylinder bleshooting for it, too.
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

5 Defective engine controller

62

ENG (female)

Resistance

Between (55) (52)

0.4 1.1 z

Between (55), (52)


chassis ground

Min. 1M z

140E-5 Series

40 Troubleshooting

SEN00153-03

Circuit diagram related to injector #3


a For with EGR

For EGR-less

Improper installation of injector wiring harness


(H)

Q: Injector wiring harness (H) is in good condition


being laid close to injector (N)

140E-5 Series

x: Injector wiring harness (H) is in bad condition


without being laid close to injector (N)
a: Injector wiring harness (H) may interfere with
rocker arm.

63

SEN00153-03

40 Troubleshooting

E-28 Code [325/CA325] Injector #6 System Open/Short Error


Error code

Failure code

325

CA325

Trouble

Disconnection or short circuit in injector #6 system

Contents of trouble

There is disconnection or short circuit in injector #6 circuit.

Action of controller

None in particular.

Problem that appears Output drops.


on machine
Rotation is unstable.
Related information

While engine is running normally, pulse voltage of about 70 V is applied to positive (+) side of
injector. This pulse voltage cannot be measured with circuit tester.
Different machine models may have different connector Nos.
Cause

Standard value in normal state/Remarks on troubleshooting


a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Defective injector #6 (Internal trouble)

CN6 (male)

Resistance

Between (1) (2)

0.4 1.1 z

Between (1), (2)


chassis ground

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wir- Wiring harness between ENG
2
Resistance Max. 1 z
ing or defective contact in
(female) (57) CN6 (female) (1)
connector)
Wiring harness between ENG
Resistance Max. 1 z
(female) (59) CN6 (female) (2)
Possible causes and
standard value in
normal state

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between ENG
Ground fault in wiring har(female) (57) CN6 (female) (1) and
3 ness (Short circuit with GND
chassis ground
circuit)
Wiring harness between ENG
(female) (59) CN6 (female) (2) and
chassis ground
4

Resistance Min. 1 Mz

Resistance Min. 1 Mz

Defective injector or wiring If failure code of another cylinder is displayed, carry out trouharness of another cylinder bleshooting for it, too.
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

5 Defective engine controller

64

ENG (female)

Resistance

Between (57) (59)

0.4 1.1 z

Between (57), (59)


chassis ground

Min. 1 Mz

140E-5 Series

40 Troubleshooting

SEN00153-03

Circuit diagram related to injector #6


a For with EGR

For EGR-less

Improper installation of injector wiring harness


(H)

Q: Injector wiring harness (H) is in good condition


being laid close to injector (N)

140E-5 Series

x: Injector wiring harness (H) is in bad condition


without being laid close to injector (N)
a: Injector wiring harness (H) may interfere with
rocker arm.

65

SEN00153-03

40 Troubleshooting

E-29 Code [331/CA331] Injector #2 System Open/Short Error


Error code

Failure code

331

CA331

Trouble

Disconnection or short circuit in injector #2 system

Contents of trouble

There is disconnection or short circuit in injector #2 circuit.

Action of controller

None in particular.

Problem that appears Output drops.


on machine
Rotation is unstable.
Related information

While engine is running normally, pulse voltage of about 70 V is applied to positive (+) side of
injector. This pulse voltage cannot be measured with circuit tester.
Different machine models may have different connector Nos.
Cause

Standard value in normal state/Remarks on troubleshooting


a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Defective injector #2 (Internal trouble)

CN2 (male)

Resistance

Between (1) (2)

0.4 1.1 z

Between (1), (2)


chassis ground

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wir- Wiring harness between ENG
2
Resistance Max. 1 z
ing or defective contact in
(female) (54) CN2 (female) (1)
connector)
Wiring harness between ENG
Resistance Max. 1 z
(female) (51) CN2 (female) (2)
Possible causes and
standard value in
normal state

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between ENG
Ground fault in wiring har(female) (54) CN2 (female) (1) and
3 ness (Short circuit with GND
chassis ground
circuit)
Wiring harness between ENG
(female) (51) CN2 (female) (2) and
chassis ground
4

Resistance Min. 1 Mz

Resistance Min. 1 Mz

Defective injector or wiring If failure code of another cylinder is displayed, carry out trouharness of another cylinder bleshooting for it, too.
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

5 Defective engine controller

66

ENG (female)

Resistance

Between (54) (51)

0.4 1.1 z

Between (54), (51)


chassis ground

Min. 1 Mz

140E-5 Series

40 Troubleshooting

SEN00153-03

Circuit diagram related to injector #2


a For with EGR

For EGR-less

Improper installation of injector wiring harness


(H)

Q: Injector wiring harness (H) is in good condition


being laid close to injector (N)

140E-5 Series

x: Injector wiring harness (H) is in bad condition


without being laid close to injector (N)
a: Injector wiring harness (H) may interfere with
rocker arm.

67

SEN00153-03

40 Troubleshooting

E-30 Code [332/CA332] Injector #4 System Open/Short Error


Error code

Failure code

332

CA332

Trouble

Disconnection or short circuit in injector #4 system

Contents of trouble

There is disconnection or short circuit in injector #4 circuit.

Action of controller

None in particular.

Problem that appears Output drops.


on machine
Rotation is unstable.
Related information

While engine is running normally, pulse voltage of about 70 V is applied to positive (+) side of
injector. This pulse voltage cannot be measured with circuit tester.
Different machine models may have different connector Nos.
Cause

Standard value in normal state/Remarks on troubleshooting


a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Defective injector #4 (Internal trouble)

CN4 (male)

Resistance

Between (1) (2)

0.4 1.1 z

Between (1), (2)


chassis ground

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wir- Wiring harness between ENG
2
Resistance Max. 1 z
ing or defective contact in
(female) (56) CN4 (female) (1)
connector)
Wiring harness between ENG
Resistance Max. 1 z
(female) (58) CN4 (female) (2)
Possible causes and
standard value in
normal state

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between ENG
Ground fault in wiring har(female) (56) CN4 (female) (1) and
3 ness (Short circuit with GND
chassis ground
circuit)
Wiring harness between ENG
(female) (58) CN4 (female) (2) and
chassis ground
4

Resistance Min. 1 Mz

Resistance Min. 1 Mz

Defective injector or wiring If failure code of another cylinder is displayed, carry out trouharness of another cylinder bleshooting for it, too.
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

5 Defective engine controller

68

ENG (female)

Resistance

Between (56) (58)

0.4 1.1 z

Between (56), (58)


chassis ground

Min. 1 Mz

140E-5 Series

40 Troubleshooting

SEN00153-03

Circuit diagram related to injector #4


a For with EGR

For EGR-less

Improper installation of injector wiring harness


(H)

Q: Injector wiring harness (H) is in good condition


being laid close to injector (N)

140E-5 Series

x: Injector wiring harness (H) is in bad condition


without being laid close to injector (N)
a: Injector wiring harness (H) may interfere with
rocker arm.

69

SEN00153-03

40 Troubleshooting

E-31 Code [342/CA342] Engine Controller Data Matching Error


Error code

Failure code

342

CA342

Trouble

Matching error in engine controller data

Contents of trouble

Matching error occurred in engine controller data.

Action of controller

None in particular.

Problem that appears Engine continues operation normally, but it may stop during operation or may not be able to
on machine
start.
Related information
Possible causes and
standard value in
normal state

70

Cause

Standard value in normal state/Remarks on troubleshooting


Carry out troubleshooting for E-1 Code [111/CA111].

140E-5 Series

40 Troubleshooting

140E-5 Series

SEN00153-03

71

SEN00153-03

40 Troubleshooting

E-32 Code [351/CA351] INJ. Drive Circuit Error


Error code

Failure code

351

CA351

Trouble

Abnormality in injector drive circuit

Contents of trouble

Abnormality occurred in injector drive circuit.

Action of controller

Limits output and continues operation (Limits common rail pressure).

Problem that appears


Output drops.
on machine
Related information

Different machine models may have different connector Nos.


Cause

Possible causes and


standard value in
normal state

Standard value in normal state/Remarks on troubleshooting

1 Defective related system

If another failure code (code of abnormality in injector system)


is indicated, carry out troubleshooting for it.

2 Defective fuse

Check fuse or circuit breaker on machine side directly for


defect.
(If fuse is broken or circuit breaker is turned OFF, circuit probably has ground fault.)

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wir- Wiring harness between E03 (female)
3
Resistance Max. 1 z
ing or defective contact in
(3), (4) battery (+)
connector)
Wiring harness between E03 (female)
Resistance Max. 1 z
(1), (2) chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring harWiring harness between E03 (female)
4 ness (Short circuit with GND
Resistance Min. 1 Mz
(3), (4) battery (+) and chassis ground
circuit)
Wiring harness between E03 (female)
Resistance Min. 1 Mz
(1), (2) chassis ground
a Prepare with starting switch OFF, then turn starting switch
ON and carry out troubleshooting.
5 Defective engine controller

72

E03

Voltage

Between (3), (4) (1), (2)

20 30 V

140E-5 Series

40 Troubleshooting

SEN00153-03

Circuit diagram related to controller power supply

140E-5 Series

73

SEN00153-03

40 Troubleshooting

E-33 Code [352/CA352] Sensor Sup. 1 Volt. Low Error


Error code

Failure code

352

CA352

Trouble

Abnormally low level in sensor power supply 1 circuit

Contents of trouble

Signal voltage in sensor power supply (5 V) circuit is abnormally low.

Action of controller

Limits output of common rail pressure sensor and continues operation (Limits common rail
pressure).

Problem that appears


Output drops.
on machine
Related information
Possible causes and
standard value in
normal state

74

Cause

Standard value in normal state/Remarks on troubleshooting


Carry out troubleshooting for E-34 Code [386/CA386].

140E-5 Series

40 Troubleshooting

SEN00153-03

E-34 Code [386/CA386] Sensor Sup. 1 Volt. High Error


Error code

Failure code

386

CA386

Trouble

Abnormally high level in sensor power supply 1 circuit

Contents of trouble

Signal voltage in sensor power supply (5 V) circuit is abnormally high.

Action of controller

Limits output of common rail pressure sensor and continues operation (Limits common rail
pressure).

Problem that appears


Output drops.
on machine
Related information

Different machine models may have different connector Nos.


Cause

Standard value in normal state/Remarks on troubleshooting

1 Defective related system If another failure code is indicated, carry out troubleshooting for it.
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
Defective sensor (Inter2
nal trouble)

Disconnection in wiring
harness (Disconnection
3
in wiring or defective
contact in connector)
Possible causes and
standard value in
normal state

Disconnect devices at
right in order. If error
code disappears when a Common rail
device is disconnected, pressure sensor
that device has a defect
in it.

PFUEL connector

a Prepare with starting switch OFF, then carry out troubleshooting


without turning starting switch ON.
Wiring harness between ENG (female)
(33) PFUEL (female) (1)

Resistance Max. 1 z

Wiring harness between ENG (female)


(47) PFUEL (female) (3)

Resistance Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting


without turning starting switch ON.
Ground fault in wiring
4 harness (Short circuit
with GND circuit)

Short circuit in wiring


5 harness (with another
wiring harness)

Wiring harness between ENG (female)


(33) PFUEL (female) (1) and chassis
ground

Resistance Min. 1 Mz

Wiring harness between CE01 (female)


(47) PFUEL (female) (3) and chassis
ground

Resistance Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting


without turning starting switch ON.
Wiring harness between ENG (female)
(33) PFUEL (female) (1) and between
ENG (female) (47) PFUEL (female) (3)

Resistance Min. 1 Mz

a Prepare with starting switch OFF, then turn starting switch ON


and carry out troubleshooting.
Defective engine control6
ler
ENG
Voltage
Between (33) (47)

140E-5 Series

4.75 5.25 V

75

SEN00153-03

40 Troubleshooting

Circuit diagram related to sensor power supply 1 (5 V)


a For with EGR

76

There are not connect for PEVA and line to the PEVA for serial No. 530897 and up.

140E-5 Series

40 Troubleshooting

SEN00153-03

Circuit diagram related to sensor power supply 1 (5 V)


a For EGR-less

140E-5 Series

77

SEN00153-03

40 Troubleshooting

E-35 Code [431/CA431] Idle Validation Switch Error

Throttle sensor of accelerator pedal type (Case of HD325/405-7)


Error code

Failure code

431

CA431

Trouble

Abnormality in idle validation switch

Contents of trouble

Abnormality occurred in idle validation switch.

Action of controller

Sets throttle angle to certain value and continues operation (depending on each model).

Problem that appears


on machine
Related information

Different machine models may have different connector Nos.


Cause

Standard value in normal state/Remarks on troubleshooting


a Prepare with starting switch OFF, then turn starting switch
ON and carry out troubleshooting.

Defective accelerator pedal


1
(Internal trouble)

WAS1

Signal name

Between (5) (4)

Signal 1

Between (6) (4)

Signal 2

Voltage
See Fig. 1

If voltage is abnormal, check wiring harness and controller,


too, for another cause of trouble, and then judge.
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wir2
ing or defective contact in
connector)

Wiring harness between E02 (female)


Resistance Max. 1 z
(32) WAS1 (female) (4)
Wiring harness between E02 (female)
Resistance Max. 1 z
(11) WAS1 (female) (5)
Wiring harness between E02 (female)
Resistance Max. 1 z
(1) WAS1 (female) (6)

Possible causes and


standard value in
normal state

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between E02 (female)
(32) WAS1 (female) (4) and chassis Resistance Min. 1 Mz
ground

Ground fault in wiring har3 ness (Short circuit with GND Wiring harness between E02 (female)
circuit)
(11) WAS1 (female) (5) and chassis Resistance Min. 1 Mz
ground
Wiring harness between E02 (female)
(1) WAS1 (female) (6) and chassis Resistance Min. 1 Mz
ground
a Prepare with starting switch OFF, then turn starting switch
ON and carry out troubleshooting.
Wiring harness between E02 (female)
(32) WAS1 (female) (4) and chassis
Hot short (Short circuit with ground
4 24V circuit) in wiring harWiring harness between E02 (female)
ness
(11) WAS1 (female) (5) and chassis
ground
Wiring harness between E02 (female)
(1) WAS1 (female) (6) and chassis
ground

78

Voltage

Max. 1 V

Voltage

Max. 1 V

Voltage

Max. 1 V

140E-5 Series

40 Troubleshooting

SEN00153-03

Cause
Possible causes and
standard value in normal state

Standard value in normal state/Remarks on troubleshooting


a Prepare with starting switch OFF, then turn starting switch
ON and carry out troubleshooting.

5 Defective engine controller

E02

Signal name

Between (11) (32)

Signal 1

Between (1) (32)

Signal 2

Voltage
See Fig. 1

Throttle sensor of accelerator pedal type (Case of HD325/405-7)

Fig. 1
Throttle:
Idle validation:
Operating range:

140E-5 Series

Signal voltage of throttle sensor


Signal voltage of idle validation
switch
Operating range of accelerator
pedal

79

SEN00153-03

40 Troubleshooting

E-36 Code [432/CA432] Idle Validation Process Error


Error code

Failure code

432

CA432

Trouble

Abnormality in processing of idle validation

Contents of trouble

Abnormality occurred in processing of idle validation switch circuit.

Action of controller

Sets throttle angle to certain value and continues operation (depending on each model).

Problem that appears


on machine
Related information
Possible causes and
standard value in
normal state

80

Cause

Standard value in normal state/Remarks on troubleshooting


Carry out troubleshooting for E-35 Code [431/CA431].

140E-5 Series

40 Troubleshooting

SEN00153-03

E-37 Code [441/CA441] Supply Voltage Low Error


Error code

Failure code

441

CA441

Trouble

Abnormally low power supply voltage

Contents of trouble

Power supply voltage is abnormally low.

Action of controller

None in particular.

Problem that appears Engine continues operation normally, but it may stop during operation or may not be able to
on machine
start.
Related information
Possible causes and
standard value in
normal state

Cause

Standard value in normal state/Remarks on troubleshooting


Carry out troubleshooting for E-1 Code [111/CA111].

E-38 Code [442/CA442] Supply Voltage High Error


Error code

Failure code

442

CA442

Trouble

Abnormally high power supply voltage

Contents of trouble

Power supply voltage is abnormally high.

Action of controller

None in particular.

Problem that appears Engine continues operation normally, but it may stop during operation or may not be able to
on machine
start.
Related information
Possible causes and
standard value in
normal state

140E-5 Series

Cause

Standard value in normal state/Remarks on troubleshooting


Carry out troubleshooting for E-1 Code [111/CA111].

81

SEN00153-03

KOMATSU 140E-5 Series engine


Form No. SEN00153-03

2010 KOMATSU
All Rights Reserved
Printed in Japan 06-10

82

SEN00154-02

ENGINE
1SHOP MANUAL

140E-5 Series

40 Troubleshooting

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

SEN00154-02

40 Troubleshooting

E-52 Code [1627/CA1627] Bypass Valve Solenoid Drive Open Error................................................ 25


E-53 Code [1628/CA1628] Bypass Valve Servo Error 1 .................................................................... 26
E-54 Code [1629/CA1629] Bypass Valve Servo Error 2 .................................................................... 27
E-55 Code [1631/CA1631] Bypass Valve Lift Sensor High Error ....................................................... 28
E-56 Code [1632/CA1632] Bypass Valve Lift Sensor Low Error ........................................................ 30
E-57 Code [1633/CA1633] KOMNET Error........................................................................................ 30
E-58 Code [1642/CA1642] EGR Inlet Press Sensor Low Error ......................................................... 31
E-59 Code [1653/CA1653] EGR Inlet Press Sensor High Error......................................................... 32
E-60 Code [2185/CA2185] Throttle Sens. Sup. Volt. High Error ........................................................ 34
E-61 Code [2186/CA2186] Throttle Sens. Sup. Volt. Low Error......................................................... 38
E-62 Code [2249/CA2249] No-pressure Feed By Supply pump 2 ..................................................... 38
E-63 Code [2271/CA2271] EGR Valve Lift Sensor High Error ........................................................... 39
E-64 Code [2272/CA2272] EGR Valve Lift Sensor Low Error ............................................................ 41
E-65 Code [2351/CA2351] EGR Valve Solenoid Drive Short Error.................................................... 42
E-66 Code [2352/CA2352] EGR Valve Solenoid Drive Open Error ................................................... 44
E-67 Code [2555/CA2555] Intake Air Heater Relay Open Error ........................................................ 45
E-68 Code [2556/CA2556] Intake Air Heater Relay Short Error ........................................................ 46
E-69 Code [(143)/B@BAZG] Eng. Oil Press Low Torque Derate....................................................... 48
E-70 Code [(146)/B@BCNS] Eng. Overheat...................................................................................... 48
E-71 Code [(415)/B@BAZG] Eng. Oil Press. Low Speed Derate ...................................................... 49

140E-5 Series

40 Troubleshooting

SEN00154-02

Troubleshooting of electrical system (E-mode), Part 2

E-39 Code [449/CA449] Rail Press. High Error 2

Error code

Failure code

449

CA449

Trouble

Abnormally high common rail pressure 2

Contents of trouble

Common rail pressure sensor circuit detected abnormally high pressure (level 2).

Action of controller

Limits output and continues operation (Limits common rail pressure).

Problem that appears


Output drops.
on machine
Related information
Possible causes and
standard value in
normal state

140E-5 Series

Cause

Standard value in normal state/Remarks on troubleshooting


Carry out troubleshooting for E-42 Code [553/CA553].

SEN00154-02

40 Troubleshooting

E-40 Code [451/CA451] Rail Press. Sensor High Error


Error code

Failure code

451

CA451

Trouble

Abnormally high level in common rail pressure sensor

Contents of trouble

Signal voltage in common rail pressure sensor circuit is abnormally high.

Action of controller

Limits output and continues operation (Limits common rail pressure).

Problem that appears


Output drops.
on machine
Related information

Different machine models may have different connector Nos.


Cause

Standard value in normal state/Remarks on troubleshooting

Defective sensor power


1
supply

If code [352/CA352] or [386/CA386] is indicated, carry out troubleshooting for it first.


a Prepare with starting switch OFF, then turn starting switch ON
or start engine and carry out troubleshooting.
PFUEL

Defective common rail


2 pressure sensor (Internal
trouble)

Voltage

Between (1) (3)

Power supply

4.75 5.25 V

Between (2) (3)

Signal

0.25 4.6 V

Sensor voltage is measured with wiring harness connected.


Accordingly, if voltage is abnormal, check wiring harness and
controller, too, for another cause of trouble, and then judge.
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring
harness (Disconnection
3
in wiring or defective contact in connector)

Possible causes and


standard value in
normal state

Wiring harness between ENG (female)


(33) PFUEL (female) (1)

Resistance Max. 1 z

Wiring harness between ENG (female)


(25) PFUEL (female) (2)

Resistance Max. 1 z

Wiring harness between ENG (female)


(47) PFUEL (female) (3)

Resistance Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Ground fault in wiring


4 harness (Short circuit
with GND circuit)

Wiring harness between ENG (female)


(33) PFUEL (female) (1) and chassis
ground

Resistance Min. 1 Mz

Wiring harness between ENG (female)


(25) PFUEL (female) (2) and chassis
ground

Resistance Min. 1 Mz

Wiring harness between ENG (female)


(47) PFUEL (female) (3) and chassis
ground

Resistance Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between ENG (female)
(33) PFUEL (female) (1) and between Resistance Min. 1 Mz
Short circuit in wiring har- ENG (female) (25) PFUEL (female) (2)
5 ness (with another wiring Wiring harness between ENG (female)
harness)
(33) PFUEL (female) (1) and between Resistance Min. 1 Mz
ENG (female) (47) PFUEL (female) (3)
Wiring harness between ENG (female)
(25) PFUEL (female) (2) and between Resistance Min. 1 Mz
ENG (female) (47) PFUEL (female) (3)

140E-5 Series

40 Troubleshooting

SEN00154-02

Cause
Possible causes and
standard value in
normal state

Standard value in normal state/Remarks on troubleshooting


a Prepare with starting switch OFF, then turn starting switch ON
or start engine and carry out troubleshooting.

Defective engine controller

ENG

Voltage

Between (33) (47)

4.75 5.25 V

Between (25) (47)

0.25 4.6 V

Circuit diagram related to common rail pressure sensor


a For with EGR

140E-5 Series

SEN00154-02

40 Troubleshooting

Circuit diagram related to common rail pressure sensor


a For EGR-less

140E-5 Series

40 Troubleshooting

SEN00154-02

E-41 Code [452/CA452] Rail Press. Sensor Low Error


Error code

Failure code

452

CA452

Trouble

Abnormally low level in common rail pressure sensor

Contents of trouble

Signal voltage in common rail pressure sensor circuit is abnormally low.

Action of controller

Limits output and continues operation (Limits common rail pressure).

Problem that appears


Output drops.
on machine
Related information
Possible causes and
standard value in
normal state

140E-5 Series

Cause

Standard value in normal state/Remarks on troubleshooting


Carry out troubleshooting for E-40 Code [451/CA451].

SEN00154-02

40 Troubleshooting

E-42 Code [553/CA553] Rail Press. High Error 1


Error code

Failure code

553

CA553

Trouble

Abnormally high common rail pressure 1

Contents of trouble

Common rail pressure sensor circuit detected abnormally high pressure (level 1).

Action of controller

None in particular.

Problem that appears


Output drops.
on machine
Related information
Cause

Possible causes and


standard value in
normal state

Standard value in normal state/Remarks on troubleshooting

1 Defective related system

If another failure code is indicated, carry out troubleshooting for


it.

2 Use of improper fuel

Check fuel used directly (for high viscosity).

Defective electrical system


3 of common rail pressure
sensor

Common rail pressure sensor may have electric trouble. Carry


out troubleshooting for code [451/CA451] (E-40).

Defective mechanical sys4 tem of common rail pressure sensor

Check mechanical system of common rail pressure sensor


directly.

5 Defective overflow valve

Check overflow valve directly for broken spring, worn seat, and
stuck ball.

6 Clogging of overflow piping Check overflow piping directly for clogging.


7 Defective pressure limiter

Check pressure limiter directly for mechanical defect.

140E-5 Series

40 Troubleshooting

SEN00154-02

E-43 Code [554/CA554] Rail Press Sensor In Range Error


Error code

Failure code

554

CA554

Trouble

In-range error in common rail pressure sensor

Contents of trouble

In-range error occurred in common rail pressure sensor circuit.

Action of controller

Limits output and continues operation (Limits common rail pressure).

Problem that appears


Output drops.
on machine
Related information
Possible causes and
standard value in
normal state

140E-5 Series

Cause

Standard value in normal state/Remarks on troubleshooting


Carry out troubleshooting for E-40 Code [451/CA451].

SEN00154-02

40 Troubleshooting

E-44 Code [559/CA559] No-pressure Feed By Supply pump 1


Error code

Failure code

559

CA559

Trouble

No-pressure feed by supply pump 1

Contents of trouble

Supply pump does not feed fuel (level 1).

Action of controller

Limits common rail pressure.

Problem that appears


Output drops.
on machine
Related information
Cause
1 Defective related system
2 Use of improper fuel

Check fuel used directly (for high viscosity).

Possible causes and


standard value in
normal state

Standard value in normal state/Remarks on troubleshooting


If another failure code is indicated, carry out troubleshooting for
it.

Defective low-pressure circuit device

a For contents of troubleshooting, see Note 1. For check of


pressure in fuel low-pressure circuit, see TESTING AND
ADJUSTING, Testing fuel pressure.
Pressure in fuel low-pressure
circuit
(At high idle or equivalent to
rated load [by models])

0.15 0.3 MPa


{1.5 3.0 kg/cm2}

4 Clogging of filter/strainer

a For contents of troubleshooting, see Note 2.

Defective electrical system


5
of supply pump PCV

Supply pump PCV may have electric trouble. Carry out troubleshooting for following codes;
[271/CA271] (E-21), [272/CA272] (E-22), [273/CA273] (E-23),
[274/CA274] (E-24)

Defective common rail pres- Common rail pressure sensor may be defective. Check wiring
sure sensor
harness for damage.
a For testing of leakage from pressure limiter, see Testing and
adjusting, Testing fuel return rate and leakage.

7 Defective pressure limiter

Leakage from pressure limiter


(At equivalent to rated operation [by models])

Max. 10 cc/min

a For testing of return (spill) limit from injector, see Testing and
adjusting, Testing fuel return rate and leakage.

8 Defective injector

9 Defective supply pump

Speed equivalent to rated


output (stall load)

Return (Spill) limit from


injector

1,600 rpm

960 cc/min

1,700 rpm

1,020 cc/min

1,800 rpm

1,080 cc/min

1,900 rpm

1,140 cc/min

2,000 rpm

1,200 cc/min

If causes 1 8 are not detected, supply pump may be defective.

<How to use check sheet>


Carry out the above troubleshooting and take a record of the contents of the attached Check sheet for nopressure feed.

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

Check sheet for no-pressure feed


Model
Machine serial No.
Engine
Engine serial No.

Work No.
Date of check
Service meter
Worker's name

#
#

/
h

A. Visual check
1 Fuel leakage to outside
2 Clogging of fuel tank breather

Good NG

B. Check with machine monitor (Fault history function, monitoring function, and reduced cylinder mode function)
3 Check of error/failure code
/
/
/
/
Check of monitoring information
Standard value
Code
Displayed item
Checking condition
Unit
Measured value
(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
(Reference value)
No. 1 cylinder
Low idle
rpm

No. 2 cylinder
Low idle
rpm

5
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

Good NG

C. Check of fuel circuit pressure


6

Checking condition

Fuel low-pressure circuit pres- High idle or equivalent to rated load


sure
[by models])

Unit
MPa
{kg/cm2}

Standard value
(Reference value)
0.15 0.3
{1.5 3.0}

Measured value

D. Check of strainers and filters


7 Visual check of strainers
8 Visual check of gauze filter
9 Visual check of fuel filter
10 Visual check of bypass valve
E. Check of leakage and
Checking condition
return rate
Leakage through pressure lim11
Equivalent to rated output [by models])
iter
Equivalent to rating<By models>1,600 rpm
Equivalent to rating<By models>1,700 rpm
12 Return rate from injector
Equivalent to rating<By models>1,800 rpm
Equivalent to rating<By models>1,900 rpm
Equivalent to rating<By models>2,000 rpm

12

Good NG

Good NG

Good NG

Good NG

Unit

Standard value
(Reference value)

cc/min

Max. 10

cc/min
cc/min
cc/min
cc/min
cc/min

960
1,020
1,080
1,140
1,200

Measured value

Good NG

Speed:

Return rate:

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.
Equivalent to rating <By models>:
When inspecting the engine unit on the bench, operate it under a load equivalent to the rating. When the
engine is installed to the machine, however, the operation load equivalent to the rating depends on the
machine model.

140E-5 Series

13

SEN00154-02

40 Troubleshooting

E-45 Code [689/CA689] Eng. Ne Speed Sensor Error


Error code

Failure code

689

CA689

Trouble

Abnormality in engine Ne speed sensor

Contents of trouble

Abnormality occurred in engine Ne speed sensor circuit.

Action of controller

Operates with signals of Bkup speed sensor.

Problem that appears Running engine stops (when Bkup speed sensor is also abnormal).
on machine
Stopped engine cannot be started (when Bkup speed sensor is also abnormal).
Related information

Different machine models may have different connector Nos.


Cause
Defective sensor power
1
supply system

Standard value in normal state/Remarks on troubleshooting


If code [238/CA238] is indicated, carry out troubleshooting for it
first.
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Disconnection in wiring
harness (Disconnection
2
in wiring or defective contact in connector)

Wiring harness between ENG (female)


(16) NE (female) (1)

Resistance Max. 1 z

Wiring harness between ENG (female)


(48) NE (female) (2)

Resistance Max. 1 z

Wiring harness between ENG (female)


(27) NE (female) (3)

Resistance Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring
3 harness (Short circuit
with GND circuit)

Wiring harness between ENG (female)


Resistance Min. 1 Mz
(16) NE (female) (1) and chassis ground
Wiring harness between ENG (female)
Resistance Min. 1 Mz
(48) NE (female) (2) and chassis ground
Wiring harness between ENG (female)
Resistance Min. 1 Mz
(27) NE (female) (3) and chassis ground

Possible causes and


standard value in
normal state

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between ENG (female)
(16) NE (female) (1) and between
Short circuit in wiring har- ENG (female) (48) NE (female) (2)
4 ness (with another wiring Wiring harness between ENG (female)
harness)
(16) NE (female) (1) and between
ENG (female) (27) NE (female) (3)
Wiring harness between ENG (female)
(48) NE (female) (2) and between
ENG (female) (27) NE (female) (3)
Defective mount of sen5 sor or defective rotation
sensing part

14

Resistance Min. 1 Mz

Resistance Min. 1 Mz

Resistance Min. 1 Mz

Check Ne speed sensor directly for defective mount (defective


clearance) or check rotation sensing part (flywheel) directly for
defect.
If causes 1 5 are not detected, engine Ne speed sensor may
be defective. (Since trouble is in system, troubleshooting cannot
be carried out.)

Defective engine Ne
speed sensor

If causes 1 6 are not detected, engine controller may be defecDefective engine controltive. (Since trouble is in system, troubleshooting cannot be carler
ried out.)

140E-5 Series

40 Troubleshooting

SEN00154-02

Circuit diagram related to engine Ne speed sensor

140E-5 Series

15

SEN00154-02

40 Troubleshooting

E-46 Code [731/CA731] Eng. Bkup Speed Sensor Phase Error


Error code

Failure code

731

CA731

Trouble

Abnormality in engine Bkup speed sensor phase

Contents of trouble

Engine Bkup sensor circuit detected abnormality in phase.

Action of controller

Controls with signals of engine Ne speed sensor.

Problem that appears Running engine stops (when Ne speed sensor is also abnormal).
on machine
Stopped engine cannot be started (when Ne speed sensor is also abnormal).
Related information
Cause
Possible causes and
standard value in
normal state

Standard value in normal state/Remarks on troubleshooting

Defective engine Ne speed Engine Ne speed sensor may be defective. Carry out trouble1
sensor system
shooting for [689/CA698] (E-45).
2

Defective engine Bkup


speed sensor system

Engine Bkup speed sensor may be defective. Carry out troubleshooting for [778/CA778] (E-48).

E-47 Code [757/CA757] All Engine Controller Data Lost Error


Error code

Failure code

757

CA757

Trouble

Loss of all data in engine controller

Contents of trouble

All data in engine controller are lost.

Action of controller

None in particular.

Problem that appears Engine continues operation normally, but it may stop during operation or may not be able to
on machine
start.
Related information
Possible causes and
standard value in
normal state

16

Cause

Standard value in normal state/Remarks on troubleshooting


Carry out troubleshooting for E-1 Code [111/CA111].

140E-5 Series

40 Troubleshooting

140E-5 Series

SEN00154-02

17

SEN00154-02

40 Troubleshooting

E-48 Code [778/CA778] Eng. Bkup Speed Sensor Error


Error code

Failure code

778

CA778

Trouble

Abnormality in engine Bkup speed sensor

Contents of trouble

Abnormality occurred in engine Bkup speed sensor circuit.

Action of controller

Operates with signals of Ne speed sensor.

Problem that appears Running engine stops (when Ne speed sensor is also abnormal).
on machine
Stopped engine cannot be started (when Ne speed sensor is also abnormal).
Related information

Different machine models may have different connector Nos.


Cause

Standard value in normal state/Remarks on troubleshooting

Defective sensor power


1
supply system

If code [187/CA187] or [227/CA227] is indicated, carry out troubleshooting for it first.


a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Disconnection in wiring
harness (Disconnection
2
in wiring or defective contact in connector)

Wiring harness between ENG (female)


(37) G (female) (1)

Resistance Max. 1 z

Wiring harness between ENG (female)


(47) G (female) (2)

Resistance Max. 1 z

Wiring harness between ENG (female)


(26) G (female) (3)

Resistance Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring
3 harness (Short circuit
with GND circuit)
Possible causes and
standard value in
normal state

Wiring harness between ENG (female)


(37) G (female) (1) and chassis ground

Resistance Min. 1 Mz

Wiring harness between ENG (female)


(47) G (female) (2) and chassis ground

Resistance Min. 1 Mz

Wiring harness between ENG (female)


(26) G (female) (3) and chassis ground

Resistance Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between ENG (female)
(37) G (female) (1) and between ENG Resistance Min. 1 Mz
Short circuit in wiring har- (female) (47) G (female) (2)
4 ness (with another wiring Wiring harness between ENG (female)
harness)
(37) G (female) (1) and between ENG Resistance Min. 1 Mz
(female) (26) G (female) (3)
Wiring harness between ENG (female)
(47) G (female) (2) and between ENG Resistance Min. 1 Mz
(female) (26) G (female) (3)
Defective mount of sen5 sor or defective rotation
sensing part

18

Check Bkup speed sensor directly for defective mount (defective


clearance) or check rotation sensing part (in supply pump)
directly for defect.
If causes 1 5 are not detected, engine Bkup speed sensor may
be defective. (Since trouble is in system, troubleshooting cannot
be carried out.)

Defective engine Bkup


speed sensor

If causes 1 6 are not detected, engine controller may be defecDefective engine controltive. (Since trouble is in system, troubleshooting cannot be carler
ried out.)

140E-5 Series

40 Troubleshooting

SEN00154-02

Circuit diagram related to engine Bkup speed sensor


a For with EGR

140E-5 Series

19

SEN00154-02

40 Troubleshooting

Circuit diagram related to engine Bkup speed sensor


a For EGR-less

20

140E-5 Series

40 Troubleshooting

SEN00154-02

E-49 Code [1228/CA1228] EGR Valve Servo Error 1


a

This code applies to only with EGR.


Error code

Failure code

1228

CA1228

Trouble

Abnormality in EGR valve servo 1

Contents of trouble

Abnormality (level 1) occurred in EGR valve servo.

Action of controller

Performs open control.

Problem that appears


on machine
Related information
Cause
1 Defective related system

Standard value in normal state/Remarks on troubleshooting


If another failure code is indicated, carry out troubleshooting for
it.
a For measurement of EGR valve drive pressure, see Testing
and adjusting, Measuring EGR valve and bypass valve
drive oil pressure.

Improper EGR valve drive


pressure

Engine speed

EGR valve drive 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
standard value in
normal state

Defective engine oil pres3


sure system (main circuit)

Engine speed

Engine oil pressure

Low idle

0.08 MPa {0.8 kg/cm2}

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).

140E-5 Series

Defective oil pump for EGR


Check oil pump and relief valve for EGR valve circuit directly.
valve

Defective oil feed piping for


Check oil feed piping for EGR valve circuit directly.
EGR valve

Defective oil return piping


for EGR valve

Check oil return piping for EGR valve circuit directly.

7 Defective EGR valve

Check mechanical section of EGR valve directly.

8 Defective engine controller

If causes 1 7 are not detected, engine controller may be


defective. (Since trouble is in system, troubleshooting cannot
be carried out.)

21

SEN00154-02

40 Troubleshooting

E-50 Code [1625/CA1625] EGR Valve Servo Error 2


a

This code applies to only with EGR.


Error code

Failure code

1625

CA1625

Trouble

Abnormality in EGR valve servo 2

Contents of trouble

Abnormality (level 2) occurred in EGR valve servo.

Action of controller

Limits output and continues operation.


Closes EGR valve and bypass valve.

Problem that appears


Output drops.
on machine
Related information
Possible causes and
standard value in
normal state

22

Cause

Standard value in normal state/Remarks on troubleshooting


Carry out troubleshooting for E-49 Code [1228/CA1228].

140E-5 Series

40 Troubleshooting

SEN00154-02

E-51 Code [1626/CA1626] Bypass Valve Solenoid Drive Short Circuit


Error
1
a

This code applies to only with EGR.


Error code

Failure code

1626

CA1626

Trouble

Short circuit in bypass valve solenoid drive circuit

Contents of trouble

There is short circuit in drive circuit of bypass valve solenoid.

Action of controller

Limits output and continues operation.


Closes EGR valve and bypass valve.

Problem that appears


Output drops.
on machine
Related information

Different machine models may have different connector Nos.


Cause

Defective bypass valve


solenoid (Internal trouble)

Standard value in normal state/Remarks on troubleshooting


a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
BP (male)

Resistance

Between (1) (2)

10 21 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Disconnection in wiring
harness (Disconnection Wiring harness between ENG (female)
2
in wiring or defective con- (31) BP (female) (1)
tact in connector)
Wiring harness between ENG (female)
(11) BP (female) (2)
Possible causes and
standard value in
normal state

Resistance Max. 1 z
Resistance Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring
3 harness (Short circuit
with GND circuit)

Wiring harness between ENG (female) (31)


Resistance Min. 1 Mz
BP (female) (1) and chassis ground
Wiring harness between ENG (female) (11)
Resistance Min. 1 Mz
BP (female) (2) and chassis ground
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.

Hot short (Short circuit


Wiring harness between ENG (female) (31)
4 with 24V circuit) in wiring
BP (female) (1) and chassis ground
harness
Wiring harness between ENG (female) (11)
BP (female) (2) and chassis ground

Voltage

Max. 1 V

Voltage

Max. 1 V

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Defective engine control5
ler
ENG (female)
Resistance
Between (31) (11)

140E-5 Series

10 21 z

23

SEN00154-02

40 Troubleshooting

Circuit diagram related to bypass valve solenoid & lift sensor

24

140E-5 Series

40 Troubleshooting

SEN00154-02

E-52 Code [1627/CA1627] Bypass Valve Solenoid Drive Open Error


a

This code applies to only with EGR.


Error code

Failure code

1627

CA1627

Trouble

Disconnection in bypass valve solenoid drive circuit

Contents of trouble

There is disconnection in drive circuit of bypass valve solenoid.

Action of controller

Limits output and continues operation.


Closes EGR valve and bypass valve.

Problem that appears


Output drops.
on machine
Related information
Possible causes and
standard value in
normal state

140E-5 Series

Cause

Standard value in normal state/Remarks on troubleshooting


Carry out troubleshooting for E-51 Code [1626/CA1626].

25

SEN00154-02

40 Troubleshooting

E-53 Code [1628/CA1628] Bypass Valve Servo Error 1


a

This code applies to only with EGR.


Error code

Failure code

1628

CA1628

Trouble

Abnormality in bypass valve servo 1

Contents of trouble

Abnormality (level 1) occurred in bypass valve servo.

Action of controller

Performs open control.

Problem that appears


on machine
Related information
Cause
1 Defective related system

Standard value in normal state/Remarks on troubleshooting


If another failure code is indicated, carry out troubleshooting
for it.
a For measurement of EGR valve drive pressure, see Testing
and adjusting, Measuring EGR valve and bypass valve
drive oil pressure.

Improper EGR valve drive


pressure

Engine speed

Bypass valve drive 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
standard value in
normal state

Defective engine oil pres3


sure system (main circuit)

Engine speed

Engine oil pressure

Low idle

0.08 MPa {0.8 kg/cm2}

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).

26

Defective oil pump for


bypass valve

Check oil pump and relief valve for bypass valve circuit
directly.

Defective oil feed piping for


Check oil feed piping for bypass valve circuit directly.
bypass valve

Defective oil return piping


for bypass valve

Check oil return piping for bypass valve circuit directly.

7 Defective bypass valve

Check mechanical section of bypass valve directly.

8 Defective engine controller

If causes 1 7 are not detected, engine controller may be


defective. (Since trouble is in system, troubleshooting cannot
be carried out.)

140E-5 Series

40 Troubleshooting

SEN00154-02

E-54 Code [1629/CA1629] Bypass Valve Servo Error 2


a

This code applies to only with EGR.


Error code

Failure code

1629

CA1629

Trouble

Abnormality in bypass valve servo 2

Contents of trouble

Abnormality (level 2) occurred in bypass valve servo.

Action of controller

Limits output and continues operation.


Closes EGR valve and bypass valve.

Problem that appears


Output drops.
on machine
Related information
Possible causes and
standard value in
normal state

140E-5 Series

Cause

Standard value in normal state/Remarks on troubleshooting


Carry out troubleshooting for E-53 Code [1628/CA1628].

27

SEN00154-02

40 Troubleshooting

E-55 Code [1631/CA1631] Bypass Valve Lift Sensor High Error


a

This code applies to only with EGR.


Error code

Failure code

1631

CA1631

Trouble

Abnormally high level in bypass valve lift sensor

Contents of trouble

Signal voltage in bypass valve lift sensor circuit is abnormally high.

Action of controller

Limits output and continues operation.


Closes EGR valve and bypass valve.

Problem that appears


Output drops.
on machine
Related information

Different machine models may have different connector Nos.


Cause
1

Standard value in normal state/Remarks on troubleshooting

Defective sensor power If code [187/CA187] or [227/CA227] is indicated, carry out troublesupply
shooting for it first.
a Prepare with starting switch OFF, then turn starting switch ON or
start engine and carry out troubleshooting.
SBP

Defective bypass valve


2 lift sensor (Internal trouble)

Voltage

Between (1) (2)

Power supply

4.75 5.25 V

Between (3) (2)

Signal

0.8 1.2 V

Between (4) (2)

Signal

0.8 1.2 V

Sensor voltage is measured with wiring harness connected.


Accordingly, if voltage is abnormal, check wiring harness and controller, too, for another cause of trouble, and then judge.
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Disconnection in wiring
harness (Disconnection
3
in wiring or defective
contact in connector)
Possible causes and
standard value in
normal state

Wiring harness between ENG (female)


(37) SBP (female) (1)

Resistance Max. 1 z

Wiring harness between ENG (female)


(38) SBP (female) (2)

Resistance Max. 1 z

Wiring harness between ENG (female)


(29) SBP (female) (3), (4)

Resistance Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting


without turning starting switch ON.
Ground fault in wiring
4 harness (Short circuit
with GND circuit)

Wiring harness between ENG (female) (37)


Resistance Min. 1 Mz
SBP (female) (1) and chassis ground
Wiring harness between ENG (female) (38)
Resistance Min. 1 Mz
SBP (female) (2) and chassis ground
Wiring harness between ENG (female)
(29) SBP (female) (3), (4) and chassis
ground

Resistance Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting


without turning starting switch ON.

Short circuit in wiring


5 harness (with another
wiring harness)

Wiring harness between ENG (female)


(37) SBP (female) (1) and between ENG Resistance Min. 1 Mz
(female) (38) SBP (female) (2)
Wiring harness between ENG (female)
(37) SBP (female) (1) and between ENG Resistance Min. 1 Mz
(female) (29) SBP (female) (3), (4)
Wiring harness between ENG (female)
(38) SBP (female) (2) and between ENG Resistance Min. 1 Mz
(female) (29) SBP (female) (3), (4)

28

140E-5 Series

40 Troubleshooting

SEN00154-02

Cause
Possible causes and
standard value in
normal state

Defective engine con6


troller

Standard value in normal state/Remarks on troubleshooting


a Prepare with starting switch OFF, then turn starting switch ON or
start engine and carry out troubleshooting.
ENG

Voltage

Between (37) (38)

4.75 5.25 V

Circuit diagram related to bypass valve solenoid & lift sensor

140E-5 Series

29

SEN00154-02

40 Troubleshooting

E-56 Code [1632/CA1632] Bypass Valve Lift Sensor Low Error


a

This code applies to only with EGR.


Error code

Failure code

1632

CA1632

Trouble

Abnormally low level in bypass valve lift sensor

Contents of trouble

Signal voltage in bypass valve lift sensor circuit is abnormally low.

Action of controller

Limits output and continues operation.


Closes EGR valve and bypass valve.

Problem that appears


Output drops.
on machine
Related information
Possible causes and
standard value in
normal state

Cause

Standard value in normal state/Remarks on troubleshooting


Carry out troubleshooting for E-55 Code [1631/CA1631].

E-57 Code [1633/CA1633] KOMNET Error


Error code

Failure code

1633

CA1633

Trouble

Abnormality in KOMNET

Contents of trouble

Abnormality occurred in circuit of KOMNET communication with machine.

Action of controller

Operates in default mode or maintains condition when abnormality occurs.

Problem that appears


on machine
Related information
Cause
Possible causes and
standard value in
normal state

30

Carry out troubleshooting


1
on machine side

Standard value in normal state/Remarks on troubleshooting


This fault is detected and indicated when KOMNET communication with machine monitor or controller on the machine side
is abnormal. Accordingly, contents of troubleshooting depends
on machine model. See Shop manual for machine.

140E-5 Series

40 Troubleshooting

SEN00154-02

E-58 Code [1642/CA1642] EGR Inlet Press Sensor Low Error


a

This code applies to only with EGR.


Error code

Failure code

1642

CA1642

Trouble

Abnormally low level in EGR inlet pressure sensor

Contents of trouble

Signal voltage in EGR inlet pressure sensor circuit is abnormally low.

Action of controller

Sets EGR inlet pressure to default value (102 kPa {1.04 kg/cm2}) and continues operation.
Limits output and continues operation.

Problem that appears


Output drops.
on machine
Related information
Possible causes and
standard value in
normal state

Cause

Standard value in normal state/Remarks on troubleshooting


Carry out troubleshooting for E-59 Code [1653/CA1653].

Reference: EGR inlet pressure sensor is applied to only machines Serial No. up to 530896.

140E-5 Series

31

SEN00154-02

40 Troubleshooting

E-59 Code [1653/CA1653] EGR Inlet Press Sensor High Error


a

This code applies to only with EGR.


Error code

Failure code

1653

CA1653

Trouble

Abnormally high level in EGR inlet pressure sensor

Contents of trouble

Signal voltage in EGR inlet pressure sensor circuit is abnormally high.

Action of controller

Sets EGR inlet pressure to default value (102 kPa {1.04 kg/cm2}) and continues operation.
Limits output and continues operation.

Problem that appears


Output drops.
on machine
Related information

Different machine models may have different connector Nos.


Cause
1

Defective sensor power


supply

Standard value in normal state/Remarks on troubleshooting


If code [187/CA187] or [227/CA227] is indicated, carry out troubleshooting for it first.
a Prepare with starting switch OFF, then turn starting switch ON
or start engine and carry out troubleshooting.

Defective EGR inlet pres2 sure sensor (Internal


trouble)

PEVA
Between (1) (2)

Voltage
Power supply

4.75 5.25 V

Sensor voltage is measured with wiring harness connected.


Accordingly, if voltage is abnormal, check wiring harness and
controller, too, for another cause of trouble, and then judge.
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Disconnection in wiring
harness (Disconnection
3
in wiring or defective contact in connector)

Possible causes and


standard value in
normal state

Wiring harness between ENG (female)


(37) PEVA (female) (1)

Resistance Max. 1 z

Wiring harness between ENG (female)


(47) PEVA (female) (2)

Resistance

Wiring harness between ENG (female)


(20) PEVA (female) (3)

Resistance Max. 1 z

Max. 1z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring
4 harness (Short circuit
with GND circuit)

Wiring harness between ENG (female) (37)


Resistance Min. 1 Mz
PEVA (female) (1) and chassis ground
Wiring harness between ENG (female) (47)
Resistance Min. 1 Mz
PEVA (female) (2) and chassis ground
Wiring harness between ENG (female) (20)
Resistance Min. 1 Mz
PEVA (female) (3) and chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Wiring harness between ENG (female)


(37) PEVA (female) (1) and between
Short circuit in wiring har- ENG (female) (47) PEVA (female) (2)
5 ness (with another wiring Wiring harness between ENG (female)
harness)
(37) PEVA (female) (1) and between
ENG (female) (20) PEVA (female) (3)
Wiring harness between ENG (female)
(47) PEVA (female) (2) and between
ENG (female) (20) PEVA (female) (3)
Defective engine control6
ler

32

Resistance Min. 1 Mz

Resistance Min. 1 Mz

Resistance Min. 1 Mz

a Prepare with starting switch OFF, then turn starting switch ON


or start engine and carry out troubleshooting.
ENG

Voltage

Between (37) (47)

4.75 5.25 V

140E-5 Series

40 Troubleshooting

SEN00154-02

Reference: EGR inlet pressure sensor is applied to only machines Serial No. up to 530896.
Circuit diagram related to EGR inlet pressure sensor

140E-5 Series

33

SEN00154-02

40 Troubleshooting

E-60 Code [2185/CA2185] Throttle Sens. Sup. Volt. High Error

Throttle sensor of accelerator pedal type (Case of HD325/405-7)


Error code

Failure code

2185

CA2185

Trouble

Abnormally high level in throttle sensor power supply

Contents of trouble

Signal voltage in throttle sensor power supply (5 V) circuit is abnormally high.

Action of controller

Sets throttle angle with signal other than throttle sensor signal and continues operation
(depending on each model).

Problem that appears


Depends on machine model.
on machine
Related information

Different machine models may have different connector Nos.


Cause

Standard value in normal state/Remarks on troubleshooting


a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.

Defective accelerator
pedal (Internal trouble)

Disconnect devices at right


in order. If error code disappears when a device is
disconnected, that device
has a defect in it.

Accelerator
pedal

WAS1 connector

a Prepare with starting switch OFF, then carry out troubleshooting


without turning starting switch ON.

Possible causes and


standard value in
normal state

Disconnection in wiring
harness (Disconnection Wiring harness between E02 (female) (22)
2
Resistance Max. 1 z
in wiring or defective
WAS1 (female) (1)
contact in connector)
Wiring harness between E02 (female) (23)
Resistance Max. 1 z
WAS1 (female) (3)

a Prepare with starting switch OFF, then carry out troubleshooting


without turning starting switch ON.
Ground fault in wiring
3 harness (Short circuit
with GND circuit)

Wiring harness between E02 (female) (22)


Resistance Min. 1 Mz
WAS1 (female) (1) and chassis ground
Wiring harness between E02 (female) (23)
Resistance Min. 1 Mz
WAS1 (female) (3) and chassis ground

Short circuit in wiring


4 harness (with another
wiring harness)

34

Defective engine controller

a Prepare with starting switch OFF, then carry out troubleshooting


without turning starting switch ON.
Wiring harness between E02 (female) (22)
WAS1 (female) (1) and between E02
Resistance Min. 1 Mz
(female) (23) WAS1 (female) (3)
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
E02

Voltage

Between (22) (23)

4.75 5.25 V

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

Throttle sensor of fuel control dial type (Case of PC800/800SE/850/850SE/850LC-8)


Error code

Failure code

2185

CA2185

Trouble

Abnormally high level in throttle sensor power supply

Contents of trouble

Signal voltage in throttle sensor power supply (5 V) circuit is abnormally high.

Action of controller

Sets throttle angle with signal other than throttle sensor signal and continues operation
(depending on each model).

Problem that appears


Depends on machine model.
on machine
Related information

Different machine models may have different connector Nos.


Cause

Standard value in normal state/Remarks on troubleshooting


a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.

Defective fuel control


dial (Internal trouble)

Disconnect devices at right


in order. If error code disappears when a device is
disconnected, that device
has a defect in it.

Fuel control
dial

P20 connector

a Prepare with starting switch OFF, then carry out troubleshooting


without turning starting switch ON.

Possible causes and


standard value in
normal state

Disconnection in wiring
harness (Disconnection Wiring harness between E02 (female) (22)
2
Resistance Max. 1 z
in wiring or defective
P20 (female) (1)
contact in connector)
Wiring harness between E02 (female) (23)
Resistance Max. 1 z
P20 (female) (3)

a Prepare with starting switch OFF, then carry out troubleshooting


without turning starting switch ON.
Ground fault in wiring
3 harness (Short circuit
with GND circuit)

Wiring harness between E02 (female) (22)


Resistance Min. 1 Mz
P20 (female) (1) and chassis ground
Wiring harness between E02 (female) (23)
Resistance Min. 1 Mz
P20 (female) (3) and chassis ground

Short circuit in wiring


4 harness (with another
wiring harness)

Defective engine con5


troller

36

a Prepare with starting switch OFF, then carry out troubleshooting


without turning starting switch ON.
Wiring harness between E02 (female) (22)
P20 (female) (1) and between E02
Resistance Min. 1 Mz
(female) (23) P20 (female) (3)
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
E02

Voltage

Between (22) (23)

4.75 5.25 V

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

E-61 Code [2186/CA2186] Throttle Sens. Sup. Volt. Low Error


Error code

Failure code

2186

CA2186

Trouble

Abnormally low level in throttle sensor power supply

Contents of trouble

Signal voltage in throttle sensor power supply (5 V) circuit is abnormally low.

Action of controller

Sets throttle angle with signal other than throttle sensor signal and continues operation
(depending on each model).

Problem that appears


Depends on machine model.
on machine
Related information
Possible causes and
standard value in
normal state

Cause

Standard value in normal state/Remarks on troubleshooting


Carry out troubleshooting for E-60 Code [2185/CA2185].

E-62 Code [2249/CA2249] No-pressure Feed By Supply pump 2


Error code

Failure code

2249

CA2249

Trouble

No-pressure feed by supply pump 2

Contents of trouble

Supply pump does not feed fuel (level 2).

Action of controller

Limits common rail pressure.

Problem that appears


Output drops.
on machine
Related information
Possible causes and
standard value in
normal state

38

Cause

Standard value in normal state/Remarks on troubleshooting


Carry out troubleshooting for E-44 Code [559/CA559].

140E-5 Series

40 Troubleshooting

SEN00154-02

E-63 Code [2271/CA2271] EGR Valve Lift Sensor High Error


a

This code applies to only with EGR.


Error code

Failure code

2271

CA2271

Trouble

Abnormally high level in EGR valve lift sensor

Contents of trouble

Signal voltage in EGR valve lift sensor circuit is abnormally high.

Action of controller

Limits output and continues operation.


Closes EGR valve and bypass valve.

Problem that appears


Output drops.
on machine
Related information

Different machine models may have different connector Nos.


Cause
1

Defective sensor
power supply

Standard value in normal state/Remarks on troubleshooting


If code [187/CA187] or [227/CA227] is indicated, carry out troubleshooting for it first.
a Prepare with starting switch OFF, then turn starting switch ON or
start engine and carry out troubleshooting.
SEGR

Defective EGR valve


2 lift sensor (Internal
trouble)

Voltage

Between (1) (2)

Power supply

4.75 5.25V

Between (3) (2)

Signal

0.8 1.2 V

Between (4) (2)

Signal

0.8 1.2 V

Sensor voltage is measured with wiring harness connected.


Accordingly, if voltage is abnormal, check wiring harness and controller, too, for another cause of trouble, and then judge.
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.

Possible causes and


standard value in
normal state

Disconnection in wiring
harness (Disconnec3 tion in wiring or defective contact in
connector)

Wiring harness between ENG (female) (37)


Resistance Max. 1 z
SEGR (female) (1)
Wiring harness between ENG (female) (47)
Resistance Max. 1 z
SEGR (female) (2)
Wiring harness between ENG (female) (19)
Resistance Max. 1 z
SEGR (female) (3), (4)
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.

Ground fault in wiring


4 harness (Short circuit
with GND circuit)

Wiring harness between ENG (female) (37)


Resistance Min. 1 Mz
SEGR (female) (1) and chassis ground
Wiring harness between ENG (female) (47)
Resistance Min. 1 Mz
SEGR (female) (2) and chassis ground
Wiring harness between ENG (female) (19)
Resistance Min. 1 Mz
SEGR (female) (3), (4) and chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.

Short circuit in wiring


5 harness (with another
wiring harness)

Wiring harness between ENG (female) (37)


SEGR (female) (1) and between ENG
Resistance Min. 1 Mz
(female) (47) SEGR (female) (2)
Wiring harness between ENG (female) (37)
SEGR (female) (1) and between ENG
Resistance Min. 1 Mz
(female) (19) SEGR (female) (3), (4)
Wiring harness between ENG (female) (47)
SEGR (female) (2) and between ENG
Resistance Min. 1 Mz
(female) (19) SEGR (female) (3), (4)

140E-5 Series

39

SEN00154-02

40 Troubleshooting

Cause
Possible causes and
standard value in
normal state

Defective engine con6


troller

Standard value in normal state/Remarks on troubleshooting


a Prepare with starting switch OFF, then turn starting switch ON or
start engine and carry out troubleshooting.
ENG

Voltage

Between (37) (47)

4.75 5.25 V

Circuit diagram related to EGR valve solenoid & lift sensor

40

140E-5 Series

40 Troubleshooting

SEN00154-02

E-64 Code [2272/CA2272] EGR Valve Lift Sensor Low Error


a

This code applies to only with EGR.


Error code

Failure code

2272

CA2272

Trouble

Abnormally low level in EGR valve lift sensor

Contents of trouble

Signal voltage in EGR valve lift sensor circuit is abnormally low.

Action of controller

Limits output and continues operation.


Closes EGR valve and bypass valve.

Problem that appears


Output drops.
on machine
Related information
Possible causes and
standard value in
normal state

140E-5 Series

Cause

Standard value in normal state/Remarks on troubleshooting


Carry out troubleshooting for E-63 Code [2271/CA2271].

41

SEN00154-02

40 Troubleshooting

E-65 Code [2351/CA2351] EGR Valve Solenoid Drive Short Error


a

This code applies to only with EGR.


Error code

Failure code

2351

CA2351

Trouble

Short circuit in drive circuit of EGR valve solenoid

Contents of trouble

There is short circuit in drive circuit of EGR valve solenoid.

Action of controller

Limits output and continues operation.


Closes EGR valve and bypass valve.

Problem that appears


Output drops.
on machine
Related information

Different machine models may have different connector Nos.


Cause

Defective EGR valve


solenoid (Internal trouble)

Standard value in normal state/Remarks on troubleshooting


a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
EGR (male)

Resistance

Between (1) (2)

10 21 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Disconnection in wiring
harness (Disconnection Wiring harness between ENG (female)
2
in wiring or defective con- (22) EGR (female) (1)
tact in connector)
Wiring harness between ENG (female)
(11) EGR (female) (2)

Resistance Max. 1 z
Resistance Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes and
standard value in
normal state

Ground fault in wiring


3 harness (Short circuit
with GND circuit)

Wiring harness between ENG (female) (22)


Resistance Min. 1 Mz
EGR (female) (1) and chassis ground
Wiring harness between ENG (female) (11)
Resistance Min. 1 Mz
EGR (female) (2) and chassis ground
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.

Wiring harness between ENG (female)


Hot short (Short circuit
(22) EGR (female) (1) and chassis
4 with 24V circuit) in wiring
ground
harness
Wiring harness between ENG (female)
(11) EGR (female) (2) and chassis
ground

Voltage

Max. 1 V

Voltage

Max. 1 V

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Defective engine control5
ler
ENG (female)
Resistance
Between (22) (11)

42

10 21 z

140E-5 Series

40 Troubleshooting

SEN00154-02

Circuit diagram related to EGR valve solenoid & lift sensor

140E-5 Series

43

SEN00154-02

40 Troubleshooting

E-66 Code [2352/CA2352] EGR Valve Solenoid Drive Open Error


a

This code applies to only with EGR.


Error code

Failure code

2352

CA2352

Trouble

Disconnection in drive circuit of EGR valve solenoid

Contents of trouble

There is disconnection in drive current of EGR valve solenoid.

Action of controller

Limits output and continues operation.


Closes EGR valve and bypass valve.

Problem that appears


Output drops.
on machine
Related information
Possible causes and
standard value in
normal state

44

Cause

Standard value in normal state/Remarks on troubleshooting


Carry out troubleshooting E-65 Code [2351/CA2351].

140E-5 Series

40 Troubleshooting

SEN00154-02

E-67 Code [2555/CA2555] Intake Air Heater Relay Open Error


Error code

Failure code

2555

CA2555

Trouble

Disconnection in intake air heater relay

Contents of trouble

There is disconnection in intake air heater relay.

Action of controller

None in particular.

Problem that appears


Engine does not start easily at low temperature.
on machine
Related information
Possible causes and
standard value in
normal state

140E-5 Series

Cause

Standard value in normal state/Remarks on troubleshooting


Carry out troubleshooting E-68 Code [2556/CA2556].

45

SEN00154-02

40 Troubleshooting

E-68 Code [2556/CA2556] Intake Air Heater Relay Short Error


Error code

Failure code

2556

CA2556

Trouble

Short circuit in intake air heater relay

Contents of trouble

There is short circuit in intake air heater relay.

Action of controller

None in particular.

Problem that appears


Engine does not start easily at low temperature.
on machine
Related information

Condition for driving heater relay depends on machine.


Different machine models may have different connector Nos.
Cause
Defective intake air
1 heater relay (Internal
trouble)

Standard value in normal state/Remarks on troubleshooting


a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
R18 (male)

Resistance

Between (1) (2)

200 400 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Possible causes and


standard value in
normal state

Disconnection in wiring
harness (Disconnection Wiring harness between E02 (female)
2
in wiring or defective con- (40) R18 (female) (1)
tact in connector)
Wiring harness between E02 (female)
(42) R18 (female) (2)

Resistance Max. 1 z
Resistance Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring
3 harness (Short circuit
with GND circuit)

Wiring harness between E02 (female) (40)


Resistance Min. 1 Mz
R18 (female) (1) and chassis ground
Wiring harness between E02 (female) (42)
Resistance Min. 1 Mz
R18 (female) (2) and chassis ground
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.

Defective engine controller

E02

Between (40) (42)

46

Heater relay

Voltage

Under operating
condition

Max. 1 V

Under stopping
condition

20 30 V

140E-5 Series

40 Troubleshooting

SEN00154-02

Circuit diagram related to intake air heater (Case of PC800/800SE/850/850SE/850LC-8)

140E-5 Series

47

SEN00154-02

40 Troubleshooting

E-69 Code [(143)/B@BAZG] Eng. Oil Press Low Torque Derate


Error code

Failure code

(143)

B@BAZG

Trouble

Derating of torque by engine oil pressure reduction

Contents of trouble

Engine oil pressure is below operating range.

Action of controller

Limits output and continues operation (Limits fuel injection rate and engine speed).

Problem that appears


Output drops.
on machine
Related information
Possible causes and
standard value in normal state

Cause
1

Standard value in normal state/Remarks on troubleshooting

Carry out troubleshooting


on machine side

This fault is indicated on only machine side when detected.


Accordingly, contents of troubleshooting depends on machine
model. See Shop manual for machine.

E-70 Code [(146)/B@BCNS] Eng. Overheat


Error code

Failure code

(146)

B@BCNS

Trouble

Engine overheat

Contents of trouble

Engine coolant temperature is above operating range.

Action of controller

Limits output and continues operation.

Problem that appears


Output drops.
on machine
Related information
Possible causes and
standard value in normal state

48

Cause
1

Carry out troubleshooting


on machine side

Standard value in normal state/Remarks on troubleshooting


This fault is indicated on only machine side when detected.
Accordingly, contents of troubleshooting depends on machine
model. See Shop manual for machine.

140E-5 Series

40 Troubleshooting

SEN00154-02

E-71 Code [(415)/B@BAZG] Eng. Oil Press. Low Speed Derate


Error code

Failure code

(415)

B@BAZG

Trouble

Derating of speed by engine oil pressure reduction

Contents of trouble

Engine oil pressure is below operating range.

Action of controller

Limits output and continues operation (Limits fuel injection rate and engine speed).

Problem that appears


Output drops.
on machine
Related information
Possible causes and
standard value in
normal state

140E-5 Series

Cause
1

Carry out troubleshooting


on machine side

Standard value in normal state/Remarks on troubleshooting


This fault is indicated on only machine side when detected.
Accordingly, contents of troubleshooting depends on machine
model. See Shop manual for machine.

49

SEN00154-02

KOMATSU 140E-5 Series engine


Form No. SEN00154-02

2007 KOMATSU
All Rights Reserved
Printed in Japan 03-07 (01)

50

SEN00156-05

ENGINE
1SHOP MANUAL

140E-5 Series

50 Disassembly and assembly


General information on disassembly
and assembly
General information on disassembly and assembly ....................................................................................... 2
How to read this manual ...................................................................................................................... 2
Coating materials list............................................................................................................................ 4
Special tools list.................................................................................................................................... 7
Sketches of special tools...................................................................................................................... 8

140E-5 Series

SEN00156-05

50 Disassembly and assembly

General information on disassembly and assembly

(Rev. 2009.01)

How to read this manual


1.

Removal and installation of assemblies


Special tools
q
Special tools which are necessary for
r e m o v a l o r i n s ta l l a t i o n o f pa r ts a r e
described as A1, X1 etc. and their part
numbers, part names and quantities are
described in the special tool list.
q
Also the following information is described in the special tool list.
1) Necessity
t : Special tools that cannot be substituted and should always be used
q : Special tools that will be useful if available and are substitutable with tools
available on the market
2) Distinction of new and existing special
tools
N:
Tools newly developed for this
model. They have a new part number respectively.
R:
Tools made available by redesigning the existing tools which were
developed for other models. Each
of them has a new part number
assigned by setting forward the
part number of the existing tool.
Blank : Tools already available for other
models. They can be used without
any modification.
3) Circle mark Q in sketch column:
q
The sketch of the special tool is presented in the section of Sketches of
special tools.
q
Part No. of special tools starting with
79 T:
means that they are not available
from Komatsu Ltd. (i.e. tools to be
made locally).

* *** ****

Removal
q
In Removal section, the work procedures,
precautions and know-how to do the work, and
the amount of oil and coolant to be drained are
described.
q
Common tools that are necessary for removal
are described as [1], [2] etc. and their part
numbers, part names and quantities are not
described.
q
Various symbols used in Removal section are
explained and listed below.
k : Precautions related to work safety
a : Guidance or precautions for the work
[*1] : This mark shows that instructions or precautions for parts installation work are given in
Installation section.
6 : Amount of oil or coolant to be drained
4:

Weight of part or component

Installation
q
Unless otherwise instructed, installation of
parts is to be done in the reverse order to
removal.
q
Instructions and precautions for parts installation is shown with the mark ([*1], [*2]...) which
corresponds to the mark in Removal section.
q
Common tools that are necessary for installation are described as [1], [2] etc. and their
part numbers, part names and quantities are
not described.
q
Marks shown in the Installation section stand
for the following.
k

: Precautions related to work safety


: Guidance or precautions for the work
2 : Type of coating material
3 : Tightening torque

: Amount of oil or coolant to be replenished

Sketches of special tools


q
Various special tools are illustrated for the local
manufacture.

140E-5 Series

50 Disassembly and assembly

2.

SEN00156-05

Disassembly and assembly of assemblies


Special tools
q
Special tools which are necessary for disassembly and assembly of parts are
described as A1, X1 etc. and their part
numbers, part names and quantities are
described in the special tool list.
q
Also the following information is described
in the special tool list.
1) Necessity
t : Special tools that cannot be substituted and should always be used.
q : Special tools that will be useful if available and are substitutable with tools
available on the market.
2) Distinction of new and existing special
tools
N:
Tools newly developed for this
model. They have a new part number respectively.
R:
Tools made available by redesigning the existing tools which were
developed for other models. Each
of them has a new part number
assigned by setting forward the
part number of the existing tool.
Blank : Tools already available for other
models. They can be used without
any modification.
3) Circle mark Q in sketch column:
q
The sketch of the special tool is presented in the section of Sketches of
special tools.
q
Part No. of special tools starting with
79 T:
means that they are not available
from Komatsu Ltd. (i.e. tools to be
made locally).

* *** ****

Disassembly
q
In Disassembly section, the work procedures,
precautions and know-how to do the work, and
the amount of oil and coolant to be drained are
described.
q
Common tools that are necessary for disassembly are described as [1], [2] etc. and
their part numbers, part names and quantities
are not described.
q
The meanings of the symbols used in Disassembly section are as follows.
k

: Precautions related to work safety


: Guidance or precautions for the work
6 : Amount of oil or coolant drained

Assembly
q
In Assembly section, the work procedures,
precautions and know-how to do the work, and
the amount of oil and coolant to be replenished
are described.
q
Common tools that are necessary for assembly are described as [1], [2] etc. and their
part numbers, part names and quantities are
not described.
q
The meanings of the symbols used in Assembly section are as follows.
k

: Precautions related to work safety


: Guidance or precautions for the work
2 : Type of coating material
3 : Tightening torque

: Amount of oil or coolant to be replenished

Sketches of special tools


Various special tools are illustrated for the local
manufacture.

140E-5 Series

SEN00156-05

50 Disassembly and assembly

Coating materials list


a
a

The recommended coating materials such as adhesives, gasket sealants, and greases used for disassembly and assembly are listed below.
For coating materials not listed below, use the equivalent of products shown in this manual.

Category

Komatsu
code

Part number

Q'ty

Container

Main features and applications

LT-1A

790-129-9030

150 g

Tube

Used to prevent rubber gaskets, rubber cushions, and cork plugs from coming out.

LT-1B

790-129-9050

20 g
(2 pcs.)

Used for plastic (except polyethylene,


polypropylene, tetrafluoroethylene and vinyl
Polyethylene
chloride), rubber, metal, and non-metal parts
container
which require immediate and strong adhesion.

LT-2

09940-00030

50 g

Polyethylene Features: Resistance to heat and chemicals.


container Used to fix and seal bolts and plugs.

Adhesive

LT-3

790-129-9040

250 g

Holtz MH 705

790-129-9120

75 g

790-129-9140

Can

Used to stick and seal metal, glass, and plastics.

Polyethylene
Used to seal plugs.
container
Tube

Heat-resistant seal used to repair engines.

50 g

Quick-setting adhesive.
Polyethylene Setting time: Within 5 sec. to 3 min.
container Used mainly to stick metals, rubbers, plastics,
and woods.
Quick-setting adhesive.
Quick-setting type.
Polyethylene
(max. strength is obtained after 30 minutes)
container
Used mainly to stick rubbers, plastics, and
metals.

Aron-alpha
201

790-129-9130

2g

Loctite
648-50

79A-129-9110

50 cc

Features: Resistance to heat and chemicals.


Polyethylene
Used for fitted portions used at high temperacontainer
tures.

1 kg

Used to seal various threaded portions, pipe


Polyethylene
joints, and flanges.
container Used to seal tapered plugs, elbows, and nipples of hydraulic piping.

LG-5

Gasket sealant

790-129-9060
Adhesive: 1 kg
(Set of adhesive
Hardener: 500 g
and hardener)

LT-4

ThreeBond
1735

790-129-9080

LG-6

790-129-9160

200 g

Tube

Features: Silicon-based heat and cold-resistant sealant.


Used to seal flange surfaces and threaded
portions.
Used to seal oil pan, final drive case, etc.

LG-7

790-129-9170

1 kg

Tube

Features: Silicon-based quick-setting sealant.


Used to seal flywheel housing, intake manifold, oil pan, thermostat housing, etc.

Tube

Features: Silicon-based, heat and cold-resistant, vibration-resistant, impact-resistant sealant.


Used to seal transfer case, etc.

LG-8
ThreeBond
1207B

(Rev. 2009.02)
1

419-15-18131

100 g

140E-5 Series

50 Disassembly and assembly

Gasket sealant

CateKomatsu code
gory

Molybdenum
disulfide
lubricant

Container

Main features and applications

790-129-9310

200 g

Tube

Used for rough surfaces such as the circle gear


top seal which does not need to be clamped,
water resistance of the clearance at the welded
area, etc.
Can be coated with paint.

LG-10
ThreeBond
1206E

790-129-9320

200 g

Tube

Used as lubricant/sealant when the radiator


hoses are inserted.
Can be coated with paint.

LG-11
ThreeBond
1121

790-129-9330

200 g

Tube

Feature: Can be used together with gaskets.


Used for covers of the transmission case and
steering case etc.

ThreeBond
1211

790-129-9090

100 g

Tube

Gasket sealant used to repair engine.

Tube

Used to prevent scuffing and seizure of press-fitted portions, shrink-fitted portions, and threaded
portions.
Used to lubricate linkages, bearings, etc.

Can

Spray type
Thin molybdenum disulphide films are made on
metal surfaces to prevent the metals from scuffing each other.
Applicable for the drive shaft splines, needle
bearings, pins and bolts of various links, etc.

Can

Feature: Seizure and scuffing prevention compound with metallic super-fine-grain, etc.
Used for the mounting bolt in the high temperature area of the exhaust manifold and the turbocharger, etc.

Various

Various

Feature: Lithium grease with extreme pressure


lubrication performance.
General purpose type.

LC-G
NEVER-SEEZ

09940-00040

09995-00250

SYG2-400LI
SYG2-350LI
SYG2-400LI-A
G2-LI
SYG2-160LI
G0-LI
SYGA-160CNLI
*: For cold district
SYG0-400LI-A (*)
SYG0-160CNLI
(*)

Grease

Q'ty

LG-9
ThreeBond
1206D

LM-P

Seizure
prevention
compound

Part number

SEN00156-05

Molybdenum
SYG2-400M
disulfide grease SYG2-400M-A
LM-G (G2-M)
SYGA-16CNM

SYG2-400T-A
SYG2-16CNT
SYG0-400T-A (*)
*: For cold district SYG0-16CNT (*)

Hyper White
Grease G2-T,
G0-T (*)

SYG2-400B
Biogrease
G2-B, G2-BT (*) SYGA-16CNB
*: For use at high SYG2-400BT (*)
temperature and SYGA-16CNBT
under high load
(*)

140E-5 Series

200 g

190 g

Used for parts under heavy load.


Caution:
400 g x 10 Bellows-type Do not apply grease to rolling bearings like
swing circle bearings, etc. and spline.
400 g x 20 container
The grease should be applied to work equipment
16 kg
Can
pins at their assembly only, not applied for
greasing afterwards.
400 g
16 kg

400 g
16 kg

Bellows-type
container
Can

Seizure resistance, heat resistance and water


resistance higher than molybdenum disulfide
grease.
Not conspicuous on machine since color is
white.

Bellows-type Since this grease is decomposed by natural baccontainer


teria in short period, it has less effects on microCan
organisms, animals, and plants.

SEN00156-05

G2-U-S
ENS grease

427-12-11871

SUNSTAR
PAINT PRIMER
580 SUPER

Caulking material

Adhesive

Primer

SUNSTAR
GLASS
PRIMER 580
SUPER

SUNSTAR
PAINT PRIMER
435-95

Q'ty

Container

Main features and applications

Tube

Feature: Silicone grease with wide using temperature range, high resistance to thermal-oxidative degradation and performance to prevent
deterioration of rubber and plastic parts.
Used for oil seals of the transmission, etc.

2 kg

Can

Feature: Urea (organic system) grease with heat


resistance and long life. Enclosed type.
Used for rubber, bearing and oil seal in damper.
Caution: Do not mix with lithium grease.

20 ml

Glass
container

Used as primer for cab side.


(Using limit: 4 months after date of manufacture)

20 ml

Glass
container

Used as primer for glass side.


(Using limit: 4 months after date of manufacture)

20 ml

Glass
container

200 g

417-926-3910

22M-54-27230

Adhesive for cab glass

G2-S
ThreeBond
1855

Part number

Used as primer for painted surface on cab


side.
(Using limit: 4 months after date of manufacture)
Used as primer for black ceramic-coated
surface on glass side and for hard polycarbonate-coated surface.
(Using limit: 4 months after date of manufacture)

SUNSTAR
GLASS
PRIMER
435-41

22M-54-27240

150 ml

Can

SUNSTAR
SASH PRIMER
GP-402

22M-54-27250

20 ml

Glass
container

Used as primer for sash (Almite).


(Using limit: 4 months after date of manufacture)

SUNSTAR
PENGUINE
SEAL 580
SUPER S or
W

417-926-3910

320 ml

Polyethylene
container

S is used for high-temperature season


and W for low-temperature season as
adhesive for glass.
(Using limit: 4 months after date of manufacture)

Sika Japan,
Sikaflex 256HV

20Y-54-39850

310 ml

Polyethylene
container

Used as adhesive for glass.


(Using limit: 6 months after date of manufacture)

SUNSTAR
PENGUINE
SUPER 560

22M-54-27210

320 ml

Ecocart
(Special
container)

SUNSTAR
PENGUINE
SEAL No. 2505

417-926-3920

320 ml

Polyethylene
container

SEKISUI
SILICONE
SEALANT

20Y-54-55130

333 ml

Polyethylene
container

Used to seal front window.


(Using limit: 6 months after date of manufacture)

Cartridge

Used to seal joint of glasses.


Translucent white seal.
(Using limit: 12 months after date of manufacture)

GE TOSHIBA
SILICONES
TOSSEAL 381

22M-54-27220

333 ml

Adhesive for cab glass

Grease

CateKomatsu code
gory

50 Disassembly and assembly

Used as adhesive for glass.


(Using limit: 6 months after date of manufacture)
Used to seal joints of glass parts.
(Using limit: 4 months after date of manufacture)

140E-5 Series

50 Disassembly and assembly

SEN00156-05

Special tools list

Disassembly and assembly of engine


assembly

Part No.

Part name

790-501-2001

Engine repair stand t 1

790-901-1261

Bracket

t 1

Removal and installation of cylinder


head valve spring

795-102-2103

Spring pusher

t 1

Removal and installation of piston ring

795-100-1191

Piston ring tool

t 1

Removal of cylinder liner

795-236-1000

Liner puller

t 1

Press fitting of cylinder liner

795-230-5472

Liner driver

t 1

Insertion of piston assembly

795-921-1100

Piston holder

t 1

Measuring projection of cylinder liner

795-502-1121

Gauge holder

t 1

Adjusting valve clearance

795-125-1210

Thickness gauge

q 1

Angle tightening of bolt

790-331-1110

Wrench

q 1

795-931-1100

Seal puller

t 1

1
M
2
Removal and installation of engine front
seal and engine rear seal

795T-521-1111 Push tool

t 1

01050-31655

Bolt

t 3

01050-31635

Bolt

Remarks

Removal of oil
seal
N Q

t 3

Press fitting of
engine front seal

795T-521-1150 Push tool

t 1

01050-31635

t 3

N Q Press fitting of
engine front seal
(sleeve type)

795T-421-1260 Push tool

t 1

N Q

01050-31640

Bolt

t 4

01643-31645

Washer

t 8

Bolt

795T-421-1240 Push tool

t 1

01050-31645

Bolt

t 4

01643-31645

Washer

t 4

795T-421-1231 Push tool

t 1

01050-31645

Bolt

t 4

01643-31645

Washer

t 8

795-630-5500

Standard puller

t 1

Bolt

t 2

Removal of fuel supply pump

01010-81090
01643-31032

Washer

t 2

Press fitting of valve stem seal

795-130-1720

Push tool

t 1

140E-5 Series

Sketch

Work item

New / Remodel

Q'ty

Necessity

Tools with part number 79*T-***-**** means that they are not available from Komatsu Ltd. (i.e. tools to be
made locally).
Necessity:
t ............ Special tools that cannot be substituted and should always be used
q ............ Special tools that will be useful if available and are substitutable with tools
available on the market
New/Redesign: N ............ Tools newly developed for this model. They have a new part number respectively.
R ............ Tools made available by redesigning the existing tools which were developed
for other models. Each of them has a new part number assigned by setting forward the part number of the existing tool.
Blank ..... Tools already available for other models. They can be used without any modification.
Tools marked with Q in the sketch column are presented in the sketches of the special tools (See
Sketches of special tools).
Symbol

Press fitting of
engine rear seal
(standard type)

N Q
Press fitting of
engine rear seal
N Q (sleeve type)

Used to remove
pump unit

SEN00156-05

Sketches of special tools

50 Disassembly and assembly

Note) We will not be liable for any result of use of special tools manufactured according to the following
drawings.
M1. Push tool

M2. Push tool

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.
N1. Push tool

N2. Push tool

140E-5 Series

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.
N3. Push tool

10

140E-5 Series

50 Disassembly and assembly

140E-5 Series

SEN00156-05

11

SEN00156-05

KOMATSU 140E-5 Series engine


Form No. SEN00156-05

2011 KOMATSU
All Rights Reserved
Printed in Japan 10-11

12

SEN00157-05

ENGINE
1SHOP MANUAL

140E-5 Series

50 Disassembly and assembly


Disassembly and assembly, Part 1
(with EGR)
Disassembly and assembly, Part 1 (with EGR)............................................................................................... 2
General disassembly of engine............................................................................................................ 2
General assembly of engine .............................................................................................................. 20

140E-5 Series

SEN00157-05

50 Disassembly and assembly

Disassembly and assembly, Part 1 (with EGR)

General disassembly of engine 1


a

The shapes, quantity, locations, etc. of the


parts depend on each applicable machine.
Take care.

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 assembly.
a Before cleaning the engine, carefully seal
or remove the openings, electric parts,
and wiring connectors so that water will
not enter them.

2.

Drain the engine coolant and engine oil.


a The quantity of the oil depends on the
applicable machines.
6

Air cleaner bracket


1) Disconnect wiring harness clamp (1).
2) Remove air cleaner bracket (2).
a The type of the bracket depends on
the applicable machines.
4 Air cleaner bracket: 30 kg

5.

EGR cover
1) Remove covers (1), (2), and (3).

Setting engine assembly


1) Prepare stable engine stands (Blocks [1])
and place the engine assembly on them
so that it will not tip over.
a The weight depends on the applicable machines.
4 Engine assembly: 2,000 kg

2)

3.

4.

Engine oil: Approx. 53 l

Starting motor assembly


1) Disconnect wiring harness (1) and connector (2).
2) Remove 3 mounting bolts (3) and remove
starting motor assembly (4).

140E-5 Series

50 Disassembly and assembly

2)

6.

Remove covers (4), (5), (6), and (7).


a Cover (6) is not installed to all the
models.

Tube clamp and bracket


1) Remove clamps (1), (2), (3), and (4).
a The clamps hold the tubes from the
front and rear.
2) Remove brackets (5), (6), and (7).

SEN00157-05

8.

Clamp and bracket


1) Remove clamp (1) and brackets (2) and
(3).
2) Remove bracket (4).

9.

Bypass valve assembly


1) Remove the wiring harness clamp and
disconnect connectors SBP (1) and BP
(2).

2)
7.

Bracket
Remove brackets (1), (2), and (3).

140E-5 Series

3)

Remove clamps (3), (5), and (11) and


remove tubes (6) and (7).
Remove bolts (8) and (9) and remove
bypass valve assembly (10).

SEN00157-05

10. EGR valve assembly


1) Remove the wiring harness clamp and
disconnect connectors SEGR (1) and
EGR (2).

2)
3)

50 Disassembly and assembly

12. EGR tube


1) Remove EGR inlet pressure sensor tube
(1).
Reference: EGR inlet pressure sensor is
applied to only machines Serial No. up to
530896.
2) Remove EGR tube (2).

Remove tubes (3) and (4).


Remove bolts (5) and (6) and remove
EGR valve assembly (7).
13. EGR cooler assembly
1) Remove brackets (1) and (2) and remove
stay (3).
2) Remove EGR cooler coolant outlet tube
(4) and bracket (5).

11. Bypass tube


Remove brackets (1), (2), and (3) and remove
bypass tube (4).

3)
4)
5)

Remove turbocharger drain tube clamps


(6).
Remove air vent tube (7), bracket (8), and
EGR cooler inlet tube (9).
Remove EGR cooler coolant inlet tube
(10).

140E-5 Series

50 Disassembly and assembly

SEN00157-05

16. Turbocharger assembly


1) Remove heat insulation cover (1) and oil
drain tube (2).
2) Remove exhaust connector (3).

6)

Remove the 4 bolts and remove EGR


cooler assembly (11).

14. Bracket
Remove bracket (12).

15. EGR valve bracket


Remove EGR valve bracket (1).
4

Bracket: 20 kg

140E-5 Series

3)

Remove wiring harness (4) and 4 turbocharger lubrication tube clamps (5) and
remove turbocharger lubrication tube (6).

4)

Remove the 4 nuts and remove air inlet


pipe and turbocharger assembly (7).
4 Air inlet pipe and turbocharger
assembly: 30 kg

SEN00157-05

50 Disassembly and assembly

17. Exhaust manifold


Remove the 24 mounting bolts and exhaust
manifold (1).
4

Exhaust manifold: 25 kg

20. Water pump assembly


1) Remove alternator drive pulley (1).
2) Remove tubes (2) and (3).
3) Remove water pump assembly (4).
18. Alternately assembly
1) Disconnect terminal B (1) and terminal R
(2).
2) Remove cover (3).
3) Loosen alternator mounting bolt (4) and
clamping bolt (5).
4) Loosen locknut (6) and tension adjustment nut (7) and remove V-belt (8).
5) Remove mounting bolt (4) and clamping
bolt (5) and remove alternator assembly
(9).

21. Oil cooler assembly


1) Using eyebolts [1], sling the oil cooler
assembly temporarily.
2) Remove the 16 mounting bolts and oil
cooler assembly (1).
4 Oil cooler assembly: 35 kg

19. Thermostat assembly


1) Remove tube (1)
2) Remove snap ring (2) and push bypass
tube (3) into the thermostat case.
3) Remove the 5 mounting bolts and thermostat assembly (4).
a One of the 5 mounting bolts is used to
clamp the thermostat assembly and
cover together and has been
removed already.

140E-5 Series

50 Disassembly and assembly

22. Oil filter, fuel filter, and corrosion resistor


Remove oil filter (1), pre-fuel filter (2), main fuel
filter (3), and corrosion resistor (4).
a Pre-fuel filter (2) may be installed on the
applicable machine side.
a Corrosion resistor is not set for some
models.

SEN00157-05

25. Oil filter head


1) Remove oil tubes (1) and (2) and the block
on the cylinder block side as a unit.
2) Remove oil filter head (3).
a The type of the oil filter head depends
on the applicable machines.

23. EGR valve and bypass valve oil drain tube


Remove drain tube (5).

24. Controller cover and oil filler


1) Remove controller cover (1).
2) Remove the clamp and oil filler (2).
a The position of the oil filler depends
on the applicable machines.

26. Fuel filter head


1) Remove fuel tube (1).
2) Remove fuel filter head (2) and bracket (3)
as a unit.
a The wiring harness clamp and the
bracket are fixed together.
a The type of the fuel filter head
depends on the applicable machines.

27. Corrosion resistor head, fuel filter head,


and priming pump
1) Remove the 2 clamps and fuel tube (1).
2) Remove the 2 clamps and fuel tubes (2)
and (3).
3) Remove the clamp and breather tube (4).
4) Remove the clamp of wiring harness (5).
5) Loosen the 2 clamps and disconnect
tubes (8) and (9).

140E-5 Series

SEN00157-05

6)

50 Disassembly and assembly

Remove corrosion resistor head (10), fuel


filter head (11), priming pump (12), and
bracket as a unit.
a Corrosion resistor is not set for some
models.

28. Air intake connector assembly


1) Disconnect EGR inlet pressure sensor
connector PEVA (1) and clamp of wiring
harness (2).
Reference: EGR inlet pressure sensor is
applied to only machines Serial No. up to
530896.
2) Remove the mounting bolts and remove
air intake connector assembly (3) and the
joint housing on the front side of the
engine as a unit.
4 Air intake connector assembly: 40 kg

29. Air intake manifold


1) Sling the air intake manifold temporarily.
2) Disconnect the clamps of connectors
TFUEL (1), TIM(2), PIM (3), and wiring
harness (4).
3) Disconnect fuel tube (5).
4) Remove wiring harness clamp (6) and
tube clamp (7).
5) Remove clamp (8) of the high-pressure
pipe.
a Remove the 5 high-pressure pipe
clamps above the air intake manifold,
too.

6)
7)
a

When replacing the


remove connector (4).

air

heater,

Disconnect clamps (9), (10), (11), (12),


and (13) of the high-pressure pipe.
Remove the mounting bolts and air intake
manifold (14).
4 Air intake manifold: 45 kg

140E-5 Series

50 Disassembly and assembly

30. Engine controller


Disconnect connector (1) and remove engine
controller (2).

31. Engine controller cooler


1) Disconnect fuel hose (1).
a Fuel hose (1) may not be installed.
2) Remove engine controller cooler (2).
32. Plate
Remove plate (3).

SEN00157-05

33. Common rail and high-pressure pipe


a Before removing the high-pressure pipe,
loosen all of the clamps, brackets, and
sleeve nuts to give the high-pressure pipe
freedom.
1) Remove bracket (1).

2)
3)
4)

5)

140E-5 Series

Remove 6 cylinder head covers (3).


a At this time, the clamp of wiring harness (4) comes off.
Remove clamps (5), (6), (7), (8), (9), (10),
and (11).
Remove all the splash prevention covers
of the high-pressure pipe.
a When removing the cylinder head
cover, remove the high-pressure pipe
covers on the injector side, too.
Remove 6 high-pressure pipes (12) and 2
high-pressure pipes (13).
a Remove 6 high-pressure pipes (12) in
the order of No. 1, No. 6, No. 5, No. 4,
No. 3, and No. 2.

SEN00157-05

6)
7)
8)

Disconnect fuel pressure sensor connector PFUEL (15) and POIL (16).
Remove clamp (17) and the eye joint of
tube (18) on the common rail side.
Remove special bolts (19) and remove
common rail (20).

34. Wiring and piping of fuel supply pump


assembly
1) Disconnect sensor connectors PCV1 (1),
PCV2 (2), and G (3).
2) Remove level gauge tube (4).
3) Remove clamps (5), (6), (8), (9), and (10).
4) Remove oil tubes (11), (12), and (13).
5) Remove fuel tubes (14) and (15).
a Before removing the pump unit,
remove the front cover.

50 Disassembly and assembly

35. EGR oil pump assembly


Remove the bolts and EGR oil pump assembly
(1).

36. Corrosion resistor tube and blow-by tube


1) Remove corrosion resistor tubes (1) and
(2).
a Corrosion resistor is not set for some
models.
2) Remove breather remote tube (3).

37. Wiring harness assembly and sensor connector


1) Disconnect the clamps of coolant temperature sensor connector TWTR (1) and wiring harnesses (2) and (3) and remove
bracket (4).

10

140E-5 Series

50 Disassembly and assembly

2)
3)
4)

Disconnect the connectors of Ne sensor


NE (6), and atmospheric pressure sensor
PAMB (7).
Remove the 6 injector connectors and
remove the wiring harness assembly.
Remove bracket (8).

5)

Move lock [1] of the housing of connector (7) in the direction of the arrow,
push down lock [2], and pull out connector (7).

Disconnect the injector connector according to the following procedure.


1] Apply flat-head screwdriver [1] to the
stepped part (part (a)).
2] While pressing stopper (1a), move
flat-head screwdriver [1] in direction
(X) to disconnect the connector.

SEN00157-05

38. Oil pan


1) Move the blocks which are supporting the
engine to positions where you can remove
the oil pan mounting bolts.
2) While supporting oil pan (1) on a pallet lift,
etc., remove the mounting bolts and oil
pan (1).

39. Suction tube


Remove bracket (1) and suction tube (2).

After removing the suction tube, sling the


engine. Set stable blocks at the front,
rear, right, and left under the cylinder
block and place the engine on them.
Arrange the above blocks so that you can
rotate the crankshaft.

40. Flywheel
1) Using sling [1], lift up flywheel (1) temporarily.
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

43. Head cover


Remove the mounting bolts and each head
cover (1).
a If the head cover was removed when the
high-pressure pipe was removed and has
not been installed, skip this step.

41. Flywheel housing


Lift up housing (1) temporarily and remove the
mounting bolts and the housing.
4

Housing: 75 kg

44. Rocker arm and shaft assembly


Remove the 3 mounting bolts and rocker arm
and shaft assembly (1).
a Loosen locknut (3) and loosen adjustment screw (4) fully so that the valve
spring tension will not be applied to
the mounting bolts when the rocker
arm is removed and installed.

42. Rear oil seal


Remove rear oil seal (1) from the flywheel
housing.

45. Fuel injector


1) Remove 2 nuts (2) of the solenoid valve of
fuel injector (1).
a Loosen nuts (2) alternately.
2) Pull out spring clamp (3).
3) Remove the bolt of clamp (4).
4) Remove bolt (7) and holder (6).
5) Push in connector (5) and remove the
injector wiring harness.
a Connector (5) has an O-ring.

12

140E-5 Series

50 Disassembly and assembly

SEN00157-05

46. Push rod


Remove push rod (1).

6)

Loosen the bolt of holder (8) of fuel injector (1).


47. Cylinder head assembly and crosshead
1) Remove crosshead (1).
2) Remove mounting bolts (2), auxiliary
bolts, and cylinder head assembly (3).
3) Remove each cylinder head gasket.

7)

Insert a small L-bar [2] under connector


(9) of fuel injector (1) and pry out fuel
injector (1) slowly.
a Do not grip the solenoid valve at the
top of the injector to pull off the injector.
4)

140E-5 Series

Disassemble the cylinder head assembly


according to the following procedure.
1] Using tool C, compress the valve
spring and remove cotter (1).
2] Remove upper seat (2), outer spring
(3), and inner spring (4).

13

SEN00157-05

3]
4]

Remove valve stem seal (5) and


lower seat (6).
Raise the cylinder head and remove
valve (7).

50 Disassembly and assembly

49. Front support


Lift up front support (1) temporarily, remove the
mounting bolts, and lift off the front support.
a The shape and weight of the front support
depends on the applicable machines.
4

48. Damper assembly


Lift up damper assembly (1) temporarily,
remove the 6 mounting bolts (2), and lift off the
damper assembly.
a The fan drive pulley may be installed.
4

Damper assembly: 40 kg

50. Cam follower assembly


1) Remove the 3 cover mounting bolts and
remove cover (1).
2) Remove mounting bolts (3) and cam follower (2).

3)

14

Front support: 65 kg

Remove snap rings (4) and remove lever


assembly (5) from shaft (6).

140E-5 Series

50 Disassembly and assembly

51. Front cover


1) Install eyebolts [1] and lift up the front
cover temporarily.
2) Remove the mounting bolts and sling front
cover (1). Remove the front cover by moving it forward.
4 Front cover: 70 kg

52. Front oil seal


Remove front oil seal (1) from the front cover.

SEN00157-05

4)

54. Camshaft
1) Match the holes of cam gear (1) to mounting bolts (2) and remove bolts (2).

2)
53. Fuel supply pump assembly and drive gear
1) Remove nut (1).
2) Set tool P to gear (3).
3) Tighten center bolt [1] of tool P and
remove gear (3).

140E-5 Series

Remove pump mounting bolts (4), bracket


(5), and fuel supply pump assembly (6).
a While supporting the fuel supply
pump assembly, remove the mounting bolts.

Sling camshaft (3) temporarily. Pull out


the camshaft while turning it so that the
cam bushing will not be damaged.
4 Camshaft: 20 kg

15

SEN00157-05

55. Oil pump assembly and sub idler gear


1) Remove oil pump assembly (1).
2) Remove sub idler gear (2).

56. Main idler gear


Remove mounting bolt (1) and main idler gear
(2).

57. Setting of engine repair stand and underframe


1) Install tool A2 to the cylinder block. Sling
the engine and set it to tool A1.
2) Remove the 4 mounting bolts from each of
2 underframes (1) and remove the underframes.
a The number of underframes (1)
depends on the applicable machines.

50 Disassembly and assembly

58. Piston cooling nozzle


Remove the mounting bolts and piston cooling
nozzles (1) and (2).
a Be sure to remove the piston cooling nozzles before pulling out the piston.

59. Piston and connecting rod assembly


a Before removing the piston and connecting rod assembly, measure its end play
with dial gauge [1], if necessary.

1)

2)
3)
4)
5)

16

Check the stamped No. of the connecting


rod cap.
q
The cap No. and cylinder No. must be
the same.
q
The cap No. must be stamped on the
cam side.
a If the No. is not stamped, stamp it
before removing the connecting rod.
Rotate the crankshaft and bring the piston
to be removed to the bottom dead center.
Scrub the carbon off the top wall of the cylinder liner with fine sandpaper.
Remove connecting rod cap mounting
bolts (1).
Hit connecting rod cap (2) with a plastic
hammer so lightly that the threads of the
connecting rod bolts will not be damaged
and remove connecting rod cap (2) and
connecting rod bearing as a unit.

140E-5 Series

50 Disassembly and assembly

SEN00157-05

8)

6)

7)

Push in and remove the piston and connecting rod assembly with a wood bar, etc.
from the oil pan side, while supporting piston (6) on the cylinder head side.
a Take care not to damage the inside of
the cylinder with a corner of the connecting rod.
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.

Disassemble the piston and connecting


rod assembly according to the following
procedure.
1] Remove 2 snap rings (3).
2] While supporting connecting rod (4),
remove piston pin (5) to disconnect
piston (6) and connecting rod.

3]
a

Using tool D, remove piston ring (7).


Keep the piston, connecting rod, connecting rod bearing, piston rings, and
piston pin by cylinder.

60. Crankshaft
a Before removing the crankshaft, measure
its end play with dial gauge [1], if necessary.

140E-5 Series

17

SEN00157-05

1)
2)

4)

Remove upper thrust bearing (5).

5)

The No. 7 main cap has lower thrust


bearing (3).

Remove upper bearing (6).


a Enter the positions of the main cap,
main bearing, and thrust bearing on
them with paint or attach position tags
to them and arrange them by journal
No.

Lift off crankshaft (4).


a When removing the crankshaft, take
care not to hit its sliding surfaces
against the cylinder block.
4 Crankshaft: 140 kg

61. Cylinder liner


a Before removing the cylinder liner, measure its projection with tool H, if necessary.

Remove mounting bolts (2) of main cap


(1).
Insert the bolts in the bolt holes of the
main cap and remove the cap, while shaking it.

3)

18

50 Disassembly and assembly

140E-5 Series

50 Disassembly and assembly

SEN00157-05

62. Using tool E, remove cylinder liner (1).

140E-5 Series

19

SEN00157-05

General assembly of engine


a
a

50 Disassembly and assembly

The shapes, quantity, locations, etc. of the


parts depend on each applicable machine.
Take care.
Clean each part carefully, and check it for
bruise, flaw, cavity, etc. Make sure each oil or
coolant path is through.

Tightening bolts by plastic-region turning angle


method
a Bolts tightened by plastic-region turning angle
method
q
Cylinder head mounting bolt
q
Main cap mounting bolt
q
Connecting rod cap mounting bolt
q
Flywheel mounting bolt
a If the plastic-region turning angle method is
applied, the tightened bolts have permanent
strain. Accordingly, the allowable number of
using times of each bolt is limited. Observe
the following precautions.
q
Before tightening each bolt, measure its
stem length and make sure that the result
is less than the using limit. If the stem is
longer than the using limit, do not reuse it
but replace it.
q
Check each mounting bolt head for punch
marks. If there are punch marks more
than the specified number, do not reuse it
but replace it.
1.

20

2)

Before inserting the cylinder liners, prepare the cylinder block according to the
following procedure.
1] Remove the rust and scales from
faces A and B with sandpaper, etc.
until the machined surfaces are
exposed.
2] Polish part R with sandpaper of about
No. 60 until it becomes a smooth
rounded surface.
3] Polish parts R and h with sandpaper
of about No. 60 until they become
smooth.
If part R is sharp or has burrs, finish it
with a scraper or sandpaper.
Finish this surface particularly
smoothly so that it will not damage
the O-ring.
4] If face B is so pitted that it cannot be
repaired, replace the cylinder block.
5] If faces A and R are pitted, finish
them smoothly.
6] Check the counterbored part and
remove burrs. If chips or dust is on
face C, the liner does not fit and coolant may leak and the projection of the
liner may become improper consequently.
a If the counterbored part is drooping, corroded, or pitted, repair it.

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

140E-5 Series

50 Disassembly and assembly

2.

Cylinder liner
a Replace the O-ring and clevis seal with
new ones.
1) Check that the cylinder liner O-ring groove
and periphery of the liner are not roughened because of rusting or pitting. If those
parts are roughened, replace the cylinder
liner.
2) Install clevis seal (1), O-rings (2) and (3) to
the cylinder liner.
a Check that there are not a burr, dust,
etc. in the groove of the liner.
a Fit the clevis seal with the chamfered
side down. When fitting it, press it
against the seal groove all round so
that it will not be twisted.
a When installing O-rings (2) and (3),
check the following.
q
O-ring (2): There is a yellow point
for distinction.
q
O-ring (3): The whole ring is red.
2 Clevis seal and O-ring:
Rubber lubricant (RF-1)
a RF-1: DAIDO CHEMICAL INDUSTRY
CO., LTD.
If RF-1 is not available, apply clean
engine oil SAE No. 30.
a Since the clevis seal and O-ring are
swollen and deteriorated by oil, apply
a small amount of oil to them thinly
with a brush just before fitting them.

140E-5 Series

SEN00157-05

3)

After fitting the liner O-ring, check it for


twist. If it is twisted, correct it with a
smooth rod (about 10 mm in diameter).

4)

Apply gasket sealant to the parts of the


cylinder block and cylinder liner which will
fit to the counterbored parts.
a Wipe off dirt and oil with cloth from
the contact faces of the counterbored
parts of the cylinder block and liner
flange.
2 Cylinder block:
Gasket sealant (LG-6)
q
Gasket sealant:
2 3 mm in diameter
q
Overlap (a) of gasket sealant:
6 6 mm
a If the applied gasket sealant is left for
a long time, its surface becomes
hard. Accordingly, install the cylinder
block in 50 minutes.

21

SEN00157-05

5)
6)

7)

22

50 Disassembly and assembly

Insert cylinder liner (1) in the cylinder


block slowly, taking care not to damage
the O-ring.
Push in cylinder liner (1) further with both
hands.
a If the liner does not enter the cylinder
smoothly, the O-ring may be broken.
In this case, check the cylinder block
for burrs.
Using tool F, press fit cylinder liner (1) to
the cylinder block.

8)

To prevent the gasket sealant from projecting through the clearance between the
block and liner after the cylinder head is
tightened, tighten the cylinder head temporarily with the used head gasket
inserted.
a At this time, observe the following
tightening torque and tightening
order.
3 Temporary tightening torque:
137 157 Nm {14 16 kgm}

9)

Remove the cylinder head and wipe off


the gasket sealant projected from the
counterbored part.
a Be sure to perform steps 8) and 9)
above since the projected gasket
sealant can deform the grommet of
the head gasket.

10) Using tool H, measure the projection of


the cylinder liner.
a When measuring the projection of the
liner, tighten the liner with a plate so
that it will not be lifted by the O-ring.
q
Projection of liner: 0.07 0.15 mm
a If the gasket sealant is projected from
the fitting parts of the cylinder block
and cylinder liner up to the top of the
cylinder block, wipe it off.

3.

Crankshaft
1) Fit upper main bearing (6) to the cylinder
block, matching the projection of the
former to the cut of the latter.
a An oil hole is made on the upper main
bearing.
a Before fitting the bearing, make sure
that its back side is free from foreign
matter.
2 Inside of bearing: Engine oil (EO30)

2)

Drive the dowel pin so that it will be projected by 2.7 3.4 mm from the block end
and then install upper thrust bearing (5) to
the No. 7 journal.
a Install the thrust bearing with the
grooved surface on the crankshaft
side.

140E-5 Series

50 Disassembly and assembly

3)

4)

5)

Sling crankshaft (4) and install it to the cylinder block.


a When replacing the crank gear, heat it
with a bearing heater (30 A) (Set temperature: 150C) and fit it just after it
is heated.
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)

Fit the lower main bearing to the main cap,


matching the projection of the former to
the cut of the latter.
a Before fitting the bearing, check that
its back side is free from foreign matter.
Drive the dowel pin of cap No. 7 so that it
will be projected by 2.7 3.4 mm from the
cap end and then install thrust bearings
(3) to both sides.
a Install each thrust bearing with the
grooved surface on the crankshaft
side.

140E-5 Series

SEN00157-05

6)

Make sure that the journal No. stamped at


the center of main cap (2) and the journal
No. of the cylinder block are the same and
then install the main cap.
a Install the main cap with the cast letter (F) toward the front of the engine.

7)

Before tightening the main cap mounting


bolts, check the following items. If any of
the following condition applies, do not
reuse that bolt but replace it.
q
Number of tightening time of bolt: 6
(Number of punch marks on bolt head
is 5.)
q
Length (a) of bolt stem:
Min. 176.3 mm

23

SEN00157-05

8)

50 Disassembly and assembly

Tighten main cap mounting bolts (1)


according to the following procedure.
a Tighten the bolts from the center one
to the outer ones in order.
2 Threaded portion of mounting bolt
and washer:
Engine oil (EO30)
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).

10) Check that the crankshaft turns smoothly.


11) Measure the end play of the crankshaft
with dial gauge [1].
a End play: 0.140 0.315 mm
a If the end play is out of the standard,
correct it. For details, see Structure,
function and maintenance standard.

4.

9)

24

When not using tool J, make


marks (b) on the main cap and
bolt with paint, then tighten the
bolt by 90 (+30/0).
Make punch mark (c) on the mounting bolt
head.
a When a new bolt is used, do not
make a punch mark on its head.

Piston and connecting rod assembly


a Select the grade of the piston according to
the grade of the cylinder liner.
q
Set grade (Stamp): S, L
q
Stamping position
Cylinder liner: Top end
Piston: Top surface
1) Using tool D, fit piston rings (7) to the piston.
a Fit the top ring and second ring to the
piston with the stamped mark side up.
q
Stamp on top ring: 1RS
q
Stamp on second ring: 2RX
a Take the expander out of the oil ring
and fit it to the piston first and then fit
the oil ring. At this time, check that
the expander is fitted to the ring
groove perfectly.

140E-5 Series

50 Disassembly and assembly

2)

Set the abutment joint of each piston ring


as shown in the following figure.
a Adjust oil ring so that the joint of the
expander will be at 180 to the abutment joint of the oil ring.

3)

Set the piston and connecting rod.


a Set the cylinder No. on the head of
piston (6) and the cast part No. of
connecting rod (4) in the same direction, then insert piston pin (5) to
assemble connecting rod (4) and piston (6).
Fit snap rings (3) on both sides of the piston pin to secure the piston pin.

4)

5)

6)

SEN00157-05

7)

Insert piston and connecting rod assembly


(8) in the cylinder block so that the cast
part number on the connecting rod will be
directed to the front of the engine (the
stamped cylinder number will be on the
camshaft side).
a Referring to step 2), check the abutment joint of each piston ring again.
2 Inside of connecting rod bearing and
inside of cylinder:
Engine oil (EO30)

8)

Using tool G, reduce the piston ring and


push in the piston head with a wood bar,
etc. into the cylinder block.

Fit the upper bearing to the connecting


rod, matching the projection of the former
to the cut of the latter.
a Before fitting the bearing, check that
its back side is free from foreign matter.
Set the crankshaft so that the cylinder to
be installed will be at the bottom dead
center.

140E-5 Series

25

SEN00157-05

9)

50 Disassembly and assembly

Before tightening the connecting rod cap


mounting bolts, check the following items.
If any of the following condition applies, do
not reuse that bolt but replace it.
q
Number of tightening time of bolt: 6
(Number of punch marks on bolt head
is 5.)
q
Length (a) of bolt stem:
Min. 95.0 mm

10) Fit lower bearing (9) to the connecting rod


cap, matching the projection of the former
to the cut of the latter.
12) Tighten connecting rod cap mounting bolts
(1) according to the following procedure.
3 Mounting bolt
1st time : 127 4.9 Nm {13 0.5 kgm}
2nd time : Using tool J, tighten the bolt by
90 (+30/0).

11) Install connecting rod cap (2) to connecting rod (4), matching yellow marks (a) on
them to each other.
a Before fitting the bearing, check that
its back side is free from foreign matter.
2 Inside of connecting rod cap bearing:
Engine oil (EO30)

26

When not using tool J, make


marks (b) on the