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ENGINE
140E-5 SERIES
SEN00076-07
140E-5 Series
140E-5 Series 1
SEN00076-07 00 Index and foreword
01 Specification SEN00078-04
Specification and technical data SEN00079-04 q
40 Troubleshooting SEN00150-03
General information on troubleshooting SEN00151-03 q
Troubleshooting of electrical system (E-mode), Part 1 SEN00153-02
Troubleshooting of electrical system (E-mode), Part 2 SEN00154-02
Troubleshooting of mechanical system (S-mode) SEN00152-02
2 140E-5 Series
00 Index and foreword SEN00076-07
Table of contents 1
00 Index and foreword
Index SEN00076-07
Composition of shop manual ................................................................................................... 2
Table of contents ..................................................................................................................... 3
01 Specification
Specification and technical data SEN00079-04
Outline ..................................................................................................................................... 2
Specifications........................................................................................................................... 6
General view............................................................................................................................ 24
Weight table............................................................................................................................. 47
Engine performance curves..................................................................................................... 49
140E-5 Series 3
SEN00076-07 00 Index and foreword
4 140E-5 Series
00 Index and foreword SEN00076-07
40 Troubleshooting
General information on troubleshooting SEN00151-03
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
140E-5 Series 5
SEN00076-07 00 Index and foreword
6 140E-5 Series
00 Index and foreword SEN00076-07
140E-5 Series 7
SEN00076-07
© 2008 KOMATSU
All Rights Reserved
Printed in Japan 04-08 (01)
8
SEN00077-06
140E-5 Series
140E-5 Series 1
SEN00077-06 00 Index and foreword
Safety notice 1
(Rev. 2008/02)
Important safety notice
Proper service and repair are extremely important for safe machine operation. The service and repair
techniques recommended by Komatsu and described in this manual are both effective and safe.
Some of these techniques require the use of tools specially designed by Komatsu for the specific
purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The
cautions accompanying these symbols should always be followed carefully. If any dangerous situa-
tion arises or may possibly arise, first consider safety, and take the necessary actions to deal with
the situation.
2 140E-5 Series
00 Index and foreword SEN00077-06
140E-5 Series 3
SEN00077-06 00 Index and foreword
4 140E-5 Series
00 Index and foreword SEN00077-06
q If the load is unstable or the wire rope 13) If the hoist stops because of a power fail-
or chains are twisted, lower the load ure, turn the power switch OFF. When
and lift it up again. turning on a switch which was turned OFF
q Do not lift up the load slantingly. by the electric shock prevention earth
13) When lifting down a load, observe the fol- leakage breaker, check that the devices
lowing. related to that switch are not in operation
q When lifting down a load, stop it tem- state.
porarily at 30 cm above the floor, and 14) If you find an obstacle around the hoist,
then lower it slowly. stop the operation.
q Check that the load is stable, and 15) After finishing the work, stop the hoist at
then remove the sling. the specified position and raise the hook
q Remove kinks and dirt from the wire to at least 2 m above the floor. Do not
ropes and chains used for the sling leave the sling installed to the hook.
work, and put them in the specified
place. 7. Selecting wire ropes
1) Select adequate ropes depending on the
5. Precautions for using mobile crane weight of parts to be hoisted, referring to
a Read the Operation and Maintenance the table below.
Manual of the crane carefully in advance
and operate the crane safely. Wire ropes
(Standard “Z” twist ropes without galvanizing)
6. Precautions for using overhead hoist crane (JIS G3525, No. 6, Type 6X37-A)
k When raising a heavy part (heavier Nominal
Allowable load
than 25 kg), use a hoist, etc. In Disas- diameter of rope
sembly and assembly, the weight of a mm kN ton
part heavier than 25 kg is indicated 10 8.8 0.9
after the mark of 4. 12 12.7 1.3
1) Before starting work, inspect the wire 14 17.3 1.7
ropes, brake, clutch, controller, rails, over 16 22.6 2.3
wind stop device, electric shock preven- 18 28.6 2.9
tion earth leakage breaker, crane collision 20 35.3 3.6
prevention device, and power application
25 55.3 5.6
warning lamp, and check safety.
30 79.6 8.1
2) Observe the signs for sling work.
40 141.6 14.4
3) Operate the hoist at a safe place.
4) Check the direction indicator plates (east, 50 221.6 22.6
west, south, and north) and the directions 60 318.3 32.4
of the control buttons without fail.
5) Do not sling a load slantingly. Do not move a The allowable load is one-sixth of the
the crane while the slung load is swinging. breaking strength of the rope used
6) Do not raise or lower a load while the (Safety coefficient: 6).
crane is moving longitudinally or laterally.
7) Do not drag a sling.
8) When lifting up a load, stop it just after it
leaves the ground and check safety, and
then lift it up.
9) Consider the travel route in advance and
lift up a load to a safe height.
10) Place the control switch on a position
where it will not be an obstacle to work
and passage.
11) After operating the hoist, do not swing the
control switch.
12) Remember the position of the main switch
so that you can turn off the power immedi-
ately in an emergency.
140E-5 Series 5
SEN00077-06 00 Index and foreword
8. Precautions for disconnecting and con- a Example of O-ring (Fitted to every joint of
necting hoses and tubes in air conditioner hoses and tubes)
circuit
1) Disconnection
k For the environment, the air condi-
tioner of this machine uses the
refrigerant (air conditioner gas:
R134a) which has fewer factors of
the depletion of the ozone layer.
However, it does not mean that you
may discharge the refrigerant into
the atmosphere as it is. Be sure to
recover the refrigerant when dis-
connecting the refrigerant gas cir-
cuit and then reuse it.
a Ask professional traders for collecting a For tightening torque, see the precautions for
and filling operation of refrigerant installation in each section of "Disassembly
(R134a). and assembly".
a Never release the refrigerant (R134a)
to the atmosphere.
k If the refrigerant gas gets in your
eyes or contacts your skin, you
may lose your sight and your skin
may be frozen. Accordingly, put
on safety glasses, safety gloves
and safety clothes when recover-
ing or adding the refrigerant.
Refrigerant gas must be recovered
and added by a qualified person.
2) Connection
1] When installing the air conditioner cir-
cuit hoses and tubes, take care that
dirt, dust, water, etc. will not enter
them.
2] When connecting the air conditioner
hoses and tubes, check that O-rings
(1) are fitted to their joints.
3] Check that each O-ring is not dam-
aged or deteriorated.
4] When connecting the refrigerant pip-
ing, apply compressor oil for refriger-
ant (R134a) (DENSO: ND-OIL8,
VA L E O T H E R M A L S Y S T E M S :
ZXL100PG (equivalent to PAG46))
to its O-rings.
6 140E-5 Series
00 Index and foreword SEN00077-06
q Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one
of them is required, consult KOMATSU distributors.
q Materials and specifications are subject to change without notice.
q Shop manuals are divided into the “Chassis volume” and “Engine volume”. For the engine unit, see the
engine volume of the engine model mounted on the machine.
01. Specification
This section explains the specifications of the machine.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is
divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also
explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
140E-5 Series 7
SEN00077-06 00 Index and foreword
3. Filing method
File by the brochures in the correct order of the form number printed in the shop manual composition
table.
q Revisions
Revised brochures are shown in the shop manual composition table.
4. Symbols
Important safety and quality portions are marked with the following symbols so that the shop manual will
be used practically.
4
Weight of parts of component or parts. Caution necessary when
Weight
selecting hoisting wire, or when working posture is important, etc.
3
Tightening Places that require special attention for tightening torque during
torque assembly.
5
Oil, coolant Places where oil, etc. must be added, and capacity.
6
Drain Places where oil, etc. must be drained, and quantity to be drained.
5. Units
In this shop manual, the units are indicated with International System of units (SI). For reference, con-
ventionally used Gravitational System of units is indicated in parentheses { }.
8 140E-5 Series
00 Index and foreword SEN00077-06
Example:
Standard size Tolerance
–0.022
120
–0.126
Example:
Tolerance
Standard size
Shaft Hole
–0.030 +0.046
60
–0.076 +0
140E-5 Series 9
SEN00077-06 00 Index and foreword
10 140E-5 Series
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140E-5 Series 11
SEN00077-06 00 Index and foreword
3) Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with
a crane with the wiring still connected, or a
heavy object hits the wiring, the crimping
of the connector may separate, or the sol-
dering may be damaged, or the wiring
may be broken.
12 140E-5 Series
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140E-5 Series 13
SEN00077-06 00 Index and foreword
2) Connecting connectors
1] Check the connector visually.
Check that there is no oil, dirt, or
water stuck to the connector pins
(mating portion).
Check that there is no deformation,
defective contact, corrosion, or dam-
age to the connector pins.
Check that there is no damage or
breakage to the outside of the con-
nector.
a If there is any oil, water, or dirt
stuck to the connector, wipe it off
with a dry cloth. If any water has
got inside the connector, warm
the inside of the wiring with a
dryer, but be careful not to make
it too hot as this will cause short
circuits.
a If there is any damage or break-
age, replace the connector.
2] Fix the connector securely.
Align the position of the connector
correctly, and then insert it securely.
For connectors with the lock stopper,
push in the connector until the stop-
per clicks into position.
3] Correct any protrusion of the boot and
any misalignment of the wiring har-
ness.
For connectors fitted with boots, cor-
rect any protrusion of the boot. In
addition, if the wiring harness is mis-
aligned, or the clamp is out of posi-
tion, adjust it to its correct position.
a If the connector cannot be cor-
rected easily, remove the clamp
and adjust the position.
q If the connector clamp has been
removed, be sure to return it to
its original position. Check also
that there are no loose clamps.
14 140E-5 Series
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3) Heavy duty wire connector (DT 8-pole, 12- q Disconnection q Connection (Example of
pole) incomplete setting of (a))
Disconnection (Left of figure)
While pressing both sides of locks (a)
and (b), pull out female connector (2).
Connection (Right of figure)
1] Push in female connector (2) horizon-
tally until the lock clicks.
Arrow: 1)
2] Since locks (a) and (b) may not be set
completely, push in female connector
(2) while moving it up and down until
the locks are set normally.
Arrow: 1), 2), 3)
a Right of figure: Lock (a) is pulled
down (not set completely) and
lock (b) is set completely.
(1): Male connector
(2): Female connector
(a), (b): Locks
140E-5 Series 15
SEN00077-06 00 Index and foreword
16 140E-5 Series
00 Index and foreword SEN00077-06
4. Handling controller
1) The controller contains a microcomputer
and electronic control circuits. These con-
trol all of the electronic circuits on the
machine, so be extremely careful when
handling the controller.
2) Do not place objects on top of the control-
ler.
3) Cover the control connectors with tape or
a vinyl bag. Never touch the connector
contacts with your hand.
4) During rainy weather, do not leave the
controller in a place where it is exposed to
rain.
5) Do not place the controller on oil, water, or
soil, or in any hot place, even for a short
time. (Place it on a suitable dry stand).
6) Precautions when carrying out arc welding
When carrying out arc welding on the
body, disconnect all wiring harness con-
nectors connected to the controller. Fit an
arc welding ground close to the welding
point.
140E-5 Series 17
SEN00077-06 00 Index and foreword
3. Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from
entering. If the opening is left open or is
blocked with a rag, there is danger of dirt
entering or of the surrounding area being
made dirty by leaking oil so never do this. Do
not simply drain oil out onto the ground, but
collect it and ask the customer to dispose of it,
or take it back with you for disposal.
18 140E-5 Series
00 Index and foreword SEN00077-06
6. Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit. Normally, flushing is
carried out twice: primary flushing is carried
out with flushing oil, and secondary flushing is
carried out with the specified hydraulic oil.
7. Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the
machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil cir-
cuit. The oil cleaning equipment is used to
remove the ultra fine (about 3 m) particles that
the filter built in the hydraulic equipment can-
not remove, so it is an extremely effective
device.
140E-5 Series 19
SEN00077-06 00 Index and foreword
20 140E-5 Series
00 Index and foreword SEN00077-06
q 114 engine
q 107 engine
140E-5 Series 21
SEN00077-06 00 Index and foreword
q 95, 125 – 170, 12V140 engine 4. Turn-housing type (Round green connector)
4) While pressing lock (E) of the connector, q 140 engine
pull out connector (5) in the direction of Example)
the arrow. Intake air pressure sensor in intake mani-
fold (CANNON-04): PIM etc.
Example)
Fuel pressure in common rail: PFUEL etc. 1) Disconnect connector (6) according to the
(AMP-3) following procedure.
1] Turn housing (H1) in the direction of
the arrow.
a When connector is unlocked,
housing (H1) becomes heavy to
turn.
2] Pull out housing (H1) in the direction
of the arrow.
a Housing (H1) is left on the wiring har-
ness side.
Example)
Injection pressure control valve of fuel
supply pump: PCV (SUMITOMO-2)
Example)
Speed sensor of fuel supply pump:
G (SUMITOMO-3)
a Pull the connector straight up.
22 140E-5 Series
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In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by sym-
bols. The electric wire code is helpful in understanding the electric circuit diagram.
Example: AEX 0.85 L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nomi-
nal No. of 0.85
Indicates color of wire by color code.
Color codes are shown in Table 3.
(Table 1)
Using
Sym-
Type Material temperature Example of use
bol
range (°C)
Low-voltage Conduc- Annealed copper for elec-
General wiring
wire for AV tor tric appliance
(Nominal No. 5 and above)
automobile Insulator Soft polyvinyl chloride
Thin-cover Conduc- Annealed copper for elec- –30 to +60
low-voltage tor tric appliance General wiring
AVS
wire for (Nominal No. 3 and below)
Insulator Soft polyvinyl chloride
automobile
Heat-resis- Conduc- Annealed copper for elec-
General wiring in extremely
tant low-volt- tor tric appliance
AEX –50 to +110 cold district, wiring at high-tem-
age wire for Heat-resistant crosslinked
Insulator perature place
automobile polyethylene
140E-5 Series 23
SEN00077-06 00 Index and foreword
2. Dimensions
(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5
Number of
strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32
eter of strand
Conductor
Sectional
0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
area (mm2)
d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0
AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 –
Cov-
AV Standard – – – – – – – 4.6
er D
AEX Standard 2.0 2.2 2.7 3.0 3.1 – 3.8 4.6
24 140E-5 Series
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(Table 3)
Color Code Color of wire Color Code Color of wire
B Black LgW Light green & White
Br Brown LgY Light green & Yellow
BrB Brown & Black LR Blue & Red
BrR Brown & Red LW Blue & White
BrW Brown & White LY Blue & Yellow
BrY Brown & Yellow O Orange
Ch Charcoal P Pink
Dg Dark green R Red
G Green RB Red & Black
GB Green & Black RG Red & Green
GL Green & Blue RL Red & Blue
Gr Gray RW Red & White
GR Green & Red RY Red & Yellow
GW Green & White Sb Sky Blue
GY Green & Yellow Y Yellow
L Blue YB Yellow & Black
LB Blue & Black YG Yellow &Green
Lg Light green YL Yellow & Blue
LgB Light green & Black YR Yellow & Red
LgR Light green & Red YW Yellow & White
Remarks: In a color code consisting of 2 colors, the first color is the color of the background and
the second color is the color of the marking.
Example: “GW” means that the background is Green and marking is White.
(Table 4)
Type of wire AVS or AV AEX
Charge R WG – – – – R –
Ground B – – – – – B –
Start R – – – – – R –
Light RW RB RY RG RL – D –
Instrument Y YR YB YG YL YW Y Gr
Signal G GW GR GY GB GL G Br
L LW LR LY LB – L –
Type of
Br BrW BrR BrY BrB – – –
circuit
Lg LgR LgY LgB LgW – – –
O – – – – – – –
Others Gr – – – – – – –
P – – – – – – –
Sb – – – – – – –
Dg – – – – – – –
Ch – – – – – – –
140E-5 Series 25
SEN00077-06 00 Index and foreword
3) If the part is not under hydraulic pressure, the following corks can be used.
Nominal Dimensions
Part Number
number D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34
26 140E-5 Series
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a When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other
hydraulic equipment removed for repair, always bleed the air as follows:
1) Start the engine and run at low idle.
2) Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times, stopping the
cylinder 100 mm from the end of its stroke.
3) Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke.
4) After doing this, run the engine at normal speed.
a When using the machine for the first time after repair or long storage, follow the same procedure.
140E-5 Series 27
SEN00077-06 00 Index and foreword
28 140E-5 Series
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Type 1
1. Disconnection
1) Hold adapter (1) and push hose joint (2)
into mating adapter (3). (Fig. 1)
a The adapter can be pushed in about
3.5 mm.
a Do not hold rubber cap portion (4).
2) After hose joint (2) is pushed into adapter
(3), press rubber cap portion (4) against
adapter (3) until it clicks. (Fig. 2)
3) Hold hose adapter (1) or hose (5) and pull
it out. (Fig. 3)
a Since some hydraulic oil flows out,
prepare an oil receiving container.
2. Connection
1) Hold hose adapter (1) or hose (5) and
insert it in mating adapter (3), aligning
them with each other. (Fig. 4)
a Do not hold rubber cap portion (4).
2) After inserting the hose in the mating
adapter perfectly, pull it back to check its
connecting condition. (Fig. 5)
a When the hose is pulled back, the
rubber cap portion moves toward the
hose about 3.5 mm. This does not
indicate abnormality, however.
140E-5 Series 29
SEN00077-06 00 Index and foreword
Type 2
1. Disconnection
1) Hold the tightening portion and push body
(7) straight until sliding prevention ring (6)
contacts contact surface (a) of the hexag-
onal portion at the male end. (Fig. 6)
2) While holding the condition of Step 1), turn
lever (8) to the right (clockwise). (Fig. 7)
3) While holding the condition of Steps 1)
and 2), pull out whole body (7) to discon-
nect it. (Fig. 8)
2. Connection
q Hold the tightening portion and push body
(7) straight until sliding prevention ring (6)
contacts contact surface (a) of the hexag-
onal portion at the male end. (Fig. 9)
30 140E-5 Series
00 Index and foreword SEN00077-06
Type 3
1. Disconnection
1) Hold the tightening portion and push body
(9) straight until sliding prevention ring (8)
contacts contact surface (b) of the hexag-
onal portion at the male end. (Fig. 10)
2) While holding the condition of Step 1),
push cover (10) straight until it contacts
contact surface (b) of the hexagonal por-
tion at the male end. (Fig. 11)
3) While holding the condition of Steps 1)
and 2), pull out whole body (9) to discon-
nect it. (Fig. 12)
2. Connection
q Hold the tightening portion and push body
(9) straight until the sliding prevention ring
contacts contact surface (b) of the hexag-
onal portion at the male end. (Fig. 13)
140E-5 Series 31
SEN00077-06 00 Index and foreword
a Fig. A a Fig. B
32 140E-5 Series
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140E-5 Series 33
SEN00077-06 00 Index and foreword
5. Table of tightening torques for hoses (taper seal type and face seal type)
a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the
torque below.
a Apply the following torque when the threads are coated (wet) with engine oil.
7. Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts)
a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114
engine series to the torque below.
Tightening torque
Thread size
Bolts and nuts
mm Nm kgm
6 10 ± 2 1.02 ± 0.20
8 24 ± 4 2.45 ± 0.41
10 43 ± 6 4.38 ± 0.61
12 77 ± 12 7.85 ± 1.22
14 — —
34 140E-5 Series
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8. Table of tightening torques for 102, 107 and 114 engine series (Eye joints)
a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine
series to the torque below.
9. Table of tightening torques for 102, 107 and 114 engine series (Taper screws)
a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114
engine series to the torque below.
140E-5 Series 35
SEN00077-06 00 Index and foreword
Conversion table 1
Method of using the conversion table
The conversion table in this section is provided to enable simple conversion of figures. For details of the
method of using the conversion table, see the example given below.
Example: Method of using the conversion table to convert from millimeters to inches
36 140E-5 Series
00 Index and foreword SEN00077-06
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
140E-5 Series 37
SEN00077-06 00 Index and foreword
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
kgm to ft.lb
1 kgm = 7.233 ft.lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
38 140E-5 Series
00 Index and foreword SEN00077-06
kg/cm2 to lb/in2
1 kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1,010 1,024 1,038 1,053 1,067 1,081 1,095 1,109 1,124
80 1,138 1,152 1,166 1,181 1,195 1,209 1,223 1,237 1,252 1,266
90 1,280 1,294 1,309 1,323 1,337 1,351 1,365 1,380 1,394 1,408
100 1,422 1,437 1,451 1,465 1,479 1,493 1,508 1,522 1,536 1,550
110 1,565 1,579 1,593 1,607 1,621 1,636 1,650 1,664 1,678 1,693
120 1,707 1,721 1,735 1,749 1,764 1,778 1,792 1,806 1,821 1,835
130 1,849 1,863 1,877 1,892 1,906 1,920 1,934 1,949 1,963 1,977
140 1,991 2,005 2,020 2,034 2,048 2,062 2,077 2,091 2,105 2,119
150 2,134 2,148 2,162 2,176 2,190 2,205 2,219 2,233 2,247 2,262
160 2,276 2,290 2,304 2,318 2,333 2,347 2,361 2,375 2,389 2,404
170 2,418 2,432 2,446 2,460 2,475 2,489 2,503 2,518 2,532 2,546
180 2,560 2,574 2,589 2,603 2,617 2,631 2,646 2,660 2,674 2,688
190 2,702 2,717 2,731 2,745 2,759 2,773 2,788 2,802 2,816 2,830
200 2,845 2,859 2,873 2,887 2,901 2,916 2,930 2,944 2,958 2,973
210 2,987 3,001 3,015 3,030 3,044 3,058 3,072 3,086 3,101 3,115
220 3,129 3,143 3,158 3,172 3,186 3,200 3,214 3,229 3,243 3,257
230 3,271 3,286 3,300 3,314 3,328 3,343 3,357 3,371 3,385 3,399
240 3,414 3,428 3,442 3,456 3,470 3,485 3,499 3,513 3,527 3,542
140E-5 Series 39
SEN00077-06 00 Index and foreword
Temperature
Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centi-
grade temperature reading or vice versa is to enter the accompanying table in the center (boldface column)
of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahren-
heit temperatures and read the corresponding Centigrade temperature in the column at the left.
When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centi-
grade values, and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
–40.4 –40 –40.0 –11.7 11 51.8 7.8 46 114.8 27.2 81 177.8
–37.2 –35 –31.0 –11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
–34.4 –30 –22.0 –10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
–31.7 –25 –13.0 –10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
–28.9 –20 –4.0 –9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
40 140E-5 Series
00 Index and foreword SEN00077-06
140E-5 Series 41
SEN00077-06
© 2008 KOMATSU
All Rights Reserved
Printed in Japan 04-08 (01)
42
SEN00079-04
140E-5 Series
01 Specification 1
Specification and technical data
Outline............................................................................................................................................................. 2
Specifications .................................................................................................................................................. 6
General view ................................................................................................................................................. 24
Weight table .................................................................................................................................................. 47
Engine performance curves .......................................................................................................................... 49
140E-5 Series 1
SEN00079-04 01 Specification
Outline 1
1. Applicable machine
2 140E-5 Series
01 Specification SEN00079-04
2. Outline of engine
(With EGR)
q The 140E-5 engine is a high-performance and 4) To secure the high output of the engine, the
high-efficiency engine, which passed strict twin cooling nozzle to cool the piston employed
emission regulations (USA: EPA Regulations for 140E-3 and after models is improved to
for 2006, EU: Regulations for 2006, Japan: increase the durability of the piston and lower
Construction machinery regulations for 2006) the back side temperature of the piston. As a
and attained low fuel consumption, low noise, result, the lubricating oil on the piston is not
better exhaust gas color, and high acceleration exposed to high temperature, thus it is not
performance. Accordingly, this newly devel- deteriorated. Since the high-pressure fuel
oped engine is suitable as a power source of injection system controlled electronically is
construction machinery and industrial machin- employed, less soot is produced and the drain-
ery used for various purposes. ing interval of the oil is lengthened. (While the
capacity of the oil pan is not changed, the oil
q The 140E-5 engine is the successor to the replacement interval of 500 hours is secured.)
140E-3 engine. While it is an in-line 6-cylinder,
water-cooled, common rail direct injection, 4- 5) The common rail high-pressure fuel injection
stroke diesel engine similar to 140E-3, it is system controlled electronically is employed
equipped with the cooled EGR system which is for all of 140E-3 and after models. This system
a new technology. can inject the fuel at high pressure of 120 MPa
{1,200 kg/cm2} from the low-speed range to the
1) The main components of the cooled EGR sys- high-speed range. In addition, this system can
tem are the EGR cooler of corrugated tube control the form of injection most properly by
type made of newly developed special stain- electronic control according to the speed and
less steel and the EGR valve driven hydrauli- load. The injection system of 140E-5 is further
cally and controlled electronically which improved to employ multiple injections and
KOMATSU developed by itself. The cooled increase the injection pressure up to 160 MPa
EGR system secures the optimum EGR rate {1,600 kg/cm2}. As a result, exhaust gas of the
from the low-speed range to the high-speed cleanest level in the world, good exhaust gas
range to attain both clean exhaust gas and low color, low fuel consumption, and low noise are
fuel consumption with the bypass assist circuit realized simultaneously.
consisting of the venturi system and bypass
valve which has the same function and struc- 6) As the injection pressure of the common rail
ture as those of the EGR valve. injection system employed for the 140E-3
engine and after models is increased (from
2) The special EGR oil pump is employed to gen- 120 to 160 MPa {from 1,200 to 1,600 kg/cm2}),
erate high oil pressure (1.47 MPa {15 kg/cm2}) the pressure resistance of the common rail,
as the drive power source of the EGR valve injector, and supply pump is improved for
driven hydraulically and controlled electroni- higher reliability.
cally. The engine oil pump has sufficient deliv-
ery for the EGR valve and increased output of 7) The main fuel filter of high efficiency and the
the engine. As a result, the reliability and dura- pre-fuel filter are installed as standard so that
bility of the engine are improved. the low grade fuel in the market (equivalent to
Class NAS13) can be used. In addition, the
3) While the 140E-3 engine has only 1 combina- delivery of the priming pump used to replace
tion filter of high performance and high effi- the filters is increased for higher serviceability.
ciency, the 140E-5 engine has 2 of the same
filter to meet the requirements of the EGR sys- 8) The high-quality piston made of cast iron which
tem and high-dispersion oil and improve the has been employed for the 140E-2 engine and
ability to capture the soot in the oil. In addition, after models is employed. This piston has a
the recommended sub-materials for operation less coefficient of thermal expansion, a reen-
(oil and fuel) are changed to improve the reli- trant combustion chamber, and a shaker cool-
ability and durability of the engine. ing gallery. As a result, clean exhaust gas,
good exhaust gas color, and low fuel consump-
tion are attained simultaneously, and high
durability and reliability are also obtained.
140E-5 Series 3
SEN00079-04 01 Specification
4 140E-5 Series
01 Specification SEN00079-04
(EGR-less)
q The 140E-5 engine is a high-performance and 4) As the injection pressure of the common rail
high-efficiency engine, which attained low fuel injection system employed for the 140E-3
consumption and low noise. Accordingly, this engine and after models is increased, the pres-
newly developed engine is suitable as a power sure resistance of the common rail, injector,
source of construction machinery and indus- and supply pump is improved for higher reli-
trial machinery used for various purposes. ability.
q The 140E-5 engine is the successor to the 5) The main fuel filter of high efficiency and the
140E-3 engine. While it is an in-line 6-cylinder, pre-fuel filter are installed as standard so that
water-cooled, 4-stroke diesel engine, it is the low grade fuel in the market can be used.
equipped with the common rail direct injection In addition, the delivery of the priming pump
system. used to replace the filters is increased for
higher serviceability.
1) While the 140E-3 engine has only 1 combina-
tion filter of high performance and high effi- 6) The high-quality piston made of cast iron which
ciency, the 140E-5 engine has 2 of the same has been employed for the 140E-2 engine and
filter to meet the requirements of the high-dis- after models is employed. This piston has a
persion oil and improve the ability to capture less coefficient of thermal expansion, a reen-
the soot in the oil. In addition, the recom- trant combustion chamber, and a shaker cool-
mended sub-materials for operation (oil and ing gallery. As a result, clean exhaust gas,
fuel) are changed to improve the reliability and good exhaust gas color, and low fuel consump-
durability of the engine. tion are attained simultaneously, and high
durability and reliability are also obtained.
2) To secure the high output of the engine, the
twin cooling nozzle to cool the piston employed 7) By using the above-mentioned high-pressure
for 140E-3 and after models is improved to fuel injection system controlled electronically,
increase the durability of the piston and lower the multiple injection and injection characteris-
the back side temperature of the piston. As a tics are set most properly to improve the start-
result, the lubricating oil on the piston is not ability and reduce the white exhaust smoke
exposed to high temperature, thus it is not when the temperature is low.
deteriorated. Since the high-pressure fuel
injection system controlled electronically is 8) Since the controller is mounted on the engine
employed, less soot is produced and the drain- and equipped with the automatic high-altitude
ing interval of the oil is lengthened. (While the compensation function, the engine can be
capacity of the oil pan is not changed, the oil operated at high altitude without replacing the
replacement interval of 500 hours is secured.) controller. As a result, the serviceability is
improved.
3) The common rail high-pressure fuel injection
system controlled electronically is employed 9) The improved type of the KTR110 turbo-
for all of 140E-3 and after models. This system charger manufactured by KOMATSU which
can inject the fuel at high pressure of 120 MPa has been employed for the 140E-2 engine and
{1,200 kg/cm2} from the low-speed range to the after models and which has high reliability and
high-speed range. In addition, this system can high performance is mounted. Besides; the
control the form of injection most properly by efficiency of the blower impeller is heightened
electronic control according to the speed and and the strength of its material is improved to
load. The injection system of 140E-5 is further obtain higher efficiency and pressure ratio.
improved to employ multiple injections and Since the design of the shaft is improved to
increase the injection pressure. As a result, increase the reliability, high performance is
exhaust gas of the cleanest level in the world, obtained from the low-speed range to the high-
good exhaust gas color, low fuel consumption, speed range. As a result, the engine has high
and low noise are realized simultaneously. performance and consumes less fuel and
attains high reliability.
140E-5 Series 5
SEN00079-04 01 Specification
Specifications 1
(Gross)
No-load max. speed
rpm 1,950 ± 50
(High idle speed)
No-load min. speed
rpm 800 ± 25
(Low idle speed)
g/kW·h
Fuel consumption ratio at rated point 209 {156}
{g/HP·h}
Dry weight kg 1,845
Fuel supply pump — DENSO ECD-U2
Governor — Electronic control type
Quantity of lubricating oil (Refill capacity) l 48 (40)
Quantity of coolant l 24
Alternator — 24V, 60A, 90A
Starting motor — 24V, 11kW
Battery — 12V, 170Ah × 2
Turbocharger — KOMATSU KTR110L
Air compressor — —
Others — With air-cooled aftercooler
With cooled EGR
6 140E-5 Series
01 Specification SEN00079-04
(Gross)
No-load max. speed
rpm 1,950 ± 50
(High idle speed)
No-load min. speed
rpm 800 ± 25
(Low idle speed)
g/kW·h
Fuel consumption ratio at rated point 205 {153}
{g/HP·h}
Dry weight kg 1,770
Fuel supply pump — DENSO ECD-U2
Governor — Electronic control type
Quantity of lubricating oil (Refill capacity) l 48 (40)
Quantity of coolant l 24
Alternator — 24V, 60A, 90A
Starting motor — 24V, 11kW
Battery — 12V, 170Ah × 2
Turbocharger — KOMATSU KTR110L
Air compressor — —
Others — With air-cooled aftercooler
140E-5 Series 7
SEN00079-04 01 Specification
(Gross)
No-load max. speed
rpm 1,980 ± 50
(High idle speed)
No-load min. speed
rpm 825 ± 25
(Low idle speed)
g/kW·h
Fuel consumption ratio at rated point 204 {152}
{g/HP·h}
Dry weight kg 1,920
Fuel supply pump — DENSO ECD-U2
Governor — Electronic control type
Quantity of lubricating oil (Refill capacity) l 58 (53)
Quantity of coolant l 25 (In only engine)
Alternator — 24V, 60A, 90A
Starting motor — 24V, 11kW
Battery — 12V, 170Ah × 2
Turbocharger — KOMATSU KTR110L
Air compressor — —
Others — With air-cooled aftercooler
With cooled EGR
8 140E-5 Series
01 Specification SEN00079-04
(Gross)
No-load max. speed
rpm 1,980 ± 50
(High idle speed)
No-load min. speed
rpm 825 ± 25
(Low idle speed)
g/kW·h
Fuel consumption ratio at rated point 204 {152}
{g/HP·h}
Dry weight kg 1,850
Fuel supply pump — DENSO ECD-U2
Governor — Electronic control type
Quantity of lubricating oil (Refill capacity) l 58 (53)
Quantity of coolant l 25 (In only engine)
Alternator — 24V, 60A, 90A
Starting motor — 24V, 11kW
Battery — 12V, 170Ah × 2
Turbocharger — KOMATSU KTR110L
Air compressor — —
Others — With air-cooled aftercooler
140E-5 Series 9
SEN00079-04 01 Specification
(Gross)
No-load max. speed
rpm 2,100 (0/–50)
(High idle speed)
No-load min. speed
rpm 740 (+40/0)
(Low idle speed)
g/kW·h
Fuel consumption ratio at rated point 215 {160}
{g/HP·h}
Dry weight kg 1,800
Fuel supply pump — DENSO ECD-U2
Governor — Electronic control type
Quantity of lubricating oil (Refill capacity) l 45 (37)
Quantity of coolant l 25 (In only engine)
Alternator — 24V, 60A, 75A, 90A
Starting motor — 24V, 11kW
Battery — 12V, 170Ah × 2
Turbocharger — KOMATSU KTR110L
Air compressor — —
Others — With air-cooled aftercooler
With cooled EGR
10 140E-5 Series
01 Specification SEN00079-04
(Gross)
No-load max. speed
rpm 2,100 (0/–50)
(High idle speed)
No-load min. speed
rpm 740 (+40/0)
(Low idle speed)
g/kW·h
Fuel consumption ratio at rated point 215 {160}
{g/HP·h}
Dry weight kg 1,725
Fuel supply pump — DENSO ECD-U2
Governor — Electronic control type
Quantity of lubricating oil (Refill capacity) l 45 (37)
Quantity of coolant l 25 (In only engine)
Alternator — 24V, 60A, 75A, 90A
Starting motor — 24V, 11kW
Battery — 12V, 170Ah × 2
Turbocharger — KOMATSU KTR110L
Air compressor — —
Others — With air-cooled aftercooler
140E-5 Series 11
SEN00079-04 01 Specification
(Gross)
No-load max. speed
rpm 2,200 ± 50
(High idle speed)
No-load min. speed
rpm 700 ± 50
(Low idle speed)
g/kW·h
Fuel consumption ratio at rated point 218 {162.3}
{g/HP·h}
Dry weight kg 1,869
Fuel supply pump — DENSO ECD-U2
Governor — Electronic control type
Quantity of lubricating oil (Refill capacity) l 58 (50)
Quantity of coolant l 25 (In only engine)
Alternator — 24V, 75A, 90A
Starting motor — 24V, 11kW
Battery — 12V, 170Ah × 2
Turbocharger — KOMATSU KTR110L
Air compressor — —
Others — With air-cooled aftercooler
With cooled EGR
12 140E-5 Series
01 Specification SEN00079-04
(Gross)
No-load max. speed
rpm 2,200 ± 50
(High idle speed)
No-load min. speed
rpm 700 ± 50
(Low idle speed)
g/kW·h
Fuel consumption ratio at rated point 215 {160}
{g/HP·h}
Dry weight kg 1,800
Fuel supply pump — DENSO ECD-U2
Governor — Electronic control type
Quantity of lubricating oil (Refill capacity) l 58 (50)
Quantity of coolant l 25 (In only engine)
Alternator — 24V, 75A, 90A
Starting motor — 24V, 11kW
Battery — 12V, 170Ah × 2
Turbocharger — KOMATSU KTR110L
Air compressor — —
Others — With air-cooled aftercooler
140E-5 Series 13
SEN00079-04 01 Specification
(Gross)
No-load max. speed
rpm 2,150 ± 50
(High idle speed)
No-load min. speed
rpm 700 ± 25
(Low idle speed)
g/kW·h
Fuel consumption ratio at rated point 216.2 {161.3}
{g/HP·h}
Dry weight kg 1,750
Fuel supply pump — DENSO ECD-U2
Governor — Electronic control type
Quantity of lubricating oil (Refill capacity) l 45 (37)
Quantity of coolant l 25
Alternator — 24V, 75A, 90A
Starting motor — 24V, 11kW
Battery — 12V, 170Ah × 2
Turbocharger — KOMATSU KTR110L
Air compressor — —
Others — With air-cooled aftercooler
With cooled EGR
14 140E-5 Series
01 Specification SEN00079-04
(Gross)
No-load max. speed
rpm 2,150 ± 50
(High idle speed)
No-load min. speed
rpm 700 ± 25
(Low idle speed)
g/kW·h
Fuel consumption ratio at rated point 211.4 {157.7}
{g/HP·h}
Dry weight kg 1,680
Fuel supply pump — DENSO ECD-U2
Governor — Electronic control type
Quantity of lubricating oil (Refill capacity) l 45 (37)
Quantity of coolant l 25
Alternator — 24V, 75A, 90A
Starting motor — 24V, 11kW
Battery — 12V, 170Ah × 2
Turbocharger — KOMATSU KTR110L
Air compressor — —
Others — With air-cooled aftercooler
140E-5 Series 15
SEN00079-04 01 Specification
(Gross)
No-load max. speed
rpm 2,300 ± 25
(High idle speed)
No-load min. speed
rpm 725 ± 25
(Low idle speed)
g/kW·h
Fuel consumption ratio at rated point 212 {158}
{g/HP·h}
Dry weight kg 1,810
Fuel supply pump — DENSO ECD-U2
Governor — Electronic control type
Quantity of lubricating oil (Refill capacity) l 58 (50)
Quantity of coolant l 25 (In only engine)
Alternator — 24V, 60A, 75A
Starting motor — 24V, 11kW
Battery — 12V, 170Ah × 2
Turbocharger — KOMATSU KTR110L
Air compressor — —
Others — With air-cooled aftercooler
With cooled EGR
16 140E-5 Series
01 Specification SEN00079-04
(Gross)
No-load max. speed
rpm 2,300 ± 25
(High idle speed)
No-load min. speed
rpm 725 ± 25
(Low idle speed)
g/kW·h
Fuel consumption ratio at rated point 207 {154}
{g/HP·h}
Dry weight kg 1,740
Fuel supply pump — DENSO ECD-U2
Governor — Electronic control type
Quantity of lubricating oil (Refill capacity) l 58 (50)
Quantity of coolant l 25 (In only engine)
Alternator — 24V, 60A, 75A
Starting motor — 24V, 11kW
Battery — 12V, 170Ah × 2
Turbocharger — KOMATSU KTR110L
Air compressor — —
Others — With air-cooled aftercooler
140E-5 Series 17
SEN00079-04 01 Specification
(Gross)
No-load max. speed
rpm 2,200 (+50/0)
(High idle speed)
No-load min. speed
rpm 725 ± 25
(Low idle speed)
g/kW·h
Fuel consumption ratio at rated point 223 {166}
{g/HP·h}
Dry weight kg 1,820
Fuel supply pump — DENSO ECD-U2
Governor — Electronic control type
Quantity of lubricating oil (Refill capacity) l 58 (50)
Quantity of coolant l 25 (In only engine)
Alternator — 24V, 60A, 75A
Starting motor — 24V, 11kW
Battery — 12V 170Ah × 2
Turbocharger — KOMATSU KTR110L
Air compressor — —
Others — With air-cooled aftercooler
With cooled EGR
18 140E-5 Series
01 Specification SEN00079-04
(Gross)
No-load max. speed
rpm 2,200 (+50/0)
(High idle speed)
No-load min. speed
rpm 725 ± 25
(Low idle speed)
g/kW·h
Fuel consumption ratio at rated point 222 {165}
{g/HP·h}
Dry weight kg 1,750
Fuel supply pump — DENSO ECD-U2
Governor — Electronic control type
Quantity of lubricating oil (Refill capacity) l 58 (50)
Quantity of coolant l 25 (In only engine)
Alternator — 24V, 60A, 75A
Starting motor — 24V, 11kW
Battery — 12V 170Ah × 2
Turbocharger — KOMATSU KTR110L
Air compressor — —
Others — With air-cooled aftercooler
140E-5 Series 19
SEN00079-04 01 Specification
(Gross)
No-load max. speed
rpm 2,200 (+50/0)
(High idle speed)
No-load min. speed
rpm 725 ± 25
(Low idle speed)
g/kW·h
Fuel consumption ratio at rated point 213 {159}
{g/HP·h}
Dry weight kg 1,820
Fuel supply pump — DENSO ECD-U2
Governor — Electronic control type
Quantity of lubricating oil (Refill capacity) l 58 (50)
Quantity of coolant l 25 (In only engine)
Alternator — 24V, 60A, 75A
Starting motor — 24V, 11kW
Battery — 12V, 170Ah × 2
Turbocharger — KOMATSU KTR110L
Air compressor — —
Others — With air-cooled aftercooler
With cooled EGR
20 140E-5 Series
01 Specification SEN00079-04
(Gross)
No-load max. speed
rpm 2,200 (+50/0)
(High idle speed)
No-load min. speed
rpm 725 ± 25
(Low idle speed)
g/kW·h
Fuel consumption ratio at rated point 218 {162}
{g/HP·h}
Dry weight kg 1,750
Fuel supply pump — DENSO ECD-U2
Governor — Electronic control type
Quantity of lubricating oil (Refill capacity) l 58 (50)
Quantity of coolant l 25 (In only engine)
Alternator — 24V, 60A, 75A
Starting motor — 24V, 11kW
Battery — 12V, 170Ah × 2
Turbocharger — KOMATSU KTR110L
Air compressor — —
Others — With air-cooled aftercooler
140E-5 Series 21
SEN00079-04 01 Specification
—
No-load max. speed
rpm —
(High idle speed)
No-load min. speed
rpm —
(Low idle speed)
g/kW·h
Fuel consumption ratio at rated point 222 {163}
{g/HP·h}
Dry weight kg 1,950
Fuel supply pump — DENSO ECD-U2
Governor — Electronic control type
Quantity of lubricating oil (Refill capacity) l 82 (73)
Quantity of coolant (With radiator) l 53
Alternator — 24V, 35A
Starting motor — 24V, 7.5kW
Battery — —
Turbocharger — KOMATSU KTR110L
Air compressor — —
Others — With air-cooled aftercooler
With cooled EGR
22 140E-5 Series
01 Specification SEN00079-04
140E-5 Series 23
SEN00079-04 01 Specification
General view 1
SAA6D140E-5 (Left side view of engine)
Machine model: PC600-8, PC600LC-8
1. Center of crankshaft
2. Rear face of flywheel housing
24 140E-5 Series
01 Specification SEN00079-04
1. Center of crankshaft
2. Center of cylinder liner
140E-5 Series 25
SEN00079-04 01 Specification
1. Center of crankshaft
2. Rear face of flywheel housing
26 140E-5 Series
01 Specification SEN00079-04
1. Center of crankshaft
2. Center of cylinder liner
140E-5 Series 27
SEN00079-04 01 Specification
1. Center of crankshaft
2. Rear face of flywheel housing
28 140E-5 Series
01 Specification SEN00079-04
1. Center of crankshaft
2. Center of cylinder liner
140E-5 Series 29
SEN00079-04 01 Specification
1. Center of crankshaft
2. Rear face of flywheel housing
30 140E-5 Series
01 Specification SEN00079-04
1. Center of crankshaft
2. Center of cylinder liner
140E-5 Series 31
SEN00079-04 01 Specification
1. Center of crankshaft
2. Rear face of flywheel housing
32 140E-5 Series
01 Specification SEN00079-04
1. Center of crankshaft
2. Center of cylinder liner
140E-5 Series 33
SEN00079-04 01 Specification
1. Center of crankshaft
2. Rear face of flywheel housing
34 140E-5 Series
01 Specification SEN00079-04
1. Center of crankshaft
2. Center of cylinder liner
140E-5 Series 35
SEN00079-04 01 Specification
1. Center of crankshaft
2. Rear face of flywheel housing
36 140E-5 Series
01 Specification SEN00079-04
1. Center of crankshaft
2. Center of cylinder liner
140E-5 Series 37
SEN00079-04 01 Specification
1. Center of crankshaft
2. Rear face of flywheel housing
38 140E-5 Series
01 Specification SEN00079-04
1. Center of crankshaft
2. Center of cylinder liner
140E-5 Series 39
SEN00079-04 01 Specification
1. Center of crankshaft
2. Rear face of flywheel housing
40 140E-5 Series
01 Specification SEN00079-04
1. Center of crankshaft
2. Center of cylinder liner
140E-5 Series 41
SEN00079-04 01 Specification
1. Center of crankshaft
2. Rear face of flywheel housing
42 140E-5 Series
01 Specification SEN00079-04
1. Center of crankshaft
2. Center of cylinder liner
140E-5 Series 43
SEN00079-04 01 Specification
1. Center of crankshaft
2. Rear face of flywheel housing
44 140E-5 Series
01 Specification SEN00079-04
1. Center of crankshaft
2. Center of cylinder liner
140E-5 Series 45
SEN00079-04 01 Specification
Dimensions table 1
Unit: mm
Dimension of each part
Engine Machine model
A B C D E F G H
PC600-8, PC600LC-8 1,494 1,863 441 227 143 920 1,155 1,151
PC600-8R,
1,482 1,863 411 227 143 920 1,155 1,151
PC600LC-8R
PC800-8, PC800LC-8,
PC800SE-8, PC850-8,
PC850SE-8,
PC800-8R,
1,350 1,902 594 196 196 1,000 1,185 1,176
PC800LC-8R,
PC800SE-8R,
PC850-8R,
PC850SE-8R
D155AX-6, D155A-6R 1,477 1,950 419 14 14 918 1,090 1,109
SAA6D140E-5
D275AX-5E0 1,505 2,178 542 15 15 794 966 1,135
D275A-5R 1,461 2,178 542 15 15 794 966 1,180
WA500-6 1,477 1,727 419 150 150 815 945 1,094
WA500-6R 1,465 1,727 419 150 150 815 945 1,094
HD325-7, HD405-7,
1,775 1,604 542 80 80 875 1,005 1,025
HD325-7R, HD405-7R
HM350-2, HM350-2R,
1,724 1,496 542 147 147 815 945 1,250
HM400-2, HM400-2R
SDG400S-6B1
(HOKUETSU INDUS- 1,785 1,523 403 213 213 877 956 1,242
TRIES GENERATOR)
a These dimensions are given for reference when the engine is set on a test bench.
46 140E-5 Series
01 Specification SEN00079-04
Weight table 1
(With EGR)
Unit: kg
No. Item Main parts SAA6D140E-5
1 Turbocharger KOMATSU KTR110L 24 (Air-cooled)/28 (Water-cooled)
2 Cylinder head assembly Cylinder head, valve, valve spring 23 × 6
Cylinder block, bearing, cap,
3 Cylinder block assembly 480
cylinder liner
4 Front cover 60
PC800-8, PC800SE-8,
PC800LC-8 36
PC850-8, PC850SE-8
PC600-8, PC600LC-8
D155AX-6 30
WA500-6
5 Oil pan
D275AX-5E0
HD325-7, HD405-7 28
HM350-2, HM400-2
SDG400S-6B1
(HOKUETSU INDUS- 62
TRIES GENERATOR)
PC600-8, PC600LC-8
PC800-8, PC800SE-8,
PC800LC-8
PC850-8, PC850SE-8 60
D155AX-6
D275AX-5E0
6 Flywheel assembly Flywheel ring gear WA500-6
HD325-7, HD405-7
47
HM350-2, HM400-2
SDG400S-6B1
(HOKUETSU INDUS- 123
TRIES GENERATOR)
7 Flywheel housing assembly 65
8 Crankshaft assembly Crankshaft, crank gear 136
9 Camshaft assembly Camshaft, cam gear, thrust plate 20
Piston and connecting rod Piston, piston ring, piston pin,
10 11 × 6
assembly connecting rod
11 Oil pump 7
12 Fuel supply pump 13
13 Water pump 18
24V, 35A 8
24V, 50A 11
14 Alternator 24V, 60A 11
24V, 75A 12.5
24V, 90A 19
24V, 7.5kW 15.5
15 Starting motor
24V, 11kW 18
16 EGR oil pump 6
17 EGR valve 10
18 Bypass valve 10
19 EGR cooler 10
140E-5 Series 47
SEN00079-04 01 Specification
(EGR-less)
Unit: kg
No. Item Main parts SAA6D140E-5
24 (Air-cooled) /
1 Turbocharger KOMATSU KTR110L
24 (Water-cooled)
2 Cylinder head assembly Cylinder head, valve, valve spring 23 × 6
Cylinder block, bearing, cap,
3 Cylinder block assembly 480
cylinder liner
4 Front cover 60
PC800-8R,
PC800SE-8R,
PC800LC-8R 36
PC850-8R,
PC850SE-8R
PC600-8R,
5 Oil pan
PC600LC-8R
30
D155A-6R
WA500-6R
D275A-5R
HD325-7R, HD405-7R 28
HM350-2R, HM400-2R
PC600-8R,
PC600LC-8R
PC800-8R,
PC800SE-8R,
PC800LC-8R
60
PC850-8R,
6 Flywheel assembly Flywheel ring gear PC850SE-8R
D155A-6R
D275A-5R
WA500-6R
HD325-7R, HD405-7R
47
HM350-2R, HM400-2R
7 Flywheel housing assembly 65
8 Crankshaft assembly Crankshaft, crank gear 136
9 Camshaft assembly Camshaft, cam gear, thrust plate 20
Piston and connecting rod Piston, piston ring, piston pin,
10 11 × 6
assembly connecting rod
11 Oil pump 7
12 Fuel supply pump 13
13 Water pump 18
24V, 35A 8
24V, 50A 11
14 Alternator 24V, 60A 11
24V, 75A 12.5
24V, 90A 19
15 Starting motor 24V, 11kW 18
48 140E-5 Series
01 Specification SEN00079-04
140E-5 Series 49
SEN00079-04 01 Specification
SAA6D140E-5
(Machine model: PC600-8, PC600LC-8, PC600-8R, PC600LC-8R) 1
50 140E-5 Series
01 Specification SEN00079-04
SAA6D140E-5
(Machine model: PC800-8, PC800SE-8, PC850-8, PC850SE-8, PC800LC-8,
PC800-8R, PC800SE-8R, PC850-8R, PC850SE-8R, PC800LC-8R) 1
140E-5 Series 51
SEN00079-04 01 Specification
52 140E-5 Series
01 Specification SEN00079-04
140E-5 Series 53
SEN00079-04 01 Specification
54 140E-5 Series
01 Specification SEN00079-04
SAA6D140E-5
(Machine model: HD325-7, HD405-7, HD325-7R, HD405-7R) 1
140E-5 Series 55
SEN00079-04 01 Specification
56 140E-5 Series
01 Specification SEN00079-04
140E-5 Series 57
SEN00079-04
© 2008 KOMATSU
All Rights Reserved
Printed in Japan 04-08 (01)
58
SEN00081-04
140E-5 Series
140E-5 Series 1
SEN00081-04 10 Structure, function and maintenance standard
2 140E-5 Series
10 Structure, function and maintenance standard SEN00081-04
A: Air intake unit (Between air-cooled aftercooler and air intake manifold)
140E-5 Series 3
SEN00081-04 10 Structure, function and maintenance standard
A: To EGR cooler
B: To turbocharger
C: From bypass valve
4 140E-5 Series
10 Structure, function and maintenance standard SEN00081-04
Air cleaner 1
ERB type
[Air cleaner of automatic exhaust gas discharge type (Radial seal type)]
A: Air inlet
B: To turbocharger (Intake air)
C: To muffler (Dust)
1. Pre-cleaner
2. Air cleaner casing
3. Outer element
4. Inner element
140E-5 Series 5
SEN00081-04 10 Structure, function and maintenance standard
FRG type
[Air cleaner of cyclone pack type with evacuator valve (Radial seal type)]
Machine
Engine Type Evacuator valve Number of elements
model
PC600-8, PC600-8R,
PC600LC-8,
PC600LC-8R
PC800-8, PC800LC-8,
PC800-8R,
PC800LC-8R
PC800SE-8,
PC800SE-8R Inner cylinder: 1,
SAA6D140E-5 FRG (Radial seal type) Automatic discharge
PC850-8, PC850-8R Outer cylinder: 1
PC850SE-8,
PC850SE-8R
WA500-6, WA500-6R
HD325-7, HD325-7R
HD405-7, HD405-7R
HM350-2, HM350-2R,
HM400-2, HM400-2R
6 140E-5 Series
10 Structure, function and maintenance standard SEN00081-04
Structure Operation
q The size of the body is reduced from the con- q Air containing dust is sucked in vertically
ventional type without changing the diameter through inlet (1) and the dust is separated by
of the element. the centrifugal effect of guide vane (3).
q Since the inlet is set in the tangential direction, q More than 99.9% of the dust is removed by pri-
air is given sufficient centrifugal force by the mary element (4) and clean air is sucked in the
simple spiral guide vane, not by the guide engine through safety element (5) and outlet
plate. (2).
q The dust and water separated by guide vane
(3) swirl along the inside wall of body (9) and
enter evacuator valve (6) and then are dis-
charged out automatically.
140E-5 Series 7
SEN00081-04 10 Structure, function and maintenance standard
Turbocharger 1
(With EGR)
Air-cooled type
Model: KTR110L
PC600-8, PC600LC-8, HD325-7, HD405-7, WA500-6, HM350-2, HM400-2,
SDG400S-6B1 (HOKUETSU INDUSTRIES GENERATOR)
8 140E-5 Series
10 Structure, function and maintenance standard SEN00081-04
1. Blower housing
2. V-band
3. Diffuser plate
4. Center housing
5. Shroud
6. Turbine housing
7. Blower impeller
8. Seal ring
9. Bearing metal
10. Journal bearing
11. Seal ring
12. Turbine impeller
Specifications
Model: KOMATSU KTR110L (Air-cooled)
Overall length: 308 mm
Overall width: 305 mm
Overall height: 287 mm
Weight: 24 kg
140E-5 Series 9
SEN00081-04 10 Structure, function and maintenance standard
(EGR-less)
Air-cooled type
Model: KTR110L
PC600-8R, PC600LC-8R, HD325-7R, HD405-7R, WA500-6R, HM350-2R, HM400-2R
10 140E-5 Series
10 Structure, function and maintenance standard SEN00081-04
1. Blower housing
2. V-band
3. Diffuser plate
4. Center housing
5. Shroud
6. Turbine housing
7. Blower impeller
8. Seal ring
9. Bearing metal
10. Journal bearing
11. Seal ring
12. Turbine impeller
Specifications
Model: KOMATSU KTR110L (Air-cooled)
Overall length: 308 mm
Overall width: 305 mm
Overall height: 287 mm
Weight: 24 kg
140E-5 Series 11
SEN00081-04 10 Structure, function and maintenance standard
(With EGR)
Water-cooled type
Model: KTR110L
PC800-8, PC800LC-8, PC800SE-8, PC850-8, PC850SE-8, D155AX-6, D275AX-5E0
12 140E-5 Series
10 Structure, function and maintenance standard SEN00081-04
1. Blower housing
2. V-band
3. Diffuser plate
4. Center housing
(Water-cooled center housing: Standard for D275A, D155A and PC800, and
optional for other machine models)
5. Shroud
6. Turbine housing
7. Blower impeller
8. Seal ring
9. Bearing metal
10. Journal bearing
11. Seal ring
12. Turbine impeller
Specifications
Model: KOMATSU KTR110L (Water-cooled)
Overall length: 308 mm
Overall width: 305 mm
Overall height: 287 mm
Weight: 28 kg
140E-5 Series 13
SEN00081-04 10 Structure, function and maintenance standard
(EGR-less)
Water-cooled type
Model: KTR110L
PC800-8R, PC800LC-8R, PC800SE-8R, PC850-8R, PC850SE-8R, D155A-6R, D275A-5R
14 140E-5 Series
10 Structure, function and maintenance standard SEN00081-04
1. Blower housing
2. V-band
3. Diffuser plate
4. Center housing
(Water-cooled center housing: Standard for D275A, D155A and PC800, and
optional for other machine models)
5. Shroud
6. Turbine housing
7. Blower impeller
8. Seal ring
9. Bearing metal
10. Journal bearing
11. Seal ring
12. Turbine impeller
Specifications
Model: KOMATSU KTR110L (Water-cooled)
Overall length: 308 mm
Overall width: 305 mm
Overall height: 287 mm
Weight: 24 kg
140E-5 Series 15
SEN00081-04 10 Structure, function and maintenance standard
Model: KTR110L
16 140E-5 Series
10 Structure, function and maintenance standard SEN00081-04
Unit: mm
Replace bearing
2 Radial play (Play in radial direction) 0.43 – 0.68 0.84
parts
Clearance between blower housing and Replace bearing
3 Clearance limit (Min.): 0.14
impeller parts
140E-5 Series 17
SEN00081-04 10 Structure, function and maintenance standard
Turbocharger mounting
1. Muffler
2. Turbocharger
18 140E-5 Series
10 Structure, function and maintenance standard SEN00081-04
Aftercooler 1
Air-cooled type
SAA6D140E-5 (HD325-7, HD325-7R, HD405-7, HD405-7R)
1. Tank
2. Side support
3. Tube
4. Fin
140E-5 Series 19
SEN00081-04 10 Structure, function and maintenance standard
Muffler 1
For PC600-8, PC600-8R, PC600LC-8, PC600LC-8R
20 140E-5 Series
10 Structure, function and maintenance standard SEN00081-04
140E-5 Series 21
SEN00081-04 10 Structure, function and maintenance standard
22 140E-5 Series
10 Structure, function and maintenance standard SEN00081-04
140E-5 Series 23
SEN00081-04 10 Structure, function and maintenance standard
EGR system 1
Features
q The exhaust gas is kept clean by sensing each
part of the EGR circuit and controlling the EGR
rate according to the operating condition.
q Since the EGR circuit is monitored and trouble-
shooted, a serious trouble is prevented.
24 140E-5 Series
10 Structure, function and maintenance standard SEN00081-04
140E-5 Series 25
SEN00081-04 10 Structure, function and maintenance standard
26 140E-5 Series
10 Structure, function and maintenance standard SEN00081-04
1. EGR valve
2. Bypass valve
3. EGR cooler
4. Venturi system
5. EGR valve position sensor
6. Bypass valve position sensor
7. Bypass piping
8. EGR piping
9. EGR oil pump
Operation
q The engine controller outputs signals for open-
ing EGR valve (1) most properly according to
the load on the engine to attain both clean
exhaust gas and low fuel consumption.
q If EGR valve (1) opens, a part of the exhaust
gas (EGR gas) flows from the exhaust mani-
fold through EGR piping (8) to EGR cooler (3).
q The exhaust gas cooled by EGR cooler (3)
flows through EGR valve (1) and mixes with
the intake air in venturi system (4), and then
flows in the air intake manifold.
q In the operating range where the boost pres-
sure is higher than the exhaust pressure on the
high load side, the EGR gas does not flow to
the air intake side easily. At this time, the
engine controller opens bypass valve (2).
q If bypass valve (2) opens, the intake air flows
through bypass piping (7). As a result, the
exhaust pressure rises and more EGR gas
mixes with the intake air.
140E-5 Series 27
SEN00081-04 10 Structure, function and maintenance standard
28 140E-5 Series
10 Structure, function and maintenance standard SEN00081-04
EGR cooler
Function
q The EGR cooler cools the high-temperature
EGR gas taken out of the exhaust gas to
increase the gas density, or the EGR effi-
ciency.
Structure
q The EGR cooler is a multi-tube heat exchanger.
When the high-temperature EGR gas flows
through heat exchange tube (1), it is cooled by
the coolant flowing outside of the tube.
q Heat exchange tube (1) is made of corrosion-
resistant stainless steel and corrugated to
increase the cooling efficiency.
140E-5 Series 29
SEN00081-04 10 Structure, function and maintenance standard
Venturi system
Structure
q The EGR gas and intake air mix together in the
venturi system.
q The venturi system consists of throat (2), ven-
turi nozzle (1), and diffuser (3).
Operation
q The boost pressure increased by the turbo-
charger is set negative temporarily with the
venturi effect of the throat to take the EGR gas
into the intake air through venturi nozzle (1).
q When the mixture of the EGR gas and intake
air flows through diffuser (3), its pressure is
increased again to the normal level and then it
flows in the intake manifold.
30 140E-5 Series
10 Structure, function and maintenance standard SEN00081-04
140E-5 Series 31
SEN00081-04 10 Structure, function and maintenance standard
Engine unit 1
Cylinder head 1
32 140E-5 Series
10 Structure, function and maintenance standard SEN00081-04
A: Intake air
B: Exhaust gas
C: To fuel tank
D: To radiator
Specifications
Cylinder head
q Direct injection type
q 4-valve type
q Split-type 1-cylinder, 1-head
q Centralized cooling system for valve bridge
and injector
q Cylinder head bolt: Plastic-region tightening
Valve seat
q Valve seat inserts are press fitted to both
intake and exhaust valves
Rocker cover
q O-ring seal
Injector
q Installation: Dry type (without sleeve)
140E-5 Series 33
SEN00081-04 10 Structure, function and maintenance standard
a Tighten the cylinder head mounting bolts in the order of (1) – (7).
Unit: mm
34 140E-5 Series
10 Structure, function and maintenance standard SEN00081-04
140E-5 Series 35
SEN00081-04 10 Structure, function and maintenance standard
Cylinder block 1
36 140E-5 Series
10 Structure, function and maintenance standard SEN00081-04
1. Front cover
2. Cylinder block
3. Cylinder liner
4. Clevis seal
5. Liner O-ring (Water)
6. Liner O-ring (Oil)
7. Thrust bearing metal
8. Main bearing metal
9. Main bearing metal cap
10. Main bearing metal cap bolt
11. Front oil seal
12. Piston cooling nozzle (Front side)
13. Piston cooling nozzle (Rear side)
Specifications
Cylinder block
q Crankshaft section: 7 bearings
q Camshaft section: High cam type, 7 bearings
q Main cap bolt: Plastic-region tightening
Front seal
q Single lip with dust seal
(Lay-down seal)
Piston cooling
q With piston cooling nozzle
(2 pieces for each cylinder)
Cylinder liner
q Wet type
q Machining on inside: Plateau honing
Soft nitriding process
Liner ring
q Upper: Clevis seal
q Middle: O-ring (Ethylene-propylene rubber)
q Lower: O-ring (Silicone rubber)
140E-5 Series 37
SEN00081-04 10 Structure, function and maintenance standard
Unit: mm
38 140E-5 Series
10 Structure, function and maintenance standard SEN00081-04
Cylinder liner 1
Unit: mm
Interference of cylinder liner and Standard interference Interference limit Replace or correct cylin-
block 0.02 – 0.12 Min. 0.02 der liner or block
140E-5 Series 39
SEN00081-04 10 Structure, function and maintenance standard
40 140E-5 Series
10 Structure, function and maintenance standard SEN00081-04
Specifications
Crankshaft: Closed die forging
Journal, fillet
Induction hardening
Piston rings
140E-5 Series 41
SEN00081-04 10 Structure, function and maintenance standard
Crankshaft 1
Unit: mm
42 140E-5 Series
10 Structure, function and maintenance standard SEN00081-04
Camshaft 1
Unit: mm
140E-5 Series 43
SEN00081-04 10 Structure, function and maintenance standard
Unit: mm
+0.038
Inside diameter of cam roller 12.7 12.78 Replace
3 +0.013
Diameter of cam roller pin 12.63 ±0.006 12.56
Standard size Tolerance
4 Diameter of push rod ball end –0.20
12.7
–0.20
Diameter of push rod socket –0.20
5 end 13.4
–0.20
6 Bend of push rod Repair limit: 0.3 (Overall swing of indicator)
44 140E-5 Series
10 Structure, function and maintenance standard SEN00081-04
140E-5 Series 45
SEN00081-04 10 Structure, function and maintenance standard
46 140E-5 Series
10 Structure, function and maintenance standard SEN00081-04
Unit: mm
Clearance between piston pin Standard clearance Clearance limit Replace piston or
and piston 0.035 – 0.051 0.10 piston pin
140E-5 Series 47
SEN00081-04 10 Structure, function and maintenance standard
Connecting rod 1
Unit: mm
Inside diameter of connecting Standard size Tolerance Repair limit Replace bushing
rod small end bushing +0.049 (Spare is half
(Ream after press fitting) 52 52.09 worked)
+0.030
1
Clearance between connect- Standard clearance Clearance limit
Replace bushing or
ing rod small end bushing and
0.030 – 0.055 0.11 piston pin
piston pin
a Do not use a connecting rod cap mounting bolt more than 5 times.
Each time the bolt is used, make a punch mark on its head.
48 140E-5 Series
10 Structure, function and maintenance standard SEN00081-04
1. Rear seal
2. Ring gear
3. Flywheel
4. Engine speed sensor (for monitor)
5. Flywheel housing
6. Engine speed sensor
(NE sensor for engine control)
140E-5 Series 49
SEN00081-04 10 Structure, function and maintenance standard
50 140E-5 Series
10 Structure, function and maintenance standard SEN00081-04
Unit: mm
140E-5 Series 51
SEN00081-04 10 Structure, function and maintenance standard
Vibration damper 1
1. Adapter
2. Pin (between adapter and crankshaft pulley)
3. Vibration damper
4. Bolt (between adapter and vibration damper)
5. Bolt (between crankshaft and adapter)
6. Pin (between adapter and vibration damper)
52 140E-5 Series
10 Structure, function and maintenance standard SEN00081-04
140E-5 Series 53
SEN00081-04 10 Structure, function and maintenance standard
Timing gear 1
(With EGR)
54 140E-5 Series
10 Structure, function and maintenance standard SEN00081-04
A: Timing mark
[Between crank gear and main idler gear (large)]
B: Timing mark
[Between main idler gear (small) and fuel supply pump drive gear]
C: Timing mark
[Between main idler gear (small) and cam gear]
Unit: mm
140E-5 Series 55
SEN00081-04 10 Structure, function and maintenance standard
(EGR-less)
56 140E-5 Series
10 Structure, function and maintenance standard SEN00081-04
A: Timing mark
[Between crank gear and main idler gear (large)]
B: Timing mark
[Between main idler gear (small) and fuel supply pump drive gear]
C: Timing mark
[Between main idler gear (small) and cam gear]
Unit: mm
140E-5 Series 57
SEN00081-04 10 Structure, function and maintenance standard
Valve system 1
58 140E-5 Series
10 Structure, function and maintenance standard SEN00081-04
Specifications
Camshaft: Drawn steel bar (Turning)
Journal and cam sections:
Induction hardening
140E-5 Series 59
SEN00081-04 10 Structure, function and maintenance standard
60 140E-5 Series
10 Structure, function and maintenance standard SEN00081-04
Unit: mm
140E-5 Series 61
SEN00081-04 10 Structure, function and maintenance standard
Unit: mm
Clearance between rocker arm Standard clearance Clearance limit Replace rocker arm shaft
shaft and rocker arm 0.0285 – 0.0935 0.13 or rocker arm
62 140E-5 Series
10 Structure, function and maintenance standard SEN00081-04
Unit: mm
140E-5 Series 63
SEN00081-04
© 2008 KOMATSU
All Rights Reserved
Printed in Japan 04-08 (01)
64
SEN00082-04
140E-5 Series
140E-5 Series 1
SEN00082-04 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 ..................................................................................................................................... 72
Starting aid ......................................................................................................................................... 74
Engine controller ................................................................................................................................ 75
2 140E-5 Series
10 Structure, function and maintenance standard SEN00082-04
140E-5 Series 3
SEN00082-04 10 Structure, function and maintenance standard
Lubrication system 1
Lubrication system diagram 1
(With EGR)
a The layout of the oil filter, shapes of the oil pan and piping, etc. are subject to machine models.
4 140E-5 Series
10 Structure, function and maintenance standard SEN00082-04
W: Coolant
1. Oil pan
2. Oil strainer
3. Oil pump
4. Oil pump relief valve
5. Oil cooler
6. Thermo-valve
7. Oil filter
8. Safety valve
9. Crankshaft
10. Piston cooling nozzle
11. Piston
12. Camshaft
13. Cam follower
14. Rocker arm
15. Air intake valve and exhaust valve
16. Timing gear
17. Turbocharger
18. Fuel supply pump
19. EGR oil pump
20. EGR oil pump relief valve
21. EGR valve
22. Bypass valve
23. Main gallery
24. Oil filter clogging switch (for SDG400S-6B1)
140E-5 Series 5
SEN00082-04 10 Structure, function and maintenance standard
(EGR-less)
a The layout of the oil filter, shapes of the oil pan and piping, etc. are subject to machine models.
6 140E-5 Series
10 Structure, function and maintenance standard SEN00082-04
W: Coolant
1. Oil pan
2. Oil strainer
3. Oil pump
4. Oil pump relief valve
5. Oil cooler
6. Thermo-valve
7. Oil filter
8. Safety valve
9. Crankshaft
10. Piston cooling nozzle
11. Piston
12. Camshaft
13. Cam follower
14. Rocker arm
15. Air intake valve and exhaust valve
16. Timing gear
17. Turbocharger
18. Fuel supply pump
19. Main gallery
140E-5 Series 7
SEN00082-04 10 Structure, function and maintenance standard
Oil pump 1
8 140E-5 Series
10 Structure, function and maintenance standard SEN00082-04
140E-5 Series 9
SEN00082-04 10 Structure, function and maintenance standard
Oil filter 1
Except SDG400S-6B1 (HOKUETSU INDUSTRIES GENERATOR)
10 140E-5 Series
10 Structure, function and maintenance standard SEN00082-04
140E-5 Series 11
SEN00082-04 10 Structure, function and maintenance standard
Oil cooler 1
12 140E-5 Series
10 Structure, function and maintenance standard SEN00082-04
A: Oil inlet
B: Oil outlet
C: Coolant inlet
Specifications
Oil cooler thermo-valve
Opening temperature: 85 ± 1.5°C
Full opening temperature: 100°C
Lift at full opening: 8 mm
Oil cooler
Heat dissipation surface area
SAA6D140E-5: 1.23 m2
Heat exchange rate
SAA6D140E-5: Min. 39,800 kcal/h
Unit: mm
No. Check item Criteria Remedy
Lift of thermostat at full opening Min. 8 mm (Before checking, leave valve in oil of 100°C for 4 – 5 minutes)
Check that valve closes fully when its temperature is lowered from 100°C Replace
6
Opening/Closing of thermostat for full opening to 85°C. (Before checking valve, leave it in oil for 4 – 5
minutes)
140E-5 Series 13
SEN00082-04 10 Structure, function and maintenance standard
Fuel system 1
CRI system diagram 1
(With EGR)
14 140E-5 Series
10 Structure, function and maintenance standard SEN00082-04
(EGR-less)
140E-5 Series 15
SEN00082-04 10 Structure, function and maintenance standard
Configuration
q The CRI system is divided by the function into
the fuel system and control system.
16 140E-5 Series
10 Structure, function and maintenance standard SEN00082-04
2. Control system
a Parts marked with * (2 places) are installed to only the engines with EGR.
140E-5 Series 17
SEN00082-04 10 Structure, function and maintenance standard
q The CRI system consists of the fuel supply q If the TWV is turned on (energized), the fuel
pump, common rail, injector, engine controller circuit is so changed that the high-pressure
to control them, and sensors. fuel in the control chamber will flow through the
q The fuel supply pump generates fuel pressure orifice. As a result, the needle valve is raised
in the common rail. The fuel pressure is con- to start fuel injection by the nozzle cracking
trolled by the fuel discharge rate of the supply pressure of the high-pressure fuel on the noz-
pump. zle side.
q The discharge rate is controlled by turning on q If the TWV is turned off (de-energized), the fuel
and off the PCV (pressure control valve) of the circuit is so changed that the high-pressure
fuel supply pump according to the electric sig- fuel will be applied to the control chamber
nals from the engine controller. through the orifice. As a result, the needle
q The common rail receives the pressurized fuel valve lowers and finishes fuel injection.
from the fuel supply pump and distributes it to q Accordingly, the fuel injection timing and fuel
the cylinders. injection rate are controlled respectively by the
q The fuel pressure is sensed by the common timing to turn on the TWV and the length of the
rail fuel pressure sensor installed to the com- turn-on time of the TWV.
mon rail.
q A feedback control is applied so that the actual
fuel pressure will match to the command pres-
sure set according to the engine speed and the
load on the engine.
q The fuel pressure in the common rail is applied
to the nozzle side of the injector and to the
control chamber through the fuel injection pipe
of each cylinder.
q The injector controls the fuel injection rate and
fuel injection timing by turning on and off the
TWV (2-way solenoid valve).
18 140E-5 Series
10 Structure, function and maintenance standard SEN00082-04
140E-5 Series 19
SEN00082-04 10 Structure, function and maintenance standard
Operation
20 140E-5 Series
10 Structure, function and maintenance standard SEN00082-04
140E-5 Series 21
SEN00082-04 10 Structure, function and maintenance standard
2. Common rail
1) Flow damper
Function
q The flow dampers damp the pressure pulses in
the high pressure piping and supply the fuel to
the injectors with stable pressure.
q If excessive fuel flows out, the flow dampers
block the fuel passage to prevent abnormal
outflow of the fuel.
q If the fuel flows out abnormally, high pressure
is applied to the piston, which moves to the
right until it reaches the seat to stop the fuel.
Operation
When fuel is not injected
q Piston (2) is in contact with stopper (1) (initial
position).
q The fuel for static leakage is supplied through
orifice (a) of piston (2) and clearance in the
sliding parts.
22 140E-5 Series
10 Structure, function and maintenance standard SEN00082-04
1. Ball
2. Housing
3. Spring
4. Body
5. Guide
140E-5 Series 23
SEN00082-04 10 Structure, function and maintenance standard
3. Injector
Outline
q The function of the injector is to inject the high-
pressure fuel from the common rail into each
combustion chamber of the engine in the opti-
mum timing, by the optimum quantity, at the
optimum injection rate, and under the optimum
spray condition.
q The TWV (2-way solenoid valve) controls the
start and finish of fuel injection by controlling
the pressure in the control chamber.
q The orifice limits the opening speed of the noz-
zle and controls the fuel injection rate.
q The hydraulic piston transmits the force gener-
ated by the pressure in the control chamber to
the needle valve of the nozzle.
q The nozzle sprays the fuel.
24 140E-5 Series
10 Structure, function and maintenance standard SEN00082-04
Structure
140E-5 Series 25
SEN00082-04 10 Structure, function and maintenance standard
Operation
1) No fuel injection (A) 3) Finish of fuel injection (C)
q While solenoid (6) is not energized, valve body q If solenoid (6) is de-energized, valve body (5)
(5) is pressed down by spring (7). is lowered by spring (7) and the fuel passage is
q Since the high-pressure fuel is applied from closed.
the common rail to pressure control chamber q At this time, the high-pressure fuel in the com-
(8), nozzle (1) is closed and the fuel is not mon rail is applied to pressure control chamber
injected. (8) suddenly and nozzle (1) is closed quickly,
fuel injection is finished sharply.
2) Start of fuel injection (B)
q If solenoid (6) is energized, valve body (5) is
pulled up by the electromagnetic force and the
fuel passage is opened.
q Since the fuel in pressure control chamber (8)
flows out through orifices (3) and (4), nozzle
(1) rises and fuel injection pump starts.
q The fuel injection rate is increased gradually by
the function of orifices (3) and (4).
q If solenoid (6) is kept energized, the fuel injec-
tion rate is increased to the maximum.
26 140E-5 Series
10 Structure, function and maintenance standard SEN00082-04
140E-5 Series 27
SEN00082-04 10 Structure, function and maintenance standard
28 140E-5 Series
10 Structure, function and maintenance standard SEN00082-04
Various controls
a Parts marked with * (3 places) are installed to only the engines with EGR.
q The CRI system controls the fuel injection rate 2. Fuel injection timing control function
and fuel injection timing more properly than the q The fuel injection timing control function is
mechanical governor or timer of the conven- employed instead of the function of the con-
tional fuel injection pump. ventional timer. It controls the fuel injection
q For the control of the system, calculations nec- timing most properly from the engine speed
essary to the engine controller are performed and fuel injection rate.
fr om th e si gn als se nt fr om the s en so rs
installed to the engine and machine.
q The energizing timing and energizing period of 3. Fuel injection pressure control func-
the injector are so controlled that the optimum tion (Common rail fuel pressure control
quantity of fuel will be injected in the optimum
function)
timing.
q The fuel injection pressure control function
(common rail fuel pressure control function) is
a function of measuring the fuel pressure with
1. Fuel injection rate control function
the common rail fuel pressure sensor and
q The fuel injection rate control function is
feeding it back to the engine controller to con-
employed instead of the function of the con-
trol the delivery of the fuel supply pump.
ventional governor. It controls the fuel injection
q This function performs pressure feedback con-
according to the signals of engine speed and
trol so that the fuel injection pressure will be
accelerator angle so that the fuel injection rate
the same as the optimum value (command
will be most proper.
value) set according to the engine speed and
fuel injection rate.
140E-5 Series 29
SEN00082-04 10 Structure, function and maintenance standard
30 140E-5 Series
10 Structure, function and maintenance standard SEN00082-04
140E-5 Series 31
SEN00082-04 10 Structure, function and maintenance standard
32 140E-5 Series
10 Structure, function and maintenance standard SEN00082-04
140E-5 Series 33
SEN00082-04 10 Structure, function and maintenance standard
A: Pressure inlet
B: Mounting screw: M5
Tightening torque: 4.5 ± 0.5 Nm {0.46 ± 0.05 kgm}
34 140E-5 Series
10 Structure, function and maintenance standard SEN00082-04
A: Mounting screw: M6
Tightening torque: 5.5 ± 0.5 Nm {0.56 ± 0.05 kgm}
1. Sensor
2. O-ring
140E-5 Series 35
SEN00082-04 10 Structure, function and maintenance standard
36 140E-5 Series
10 Structure, function and maintenance standard SEN00082-04
140E-5 Series 37
SEN00082-04 10 Structure, function and maintenance standard
Fuel piping 1
(With EGR)
38 140E-5 Series
10 Structure, function and maintenance standard SEN00082-04
1. Fuel injection pipe (No. 1 cylinder) 11. Oil inlet pipe (for pump lubricating oil)
2. Fuel injection pipe (No. 2 cylinder) 12. Fuel supply pump
3. Fuel injection pipe (No. 3 cylinder) 13. Drive gear (Number of teeth: 48)
4. Fuel injection pipe (No. 4 cylinder) 14. Overflow valve
5. Fuel injection pipe (No. 5 cylinder) 15. PCV
6. Fuel injection pipe (No. 6 cylinder) 16. Priming pump (main)
7. Common rail 17. Pre-fuel filter
8. Fuel return pipe 18. Main fuel filter
9. Priming pump (sub)
10. Feed pump
140E-5 Series 39
SEN00082-04 10 Structure, function and maintenance standard
(EGR-less)
40 140E-5 Series
10 Structure, function and maintenance standard SEN00082-04
1. Fuel injection pipe (No. 1 cylinder) 11. Oil inlet pipe (for pump lubricating oil)
2. Fuel injection pipe (No. 2 cylinder) 12. Fuel supply pump
3. Fuel injection pipe (No. 3 cylinder) 13. Drive gear (Number of teeth: 48)
4. Fuel injection pipe (No. 4 cylinder) 14. Overflow valve
5. Fuel injection pipe (No. 5 cylinder) 15. PCV
6. Fuel injection pipe (No. 6 cylinder) 16. Electric priming pump
7. Common rail 17. Pre-fuel filter
8. Fuel return pipe 18. Main fuel filter (double cartridges)
9. Priming pump 19. Air bleeding valve for electric priming pump
10. Feed pump
140E-5 Series 41
SEN00082-04 10 Structure, function and maintenance standard
Fuel cooler 1
(Installed on the machine)
1. Mount bracket
2. Core
Specifications
Cooling method: Cooling with air
Type of core: Drawn cup, 23 layers
Heat dissipation surface area: 2.12 m2
42 140E-5 Series
10 Structure, function and maintenance standard SEN00082-04
Fuel filter 1
Main fuel filter
(With EGR)
A: Fuel inlet
B: Fuel outlet
Specifications
Filtration area: 1.06 m2
140E-5 Series 43
SEN00082-04 10 Structure, function and maintenance standard
(EGR-less)
A: Fuel inlet
B: Fuel outlet
Specifications
Filtration area: 1.06 m2 x 2
with water separator
44 140E-5 Series
10 Structure, function and maintenance standard SEN00082-04
Pre-fuel filter
A: Fuel inlet
B: Fuel outlet
Specifications
Filtration area: 1.06 m2
140E-5 Series 45
SEN00082-04 10 Structure, function and maintenance standard
Priming pump 1
(With EGR)
46 140E-5 Series
10 Structure, function and maintenance standard SEN00082-04
A: Fuel IN
B: Fuel OUT
1. Connector
2. Vibration prevention rubber
140E-5 Series 47
SEN00082-04 10 Structure, function and maintenance standard
1. Engine controller
2. Engine controller cooler
Outline
q The fuel is circulated as refrigerant through
engine controller cooler (2) to prevent engine
controller (1) from overheating.
48 140E-5 Series
10 Structure, function and maintenance standard SEN00082-04
Cooling system 1
Cooling system diagram 1
SAA6D140E-5 (For construction machinery)
A: Oil inlet
B: Oil outlet
C: Exhaust gas inlet
D: Exhaust gas outlet
1. Radiator
2. Thermostat
3. Oil cooler
4. Water pump
5. EGR cooler
6. Corrosion resistor
7. Hydraulic cooling fan
8. Hydraulic fan motor
140E-5 Series 49
SEN00082-04 10 Structure, function and maintenance standard
A: Oil inlet
B: Oil outlet
1. Radiator
2. Thermostat
3. Oil cooler
4. Water pump
5. Corrosion resistor
6. Hydraulic cooling fan
7. Hydraulic fan motor
50 140E-5 Series
10 Structure, function and maintenance standard SEN00082-04
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
7. Engine-driven cooling fan
140E-5 Series 51
SEN00082-04 10 Structure, function and maintenance standard
A: Oil inlet
B: Oil outlet
1. Radiator
2. Thermostat
3. Oil cooler
4. Water pump
5. Corrosion resistor
6. Engine-driven cooling fan
52 140E-5 Series
10 Structure, function and maintenance standard SEN00082-04
140E-5 Series 53
SEN00082-04 10 Structure, function and maintenance standard
Water pump 1
SAA6D140E-5
54 140E-5 Series
10 Structure, function and maintenance standard SEN00082-04
A: From radiator
B: To oil cooler
C: Rotation direction
D: Pump mounting face
Specifications
Type: Centrifugal type driven with gear
Speed: Engine speed × 1.56
Delivery: 785 l/min
Total head: Min. 18.5 m
Unit: mm
No. Check item Criteria Remedy
Tolerance Standard inter-
Standard size
Interference between impeller and Shaft Hole ference
10 shaft –0.082 –0.120
16 0.025 – 0.068
–0.095 –0.150
Interference between drive gear and +0.015 –0.023
11 shaft
28
+0.002 –0.055
0.025 – 0.070 Replace
+0.015 –0.023
12 Interference between flange and shaft 25
+0.002 –0.053
0.025 – 0.068
13 Clearance between impeller and body Standard clearance: 0.6 – 0.9 (including end play)
14 Wear of water seal ring Limits of size: 1.5
140E-5 Series 55
SEN00082-04 10 Structure, function and maintenance standard
1. Oil cooler
2. Thermostat housing
3. Water pump
56 140E-5 Series
10 Structure, function and maintenance standard SEN00082-04
Thermostat 1
Unit: mm
No. Check item Criteria Remedy
Min. 9 mm (Before checking, leave valve in water of 90°C for 4 – 5 min-
Lift of thermostat at full opening
utes)
3 Check that valve closes fully when its temperature is lowered from 90°C Replace
Opening/Closing of thermostat for full opening to 76.5°C. (Before checking valve, leave it in water for 4 –
5 minutes)
140E-5 Series 57
SEN00082-04 10 Structure, function and maintenance standard
Corrosion resistor 1
58 140E-5 Series
10 Structure, function and maintenance standard SEN00082-04
140E-5 Series 59
SEN00082-04 10 Structure, function and maintenance standard
1. Crankshaft pulley
2. Tension pulley
3. Adjustment bolt
4. Fan belt
5. Fan pulley
60 140E-5 Series
10 Structure, function and maintenance standard SEN00082-04
Tension pulley
SAA6D140E-5 [HD325-7, HD405-7, HM350-2, HM400-2, HD325-7R, HD405-7R,
HM350-2R, HM400-2R,
SDG400S-6B1 (HOKUETSU INDUSTRIES GENERATOR)]
1. Tension pulley
2. Spacer
3. Ball bearing
4. Tension shaft
5. Oil seal
6. Adjustment bolt
7. Bracket
140E-5 Series 61
SEN00082-04 10 Structure, function and maintenance standard
62 140E-5 Series
10 Structure, function and maintenance standard SEN00082-04
Accessories 1
Front PTO 1
1. Shaft
2. Pulley
3. Oil seal
4. Bearing (2 pieces)
5. Housing
6. O-ring
7. Gear (Number of teeth: 14)
8. Snap ring
9. Sleeve
140E-5 Series 63
SEN00082-04 10 Structure, function and maintenance standard
64 140E-5 Series
10 Structure, function and maintenance standard SEN00082-04
Electrical equipment 1
Alternator 1
1. Alternator with built-in regulator (Open type, 35 A)
140E-5 Series 65
SEN00082-04 10 Structure, function and maintenance standard
66 140E-5 Series
10 Structure, function and maintenance standard SEN00082-04
140E-5 Series 67
SEN00082-04 10 Structure, function and maintenance standard
68 140E-5 Series
10 Structure, function and maintenance standard SEN00082-04
Outside diameter of
Engine Machine model Type Specification Weight (kg)
pulley (mm)
D155AX-6, D155A-6R Open type (brushless) manufactured
24V, 75A
(If equipped) by SAWAFUJI DENKI
D275AX-5E0, Open type (brushless) manufactured
24V, 75A
D275A-5R by SAWAFUJI DENKI
Open type (brushless) manufactured
WA500-6, WA500-6R 24V, 75A
by SAWAFUJI DENKI
SAA6D140E-5
HD325-7, HD325-7R
Open type (brushless) manufactured
HD405-7, HD405-7R 24V, 75A
by SAWAFUJI DENKI
(If equipped)
HM350-2, HM350-2R
Open type (brushless) manufactured
HM400-2, HM400-2R 24V, 75A
by SAWAFUJI DENKI
(If equipped)
140E-5 Series 69
SEN00082-04 10 Structure, function and maintenance standard
70 140E-5 Series
10 Structure, function and maintenance standard SEN00082-04
Alternator mounting
1. Alternator
2. Adjustment rod
3. Nut (2 pieces)
4. Plate
5. Cover
6. V-belt (2 pieces)
7. Spacer
140E-5 Series 71
SEN00082-04 10 Structure, function and maintenance standard
Starting motor 1
Number of Type of
Engine Machine model Type Specification Weight (kg)
pinion teeth connector
SDG400S-6B1
Water-resistant, oil-resistant
(HOKUETSU
SAA6D140E-5 type manufactured by 24V, 7.5kW 12 15.5 DT
INDUSTRIES
NIKKO DENKI
GENERATOR)
72 140E-5 Series
10 Structure, function and maintenance standard SEN00082-04
Number of Type of
Engine Machine model Type Specification Weight (kg)
pinion teeth connector
Water-resistant, oil-resistant
SAA6D140E-5 All machines type manufactured by 24V, 11kW 12 18 DT
NIKKO DENKI
140E-5 Series 73
SEN00082-04 10 Structure, function and maintenance standard
Starting aid 1
Electric heater
For SAA6D140E-5
1. Body Specifications
2. Heater coil Type of heater: Electrical intake air heater
3. Terminal q Rated voltage: 22 V (DC)
4. Connection diagram q Load current: 175 A
74 140E-5 Series
10 Structure, function and maintenance standard SEN00082-04
Engine controller 1
Features
Mounting of engine controller on engine
q Since the engine controller is mounted on the
engine, the operator can service it easily in the
field.
q The engine controller cooler (if equipped) is
prepared to cool the engine controller with the
fuel to secure the reliability of the mounted
engine controller.
q Vibrations are damped by the vibration-proof
rubber.
140E-5 Series 75
SEN00082-04
© 2008 KOMATSU
All Rights Reserved
Printed in Japan 04-08 (01)
76
SEN00147-05
140E-5 Series
Standard service value table for testing, adjusting, and troubleshooting ........................................................ 2
Running-in standard and performance test standard.................................................................................... 19
140E-5 Series 1
SEN00147-05 20 Standard value table
Engine SAA6D140E-5
Applicable machine D155AX-6
Performance Category
2 140E-5 Series
20 Standard value table SEN00147-05
Engine SAA6D140E-5
Applicable machine D155A-6R
Performance Category
kPa Min. 92 77
Exhaust pressure At rated output
{mmHg} {Min. 690} {580}
Exhaust temperature Whole speed range (20°C) °C 670 720
% (Bosch Max. 30 40
At sudden acceleration (Low → High)
index) (Max. 3.0) (4.0)
Bosch
Exhaust gas color At rated output Max. 1.5 2.5
index
Bosch
At high idle Max. 1.0 2.0
index
Intake valve mm 0.35 —
Valve clearance
Exhaust valve mm 0.57 —
Engine oil temperature: 40 – 60°C MPa Min. 4.1 2.8
Compression pressure
Engine speed: 200 – 250 rpm {kg/cm2} {Min. 42} {29}
Body
140E-5 Series 3
SEN00147-05 20 Standard value table
Engine SAA6D140E-5
Applicable machine D275AX-5E0
Performance Category
Min. 80°C
Oil pressure SAE10W30DH
At low idle SAE15W40DH MPa Min. 0.10 0.08
Engine oil temperature:
SAE30DH {kg/cm2} {Min. 1.0} {0.8}
Min. 80°C
Oil temperature Whole speed range °C 90 – 110 120
Ratio to fuel consumption at continuous
Oil consumption % Max. 0.15 0.3
rated output
Function of radiator Cracking pressure kPa
— —
pressure valve (Differential pressure) {kg/cm2}
Cooling system
4 140E-5 Series
20 Standard value table SEN00147-05
Engine SAA6D140E-5
Applicable machine D275A-5R
Performance Category
Min. 80°C
Oil pressure SAE10W30DH
At low idle SAE15W40DH MPa Min. 0.10 0.08
Engine oil temperature:
SAE30DH {kg/cm2} {Min. 1.0} {0.8}
Min. 80°C
Oil temperature Whole speed range °C 90 – 110 120
Ratio to fuel consumption at continuous
Oil consumption % Max. 0.15 0.3
rated output
Function of radiator Cracking pressure kPa
— —
pressure valve (Differential pressure) {kg/cm2}
Cooling system
140E-5 Series 5
SEN00147-05 20 Standard value table
Engine SAA6D140E-5
Applicable machine PC600, 600LC-8
Performance Category
Min. 80°C
Oil pressure SAE10W30DH
At low idle SAE15W40DH MPa Min. 0.10 0.08
Engine oil temperature:
SAE30DH {kg/cm2} {Min. 1.0} {0.8}
Min. 80°C
Oil temperature Whole speed range °C 90 – 110 120
Ratio to fuel consumption at continuous
Oil consumption % Max. 0.15 0.3
rated output
Function of radiator Cracking pressure kPa
— —
pressure valve (Differential pressure) {kg/cm2}
Cooling system
6 140E-5 Series
20 Standard value table SEN00147-05
Engine SAA6D140E-5
Applicable machine PC600, 600LC-8R
Performance Category
Min. 80°C
Oil pressure SAE10W30DH
At low idle SAE15W40DH MPa Min. 0.10 0.08
Engine oil temperature:
SAE30DH {kg/cm2} {Min. 1.0} {0.8}
Min. 80°C
Oil temperature Whole speed range °C 90 – 110 120
Ratio to fuel consumption at continuous
Oil consumption % Max. 0.15 0.3
rated output
Function of radiator Cracking pressure kPa
— —
pressure valve (Differential pressure) {kg/cm2}
Cooling system
140E-5 Series 7
SEN00147-05 20 Standard value table
Engine SAA6D140E-5
PC800, 800SE-8, 800LC-8
Applicable machine
PC850, 850SE-8
Performance Category
Min. 80°C
Oil pressure SAE10W30DH
At low idle SAE15W40DH MPa Min. 0.10 0.08
Engine oil temperature:
SAE30DH {kg/cm2} {Min. 1.0} {0.8}
Min. 80°C
Oil temperature Whole speed range °C 90 – 110 120
Ratio to fuel consumption at continuous
Oil consumption % Max. 0.15 Max. 0.3
rated output
Function of radiator Cracking pressure kPa
— —
pressure valve (Differential pressure) {kg/cm2}
Cooling system
8 140E-5 Series
20 Standard value table SEN00147-05
Engine SAA6D140E-5
PC800, 800SE-8R, 800LC-8R
Applicable machine
PC850, 850SE-8R
Performance Category
Min. 80°C
Oil pressure SAE10W30DH
At low idle SAE15W40DH MPa Min. 0.10 0.08
Engine oil temperature:
SAE30DH {kg/cm2} {Min. 1.0} {0.8}
Min. 80°C
Oil temperature Whole speed range °C 90 – 110 120
Ratio to fuel consumption at continuous
Oil consumption % Max. 0.15 Max. 0.3
rated output
Function of radiator Cracking pressure kPa
— —
pressure valve (Differential pressure) {kg/cm2}
Cooling system
140E-5 Series 9
SEN00147-05 20 Standard value table
Engine SAA6D140E-5
Applicable machine WA500-6
Performance Category
10 140E-5 Series
20 Standard value table SEN00147-05
Engine SAA6D140E-5
Applicable machine WA500-6R
Performance Category
pressure valve
Fan speed At rated speed rpm Hydraulically driven on machine side
Deflection under finger pressure of 98 N
Fan belt tension mm Hydraulically driven on machine side
{10 kg}
Deflection under finger pressure of 98 N
Alternator belt tension mm 13 – 16 13 – 16
{10 kg}
140E-5 Series 11
SEN00147-05 20 Standard value table
Engine SAA6D140E-5
HD325-7
Applicable machine
HD405-7
Performance Category
Min. 80°C
Oil pressure SAE10W30DH
At low idle SAE15W40DH MPa Min. 0.10 0.08
Engine oil temperature:
SAE30DH {kg/cm2} {Min. 1.0} {0.8}
Min. 80°C
Oil temperature Whole speed range °C 90 – 110 120
Ratio to fuel consumption at continuous
Oil consumption % Max. 0.15 0.3
rated output
Function of radiator Cracking pressure kPa
— —
pressure valve (Differential pressure) {kg/cm2}
Cooling system
12 140E-5 Series
20 Standard value table SEN00147-05
Engine SAA6D140E-5
HD325-7R
Applicable machine
HD405-7R
Performance Category
Min. 80°C
Oil pressure SAE10W30DH
At low idle SAE15W40DH MPa Min. 0.10 0.08
Engine oil temperature:
SAE30DH {kg/cm2} {Min. 1.0} {0.8}
Min. 80°C
Oil temperature Whole speed range °C 90 – 110 120
Ratio to fuel consumption at continuous
Oil consumption % Max. 0.15 0.3
rated output
Function of radiator Cracking pressure kPa
— —
pressure valve (Differential pressure) {kg/cm2}
Cooling system
140E-5 Series 13
SEN00147-05 20 Standard value table
Engine SAA6D140E-5
Applicable machine HM350-2
Performance Category
Min. 80°C
Oil pressure SAE10W30DH
At low idle SAE15W40DH MPa Min. 0.10 0.08
Engine oil temperature:
SAE30DH {kg/cm2} {Min. 1.0} {0.8}
Min. 80°C
Oil temperature Whole speed range °C 90 – 110 120
Ratio to fuel consumption at continuous
Oil consumption % Max. 0.15 0.3
rated output
Function of radiator Cracking pressure kPa
— —
pressure valve (Differential pressure) {kg/cm2}
Cooling system
14 140E-5 Series
20 Standard value table SEN00147-05
Engine SAA6D140E-5
Applicable machine HM350-2R
Performance Category
Min. 80°C
Oil pressure SAE10W30DH
At low idle SAE15W40DH MPa Min. 0.10 0.08
Engine oil temperature:
SAE30DH {kg/cm2} {Min. 1.0} {0.8}
Min. 80°C
Oil temperature Whole speed range °C 90 – 110 120
Ratio to fuel consumption at continuous
Oil consumption % Max. 0.15 0.3
rated output
Function of radiator Cracking pressure kPa
— —
pressure valve (Differential pressure) {kg/cm2}
Cooling system
140E-5 Series 15
SEN00147-05 20 Standard value table
Engine SAA6D140E-5
Applicable machine HM400-2
Performance Category
Min. 80°C
Oil pressure SAE10W30DH
At low idle SAE15W40DH MPa Min. 0.10 0.08
Engine oil temperature:
SAE30DH {kg/cm2} {Min. 1.0} {0.8}
Min. 80°C
Oil temperature Whole speed range °C 90 – 110 120
Ratio to fuel consumption at continuous
Oil consumption % Max. 0.15 0.3
rated output
Function of radiator Cracking pressure kPa
— —
pressure valve (Differential pressure) {kg/cm2}
Cooling system
16 140E-5 Series
20 Standard value table SEN00147-05
Engine SAA6D140E-5
Applicable machine HM400-2R
Performance Category
Min. 80°C
Oil pressure SAE10W30DH
At low idle SAE15W40DH MPa Min. 0.10 0.08
Engine oil temperature:
SAE30DH {kg/cm2} {Min. 1.0} {0.8}
Min. 80°C
Oil temperature Whole speed range °C 90 – 110 120
Ratio to fuel consumption at continuous
Oil consumption % Max. 0.15 0.3
rated output
Function of radiator Cracking pressure kPa
— —
pressure valve (Differential pressure) {kg/cm2}
Cooling system
140E-5 Series 17
SEN00147-05 20 Standard value table
Engine SAA6D140E-5
SDG400S-6B1
Applicable machine
(HOKUETSU INDUSTRIES GENERATOR)
Performance Category
18 140E-5 Series
20 Standard value table SEN00147-05
Engine SAA6D140E-5
Applicable machine D155AX-6
Procedure
Item
1 2 3 4 5
Running time min. 1 3 6 8 2
Speed rpm 740 1,197 1,501 1,729 1,900
Dynamometer load N{kg} 0{0} 747{76} 1,192{122} 1,552{158} 1,883{192}
Output kW{HP} 0{0} 67{90} 134{181} 201{270} 268{360}
a This table shows the values when the fan is not installed.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Engine SAA6D140E-5
Applicable machine D155AX-6
Test item Rated horsepower Max. torque High idle speed Low idle speed
Specification value 268 kW/1,900 rpm 1,834 Nm/1,300 rpm
— 2,100(0/–50) rpm 740(+40/0) rpm
(Gross value) {359.9 HP/1,900 rpm} {187 kgm/1,300 rpm}
Speed rpm 1,900 1,300 2,100(0/–50) 740(+40/0)
N 1,823 – 1,940 2,460 – 2,607
Dynamometer load — —
{kg} {186 – 198} {251 – 266}
kW 260 – 277
Output (Gross value) — — —
{HP} {349 – 371}
Nm 1,758 – 1,868
Torque (Gross value) — — —
{kgm} {179.4 – 190.6}
Fuel consumption sec/300cc Min. 16.0 — — —
Coolant temperature °C 70 – 90 70 – 90 70 – 90 70 – 90
Lubricating oil
°C 90 – 110 90 – 110 90 – 110 80 – 110
temperature
Lubricating oil kPa 340 – 490 340 – 490 340 – 490 Min. 120
pressure {kg/cm2} {3.5 – 5.0} {3.5 – 5.0} {3.5 – 5.0} {Min. 1.2}
Exhaust temperature °C Max. 650 Max. 650 — —
a This table shows the standard values obtained by using the JIS correction coefficients.
a Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.
a This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
a Use ASTM No.1 or No. 2 diesel fuel as fuel.
a Use SAE15W-40 as lubricating oil.
140E-5 Series 19
SEN00147-05 20 Standard value table
Running-in standard
Engine SAA6D140E-5
Applicable machine D155A-6R
Procedure
Item
1 2 3 4 5
Running time min. 1 3 6 8 2
Speed rpm 740 1,197 1,501 1,729 1,900
Dynamometer load N{kg} 0{0} 747{76} 1,192{122} 1,552{158} 1,883{192}
Output kW{HP} 0{0} 67{90} 134{181} 201{270} 268{360}
a This table shows the values when the fan is not installed.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Engine SAA6D140E-5
Applicable machine D155A-6R
Test item Rated horsepower Max. torque High idle speed Low idle speed
Specification value 268 kW/1,900 rpm 1,834 Nm/1,300 rpm
— 2,100(0/–50) rpm 740(+40/0) rpm
(Gross value) {359.9 HP/1,900 rpm} {187 kgm/1,300 rpm}
Speed rpm 1,900 1,300 2,100(0/–50) 740(+40/0)
N 1,823 – 1,940 2,482 – 2,635
Dynamometer load — —
{kg} {186 – 198} {253 – 269}
kW 260 – 277
Output (Gross value) — — —
{HP} {349 – 371}
Nm 1,778 – 1,888
Torque (Gross value) — — —
{kgm} {181.4 – 192.6}
Fuel consumption sec/300cc Min. 16.0 — — —
Coolant temperature °C 70 – 90 70 – 90 70 – 90 70 – 90
Lubricating oil
°C 90 – 110 90 – 110 90 – 110 80 – 110
temperature
Lubricating oil kPa 340 – 490 340 – 490 340 – 490 Min. 120
pressure {kg/cm2} {3.5 – 5.0} {3.5 – 5.0} {3.5 – 5.0} {Min. 1.2}
Exhaust temperature °C Max. 670 Max. 670 — —
a This table shows the standard values obtained by using the JIS correction coefficients.
a Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.
a This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
a Use ASTM No.1 or No. 2 diesel fuel as fuel.
a Use SAE15W-40 as lubricating oil.
20 140E-5 Series
20 Standard value table SEN00147-05
Running-in standard
Engine SAA6D140E-5
Applicable machine D275AX-5E0
Procedure
Item
1 2 3 4 5
Running time min. 1 3 6 8 2
Speed rpm 740 1,260 1,580 1,820 2,000
Dynamometer load N{kg} 0{0} 891{91} 1,420{145} 1,850{189} 2,244{229}
Output kW{HP} 0{0} 84{113} 168{226} 253{339} 337{452}
a This table shows the values when the fan is not installed.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Engine SAA6D140E-5
Applicable machine D275AX-5E0
Test item Rated horsepower Max. torque High idle speed Low idle speed
Specification value 337 kW/2,000 rpm 2,030 Nm/1,400 rpm
— 2,200 ± 50 rpm 700 ± 50 rpm
(Gross value) {451.6 HP/2,000 rpm} {207 kgm/1,400 rpm}
Speed rpm 2,000 1,400 2,200 ± 50 700 ± 50
N 2,177 – 2,314 2,753 – 2,917
Dynamometer load — —
{kg} {222.0 – 236.0} {280.7 – 297.5}
Output kW 327 – 347
— — —
(Gross value) {HP} {438 – 465}
Nm 1,970 – 2,087
Torque (Gross value) — — —
{kgm} {201 – 213}
Fuel consumption sec/300cc Min. 12.8 — — —
Coolant temperature °C 70 – 90 70 – 90 70 – 90 70 – 90
Lubricating oil
°C 90 – 110 90 – 110 90 – 110 90 – 110
temperature
Lubricating oil kPa 340 – 490 340 – 490 340 – 490 Min. 120
pressure {kg/cm2} {3.5 – 5.0} {3.5 – 5.0} {3.5 – 5.0} {Min. 1.2}
Exhaust temperature °C Max. 650 Max. 650 — —
a This table shows the standard values obtained by using the JIS correction coefficients.
a Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.
a This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
a Use ASTM No.1 or No. 2 diesel fuel as fuel.
a Use SAE15W-40 as lubricating oil.
140E-5 Series 21
SEN00147-05 20 Standard value table
Running-in standard
Engine SAA6D140E-5
Applicable machine D275A-5R
Procedure
Item
1 2 3 4 5
Running time min. 1 3 6 8 2
Speed rpm 740 1,260 1,580 1,820 2,000
Dynamometer load N{kg} 0{0} 891{91} 1,420{145} 1,850{189} 2,244{229}
Output kW{HP} 0{0} 84{113} 168{226} 253{339} 337{452}
a This table shows the values when the fan is not installed.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Engine SAA6D140E-5
Applicable machine D275A-5R
Test item Rated horsepower Max. torque High idle speed Low idle speed
Specification value 337 kW/2,000 rpm 2,030 Nm/1,400 rpm
— 2,200 ± 50 rpm 700 ± 50 rpm
(Gross value) {451.6 HP/2,000 rpm} {207 kgm/1,400 rpm}
Speed rpm 2,000 1,400 2,200 ± 50 700 ± 50
N 2,177 – 2,314 2,753 – 2,917
Dynamometer load — —
{kg} {222.0 – 236.0} {280.7 – 297.5}
Output kW 327 – 347
— — —
(Gross value) {HP} {438 – 465}
Nm 1,970 – 2,087
Torque (Gross value) — — —
{kgm} {201 – 213}
Fuel consumption sec/300cc Min. 12.8 — — —
Coolant temperature °C 70 – 90 70 – 90 70 – 90 70 – 90
Lubricating oil
°C 90 – 110 90 – 110 90 – 110 90 – 110
temperature
Lubricating oil kPa 340 – 490 340 – 490 340 – 490 Min. 120
pressure {kg/cm2} {3.5 – 5.0} {3.5 – 5.0} {3.5 – 5.0} {Min. 1.2}
Exhaust temperature °C Max. 670 Max. 670 — —
a This table shows the standard values obtained by using the JIS correction coefficients.
a Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.
a This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
a Use ASTM No.1 or No. 2 diesel fuel as fuel.
a Use SAE15W-40 as lubricating oil.
22 140E-5 Series
20 Standard value table SEN00147-05
Running-in standard
Engine SAA6D140E-5
Applicable machine PC600, 600LC-8
Procedure
Item
1 2 3 4 5
Running time min. 1 3 6 8 2
Speed rpm 800 1,134 1,422 1,638 1,800
Dynamometer load N{kg} 0{0} 948{97} 1,513{154} 1,970{201} 2,390{244}
Output kW{HP} 0{0} 81{108} 161{217} 242{324} 323{433}
a This table shows the values when the fan is not installed.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Engine SAA6D140E-5
Applicable machine PC600, 600LC-8
Test item Rated horsepower Max. torque High idle speed Low idle speed
323 kW/1,800 rpm 1,944Nm/1,400rpm
Specification value
— {433.3 HP/ {198.4 kgm/ 1,950 ± 50 rpm 800 ± 25 rpm
(Gross value)
1,800 rpm} 1,400 rpm}
Speed rpm 1,800 1,400 1,950 ± 50 800 ± 25
N 2,323 – 2,470 2,626 – 2,793
Dynamometer load — —
{kg} {237 – 252} {268 – 285}
kW 313 – 333
Output (Gross value) — — —
{HP} {420 – 447}
Nm 1,882 – 1,999
Torque (Gross value) — — —
{kgm} {192 – 204}
Fuel consumption sec/300cc Min. 13.8 — — —
Coolant temperature °C 70 – 90 70 – 90 70 – 90 70 – 90
Lubricating oil
°C 90 – 110 90 – 110 90 – 110 80 – 110
temperature
Lubricating oil kPa 340 – 490 340 – 490 340 – 490 Min. 120
pressure {kg/cm2} {3.5 – 5.0} {3.5 – 5.0} {3.5 – 5.0} {Min. 1.2}
Exhaust temperature °C Max. 650 Max. 650 — —
a This table shows the standard values obtained by using the JIS correction coefficients.
a Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.
a This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
a Use ASTM No.1 or No. 2 diesel fuel as fuel.
a Use SAE15W-40 as lubricating oil.
140E-5 Series 23
SEN00147-05 20 Standard value table
Running-in standard
Engine SAA6D140E-5
Applicable machine PC600, 600LC-8R
Procedure
Item
1 2 3 4 5
Running time min. 1 3 6 8 2
Speed rpm 800 1,134 1,422 1,638 1,800
Dynamometer load N{kg} 0{0} 948{97} 1,513{154} 1,970{201} 2,390{244}
Output kW{HP} 0{0} 81{108} 161{217} 242{324} 323{433}
a This table shows the values when the fan is not installed.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Engine SAA6D140E-5
Applicable machine PC600, 600LC-8R
Test item Rated horsepower Max. torque High idle speed Low idle speed
323 kW/1,800 rpm 1,944Nm/1,400rpm
Specification value
— {433.3 HP/ {198.4 kgm/ 1,950 ± 50 rpm 800 ± 25 rpm
(Gross value)
1,800 rpm} 1,400 rpm}
Speed rpm 1,800 1,400 1,950 ± 50 800 ± 25
N 2,323 – 2,470 2,626 – 2,793
Dynamometer load — —
{kg} {237 – 252} {268 – 285}
kW 313 – 333
Output (Gross value) — — —
{HP} {420 – 447}
Nm 1,882 – 1,999
Torque (Gross value) — — —
{kgm} {192 – 204}
Fuel consumption sec/300cc Min. 13.8 — — —
Coolant temperature °C 70 – 90 70 – 90 70 – 90 70 – 90
Lubricating oil
°C 90 – 110 90 – 110 90 – 110 80 – 110
temperature
Lubricating oil kPa 340 – 490 340 – 490 340 – 490 Min. 120
pressure {kg/cm2} {3.5 – 5.0} {3.5 – 5.0} {3.5 – 5.0} {Min. 1.2}
Exhaust temperature °C Max. 700 Max. 700 — —
a This table shows the standard values obtained by using the JIS correction coefficients.
a Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.
a This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
a Use ASTM No.1 or No. 2 diesel fuel as fuel.
a Use SAE15W-40 as lubricating oil.
24 140E-5 Series
20 Standard value table SEN00147-05
Running-in standard
Engine SAA6D140E-5
PC800, 800SE, 800LC-8
Applicable machine
PC850, 850SE-8
Procedure
Item
1 2 3 4 5
Running time min. 1 3 6 8 2
Speed rpm 825 1,134 1,422 1,638 1,800
Dynamometer load N{kg} 0{0} 1,087{111} 1,733{177} 2,257{230} 2,739{279}
Output kW{HP} 0{0} 92{124} 185{248} 277{372} 370{496}
a This table shows the values when the fan is not installed.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Engine SAA6D140E-5
PC800, 800SE, 800LC-8
Applicable machine
PC850, 850SE-8
Test item Rated horsepower Max. torque High idle speed Low idle speed
370 kW/1,800 rpm 2,195 Nm/1,350 rpm
Specification value
— {496.4 HP/ {223.8 kgm/ 1,980 ± 50 rpm 825 ± 25 rpm
(Gross value)
1,800 rpm} 1,350 rpm}
Speed rpm 1,800 1,350 1,980 ± 50 825 ± 25
N 2,550 – 2,690 2,930 – 3,100
Dynamometer load — —
{kg} {260 – 274} {299 – 316}
kW 359 – 381
Output (Gross value) — — —
{HP} {481 – 512}
Nm 2,126 – 2,264
Torque (Gross value) — — —
{kgm} {217 – 231}
Fuel consumption sec/300cc Min. 12.3 — — —
Coolant temperature °C 70 – 90 70 – 90 70 – 90 70 – 90
Lubricating oil
°C 90 – 110 90 – 110 90 – 110 80 – 110
temperature
Lubricating oil kPa 340 – 490 340 – 490 340 – 490 Min. 120
pressure {kg/cm2} {3.5 – 5.0} {3.5 – 5.0} {3.5 – 5.0} {Min. 1.2}
Exhaust temperature °C Max. 650 Max. 650 — —
a This table shows the standard values obtained by using the JIS correction coefficients.
a Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.
a This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
a Use ASTM No.1 or No. 2 diesel fuel as fuel.
a Use SAE15W-40 as lubricating oil.
140E-5 Series 25
SEN00147-05 20 Standard value table
Running-in standard
Engine SAA6D140E-5
PC800, 800SE, 800LC-8R
Applicable machine
PC850, 850SE-8R
Procedure
Item
1 2 3 4 5
Running time min. 1 3 6 8 2
Speed rpm 825 1,134 1,422 1,638 1,800
Dynamometer load N{kg} 0{0} 1,087{111} 1,733{177} 2,257{230} 2,739{279}
Output kW{HP} 0{0} 92{124} 185{248} 277{372} 370{496}
a This table shows the values when the fan is not installed.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Engine SAA6D140E-5
PC800, 800SE, 800LC-8R
Applicable machine
PC850, 850SE-8R
Test item Rated horsepower Max. torque High idle speed Low idle speed
370 kW/1,800 rpm 2,195 Nm/1,350 rpm
Specification value
— {496.4 HP/ {223.8 kgm/ 1,980 ± 50 rpm 825 ± 25 rpm
(Gross value)
1,800 rpm} 1,350 rpm}
Speed rpm 1,800 1,350 1,980 ± 50 825 ± 25
N 2,550 – 2,690 2,969 – 3,162
Dynamometer load — —
{kg} {260 – 274} {303 – 323}
kW 359 – 381
Output (Gross value) — — —
{HP} {481 – 512}
Nm 2,126 – 2,264
Torque (Gross value) — — —
{kgm} {217 – 231}
Fuel consumption sec/300cc Min. 12.3 — — —
Coolant temperature °C 70 – 90 70 – 90 70 – 90 70 – 90
Lubricating oil
°C 90 – 110 90 – 110 90 – 110 80 – 110
temperature
Lubricating oil kPa 340 – 490 340 – 490 340 – 490 Min. 120
pressure {kg/cm2} {3.5 – 5.0} {3.5 – 5.0} {3.5 – 5.0} {Min. 1.2}
Exhaust temperature °C Max. 700 Max. 700 — —
a This table shows the standard values obtained by using the JIS correction coefficients.
a Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.
a This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
a Use ASTM No.1 or No. 2 diesel fuel as fuel.
a Use SAE15W-40 as lubricating oil.
26 140E-5 Series
20 Standard value table SEN00147-05
Running-in standard
Engine SAA6D140E-5
Applicable machine WA500-6
Procedure
Item
1 2 3 4 5
Running time min. 1 3 6 8 2
Speed rpm 675 1,197 1,501 1,729 1,900
Dynamometer load N{kg} 0{0} 712{73} 1,136{116} 1,479{151} 1,795{183}
Output kW{HP} 0{0} 64{86} 128{172} 192{257} 256{343}
a This table shows the values when the fan is not installed.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Engine SAA6D140E-5
Applicable machine WA500-6
Test item Rated horsepower Max. torque High idle speed Low idle speed
Specification value 266 kW/1,900 rpm 1,803 Nm/1,250 rpm
— 2,150 ± 50 rpm 700 ± 25 rpm
(Gross value) {356.9 HP/1,900 rpm} {184 kgm/1,250 rpm}
Speed rpm 1,900 1,250 2,150 ± 50 700 ± 25
N 1,744 – 1,852 2,440 – 2,597
Dynamometer load — —
{kg} {178 – 189} {249 – 265}
kW 248 – 263
Output (Gross value) — — —
{HP} {333 – 353}
Nm 1,744 – 1,862
Torque (Gross value) — — —
{kgm} {178 – 190}
Fuel consumption sec/300cc Min. 16.8 — — —
Coolant temperature °C 70 – 90 70 – 90 70 – 90 70 – 90
Lubricating oil
°C 90 – 110 90 – 110 90 – 110 80 – 110
temperature
Lubricating oil kPa 340 – 490 340 – 490 340 – 490 Min. 120
pressure {kg/cm2} {3.5 – 5.0} {3.5 – 5.0} {3.5 – 5.0} {Min. 1.2}
Exhaust temperature °C Max. 650 Max. 650 — —
a This table shows the standard values obtained by using the JIS correction coefficients.
a Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.
a This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
a Use ASTM No.1 or No. 2 diesel fuel as fuel.
a Use SAE15W-40 as lubricating oil.
140E-5 Series 27
SEN00147-05 20 Standard value table
Running-in standard
Engine SAA6D140E-5
Applicable machine WA500-6R
Procedure
Item
1 2 3 4 5
Running time min. 1 3 6 8 2
Speed rpm 675 1,197 1,501 1,729 1,900
Dynamometer load N{kg} 0{0} 712{73} 1,136{116} 1,479{151} 1,795{183}
Output kW{HP} 0{0} 64{86} 128{172} 192{257} 256{343}
a This table shows the values when the fan is not installed.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Engine SAA6D140E-5
Applicable machine WA500-6R
Test item Rated horsepower Max. torque High idle speed Low idle speed
Specification value 266 kW/1,900 rpm 1,803 Nm/1,250 rpm
— 2,150 ± 50 rpm 700 ± 25 rpm
(Gross value) {356.9 HP/1,900 rpm} {184 kgm/1,250 rpm}
Speed rpm 1,900 1,250 2,150 ± 50 700 ± 25
N 1,814 – 1,922 2,440 – 2,597
Dynamometer load — —
{kg} {185 – 196} {249 – 265}
kW 258 – 274
Output (Gross value) — — —
{HP} {346 – 368}
Nm 1,744 – 1,862
Torque (Gross value) — — —
{kgm} {178 – 190}
Fuel consumption sec/300cc Min. 16.8 — — —
Coolant temperature °C 70 – 90 70 – 90 70 – 90 70 – 90
Lubricating oil
°C 90 – 110 90 – 110 90 – 110 80 – 110
temperature
Lubricating oil kPa 340 – 490 340 – 490 340 – 490 Min. 120
pressure {kg/cm2} {3.5 – 5.0} {3.5 – 5.0} {3.5 – 5.0} {Min. 1.2}
Exhaust temperature °C Max. 670 Max. 670 — —
a This table shows the standard values obtained by using the JIS correction coefficients.
a Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.
a This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
a Use ASTM No.1 or No. 2 diesel fuel as fuel.
a Use SAE15W-40 as lubricating oil.
28 140E-5 Series
20 Standard value table SEN00147-05
Running-in standard
Engine SAA6D140E-5
HD325-7
Applicable machine
HD405-7
Procedure
Item
1 2 3 4 5
Running time min. 1 3 6 8 2
Speed rpm 725 1,260 1,580 1,820 2,000
Dynamometer load N{kg} 0{0} 1,021{104} 1,628{166} 2,120{216} 2,573{263}
Output kW{HP} 0{0} 97{129} 193{259} 290{388} 386{518}
a This table shows the values when the fan is not installed.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Engine SAA6D140E-5
HD325-7
Applicable machine
HD405-7
Test item Rated horsepower Max. torque High idle speed Low idle speed
Specification value 386 kW/2,000 rpm 2,170 Nm/1,400 rpm
— 2,300 ± 25 rpm 725 ± 25 rpm
(Gross value) {517.7 HP/2,000 rpm} {221.3 kgm/1,400 rpm}
Speed rpm 2,000 1,400 2,300 ± 25 725 ± 25
N 2,499 – 2,646 2,930 – 3,120
Dynamometer load — —
{kg} {255 – 270} {299 – 318}
kW 374 – 398
Output (Gross value) — — —
{HP} {502 – 533}
Nm 2,100 – 2,230
Torque (Gross value) — — —
{kgm} {214 – 228}
Fuel consumption sec/300cc Min. 11.4 — — —
Coolant temperature °C 70 – 90 70 – 90 70 – 90 70 – 90
Lubricating oil
°C 90 – 110 90 – 110 90 – 110 80 – 110
temperature
Lubricating oil kPa 340 – 490 340 – 490 340 – 490 Min. 120
pressure {kg/cm2} {3.5 – 5.0} {3.5 – 5.0} {3.5 – 5.0} {Min. 1.2}
Exhaust temperature °C Max. 650 Max. 650 — —
a This table shows the standard values obtained by using the JIS correction coefficients.
a Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.
a This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
a Use ASTM No.1 or No. 2 diesel fuel as fuel.
140E-5 Series 29
SEN00147-05 20 Standard value table
Running-in standard
Engine SAA6D140E-5
HD325-7R
Applicable machine
HD405-7R
Procedure
Item
1 2 3 4 5
Running time min. 1 3 6 8 2
Speed rpm 725 1,260 1,580 1,820 2,000
Dynamometer load N{kg} 0{0} 1,021{104} 1,628{166} 2,120{216} 2,573{263}
Output kW{HP} 0{0} 97{129} 193{259} 290{388} 386{518}
a This table shows the values when the fan is not installed.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Engine SAA6D140E-5
HD325-7R
Applicable machine
HD405-7R
Test item Rated horsepower Max. torque High idle speed Low idle speed
Specification value 386 kW/2,000 rpm 2,170 Nm/1,400 rpm
— 2,300 ± 25 rpm 725 ± 25 rpm
(Gross value) {517.7 HP/2,000 rpm} {221.3 kgm/1,400 rpm}
Speed rpm 2,000 1,400 2,300 ± 25 725 ± 25
N 2,499 – 2,646 2,930 – 3,120
Dynamometer load — —
{kg} {255 – 270} {299 – 318}
kW 374 – 398
Output (Gross value) — — —
{HP} {502 – 533}
Nm 2,100 – 2,230
Torque (Gross value) — — —
{kgm} {214 – 228}
Fuel consumption sec/300cc Min. 11.4 — — —
Coolant temperature °C 70 – 90 70 – 90 70 – 90 70 – 90
Lubricating oil
°C 90 – 110 90 – 110 90 – 110 80 – 110
temperature
Lubricating oil kPa 340 – 490 340 – 490 340 – 490 Min. 120
pressure {kg/cm2} {3.5 – 5.0} {3.5 – 5.0} {3.5 – 5.0} {Min. 1.2}
Exhaust temperature °C Max. 680 Max. 680 — —
a This table shows the standard values obtained by using the JIS correction coefficients.
a Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.
a This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
a Use ASTM No.1 or No. 2 diesel fuel as fuel.
a Use SAE15W-40 as lubricating oil.
30 140E-5 Series
20 Standard value table SEN00147-05
Running-in standard
Engine SAA6D140E-5
Applicable machine HM350-2
Procedure
Item
1 2 3 4 5
Running time min. 1 3 6 8 2
Speed rpm 725 1,260 1,580 1,820 2,000
Dynamometer load N{kg} 0{0} 803{82} 1,281{131} 1,668{170} 2,024{207}
Output kW{HP} 0{0} 76{102} 152{204} 228{306} 304{407}
a This table shows the values when the fan is not installed.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Engine SAA6D140E-5
Applicable machine HM350-2
Test item Rated horsepower Max. torque High idle speed Low idle speed
Specification value 304 kW/2,000 rpm 1,990 Nm/1,400 rpm
— 2,200(+50/0) rpm 725 ± 25 rpm
(Gross value) {407.2 HP/2,000 rpm} {203 kgm/1,400 rpm}
Speed rpm 2,000 1,400 2,200(+50/0) 725 ± 25
N 1,960 – 2,087 2,695 – 2,862
Dynamometer load — —
{kg} {200 – 213} {275 – 292}
kW 295 – 315
Output (Gross value) — — —
{HP} {395 – 419}
Nm 1,931 – 2,048
Torque (Gross value) — — —
{kgm} {197 – 209}
Fuel consumption sec/300cc Min. 13.8 — — —
Coolant temperature °C 70 – 90 70 – 90 70 – 90 70 – 90
Lubricating oil tem-
°C 90 – 110 90 – 110 90 – 110 80 – 110
perature
Lubricating oil pres- kPa 340 – 490 340 – 490 340 – 490 Min. 120
sure {kg/cm2} {3.5 – 5.0} {3.5 – 5.0} {3.5 – 5.0} {Min. 1.2}
Exhaust temperature °C Max. 650 Max. 650 — —
a This table shows the standard values obtained by using the JIS correction coefficients.
a Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.
a This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
a Use ASTM No.1 or No. 2 diesel fuel as fuel.
a Use SAE15W-40 as lubricating oil.
140E-5 Series 31
SEN00147-05 20 Standard value table
Running-in standard
Engine SAA6D140E-5
Applicable machine HM350-2R
Procedure
Item
1 2 3 4 5
Running time min. 1 3 6 8 2
Speed rpm 725 1,260 1,580 1,820 2,000
Dynamometer load N{kg} 0{0} 803{82} 1,281{131} 1,668{170} 2,024{207}
Output kW{HP} 0{0} 76{102} 152{204} 228{306} 304{407}
a This table shows the values when the fan is not installed.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Engine SAA6D140E-5
Applicable machine HM350-2R
Test item Rated horsepower Max. torque High idle speed Low idle speed
Specification value 304 kW/2,000 rpm 1,991 Nm/1,400 rpm
— 2,200(+50/0) rpm 725 ± 25 rpm
(Gross value) {407.2 HP/2,000 rpm} {203 kgm/1,400 rpm}
Speed rpm 2,000 1,400 2,200(+50/0) 725 ± 25
N 1,960 – 2,087 2,695 – 2,862
Dynamometer load — —
{kg} {200 – 213} {275 – 292}
kW 295 – 315
Output (Gross value) — — —
{HP} {395 – 419}
Nm 1,931 – 2,048
Torque (Gross value) — — —
{kgm} {197 – 209}
Fuel consumption sec/300cc Min. 13.8 — — —
Coolant temperature °C 70 – 90 70 – 90 70 – 90 70 – 90
Lubricating oil tem-
°C 90 – 110 90 – 110 90 – 110 80 – 110
perature
Lubricating oil pres- kPa 340 – 490 340 – 490 340 – 490 Min. 120
sure {kg/cm2} {3.5 – 5.0} {3.5 – 5.0} {3.5 – 5.0} {Min. 1.2}
Exhaust temperature °C Max. 670 Max. 670 — —
a This table shows the standard values obtained by using the JIS correction coefficients.
a Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.
a This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
a Use ASTM No.1 or No. 2 diesel fuel as fuel.
a Use SAE15W-40 as lubricating oil.
32 140E-5 Series
20 Standard value table SEN00147-05
Running-in standard
Engine SAA6D140E-5
Applicable machine HM400-2
Procedure
Item
1 2 3 4 5
Running time min. 1 3 6 8 2
Speed rpm 725 1,260 1,580 1,820 2,000
Dynamometer load N{kg} 0{0} 893{91} 1,423{145} 1,854{189} 2,249{230}
Output kW{HP} 0{0} 84{113} 169{227} 253{339} 338{453}
a This table shows the values when the fan is not installed.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Engine SAA6D140E-5
Applicable machine HM400-2
Test item Rated horsepower Max. torque High idle speed Low idle speed
Specification value 338 kW/2,000 rpm 2,090 Nm/1,400 rpm
— 2,200(+50/0) rpm 725 ± 25 rpm
(Gross value) {452.6 HP/2,000 rpm} {213 kgm/1,400 rpm}
Speed rpm 2,000 1,400 2,200(+50/0) 725 ± 25
N 2,185 – 2,313 2,832 – 2,999
Dynamometer load — —
{kg} {223 – 236} {289 – 306}
kW 327 – 348
Output (Gross value) — — —
{HP} {439 – 466}
Nm 2,029 – 2,146
Torque (Gross value) — — —
{kgm} {207 – 219}
Fuel consumption sec/300cc Min. 13.0 — — —
Coolant temperature °C 70 – 90 70 – 90 70 – 90 70 – 90
Lubricating oil
°C 90 – 110 90 – 110 90 – 110 80 – 110
temperature
Lubricating oil kPa 340 – 490 340 – 490 340 – 490 Min. 120
pressure {kg/cm2} {3.5 – 5.0} {3.5 – 5.0} {3.5 – 5.0} {Min. 1.2}
Exhaust temperature °C Max. 650 Max. 650 — —
a This table shows the standard values obtained by using the JIS correction coefficients.
a Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.
a This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
a Use ASTM No.1 or No. 2 diesel fuel as fuel.
a Use SAE15W-40 as lubricating oil.
140E-5 Series 33
SEN00147-05 20 Standard value table
Running-in standard
Engine SAA6D140E-5
Applicable machine HM400-2R
Procedure
Item
1 2 3 4 5
Running time min. 1 3 6 8 2
Speed rpm 725 1,260 1,580 1,820 2,000
Dynamometer load N{kg} 0{0} 893{91} 1,423{145} 1,854{189} 2,249{230}
Output kW{HP} 0{0} 84{113} 169{227} 253{339} 338{453}
a This table shows the values when the fan is not installed.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Engine SAA6D140E-5
Applicable machine HM400-2R
Test item Rated horsepower Max. torque High idle speed Low idle speed
Specification value 338 kW/2,000 rpm 2,090 Nm/1,400 rpm
— 2,200(+50/0) rpm 725 ± 25 rpm
(Gross value) {452.6 HP/2,000 rpm} {213 kgm/1,400 rpm}
Speed rpm 2,000 1,400 2,200(+50/0) 725 ± 25
N 2,185 – 2,313 2,832 – 2,999
Dynamometer load — —
{kg} {223 – 236} {289 – 306}
kW 327 – 348
Output (Gross value) — — —
{HP} {439 – 466}
Nm 2,029 – 2,146
Torque (Gross value) — — —
{kgm} {207 – 219}
Fuel consumption sec/300cc Min. 13.0 — — —
Coolant temperature °C 70 – 90 70 – 90 70 – 90 70 – 90
Lubricating oil
°C 90 – 110 90 – 110 90 – 110 80 – 110
temperature
Lubricating oil kPa 340 – 490 340 – 490 340 – 490 Min. 120
pressure {kg/cm2} {3.5 – 5.0} {3.5 – 5.0} {3.5 – 5.0} {Min. 1.2}
Exhaust temperature °C Max. 670 Max. 670 — —
a This table shows the standard values obtained by using the JIS correction coefficients.
a Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.
a This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
a Use ASTM No.1 or No. 2 diesel fuel as fuel.
a Use SAE15W-40 as lubricating oil.
34 140E-5 Series
20 Standard value table SEN00147-05
Running-in standard
Engine SAA6D140E-5
Applicable machine SDG400S-6B1 (HOKUETSU INDUSTRIES GENERATOR)
Procedure
Item
1 2 3 4 5
Running time min. 1 3 6 8 2
Speed rpm 875 1,134 1,422 1,638 1,800
Dynamometer load N{kg} 0{0} 1,087{111} 1,733{177} 2,253{230} 2,751{281}
Output kW{HP} 0{0} 92{123} 185{248} 277{371} 371{498}
a This table shows the values when the fan is not installed.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Engine SAA6D140E-5
Applicable machine SDG400S-6B1 (HOKUETSU INDUSTRIES GENERATOR)
Test item Rated horsepower Max. torque High idle speed Low idle speed
Specification value 371 kW/1,800 rpm —
— 1,890 ± 50 rpm 875 ± 25 rpm
(Gross value) {498 HP/1,800 rpm} —
Speed rpm 1,800 — 1,890 ± 50 875 ± 25
N 2,695 – 2,813 —
Dynamometer load — —
{kg} {275 – 287} —
kW 360 – 382
Output (Gross value) — — —
{HP} {483 – 512}
Nm
Torque (Gross value) — — — —
{kgm}
Fuel consumption sec/300cc Min. 10.8 — — —
Coolant temperature °C 70 – 90 — 70 – 90 70 – 90
Lubricating oil
°C 90 – 110 — 90 – 110 80 – 110
temperature
Lubricating oil kPa 340 – 490 — 340 – 490 Min. 120
pressure {kg/cm2} {3.5 – 5.0} {—} {3.5 – 5.0} {Min. 1.2}
Exhaust temperature °C Max. 670 — — —
a This table shows the standard values obtained by using the JIS correction coefficients.
a Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.
a This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
a Use ASTM No.1 or No. 2 diesel fuel as fuel.
a Use SAE15W-40 as lubricating oil.
140E-5 Series 35
SEN00147-05 20 Standard value table
© 2008 KOMATSU
All Rights Reserved
Printed in Japan 04-08 (01)
36 140E-5 Series
SEN00149-02
140E-5 Series
140E-5 Series 1
SEN00149-02 30 Testing and adjusting
2 140E-5 Series
30 Testing and adjusting SEN00149-02
Testing fuel pressure G 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
2 799-401-2320 Hydraulic tester 1 Pressure gauge: 1 MPa {10 kg/cm2}
795-471-1450 Adapter 1 8 × 1.25 mm o R1/8
3
07005-00812 Gasket 1
1 6151-51-8490 Spacer 1 Inside diameter: 14 mm
2 6206-71-1770 Joint 1 Inside diameter of joint: 10 mm
Commercially
3 Hose 1 ∅5mm × 2 – 3 m
available
Testing fuel return rate Commercially
H 4 Hose 1 ∅15mm × 2 – 3 m
and leakage available
Commercially
5 Measuring cylinder 1
available
Commercially
6 Stopwatch 1
available
140E-5 Series 3
SEN00149-02 30 Testing and adjusting
4 140E-5 Series
30 Testing and adjusting SEN00149-02
140E-5 Series 5
SEN00149-02 30 Testing and adjusting
6 140E-5 Series
30 Testing and adjusting SEN00149-02
Adjusting valve clearance 1 3. While fixing adjustment screw (3), loosen lock-
nut (4).
a Adjusting tool for valve clearance a After setting the No. 1 cylinder to the com-
pression top dead center, adjust the valve
Symbol Part No. Part name clearance of the No. 1 cylinder.
Commercially
C Clearance gauge
available
4. Insert clearance gauge C in the clearance
between rocker arm (5) and crosshead (6) and
1. Remove 6 cylinder head covers (1). adjust the valve clearance with adjustment
screw (3).
a With the clearance gauge inserted, turn
the adjustment screw to a degree that you
can move the thickness gauge lightly.
a Valve clearance
Intake valve: 0.35 mm, Exhaust valve:
0.57 mm
140E-5 Series 7
SEN00149-02 30 Testing and adjusting
8 140E-5 Series
30 Testing and adjusting SEN00149-02
140E-5 Series 9
SEN00149-02 30 Testing and adjusting
10 140E-5 Series
30 Testing and adjusting SEN00149-02
140E-5 Series 11
SEN00149-02 30 Testing and adjusting
Testing EGR valve and bypass 3. Connect hydraulic tester [2] (Component part
valve drive oil pressure 1 of tool F1) to the nipple.
12 140E-5 Series
30 Testing and adjusting SEN00149-02
140E-5 Series 13
SEN00149-02 30 Testing and adjusting
Testing fuel pressure 1 3. Run the engine at high idle and measure the
fuel pressure.
a If the fuel pressure is in the following
a Testing tools for fuel pressure range, it is normal.
Symbol Part No. Part name
799-101-5002 Hydraulic tester Engine speed Fuel pressure
1
790-261-1204 Digital hydraulic tester 0.15 – 0.3 MPa
High idle
G 2 799-401-2320 Hydraulic tester {1.5 – 3 kg/cm2}
795-471-1450 Adapter
3
07005-00812 Gasket
14 140E-5 Series
30 Testing and adjusting SEN00149-02
140E-5 Series 15
SEN00149-02 30 Testing and adjusting
16 140E-5 Series
30 Testing and adjusting SEN00149-02
140E-5 Series 17
SEN00149-02 30 Testing and adjusting
18 140E-5 Series
30 Testing and adjusting SEN00149-02
140E-5 Series 19
SEN00149-02 30 Testing and adjusting
20 140E-5 Series
30 Testing and adjusting SEN00149-02
140E-5 Series 21
SEN00149-02 30 Testing and adjusting
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.
22 140E-5 Series
30 Testing and adjusting SEN00149-02
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.
140E-5 Series 23
SEN00149-02 30 Testing and adjusting
24 140E-5 Series
30 Testing and adjusting SEN00149-02
Testing fuel pressure G 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
2 799-401-2320 Hydraulic tester 1 Pressure gauge: 1 MPa {10 kg/cm2}
795-471-1450 Adapter 1 8 × 1.25 mm o R1/8
3
07005-00812 Gasket 1
1 6151-51-8490 Spacer 1 Inside diameter: 14 mm
2 6206-71-1770 Joint 1 Inside diameter of joint: 10 mm
Commercially
3 Hose 1 ∅5mm × 2 – 3 m
available
Testing fuel return rate Commercially
H 4 Hose 1 ∅15mm × 2 – 3 m
and leakage available
Commercially
5 Measuring cylinder 1
available
Commercially
6 Stopwatch 1
available
140E-5 Series 25
SEN00149-02 30 Testing and adjusting
26 140E-5 Series
30 Testing and adjusting SEN00149-02
140E-5 Series 27
SEN00149-02 30 Testing and adjusting
28 140E-5 Series
30 Testing and adjusting SEN00149-02
Adjusting valve clearance 1 3. While fixing adjustment screw (3), loosen lock-
nut (4).
a Adjusting tool for valve clearance a After setting the No. 1 cylinder to the com-
pression top dead center, adjust the valve
Symbol Part No. Part name clearance of the No. 1 cylinder.
Commercially
C Clearance gauge
available
4. Insert clearance gauge C in the clearance
between rocker arm (5) and crosshead (6) and
1. Remove 6 cylinder head covers (1). adjust the valve clearance with adjustment
screw (3).
a With the clearance gauge inserted, turn
the adjustment screw to a degree that you
can move the thickness gauge lightly.
a Valve clearance
Intake valve: 0.35 mm, Exhaust valve:
0.57 mm
140E-5 Series 29
SEN00149-02 30 Testing and adjusting
30 140E-5 Series
30 Testing and adjusting SEN00149-02
140E-5 Series 31
SEN00149-02 30 Testing and adjusting
32 140E-5 Series
30 Testing and adjusting SEN00149-02
140E-5 Series 33
SEN00149-02 30 Testing and adjusting
34 140E-5 Series
30 Testing and adjusting SEN00149-02
Testing fuel pressure 1 3. Run the engine at high idle and measure the
fuel pressure.
a If the fuel pressure is in the following
a Testing tools for fuel pressure range, it is normal.
Symbol Part No. Part name
799-101-5002 Hydraulic tester Engine speed Fuel pressure
1
790-261-1204 Digital hydraulic tester 0.15 – 0.3 MPa
High idle
G 2 799-401-2320 Hydraulic tester {1.5 – 3 kg/cm2}
795-471-1450 Adapter
3
07005-00812 Gasket
140E-5 Series 35
SEN00149-02 30 Testing and adjusting
36 140E-5 Series
30 Testing and adjusting SEN00149-02
140E-5 Series 37
SEN00149-02 30 Testing and adjusting
38 140E-5 Series
30 Testing and adjusting SEN00149-02
140E-5 Series 39
SEN00149-02 30 Testing and adjusting
Bleeding air from fuel circuit 1 4. Turn “ON” switch (3) of electric priming pump
(2) installed to the chassis.
Reference: The electric priming pump switch is a The electric priming pump operates and
installed to the chassis. lamp (4) blinks.
a Bleed air from the fuel circuit in the following
cases according to this procedure.
q When the fuel filter is replaced
q When fuel is used up
q When the engine is started for the first
time after the fuel piping or supply pump is
replaced
a If the fuel filter was replaced, do not fill the
main filter and prefilter with the fuel.
40 140E-5 Series
30 Testing and adjusting SEN00149-02
140E-5 Series 41
SEN00149-02 30 Testing and adjusting
42 140E-5 Series
30 Testing and adjusting SEN00149-02
Testing
Press the intermediate point of the belt between
alternator pulley and drive pulley with a finger and
measure deflection (a) of the belt.
a Pressing force: Approx. 98 N {Approx. 10 kg}
a Deflection (a): 13 – 16 mm (1 piece)
Adjusting
a If the deflection is out of the standard range,
adjust it according to the following procedure.
140E-5 Series 43
SEN00149-02 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.
44 140E-5 Series
30 Testing and adjusting SEN00149-02
140E-5 Series 45
SEN00149-02
© 2007 KOMATSU
All Rights Reserved
Printed in Japan 03-07 (01)
46
SEN00151-03
140E-5 Series
40 Troubleshooting 1
General information on troubleshooting
140E-5 Series 1
SEN00151-03 40 Troubleshooting
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent
reoccurrence of the failure. When carrying out troubleshooting, an important point is of course to understand
the structure and function. However, a short cut to effective troubleshooting is to ask the operator various ques-
tions to form some idea of possible causes of the failure that would produce the reported symptoms.
1. When carrying out troubleshooting, do not 3) Check other inspection items, if neces-
hurry to disassemble the components. sary.
If components are disassembled immediately 4) Some other maintenance items can be
after any failure occurs: checked externally, so check any item that
q Parts that have no connection with the fail- is considered to be necessary.
ure or other unnecessary parts will be dis- 5) Check the controller for display of an error.
assembled.
q It will become impossible to find the cause 4. Confirming failure
of the failure. Confirm the extent of the failure yourself, and
It will also cause a waste of manhours, parts, judge whether to handle it as a real failure or
or oil or grease, and at the same time, will also as a problem with the method of operation, etc.
lose the confidence of the user or operator. a When operating the machine or engine to
For this reason, when carrying out troubleshoot- reenact the troubleshooting symptoms, do
ing, it is necessary to carry out thorough prior not carry out any investigation or mea-
investigation and to carry out troubleshooting in surement that may make the problem
accordance with the fixed procedure. worse.
2 140E-5 Series
40 Troubleshooting SEN00151-03
Combination of trouble diagnosis lamps and diagnosis lamp indication selector switch
Normal display mode Error code display mode
Item (While starting switch is ON or engine is running) (While starting switch is ON and engine is stopped)
When normal When error occurs When error occurs
Diagnosis lamp
indication selector OFF ON
switch
R Error code is indicated by number of flashes.
Lamp off Either lamp lights up
Y Lamp off
140E-5 Series 3
SEN00151-03 40 Troubleshooting
Indication in normal display mode (when diagnosis lamp indication selector switch is OFF)
q The normal display mode means the state in which the diagnosis lamp indication selector switch is kept
OFF while the starting switch is ON or the engine is running.
q While the engine controller system is operating normally in the normal state, the red lamp and yellow
lamp are turned OFF. If the system has an error, either lamp is turned ON.
Indication in error code display mode (when diagnosis lamp indication selector switch is ON)
q The error code display mode means the state in which the diagnosis lamp indication selector switch is
kept ON while the engine is stopped (with the starting switch is ON).
q In this state, the red lamp indicates the error code by the number of flashes. The yellow lamp is kept
turned OFF at this time.
q When starting the engine, turn the diagnosis lamp indication selector switch OFF. Do not turn the diag-
nosis lamp indication selector switch ON while the engine is running.
4 140E-5 Series
40 Troubleshooting SEN00151-03
140E-5 Series 5
SEN00151-03 40 Troubleshooting
Machine failure
INSITE error code Failure phenomenon Reference document No.
code
449 CA449 Rail Press. High Error 2
451 CA451 Rail Press. Sensor High Error
452 CA452 Rail Press. Sensor Low Error
553 CA553 Rail Press. High Error 1
554 CA554 Rail Press Sensor In Range Error
559 CA559 No-pressure Feed By Supply pump 1
689 CA689 Eng. Ne Speed Sensor Error
731 CA731 Eng. Bkup Speed Sensor Phase Error
757 CA757 All Engine Controller Data Lost Error
778 CA778 Eng. Bkup Speed Sensor Error
1228 CA1228 EGR Valve Servo Error 1
1625 CA1625 EGR Valve Servo Error 2
1626 CA1626 Bypass Valve Solenoid Drive Short Circuit Error
1627 CA1627 Bypass Valve Solenoid Drive Open Error
1628 CA1628 Bypass Valve Servo Error 1
1629 CA1629 Bypass Valve Servo Error 2 Troubleshooting of
electrical system
1631 CA1631 Bypass Valve Lift Sensor High Error
(E-mode), Part 2
1632 CA1632 Bypass Valve Lift Sensor Low Error SEN00154-02
1633 CA1633 KOMNET Error
1642 CA1642 EGR Inlet Press Sensor Low Error
1653 CA1653 EGR Inlet Press Sensor High Error
2185 CA2185 Throttle Sens. Sup. Volt. High Error
2186 CA2186 Throttle Sens. Sup. Volt. Low Error
2249 CA2249 No-pressure Feed By Supply pump 2
2271 CA2271 EGR Valve Lift Sensor High Error
2272 CA2272 EGR Valve Lift Sensor Low Error
2351 CA2351 EGR Valve Solenoid Drive Short Error
2352 CA2352 EGR Valve Solenoid Drive Open Error
2555 CA2555 Intake Air Heater Relay Open Error
2556 CA2556 Intake Air Heater Relay Short Error
(143) B@BAZG Eng. Oil Press Low Torque Derate
(146) B@BCNS Eng. Overheat
(415) B@BAZG Eng. Oil Press. Low Speed Derate
6 140E-5 Series
40 Troubleshooting SEN00151-03
For generator
Machine failure
Failure phenomenon Reference document No.
code
A8 Speed Adj. Vol. High (Isochronous) A8
A9 Speed Adj. Vol. Low (Isochronous) A9
AA Speed Adj. Vol. High (Droop) AA
AB Speed Adj. Vol. Low (Droop) AB
AF KOMNET Error (CR710) AF
b6 Droop Rate Adj. Vol. High b6
b7 Droop Rate Adj. Vol. Low b7 –
b8 Low Idle Speed Adj. Vol. High b8
b9 Low Idle Speed Adj. Vol. Low b9
bc Speed Adj. Vol. High (Default) bc
bd Speed Adj. Vol. Low (Default) bd
bE Ramptime Adj. Vol. High bE
bF Ramptime Adj. Vol. Low bF
CA111 Engine Controller Internal Failure
CA115 Eng. Ne and Bkup Speed Sensor Error
CA122 Charge (boost) Air Press Sensor High Error
CA123 Charge (boost) Air Press Sensor Low Error
CA135 Oil Press. Sensor High Error
CA141 Oil Press. Sensor Low Error
CA144 Coolant Temp. Sensor High Error
CA145 Coolant Temp. Sensor Low Error
CA153 Charge (boost) Air Temp. Sensor High Error
CA154 Charge (boost) Air Temp. Sensor Low Error
CA187 Sensor Sup. 2 Volt. Low Error
CA221 Ambient Air Press. Sensor High Error
Troubleshooting of
CA222 Ambient Air Press. Sensor Low Error electrical system
CA227 Sensor Sup. 2 Volt. High Error (E-mode), Part 1
SEN00153-02
CA234 Eng. Overspeed
CA238 Ne Speed Sensor Sup. Volt. Error
CA263 Fuel Temp. Sensor High Error
CA265 Fuel Temp. Sensor Low Error
CA271 PCV1 Short Error
CA272 PCV1 Open Error
CA273 PCV2 Short Error
CA274 PCV2 Open Error
CA322 Injector #1 System Open/Short Error
CA323 Injector #5 System Open/Short Error
CA324 Injector #3 System Open/Short Error
CA325 Injector #6 System Open/Short Error
140E-5 Series 7
SEN00151-03 40 Troubleshooting
Machine failure
Failure phenomenon Reference document No.
code
CA331 Injector #2 System Open/Short Error
CA332 Injector #4 System Open/Short Error
CA342 Engine Controller Data Matching Error
Troubleshooting of
CA351 INJ. Drive Circuit Error electrical system
CA352 Sensor Sup. 1 Volt. Low Error (E-mode), Part 1
SEN00153-02
CA386 Sensor Sup. 1 Volt. High Error
CA441 Supply Voltage Low Error
CA442 Supply Voltage High Error
CA449 Rail Press. High Error 2
CA451 Rail Press. Sensor High Error
CA452 Rail Press. Sensor Low Error
CA553 Rail Press. High Error 1
CA559 No-pressure Feed By Supply pump 1
CA689 Eng. Ne Speed Sensor Error
CA731 Eng. Bkup Speed Sensor Phase Error
CA757 All Engine Controller Data Lost Error
CA778 Eng. Bkup Speed Sensor Error
CA1228 EGR Valve Servo Error 1
CA1625 EGR Valve Servo Error 2 Troubleshooting of
electrical system
CA1633 KOMNET Error
(E-mode), Part 2
CA2185 Throttle Sens. Sup. Volt. High Error SEN00154-02
CA2186 Throttle Sens. Sup. Volt. Low Error
CA2249 No-pressure Feed By Supply pump 2
CA2271 EGR Valve Lift Sensor High Error
CA2272 EGR Valve Lift Sensor Low Error
CA2351 EGR Valve Solenoid Drive Short Error
CA2352 EGR Valve Solenoid Drive Open Error
CA2555 Intake Air Heater Relay Open Error
CA2556 Intake Air Heater Relay Short Error
CA143 Eng. Oil Press Low Torque Derate
CA146 Eng. Overheat
8 140E-5 Series
40 Troubleshooting SEN00151-03
140E-5 Series 9
SEN00151-03 40 Troubleshooting
<Contents of description>
• Standard value in normal state to judge possible causes
• Remarks on judgment
1
<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) cir-
2 cuit.
• Short circuit
Independent wiring harnesses are in contact with each
Possible causes and other abnormally.
Possible causes of trouble
standard value in (Given numbers are refer-
normal state ence numbers, which do not <Precautions for troubleshooting>
indicate priority) 1) Method of indicating connector No. and handling of T-
adapter
Insert or connect T-adapter as explained below for trou-
3 bleshooting, unless otherwise specified.
• 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 other-
4 wise specified.
• 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.
10 140E-5 Series
40 Troubleshooting SEN00151-03
140E-5 Series 11
SEN00151-03
© 2008 KOMATSU
All Rights Reserved
Printed in Japan 04-08 (01)
12
SEN00153-02
140E-5 Series
40 Troubleshooting 1
Troubleshooting of electrical system
(E-mode), Part 1
Troubleshooting of electrical system (E-mode), Part 1 ................................................................................... 3
E-1 Code [111/CA111] Engine Controller Internal Failure .................................................................... 3
E-2 Code [115/CA115] Eng. Ne and Bkup Speed Sensor Error........................................................... 4
E-3 Code [122/CA122] Charge (boost) Air Press Sensor High Error................................................... 6
E-4 Code [123/CA123] Charge (boost) Air Press Sensor Low Error ................................................. 10
E-5 Code [131/CA131] Throttle Sensor High Error ............................................................................ 12
E-6 Code [132/CA132] Throttle Sensor Low Error............................................................................. 16
E-7 Code [135/CA135] Oil Press. Sensor High Error......................................................................... 17
E-8 Code [141/CA141] Oil Press. Sensor Low Error ......................................................................... 19
E-9 Code [144/CA144] Coolant Temp. Sensor High Error ................................................................. 20
E-10 Code [145/CA145] Coolant Temp. Sensor Low Error................................................................ 22
E-11 Code [153/CA153] Charge (boost) Air Temp. Sensor High Error .............................................. 23
E-12 Code [154/CA154] Charge (boost) Air Temp. Sensor Low Error............................................... 25
E-13 Code [187/CA187] Sensor Sup. 2 Volt. Low Error..................................................................... 25
140E-5 Series 1
SEN00153-02 40 Troubleshooting
2 140E-5 Series
40 Troubleshooting SEN00153-02
140E-5 Series 3
SEN00153-02 40 Troubleshooting
4 140E-5 Series
40 Troubleshooting SEN00153-02
140E-5 Series 5
SEN00153-02 40 Troubleshooting
E-3 Code [122/CA122] Charge (boost) Air Press Sensor High Error 1
a For “with EGR”
6 140E-5 Series
40 Troubleshooting SEN00153-02
140E-5 Series 7
SEN00153-02 40 Troubleshooting
a For “EGR-less”
8 140E-5 Series
40 Troubleshooting SEN00153-02
140E-5 Series 9
SEN00153-02 40 Troubleshooting
E-4 Code [123/CA123] Charge (boost) Air Press Sensor Low Error 1
10 140E-5 Series
40 Troubleshooting SEN00153-02
140E-5 Series 11
SEN00153-02 40 Troubleshooting
12 140E-5 Series
40 Troubleshooting SEN00153-02
Circuit diagram related to throttle sensor of accelerator pedal type (Case of HD325/405-7)
140E-5 Series 13
SEN00153-02 40 Troubleshooting
1
Throttle sensor of fuel control dial type (Case of PC800/800SE/850/850SE/850LC-8)
14 140E-5 Series
40 Troubleshooting SEN00153-02
140E-5 Series 15
SEN00153-02 40 Troubleshooting
16 140E-5 Series
40 Troubleshooting SEN00153-02
140E-5 Series 17
SEN00153-02 40 Troubleshooting
a For “EGR-less”
18 140E-5 Series
40 Troubleshooting SEN00153-02
140E-5 Series 19
SEN00153-02 40 Troubleshooting
20 140E-5 Series
40 Troubleshooting SEN00153-02
a For “EGR-less”
140E-5 Series 21
SEN00153-02 40 Troubleshooting
22 140E-5 Series
40 Troubleshooting SEN00153-02
E-11 Code [153/CA153] Charge (boost) Air Temp. Sensor High Error 1
140E-5 Series 23
SEN00153-02 40 Troubleshooting
a For “EGR-less”
24 140E-5 Series
40 Troubleshooting SEN00153-02
E-12 Code [154/CA154] Charge (boost) Air Temp. Sensor Low Error 1
140E-5 Series 25
SEN00153-02 40 Troubleshooting
26 140E-5 Series
40 Troubleshooting SEN00153-02
140E-5 Series 27
SEN00153-02 40 Troubleshooting
a For “EGR-less”
28 140E-5 Series
40 Troubleshooting SEN00153-02
140E-5 Series 29
SEN00153-02 40 Troubleshooting
30 140E-5 Series
40 Troubleshooting SEN00153-02
140E-5 Series 31
SEN00153-02 40 Troubleshooting
32 140E-5 Series
40 Troubleshooting SEN00153-02
140E-5 Series 33
SEN00153-02 40 Troubleshooting
34 140E-5 Series
40 Troubleshooting SEN00153-02
140E-5 Series 35
SEN00153-02 40 Troubleshooting
36 140E-5 Series
40 Troubleshooting SEN00153-02
140E-5 Series 37
SEN00153-02 40 Troubleshooting
38 140E-5 Series
40 Troubleshooting SEN00153-02
a For “EGR-less”
140E-5 Series 39
SEN00153-02 40 Troubleshooting
40 140E-5 Series
40 Troubleshooting SEN00153-02
140E-5 Series 41
SEN00153-02 40 Troubleshooting
42 140E-5 Series
40 Troubleshooting SEN00153-02
140E-5 Series 43
SEN00153-02 40 Troubleshooting
44 140E-5 Series
40 Troubleshooting SEN00153-02
140E-5 Series 45
SEN00153-02 40 Troubleshooting
46 140E-5 Series
40 Troubleshooting SEN00153-02
140E-5 Series 47
SEN00153-02 40 Troubleshooting
48 140E-5 Series
40 Troubleshooting SEN00153-02
140E-5 Series 49
SEN00153-02 40 Troubleshooting
50 140E-5 Series
40 Troubleshooting SEN00153-02
a For “EGR-less”
140E-5 Series 51
SEN00153-02 40 Troubleshooting
52 140E-5 Series
40 Troubleshooting SEN00153-02
a For “EGR-less”
140E-5 Series 53
SEN00153-02 40 Troubleshooting
54 140E-5 Series
40 Troubleshooting SEN00153-02
a For “EGR-less”
140E-5 Series 55
SEN00153-02 40 Troubleshooting
56 140E-5 Series
40 Troubleshooting SEN00153-02
a For “EGR-less”
140E-5 Series 57
SEN00153-02 40 Troubleshooting
58 140E-5 Series
40 Troubleshooting SEN00153-02
a For “EGR-less”
140E-5 Series 59
SEN00153-02 40 Troubleshooting
60 140E-5 Series
40 Troubleshooting SEN00153-02
a For “EGR-less”
140E-5 Series 61
SEN00153-02 40 Troubleshooting
62 140E-5 Series
40 Troubleshooting SEN00153-02
140E-5 Series 63
SEN00153-02 40 Troubleshooting
64 140E-5 Series
40 Troubleshooting SEN00153-02
140E-5 Series 65
SEN00153-02 40 Troubleshooting
66 140E-5 Series
40 Troubleshooting SEN00153-02
140E-5 Series 67
SEN00153-02 40 Troubleshooting
68 140E-5 Series
40 Troubleshooting SEN00153-02
140E-5 Series 69
SEN00153-02 40 Troubleshooting
70 140E-5 Series
40 Troubleshooting SEN00153-02
Fig. 1
Throttle: Signal voltage of throttle sensor
Idle validation: Signal voltage of idle validation
switch
Operating range: Operating range of accelerator
pedal
140E-5 Series 71
SEN00153-02 40 Troubleshooting
72 140E-5 Series
40 Troubleshooting SEN00153-02
140E-5 Series 73
SEN00153-02
© 2007 KOMATSU
All Rights Reserved
Printed in Japan 03-07 (01)
74
SEN00154-02
140E-5 Series
40 Troubleshooting 1
Troubleshooting of electrical system
(E-mode), Part 2
Troubleshooting of electrical system (E-mode), Part 2 ................................................................................... 3
E-39 Code [449/CA449] Rail Press. High Error 2 ................................................................................ 3
E-40 Code [451/CA451] Rail Press. Sensor High Error ....................................................................... 4
E-41 Code [452/CA452] Rail Press. Sensor Low Error........................................................................ 7
E-42 Code [553/CA553] Rail Press. High Error 1 ................................................................................ 8
E-43 Code [554/CA554] Rail Press Sensor In Range Error................................................................. 9
E-44 Code [559/CA559] No-pressure Feed By Supply pump 1......................................................... 10
E-45 Code [689/CA689] Eng. Ne Speed Sensor Error ...................................................................... 14
E-46 Code [731/CA731] Eng. Bkup Speed Sensor Phase Error........................................................ 16
E-47 Code [757/CA757] All Engine Controller Data Lost Error .......................................................... 16
E-48 Code [778/CA778] Eng. Bkup Speed Sensor Error................................................................... 18
E-49 Code [1228/CA1228] EGR Valve Servo Error 1 ........................................................................ 21
E-50 Code [1625/CA1625] EGR Valve Servo Error 2 ........................................................................ 22
E-51 Code [1626/CA1626] Bypass Valve Solenoid Drive Short Circuit Error .................................... 23
140E-5 Series 1
SEN00154-02 40 Troubleshooting
2 140E-5 Series
40 Troubleshooting SEN00154-02
140E-5 Series 3
SEN00154-02 40 Troubleshooting
4 140E-5 Series
40 Troubleshooting SEN00154-02
140E-5 Series 5
SEN00154-02 40 Troubleshooting
6 140E-5 Series
40 Troubleshooting SEN00154-02
140E-5 Series 7
SEN00154-02 40 Troubleshooting
8 140E-5 Series
40 Troubleshooting SEN00154-02
140E-5 Series 9
SEN00154-02 40 Troubleshooting
10 140E-5 Series
40 Troubleshooting SEN00154-02
Note 1: Check the low-pressure circuit parts for the following items.
1) Fuel level
2) Clogging of fuel tank breather
3) Sticking and wear of feed pump and clogging of filter
4) Leakage through and clogging of low-pressure fuel piping
5) Defective operation of bypass valve and installation of wrong part (See Fig. 1)
6) Clogging of fuel filter
7) Fuel in oil pan (Fuel leakage inside head cover)
Fig. 1: Locations of overflow valve (1), bypass valve (2), and fuel inlet joint (3)
q Overflow valve (1): Spring is seen through both holes.
q Bypass valve (2): Spring is seen through hole on nut side.
q Fuel inlet joint (3): Gauze filter is seen through both holes.
Note 2: Check, clean, and replace the filters and strainers according to the following procedure.
1) Gauze filter: Disassemble and check. If clogged, clean.
2) Upstream strainer of gauze filter: If the gauze filter is clogged, clean the upstream filter, too.
3) Fuel filter: If the trouble is not solved by performing 1) and 2) above, replace the fuel filter.
140E-5 Series 11
SEN00154-02 40 Troubleshooting
B. Check with machine monitor (Fault history function, monitoring function, and reduced cylinder mode function) Good NG
3 Check of error/failure code / / / /
Check of monitoring information
Standard value
Code Displayed item Checking condition Unit Measured value Good NG
(Reference value)
Low idle rpm <By models>
*1 Engine speed High idle rpm <By models>
Equivalent to rating <By models> rpm <By models>
Low idle % 0
*2 Throttle opening
High idle % 100
Fuel injection com-
*3 Equivalent to rating <By models> mm3 — — —
mand
4 Common rail pres-
*4 Equivalent to rating <By models> MPa
sure command
Common rail fuel
*5 Equivalent to rating <By models> MPa
pressure
Low idle CA — — —
Fuel injection tim-
*6 High idle CA — — —
ing command
Equivalent to rating <By models> CA — — —
*7 Boost pressure Equivalent to rating <By models> kPa — — —
Engine coolant tem-
*8 Low idle °C — — —
perature
*9 Fuel temperature Low idle °C — — —
Check of reduced cylinder mode operation (Engine speed)
Standard value
Function Reduced cylinder Checking condition Unit Measured value Good NG
(Reference value)
No. 1 cylinder Low idle rpm — — —
5 No. 2 cylinder Low idle rpm — — —
No. 3 cylinder Low idle rpm — — —
*10
No. 4 cylinder Low idle rpm — — —
No. 5 cylinder Low idle rpm — — —
No. 6 cylinder Low idle rpm — — —
Standard value
C. Check of fuel circuit pressure Checking condition Unit Measured value Good NG
(Reference value)
Fuel low-pressure circuit pres- High idle or equivalent to rated load MPa 0.15 – 0.3
6
sure [by models]) {kg/cm2} {1.5 – 3.0}
12 140E-5 Series
40 Troubleshooting SEN00154-02
*1 – *10:
When inspecting with INSITE (bench test tool), see Operation and Maintenance Manual (Testing method).
When inspecting with the monitoring function of the machine, use the codes specified for each machine
model.
140E-5 Series 13
SEN00154-02 40 Troubleshooting
14 140E-5 Series
40 Troubleshooting SEN00154-02
140E-5 Series 15
SEN00154-02 40 Troubleshooting
16 140E-5 Series
40 Troubleshooting SEN00154-02
140E-5 Series 17
SEN00154-02 40 Troubleshooting
18 140E-5 Series
40 Troubleshooting SEN00154-02
140E-5 Series 19
SEN00154-02 40 Troubleshooting
20 140E-5 Series
40 Troubleshooting SEN00154-02
Improper EGR valve drive Engine speed EGR valve drive pressure
2
pressure Low idle 1.18 MPa {12 kg/cm2}
High idle 1.43 MPa {14.6 kg/cm2}
If EGR valve drive pressure is abnormal, check causes 3 and
4.
a For check of engine oil pressure, see TESTING AND
ADJUSTING, Testing engine oil pressure.
Possible causes and
Engine speed Engine oil pressure
standard value in Defective engine oil pres-
normal state 3 Low idle 0.08 MPa {0.8 kg/cm2}
sure system (main circuit)
High idle 0.21 MPa {2.1 kg/cm2}
If engine oil pressure is abnormal, carry out troubleshooting for
mechanical system (S-12 Oil pressure lowers).
Defective oil pump for EGR
4 Check oil pump and relief valve for EGR valve circuit directly.
valve
Defective oil feed piping for
5 Check oil feed piping for EGR valve circuit directly.
EGR valve
Defective oil return piping
6 Check oil return piping for EGR valve circuit directly.
for EGR valve
7 Defective EGR valve Check mechanical section of EGR valve directly.
If causes 1 – 7 are not detected, engine controller may be
8 Defective engine controller defective. (Since trouble is in system, troubleshooting cannot
be carried out.)
140E-5 Series 21
SEN00154-02 40 Troubleshooting
22 140E-5 Series
40 Troubleshooting SEN00154-02
140E-5 Series 23
SEN00154-02 40 Troubleshooting
24 140E-5 Series
40 Troubleshooting SEN00154-02
140E-5 Series 25
SEN00154-02 40 Troubleshooting
Improper EGR valve drive Engine speed Bypass valve drive pressure
2
pressure Low idle 1.18 MPa {12 kg/cm2}
High idle 1.43 MPa {14.6 kg/cm2}
If EGR valve drive pressure is abnormal, check causes 3 and
4.
a For check of engine oil pressure, see TESTING AND
ADJUSTING, Testing engine oil pressure.
Possible causes and
Engine speed Engine oil pressure
standard value in Defective engine oil pres-
normal state 3 Low idle 0.08 MPa {0.8 kg/cm2}
sure system (main circuit)
High idle 0.21 MPa {2.1 kg/cm2}
If engine oil pressure is abnormal, carry out troubleshooting
for mechanical system (S-12 Oil pressure lowers).
Defective oil pump for Check oil pump and relief valve for bypass valve circuit
4
bypass valve directly.
Defective oil feed piping for
5 Check oil feed piping for bypass valve circuit directly.
bypass valve
Defective oil return piping
6 Check oil return piping for bypass valve circuit directly.
for bypass valve
7 Defective bypass valve Check mechanical section of bypass valve directly.
If causes 1 – 7 are not detected, engine controller may be
8 Defective engine controller defective. (Since trouble is in system, troubleshooting cannot
be carried out.)
26 140E-5 Series
40 Troubleshooting SEN00154-02
140E-5 Series 27
SEN00154-02 40 Troubleshooting
28 140E-5 Series
40 Troubleshooting SEN00154-02
140E-5 Series 29
SEN00154-02 40 Troubleshooting
30 140E-5 Series
40 Troubleshooting SEN00154-02
Reference: EGR inlet pressure sensor is applied to only machines Serial No. up to 530896.
140E-5 Series 31
SEN00154-02 40 Troubleshooting
32 140E-5 Series
40 Troubleshooting SEN00154-02
Reference: EGR inlet pressure sensor is applied to only machines Serial No. up to 530896.
140E-5 Series 33
SEN00154-02 40 Troubleshooting
34 140E-5 Series
40 Troubleshooting SEN00154-02
Circuit diagram related to throttle sensor of accelerator pedal type (Case of HD325/405-7)
140E-5 Series 35
SEN00154-02 40 Troubleshooting
36 140E-5 Series
40 Troubleshooting SEN00154-02
Circuit diagram related to throttle sensor of fuel control dial type (Case of PC800/800SE/850/850SE/
850LC-8)
140E-5 Series 37
SEN00154-02 40 Troubleshooting
38 140E-5 Series
40 Troubleshooting SEN00154-02
140E-5 Series 39
SEN00154-02 40 Troubleshooting
40 140E-5 Series
40 Troubleshooting SEN00154-02
140E-5 Series 41
SEN00154-02 40 Troubleshooting
42 140E-5 Series
40 Troubleshooting SEN00154-02
140E-5 Series 43
SEN00154-02 40 Troubleshooting
44 140E-5 Series
40 Troubleshooting SEN00154-02
140E-5 Series 45
SEN00154-02 40 Troubleshooting
46 140E-5 Series
40 Troubleshooting SEN00154-02
140E-5 Series 47
SEN00154-02 40 Troubleshooting
48 140E-5 Series
40 Troubleshooting SEN00154-02
140E-5 Series 49
SEN00154-02
© 2007 KOMATSU
All Rights Reserved
Printed in Japan 03-07 (01)
50
SEN00152-02
140E-5 Series
40 Troubleshooting 1
Troubleshooting of mechanical system
(S-mode)
Troubleshooting of mechanical system (S-mode)........................................................................................... 4
Method of using troubleshooting charts ............................................................................................... 4
S-1 Starting performance is poor ......................................................................................................... 8
S-2 Engine does not start................................................................................................................... 10
S-3 Engine does not pick up smoothly............................................................................................... 14
S-4 Engine stops during operations ................................................................................................... 15
S-5 Engine does not rotate smoothly ................................................................................................. 16
S-6 Engine lacks output (or lacks power)........................................................................................... 17
S-7 Exhaust smoke is black (incomplete combustion)....................................................................... 18
S-8 Oil consumption is excessive (or exhaust smoke is blue) ........................................................... 20
S-9 Oil becomes contaminated quickly .............................................................................................. 21
S-10 Fuel consumption is excessive.................................................................................................. 22
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) ........................................ 23
S-12 Oil pressure drops ..................................................................................................................... 24
140E-5 Series 1
SEN00152-02 40 Troubleshooting
2 140E-5 Series
40 Troubleshooting SEN00152-02
140E-5 Series 3
SEN00152-02 40 Troubleshooting
Questions:
Items to be drawn from the user or operator. They correspond to A and B in the chart on the right.
The items in A are basic ones. The items in B can be drawn from the user or operator, depending on their
level.
Check items:
Simple check items used by the serviceman to narrow the causes. They correspond to C in the chart on the
right.
Causes:
Items to be narrowed from the questions and check items.
The serviceman narrows down the probable causes from A, B, and C.
Troubleshooting:
Items used to find out the true cause by verifying the narrowed causes finally in order from the most probable
one by applying troubleshooting tools or direct inspection.
Items listed in the [Questions] and [Check items] and related to the [Causes] are marked with E, Q, and w.
E: Causes to be referred to for questions and check items
Q: Causes related to questions and check items
w: Causes highly probable among ones marked with Q
a When narrowing the “causes”, apply the items marked with w before those marked with Q.
When narrowing the “causes”, do not apply the items marked with E (If no items have other marks and
the causes cannot be narrowed, however, you may apply them.)
4 140E-5 Series
40 Troubleshooting SEN00152-02
140E-5 Series 5
SEN00152-02 40 Troubleshooting
6 140E-5 Series
40 Troubleshooting SEN00152-02
There is a causal relationship between 3 items in the [Questions] and [Check items] sections and 6 items in
the [Causes] sections.
The method of pinpointing the [cause] from the causal relationship and approaching the [troubleshooting] is
explained according to Step 1 — Step 3 shown below.
140E-5 Series 7
SEN00152-02 40 Troubleshooting
a The common rail fuel injection system (CRI) controls the fuel
Defective injector
["with EGR" only]
injection timing electrically. Accordingly, even if the starting
operation is carried out, the engine may not start until the crank-
shaft revolves 2 turns at maximum. This phenomenon does not
indicate a trouble, however.
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Clean
Clean
Clean
Clean
Remedy
8 140E-5 Series
40 Troubleshooting SEN00152-02
140E-5 Series 9
SEN00152-02 40 Troubleshooting
machine
Operated for long period E EE
Condition of horn when Horn does not sound Q Q w
starting switch is turned
ON Horn volume is low w
Battery electrolyte is low w
Battery terminal is loose w
When starting switch is turned ON, there is no operating sound from battery relay Q w
When starting switch is turned to START, starting pinion does not move out Q Q w
Check items
When specific gravity of electrolyte and voltage of battery are measured, they are low q
Troubleshooting
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Remedy —
10 140E-5 Series
40 Troubleshooting SEN00152-02
140E-5 Series 11
SEN00152-02 40 Troubleshooting
machine
Operated for long period EEE
Exhaust smoke suddenly stopped coming out (when starting again) wQwww EE
Replacement of filters has not been carried out according to Operation and Main-
tenance Manual
ww E Q
When fuel tank is inspected, it is found to be empty w
Air breather hole of fuel tank cap is clogged w
Rust and water are found when fuel tank is drained QQQ QQ
When fuel filter is removed, there is not fuel in it w w
Fuel is leaking from fuel piping w
Check items
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Remedy
Clean
Clean
Add
12 140E-5 Series
40 Troubleshooting SEN00152-02
c) Exhaust smoke comes out but engine does not start (fuel is being injected) Causes
While engine is cranked If air bleeding plug of fuel filter is removed, fuel does not flow out Q ww
with starting motor, If spill hose from injector is disconnected, little fuel spills w
When exhaust manifold is touched immediately after starting engine, temperature of some
cylinders is low
w
Replace
Replace
Replace
Replace
Correct
Remedy
Clean
Clean
Clean
Clean
Clean
140E-5 Series 13
SEN00152-02 40 Troubleshooting
Black
When engine is cranked, abnormal sound is generated around cylinder head w
When engine is cranked, interference sound is generated around turbocharger w
High idle speed under no load is normal, but speed suddenly drops when load is
Q w w
applied
There is hunting from engine (rotation is irregular) Q Q w Q
Blow-by gas is excessive w w
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Clean
Clean
Clean
Clean
Remedy
*1: Code [1228/CA1228] and code [1625/CA1625] or code [1628/CA1628] and code [1629/CA1629] in E-
mode
*2: Code [559/CA559] and code [2249/CA2249] in E-mode
14 140E-5 Series
40 Troubleshooting SEN00152-02
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Clean
Clean
Clean
Add
Remedy —
140E-5 Series 15
SEN00152-02 40 Troubleshooting
Carry out troubleshooting according to “Abnormality in EGR valve servo (*1)” in E-mode
q
["with EGR" only]
Carry out troubleshooting according to “Abnormality in bypass valve servo (*2)” in E-
q
mode ["with EGR" only]
Troubleshooting
Carry out troubleshooting according to “Abnormality in engine Bkup speed sensor (*4)”
in E-mode q
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Clean
Add
Remedy
16 140E-5 Series
40 Troubleshooting SEN00152-02
Suddenly
Power was lost
Gradually Q Q Q Q Q Q Q
Non-specified fuel is being used Q Q
Replacement of filters has not been carried out according to Operation and Mainte-
nance Manual
w
Engine oil must be added more frequently Q Q Q
Dust indicator is red (if indicator is installed) w
Air breather hole of fuel tank cap is clogged w
Fuel is leaking from fuel piping w
Output becomes insufficient after short stop of operation w
Black w w w
Color of exhaust gas
Blue under light load w
When exhaust manifold is touched immediately after starting engine, temperature of
some cylinders is low
w
When engine is cranked, interference sound is generated around turbocharger w
Check items
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Clean
Clean
140E-5 Series 17
SEN00152-02 40 Troubleshooting
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Adjust
Adjust
Clean
Remedy
18 140E-5 Series
40 Troubleshooting SEN00152-02
*1: Code [1228/CA1228] and code [1625/CA1625] or code [1628/CA1628] and code [1629/CA1629] in E-
mode
*2: EGR inlet pressure pipings
Remove 2 EGR inlet pressure pipings (2) and check their inside for clogging.
Reference: EGR inlet pressure sensor is applied to only machines Serial No. up to 530896.
140E-5 Series 19
SEN00152-02 40 Troubleshooting
Turbocharger
• Long-time operation of engine at low idle or high idle (Do not run engine
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
20 140E-5 Series
40 Troubleshooting SEN00152-02
machine
Non-specified fuel is being used Q
Engine oil must be added more frequently Q w
Even when engine oil temperature rises, oil filter clogging monitor indi-
w Q
cates clogging (if monitor is installed)
Metal particles are found when oil is drained Q Q
Inside of exhaust pipe is dirty with oil w
Engine oil temperature rises quickly w
Color of exhaust gas Blue under light load w
Check items
color Black w
Excessive Q Q w
Amount of blow-by gas
None w
Excessive play of turbocharger shaft q
When EGR valve is removed, exhaust port is found to be dirty with oil
q
["with EGR" only]
Troubleshooting
Replace
Replace
Replace
Clean
Clean
Remedy —
140E-5 Series 21
SEN00152-02 40 Troubleshooting
q
in E-mode
When a cylinder is cut out for reduced cylinder mode operation, engine speed
q
does not change
If spill hose from injector is disconnected, much fuel spills q
Carry out troubleshooting according to “Abnormality in coolant temperature
q
sensor (*2)” in E-mode
Confirm with INSITE or with monitoring function on applicable machine side q q
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Remedy
22 140E-5 Series
40 Troubleshooting SEN00152-02
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)1
Broken hydraulic oil cooler or power train oil cooler on applicable machine side
• Internal leakage in lubrication system
Remedy —
140E-5 Series 23
SEN00152-02 40 Troubleshooting
machine
Oil pressure monitor indicates low oil pressure (if monitor is installed) Q w
Non-specified oil is being used Q Q
Replacement of filters has not been carried out according to Operation and
w
Maintenance Manual
Indicates pressure drop at low idle w Q Q
Oil pressure Indicates pressure drop at low, high idle Q w w w Q Q Q
monitor
Indicates pressure drop on slopes w
(if installed)
Sometimes indicates pressure drop w Q Q
Oil level monitor indicates oil level drop (if monitor is installed) w w
Oil level in oil pan is low w
External hydraulic piping is leaking, crushed w w
Check items
Valve and spring of oil pump relief valve are fatigued, damaged q
See S-13
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Clean
Clean
Remedy —
Add
24 140E-5 Series
40 Troubleshooting SEN00152-02
Degree of use of
Operated for long period EE E E
machine
Fuel must be added more frequently w w
Coolant must be added more frequently Q Q
There is oil in coolant Q Q Q w
Oil smells of diesel fuel w w
Oil is milky Q Q
When engine is started, drops of water come from muffler Q Q
When radiator cap is removed and engine is run at low idle, an abnormal number of
w Q
bubbles appear, or coolant spurts back
Check items
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Remedy
140E-5 Series 25
SEN00152-02 40 Troubleshooting
26 140E-5 Series
40 Troubleshooting SEN00152-02
machine
Condition of Sudden overheated Q Q w Q
overheating Always tends to overheat Q w w Q
Coolant temperature Rises quickly Q w
gauge (if installed) Does not go down from red range w
Radiator coolant level monitor indicates drop of coolant level (if monitor is installed) Q w
Engine oil level has risen, oil is milky w Q
Fan belt tension is low w
When fan pulley is turned, it has play w
Milky oil is floating on coolant w
There are excessive air bubbles in radiator, coolant spurts back w
When light bulb is held behind radiator core, no light passes through w
Check items
Radiator shroud, inside of underguard on applicable machine side are clogged with
w w
dirt or mud
Coolant is leaking because of cracks in hose or loose clamps w
Coolant flows out from radiator overflow hose w
Fan belt whines under sudden acceleration w
Power train oil temperature enters red range faster than engine coolant temperature
w
(if oil temperature gauge and coolant temperature gauge are installed)
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Remedy —
Add
140E-5 Series 27
SEN00152-02 40 Troubleshooting
belt
Confirm recent repair history
Degree of use of
Operated for long period E
machine
Questions
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Remedy
28 140E-5 Series
40 Troubleshooting SEN00152-02
• Abnormal combustion
Replace
Replace
Adjust
Remedy
140E-5 Series 29
SEN00152-02
© 2007 KOMATSU
All Rights Reserved
Printed in Japan 03-07 (01)
30
SEN00156-01
140E-5 Series
140E-5 Series 1
SEN00156-01 50 Disassembly and assembly
Removal
q The “Removal” section contains procedures,
precautions and the amount of oil or coolant to
be drained.
q As to the multi purpose tools used in removal,
the numbers such [1], [2]··· are given. Their
part numbers, part names and quantity are not
described.
q Various symbols used in the “Removal” section
are explained and listed below.
k : Precautions related to safety in execution
of work.
a : This mark gives guidance or precautions
when doing the procedure.
[*1] : This mark shows that there are instructions
or precautions for installing parts.
6 This mark shows oil or coolant to be drained.
4 : Weight of part or component
2 140E-5 Series
50 Disassembly and assembly SEN00156-01
Disassembly
q In “Disassembly” section, the work procedures,
precautions and know-how for carrying out
those procedures, and quantity of the oil and
coolant drained are described.
q As to the multi purpose tools used in disas-
sembly, the numbers such [1], [2]··· are given.
Their part numbers, part names and quantity
are not described.
q Various symbols used in the “Disassembly”
section are explained and listed below.
k : Precautions related to safety in execution
of work.
a : This mark gives guidance or precautions
when doing the procedure.
6 This mark shows oil or coolant to be drained.
140E-5 Series 3
SEN00156-01 50 Disassembly and assembly
a The recommended coating materials such as adhesives, gasket sealants, and greases used for disas-
sembly and assembly are listed below.
a For coating materials not listed below, use the equivalent of products shown in this manual.
Cate- Komatsu
Part number Q'ty Container Main features and applications
gory code
• Used to prevent rubber gaskets, rubber cush-
LT-1A 790-129-9030 150 g Tube
ions, and cork plugs from coming out.
• Used for plastic (except polyethylene,
polypropylene, tetrafluoroethylene and vinyl
20 g Polyethylene
LT-1B 790-129-9050 chloride), rubber, metal, and non-metal parts
(2 pcs.) container
which require immediate and strong adhe-
sion.
Polyethylene • Features: Resistance to heat and chemicals.
LT-2 09940-00030 50 g
container • Used to fix and seal bolts and plugs.
790-129-9060
Adhesive: 1 kg • Used to stick and seal metal, glass, and plas-
LT-3 (Set of adhesive Can
Hardener: 500 g tics.
and hardener)
Adhesive
Polyethylene
LT-4 790-129-9040 250 g • Used to seal plugs.
container
Holtz MH 705 790-129-9120 75 g Tube • Heat-resistant seal used to repair engines.
• Quick-setting adhesive.
ThreeBond Polyethylene • Setting time: Within 5 sec. to 3 min.
790-129-9140 50 g
1735 container • Used mainly to stick metals, rubbers, plastics,
and woods.
• Quick-setting adhesive.
• Quick-setting type.
Aron-alpha Polyethylene
790-129-9130 2g (max. strength is obtained after 30 minutes)
201 container
• Used mainly to stick rubbers, plastics, and
metals.
• Features: Resistance to heat and chemicals.
Loctite Polyethylene
79A-129-9110 50 cc • Used for fitted portions used at high tempera-
648-50 container
tures.
• Used to stick or seal gaskets and packings of
LG-1 790-129-9010 200 g Tube
power train case, etc.
• Used to seal various threaded portions, pipe
Polyethylene joints, and flanges.
LG-5 790-129-9080 1 kg
container • Used to seal tapered plugs, elbows, and nip-
ples of hydraulic piping.
• Features: Silicon-based heat and cold-resis-
Gasket sealant
tant sealant.
LG-6 790-129-9020 200 g Tube • Used to seal flange surfaces and threaded
portions.
• Used to seal oil pan, final drive case, etc.
• Features: Silicon-based quick-setting sealant.
LG-7 790-129-9070 1 kg Tube • Used to seal flywheel housing, intake mani-
fold, oil pan, thermostat housing, etc.
• Features: Silicon-based, heat and cold-resis-
LG-8
tant, vibration-resistant, impact-resistant seal-
ThreeBond 419-15-18131 100 g Tube
ant.
1207B
• Used to seal transfer case, etc.
4 140E-5 Series
50 Disassembly and assembly SEN00156-01
Cate-
Komatsu code Part number Q'ty Container Main features and applications
gory
• Feature: Can be coated with paint.
LG-9 • Used for rough surfaces such as the circle gear
ThreeBond 790-129-9310 200 g Tube top seal which does not need to be clamped,
1206D water resistance of the clearance at the welded
area, etc.
Gasket sealant
LC-G
— — Can • Used for the mounting bolt in the high tempera-
NEVER-SEEZ
ture area of the exhaust manifold and the turbo-
charger, etc.
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
G2-LI • Feature: Lithium grease with extreme pressure
SYG2-160LI
G0-LI Various Various lubrication performance.
SYGA-160CNLI
*: For cold district • General purpose type.
SYG0-400LI-A (*)
SYG0-160CNLI
(*)
• Used for parts under heavy load.
Caution:
Molybdenum SYG2-400M 400 g x 10 Bellows-type • Do not apply grease to rolling bearings like
disulfide grease SYG2-400M-A 400 g x 20 container swing circle bearings, etc. and spline.
LM-G (G2-M) SYGA-16CNM 16 kg Can • The grease should be applied to work equipment
pins at their assembly only, not applied for
Grease
greasing afterwards.
• Seizure resistance, heat resistance and water
Hyper White SYG2-400T-A
400 g Bellows-type resistance higher than molybdenum disulfide
Grease G2-T, SYG2-16CNT
container grease.
G0-T (*) SYG0-400T-A (*)
16 kg Can • Not conspicuous on machine since color is
*: For cold district SYG0-16CNT (*)
white.
Biogrease SYG2-400B
G2-B, G2-BT (*) SYGA-16CNB 400 g Bellows-type • Since this grease is decomposed by natural bac-
*: For use at high SYG2-400BT (*) container teria in short period, it has less effects on micro-
temperature and SYGA-16CNBT 16 kg Can organisms, animals, and plants.
under high load (*)
• Feature: Silicone grease with wide using tem-
G2-S perature range, high resistance to thermal-oxi-
ThreeBond — 200 g Tube dative degradation and performance to prevent
1855 deterioration of rubber and plastic parts.
• Used for oil seals of the transmission, etc.
140E-5 Series 5
SEN00156-01 50 Disassembly and assembly
Cate-
Komatsu code Part number Q'ty Container Main features and applications
gory
SUNSTAR • Used as primer for cab side.
Glass
PAINT PRIMER 20 ml (Using limit: 4 months after date of manu-
container
580 SUPER facture)
SUNSTAR 417-926-3910
• Used as primer for glass side.
GLASS Glass
20 ml (Using limit: 4 months after date of manu-
PRIMER 580 container
facture)
facture)
SUNSTAR Ecocart • Used as adhesive for glass.
PENGUINE 22M-54-27210 320 ml (Special (Using limit: 6 months after date of manu-
SUPER 560 container) facture)
SUNSTAR • Used to seal joints of glass parts.
Polyethylene
PENGUINE 417-926-3920 320 ml (Using limit: 4 months after date of manu-
container
SEAL No. 2505 facture)
Caulking material
6 140E-5 Series
50 Disassembly and assembly SEN00156-01
New / Remodel
Necessity
Symbol
Sketch
Q'ty
Work item Part No. Part name Remarks
140E-5 Series 7
SEN00156-01 50 Disassembly and assembly
N1 Push tool
N2 Push tool
8 140E-5 Series
50 Disassembly and assembly SEN00156-01
140E-5 Series 9
SEN00156-01
© 2007 KOMATSU
All Rights Reserved
Printed in Japan 03-07 (01)
10
SEN00157-02
140E-5 Series
140E-5 Series 1
SEN00157-02 50 Disassembly and assembly
1. Preparation work
Before disassembling the engine, check its
parts for cracking, damage, etc. and clean it
generally and carefully for accurate inspection
of its parts and quick disassembly and assem-
bly.
a Before cleaning the engine, carefully seal
or remove the openings, electric parts,
and wiring connectors so that water will
not enter them. 4. Air cleaner bracket
1) Disconnect wiring harness clamp (1).
2. Setting engine assembly 2) Remove air cleaner bracket (2).
1) Prepare stable engine stands (Blocks [1]) a The type of the bracket depends on
and place the engine assembly on them the applicable machines.
4 Air cleaner bracket: 30 kg
so that it will not tip over.
a The weight depends on the applica-
ble machines.
4 Engine assembly: 2,000 kg
5. EGR cover
1) Remove covers (1), (2), and (3).
2) Drain the engine coolant and engine oil.
a The quantity of the oil depends on the
applicable machines.
6 Engine oil: Approx. 53 l
2 140E-5 Series
50 Disassembly and assembly SEN00157-02
2) Remove covers (4), (5), (6), and (7). 8. Clamp and bracket
a Cover (6) is not installed to all the 1) Remove clamp (1) and brackets (2) and
models. (3).
2) Remove bracket (4).
140E-5 Series 3
SEN00157-02 50 Disassembly and assembly
4 140E-5 Series
50 Disassembly and assembly SEN00157-02
14. Bracket
Remove bracket (12).
3) Remove wiring harness (4) and 4 turbo-
charger lubrication tube clamps (5) and
remove turbocharger lubrication tube (6).
140E-5 Series 5
SEN00157-02 50 Disassembly and assembly
6 140E-5 Series
50 Disassembly and assembly SEN00157-02
22. Oil filter, fuel filter, and corrosion resistor 25. Oil filter head
Remove oil filter (1), pre-fuel filter (2), main fuel 1) Remove oil tubes (1) and (2) and the block
filter (3), and corrosion resistor (4). on the cylinder block side as a unit.
a Pre-fuel filter (2) may be installed on the 2) Remove oil filter head (3).
applicable machine side. a The type of the oil filter head depends
on the applicable machines.
23. EGR valve and bypass valve oil drain tube
Remove drain tube (5).
140E-5 Series 7
SEN00157-02 50 Disassembly and assembly
6) Remove corrosion resistor head (10), fuel 29. Air intake manifold
filter head (11), priming pump (12), and 1) Sling the air intake manifold temporarily.
bracket as a unit. 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.
8 140E-5 Series
50 Disassembly and assembly SEN00157-02
140E-5 Series 9
SEN00157-02 50 Disassembly and assembly
6) Disconnect fuel pressure sensor connec- 35. EGR oil pump assembly
tor PFUEL (15) and POIL (16). Remove the bolts and EGR oil pump assembly
7) Remove clamp (17) and the eye joint of (1).
tube (18) on the common rail side.
8) Remove special bolts (19) and remove
common rail (20).
10 140E-5 Series
50 Disassembly and assembly SEN00157-02
5) Disconnect the injector connector accord- a After removing the suction tube, sling the
ing to the following procedure. engine. Set stable blocks at the front,
1] Apply flat-head screwdriver [1] to the rear, right, and left under the cylinder
stepped part (part (a)). block and place the engine on them.
2] While pressing stopper (1a), move a Arrange the above blocks so that you can
flat-head screwdriver [1] in direction rotate the crankshaft.
(X) to disconnect the connector.
40. Flywheel
1) Using sling [1], lift up flywheel (1) tempo-
rarily.
2) Remove the 8 mounting bolts and lift off
the flywheel.
a Take care that the flywheel will not
contact the Ne sensor on the back
side.
4 Flywheel: 65 kg
140E-5 Series 11
SEN00157-02 50 Disassembly and assembly
12 140E-5 Series
50 Disassembly and assembly SEN00157-02
140E-5 Series 13
SEN00157-02 50 Disassembly and assembly
14 140E-5 Series
50 Disassembly and assembly SEN00157-02
54. Camshaft
1) Match the holes of cam gear (1) to mount-
52. Front oil seal ing bolts (2) and remove bolts (2).
Remove front oil seal (1) from the front cover.
140E-5 Series 15
SEN00157-02 50 Disassembly and assembly
55. Oil pump assembly and sub idler gear 58. Piston cooling nozzle
1) Remove oil pump assembly (1). Remove the mounting bolts and piston cooling
2) Remove sub idler gear (2). nozzles (1) and (2).
a Be sure to remove the piston cooling noz-
zles before pulling out the piston.
16 140E-5 Series
50 Disassembly and assembly SEN00157-02
60. Crankshaft
a Before removing the crankshaft, measure
its end play with dial gauge [1], if neces-
sary.
140E-5 Series 17
SEN00157-02 50 Disassembly and assembly
1) Remove mounting bolts (2) of main cap 4) Remove upper thrust bearing (5).
(1).
2) Insert the bolts in the bolt holes of the
main cap and remove the cap, while shak-
ing it.
18 140E-5 Series
50 Disassembly and assembly SEN00157-02
140E-5 Series 19
SEN00157-02 50 Disassembly and assembly
1. Cylinder block
1) Install tool A2 to the cylinder block, and
then sling the cylinder block and set it to
tool A1.
4 Cylinder block: 390 kg
20 140E-5 Series
50 Disassembly and assembly SEN00157-02
140E-5 Series 21
SEN00157-02 50 Disassembly and assembly
5) Insert cylinder liner (1) in the cylinder 10) Using tool H, measure the projection of
block slowly, taking care not to damage the cylinder liner.
the O-ring. a When measuring the projection of the
6) Push in cylinder liner (1) further with both liner, tighten the liner with a plate so
hands. that it will not be lifted by the O-ring.
a If the liner does not enter the cylinder q Projection of liner: 0.07 – 0.15 mm
smoothly, the O-ring may be broken. a If the gasket sealant is projected from
In this case, check the cylinder block the fitting parts of the cylinder block
for burrs. and cylinder liner up to the top of the
7) Using tool F, press fit cylinder liner (1) to cylinder block, wipe it off.
the cylinder block.
9) Remove the cylinder head and wipe off 2) Drive the dowel pin so that it will be pro-
the gasket sealant projected from the jected by 2.7 – 3.4 mm from the block end
counterbored part. and then install upper thrust bearing (5) to
a Be sure to perform steps 8) and 9) the No. 7 journal.
above since the projected gasket a Install the thrust bearing with the
sealant can deform the grommet of grooved surface on the crankshaft
the head gasket. side.
22 140E-5 Series
50 Disassembly and assembly SEN00157-02
3) Sling crankshaft (4) and install it to the cyl- 6) Make sure that the journal No. stamped at
inder block. the center of main cap (2) and the journal
a When replacing the crank gear, heat it No. of the cylinder block are the same and
with a bearing heater (30 A) (Set tem- then install the main cap.
perature: 150°C) and fit it just after it a Install the main cap with the cast let-
is heated. ter (F) toward the front of the engine.
a When installing the crankshaft, take
care not to hit its sliding surfaces
against the cylinder block.
4 Crankshaft: 140 kg
2 Cylinder block journal:
Engine oil (EO30)
140E-5 Series 23
SEN00157-02 50 Disassembly and assembly
8) Tighten main cap mounting bolts (1) 10) Check that the crankshaft turns smoothly.
according to the following procedure. 11) Measure the end play of the crankshaft
a Tighten the bolts from the center one with dial gauge [1].
to the outer ones in order. a End play: 0.140 – 0.315 mm
2 Threaded portion of mounting bolt a If the end play is out of the standard,
and washer: correct it. For details, see “Structure,
Engine oil (EO30) function and maintenance standard”.
3 Mounting bolt
1st time:
108 – 128 Nm {11 – 13 kgm}
2nd time:
230 – 240 Nm {23.5 – 24.5 kgm}
3rd time:
Using tool J, tighten the bolt by
90° (+30°/0).
24 140E-5 Series
50 Disassembly and assembly SEN00157-02
2) Set the abutment joint of each piston ring 7) Insert piston and connecting rod assembly
as shown in the following figure. (8) in the cylinder block so that the cast
a Adjust oil ring so that the joint of the part number on the connecting rod will be
expander will be at 180° to the abut- directed to the front of the engine (the
ment joint of the oil ring. stamped cylinder number will be on the
camshaft side).
a Referring to step 2), check the abut-
ment joint of each piston ring again.
2 Inside of connecting rod bearing and
inside of cylinder:
Engine oil (EO30)
140E-5 Series 25
SEN00157-02 50 Disassembly and assembly
26 140E-5 Series
50 Disassembly and assembly SEN00157-02
13) After tightening the bolt, make a punch 2) Install piston cooling nozzles (1) and (2) to
mark (c) on its head. each cylinder in order.
a When a new bolt is used, do not a Install the piston cooling nozzles hav-
make a punch mark on its head. ing the stamps of (F1) to the front side
of the cylinder and install those hav-
ing the stamps of (N1) to the rear side
of the cylinder.
a Push in each piston cooling nozzle
with the hand until its flange touches
the cylinder block and then tighten the
mounting bolt.
a Take care not to mistake the hexago-
nal part of the nozzle for the mounting
bolt.
3 Mounting bolt:
27.4 – 34.3 Nm {2.8 – 3.5 kgm}
6. Underframe
Install underframes (1).
a The number of the underframes depends
on the applicable machines.
140E-5 Series 27
SEN00157-02 50 Disassembly and assembly
9. Camshaft
1) Install camshaft (1) to the cylinder block,
turning it so that it will not damage the
cam bushing.
a If the cam gear is replaced, heat the
new gear in an electric oven, etc. and
heat it at 220 – 240°C for 30 – 60
minutes and then install it by shrink
fit.
4 Camshaft: 20 kg
2 Camshaft journal surface:
8. Sub idler gear and oil pump assembly
Engine oil (EO30)
1) Install sub idler gear (2), shaft (4) and
plate (3) together.
a Direct the stamp of TOP on shaft (4)
up and direct the chamfered inside
edge toward the gear.
3 Sub idler gear mounting bolt:
377.6 – 426.6 Nm {38.5 – 43.5 kgm}
2) Install oil pump assembly (1).
3 Oil pump assembly mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
28 140E-5 Series
50 Disassembly and assembly SEN00157-02
2) Matching the stamped (C) of the camshaft 4) Fit the O-ring and install cover (3).
gear to that of the main idler gear, tighten 3 Mounting bolt:
mounting bolt (2). 9.8 – 12.7 Nm {1.0 – 1.3 kgm}
3 Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
140E-5 Series 29
SEN00157-02 50 Disassembly and assembly
3) Install fuel supply pump drive gear (3) to q Standard backlash of each gear
the fuel supply pump shaft and tighten
Position Range (mm)
mounting nut (1).
a When installing to the fuel supply A 0.141 – 0.425
pump shaft, set stamp (B) of fuel sup- B 0.129 – 0.391
ply pump drive gear (3) to stamp (B) C 0.129 – 0.391
of the main idler gear (circled in the
D 0.141 – 0.425
figure).
3 Mounting nut: E 0.080 – 0.417
176 – 196 Nm {18 – 20 kgm} F 0.095 – 0.346
G 0.118 – 0.369
30 140E-5 Series
50 Disassembly and assembly SEN00157-02
14. Front cover and front support 1) Set large inside diameter side (a) of plas-
a The front cover and front support are tic inside cylinder (2) to the end of crank-
installed with the same mounting bolts. shaft (3).
1) Fit the gasket and install front cover (1) a Take care not to mistake the direction
temporarily, using eyebolt [1]. of the plastic inside cylinder.
4 Front cover: 70 kg
140E-5 Series 31
SEN00157-02 50 Disassembly and assembly
32 140E-5 Series
50 Disassembly and assembly SEN00157-02
3 Mounting bolt:
a Tighten the mounting bolts according
to the following procedure.
1st time:
137 – 157 Nm {14 – 16 kgm}
2nd time:
284 – 294 Nm {29.0 – 30.0 kgm}
3rd time:
Using tool J, tighten the bolt by
90° (+30°/0).
140E-5 Series 33
SEN00157-02 50 Disassembly and assembly
34 140E-5 Series
50 Disassembly and assembly SEN00157-02
140E-5 Series 35
SEN00157-02 50 Disassembly and assembly
5) Tighten clamps and brackets (7), (8), (9), 22. Rocker arm and shaft assembly
(10), (11) and (12) with the hand first, then Install rocker arm and shaft assembly (1) and
tighten clamp side permanently. tighten mounting bolts (2), (3) and (4).
3 Clamp bolt: a Note that the lengths of the mounting bolts
9.8 ± 1.0 Nm {1.0 ± 0.1 kgm} are different.
6) Tighten clamps and brackets (7), (8), (9), Mounting bolt (2): Stem length; 120 mm
(10), (11) and (12) of bracket side perma- Mounting bolt (3): Stem length; 90 mm
nently. Mounting bolt (4): Stem length; 75 mm
7) Install covers (13) and (14) to the sleeve a Before tightening the mounting bolts,
nut. check that the ball of the adjustment screw
a Direct the cut of cover (13) down and is fitted to the socket of the push rod.
direct the cut of cover (14) toward the 3 Mounting bolt:
cylinder block. 93 – 103 Nm {9.5 – 10.5 kgm}
36 140E-5 Series
50 Disassembly and assembly SEN00157-02
140E-5 Series 37
SEN00157-02 50 Disassembly and assembly
38 140E-5 Series
50 Disassembly and assembly SEN00157-02
4) Tighten the 3 bolts evenly to press fit seal 1) Set sleeve/seal (2) to tool N2.
(1) until the end of tool N1 reaches the 2 Inside of sleeve:
end of crankshaft (4). Gasket sealant (LG-7)
a First, tighten tool N1 until bolt N3 (45
mm) stops, then tighten N4 (25 mm).
a When press fitting the seal, take care
not to damage the lip on the seal side
with the tool set, etc.
Press fit dimension of rear oil seal
from the crankshaft end surface: 13.2
± 2 mm
a After press fitting the seal, remove the
red sealant layer from its periphery.
140E-5 Series 39
SEN00157-02 50 Disassembly and assembly
40 140E-5 Series
50 Disassembly and assembly SEN00157-02
140E-5 Series 41
SEN00157-02 50 Disassembly and assembly
42 140E-5 Series
50 Disassembly and assembly SEN00157-02
140E-5 Series 43
SEN00157-02 50 Disassembly and assembly
2) Install brackets (7), (8), (9), (10) and (11). 37. Air intake connector assembly
3) Install brackets (2), (3), (4), (5) and (6). 1) Install joint housing (6) to bracket (7).
2) Install venturi nozzle, air heater (5) and
connector (4) to joint housing (6).
a Direct the terminal of the air heater
toward the original direction of the
engine. (The direction of the terminal
depends on the applicable
machines.)
44 140E-5 Series
50 Disassembly and assembly SEN00157-02
140E-5 Series 45
SEN00157-02 50 Disassembly and assembly
46 140E-5 Series
50 Disassembly and assembly SEN00157-02
140E-5 Series 47
SEN00157-02 50 Disassembly and assembly
5) Fit the gasket and install turbocharger oil 2) Install bracket (8).
drain tube (2). 3) Fit the O-ring and the gasket and install
6) Install exhaust connector (3) and heat EGR cooler coolant inlet tube (10).
insulation cover (1). 3 Rubber hose:
(Nut of tube clamp U-bolt)
10.8 – 26.5 Nm {1.1 – 2.7 kgm}
4) Fit the gasket and install EGR cooler gas
inlet tube (9).
2 Threaded portion and seat of bolt:
Seizure prevention compound (LC-G)
3 Mounting bolt:
44.1 – 53.9 Nm {4.5 – 5.5 kgm}
5) Install air vent tube (7).
3 Joint bolt:
19.6 – 29.4 Nm {2.0 – 3.0 kgm}
6) Install turbocharger drain tube clamps (6).
49. Bracket
Install exhaust manifold cover bracket (12).
48 140E-5 Series
50 Disassembly and assembly SEN00157-02
140E-5 Series 49
SEN00157-02 50 Disassembly and assembly
4) Connect wiring harness connectors BP (2) 57. Bracket and tube clamp
and SBP (1) and install the clamp. 1) Install brackets (7), (6) and (5).
2) Install clamps (4), (3), (2) and (1).
50 140E-5 Series
50 Disassembly and assembly SEN00157-02
140E-5 Series 51
SEN00157-02 50 Disassembly and assembly
52 140E-5 Series
50 Disassembly and assembly SEN00157-02
140E-5 Series 53
SEN00157-02
© 2007 KOMATSU
All Rights Reserved
Printed in Japan 03-07 (01)
54
SEN00158-02
140E-5 Series
140E-5 Series 1
SEN00158-02 50 Disassembly and assembly
1. Preparation work
Before disassembling the engine, check its
parts for cracking, damage, etc. and clean it
generally and carefully for accurate inspection
of its parts and quick disassembly and assem-
bly.
a Before cleaning the engine, carefully seal
or remove the openings, electric parts,
and wiring connectors so that water will
not enter them. 4. Air cleaner bracket
1) Disconnect wiring harness clamp (1).
2. Setting engine assembly 2) Remove air cleaner bracket (2).
1) Prepare stable engine stands (Blocks [1]) a The type of the bracket depends on
and place the engine assembly on them the applicable machines.
4 Air cleaner bracket: 30 kg
so that it will not tip over.
a The weight depends on the applica-
ble machines.
4 Engine assembly: 1,900 kg
2 140E-5 Series
50 Disassembly and assembly SEN00158-02
8. Turbocharger assembly
1) Remove heat insulation cover (1) and oil 9. Exhaust manifold
drain tube (2). Remove the 24 mounting bolts and exhaust
manifold (1).
4 Exhaust manifold: 25 kg
140E-5 Series 3
SEN00158-02 50 Disassembly and assembly
4 140E-5 Series
50 Disassembly and assembly SEN00158-02
14. Corrosion resistor, oil filter and fuel filter 16. Fuel filter head
1) Remove corrosion resistor. 1) Remove fuel tube clamp (1), then remove
2) Remove oil filters (1) and main fuel filters fuel tubes (2) and (3).
(2). 2) Remove fuel tube (4).
a The locations of the fuel filter and oil filter 3) Remove fuel filter head (5).
may be different from the photo, depend-
ing on the applicable machine.
140E-5 Series 5
SEN00158-02 50 Disassembly and assembly
19. Electric priming pump 3) Remove the mounting bolts and remove
1) Remove joint bolts (1) and fuel tube (2). air intake connector (1) and joint housing
2) Remove joint bolt (3) and fuel tube (4). (8) together.
3) Remove joint bolts (5) and (6) and fuel 4 Air intake connector assembly:
tube (7). 40 kg
4) Remove fuel tube sleeve nut (8).
5) Remove the all mounting bolts and
remove electric priming pump (9) and
bracket (10) together.
6 140E-5 Series
50 Disassembly and assembly SEN00158-02
24. Plate
Remove plate (3).
140E-5 Series 7
SEN00158-02 50 Disassembly and assembly
8 140E-5 Series
50 Disassembly and assembly SEN00158-02
28. Wiring harness assembly and sensor con- a Move lock [1] of the housing of con-
nector nector (6) in the direction of the arrow,
1) Disconnect the clamps of coolant temper- push down lock [2], and pull out con-
ature sensor connector TWTR (1) and wir- nector (6).
ing harnesses (2) and (3) and remove
bracket (4).
140E-5 Series 9
SEN00158-02 50 Disassembly and assembly
10 140E-5 Series
50 Disassembly and assembly SEN00158-02
140E-5 Series 11
SEN00158-02 50 Disassembly and assembly
12 140E-5 Series
50 Disassembly and assembly SEN00158-02
140E-5 Series 13
SEN00158-02 50 Disassembly and assembly
45. Camshaft
1) Match the holes of cam gear (1) to mount-
ing bolts (2) and remove bolts (2).
14 140E-5 Series
50 Disassembly and assembly SEN00158-02
50. Piston and connecting rod assembly 6) Push in and remove the piston and con-
a Before removing the piston and connect- necting rod assembly with a wood bar, etc.
ing rod assembly, measure its end play from the oil pan side, while supporting pis-
with dial gauge [1], if necessary. ton (6) on the cylinder head side.
a Take care not to damage the inside of
the cylinder with a corner of the con-
necting rod.
7) Remove the other piston and connecting
rod assemblies according to the above
procedure.
a Take care not to damage the sliding
portions of the pistons and bearings.
a Assemble each connecting rod and
cap temporarily so that they will not
be assembled with other ones and
keep them and the bearing together.
140E-5 Series 15
SEN00158-02 50 Disassembly and assembly
3] Using tool D, remove piston ring (7). a The No. 7 main cap has lower thrust
a Keep the piston, connecting rod, con- bearing (3).
necting rod bearing, piston rings, and
piston pin by cylinder.
1) Remove mounting bolts (2) of main cap 4) Remove upper thrust bearing (5).
(1).
2) Insert the bolts in the bolt holes of the
main cap and remove the cap, while shak-
ing it.
16 140E-5 Series
50 Disassembly and assembly SEN00158-02
140E-5 Series 17
SEN00158-02 50 Disassembly and assembly
1. Cylinder block
1) Install tool A2 to the cylinder block, and
then sling the cylinder block and set it to
tool A1.
4 Cylinder block: 390 kg
18 140E-5 Series
50 Disassembly and assembly SEN00158-02
140E-5 Series 19
SEN00158-02 50 Disassembly and assembly
5) Insert cylinder liner (1) in the cylinder 10) Using tool H, measure the projection of
block slowly, taking care not to damage the cylinder liner.
the O-ring. a When measuring the projection of the
6) Push in cylinder liner (1) further with both liner, tighten the liner with a plate so
hands. that it will not be lifted by the O-ring.
a If the liner does not enter the cylinder q Projection of liner: 0.07 – 0.15 mm
smoothly, the O-ring may be broken. a If the gasket sealant is projected from
In this case, check the cylinder block the fitting parts of the cylinder block
for burrs. and cylinder liner up to the top of the
7) Using tool F, press fit cylinder liner (1) to cylinder block, wipe it off.
the cylinder block.
9) Remove the cylinder head and wipe off 2) Drive the dowel pin so that it will be pro-
the gasket sealant projected from the jected by 2.7 – 3.4 mm from the block end
counterbored part. and then install upper thrust bearing (5) to
a Be sure to perform steps 8) and 9) the No. 7 journal.
above since the projected gasket a Install the thrust bearing with the
sealant can deform the grommet of grooved surface on the crankshaft
the head gasket. side.
20 140E-5 Series
50 Disassembly and assembly SEN00158-02
3) Sling crankshaft (4) and install it to the cyl- 6) Make sure that the journal No. stamped at
inder block. the center of main cap (2) and the journal
a When replacing the crank gear, heat it No. of the cylinder block are the same and
with a bearing heater (30 A) (Set tem- then install the main cap.
perature: 150°C) and fit it just after it a Install the main cap with the cast let-
is heated. ter (F) toward the front of the engine.
a When installing the crankshaft, take
care not to hit its sliding surfaces
against the cylinder block.
4 Crankshaft: 140 kg
2 Cylinder block journal:
Engine oil (EO30)
140E-5 Series 21
SEN00158-02 50 Disassembly and assembly
8) Tighten main cap mounting bolts (1) 10) Check that the crankshaft turns smoothly.
according to the following procedure. 11) Measure the end play of the crankshaft
a Tighten the bolts from the center one with dial gauge [1].
to the outer ones in order. a End play: 0.140 – 0.315 mm
2 Threaded portion of mounting bolt a If the end play is out of the standard,
and washer: correct it. For details, see “Structure,
Engine oil (EO30) function and maintenance standard”.
3 Mounting bolt
1st time:
108 – 128 Nm {11 – 13 kgm}
2nd time:
230 – 240 Nm {23.5 – 24.5 kgm}
3rd time:
Using tool J, tighten the bolt by
90° (+30°/0).
22 140E-5 Series
50 Disassembly and assembly SEN00158-02
2) Set the abutment joint of each piston ring 7) Insert piston and connecting rod assembly
as shown in the following figure. (8) in the cylinder block so that the cast
a Adjust oil ring so that the joint of the part number on the connecting rod will be
expander will be at 180° to the abut- directed to the front of the engine (the
ment joint of the oil ring. stamped cylinder number will be on the
camshaft side).
a Referring to step 2), check the abut-
ment joint of each piston ring again.
2 Inside of connecting rod bearing and
inside of cylinder:
Engine oil (EO30)
140E-5 Series 23
SEN00158-02 50 Disassembly and assembly
24 140E-5 Series
50 Disassembly and assembly SEN00158-02
13) After tightening the bolt, make a punch 2) Install piston cooling nozzles (1) and (2) to
mark (c) on its head. each cylinder in order.
a When a new bolt is used, do not a Install the piston cooling nozzles hav-
make a punch mark on its head. ing the stamps of (F1) to the front side
of the cylinder and install those hav-
ing the stamps of (N1) to the rear side
of the cylinder.
a Push in each piston cooling nozzle
with the hand until its flange touches
the cylinder block and then tighten the
mounting bolt.
a Take care not to mistake the hexago-
nal part of the nozzle for the mounting
bolt.
3 Mounting bolt:
27.4 – 34.3 Nm {2.8 – 3.5 kgm}
6. Underframe
Install underframes (1).
a The number of the underframes depends
on the applicable machines.
140E-5 Series 25
SEN00158-02 50 Disassembly and assembly
9. Camshaft
1) Install camshaft (1) to the cylinder block,
turning it so that it will not damage the
cam bushing.
a If the cam gear is replaced, heat the
new gear in an electric oven, etc. and
heat it at 220 – 240°C for 30 – 60
minutes and then install it by shrink
fit.
4 Camshaft: 20 kg
2 Camshaft journal surface:
8. Sub idler gear and oil pump assembly
Engine oil (EO30)
1) Install sub idler gear (2), shaft (4) and
plate (3) together.
a Direct the stamp of TOP on shaft (4)
up and direct the chamfered inside
edge toward the gear.
3 Sub idler gear mounting bolt:
377.6 – 426.6 Nm {38.5 – 43.5 kgm}
2) Install oil pump assembly (1).
3 Oil pump assembly mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
26 140E-5 Series
50 Disassembly and assembly SEN00158-02
2) Matching the stamped (C) of the camshaft 4) Fit the O-ring and install cover (3).
gear to that of the main idler gear, tighten 3 Mounting bolt:
mounting bolt (2). 9.8 – 12.7 Nm {1.0 – 1.3 kgm}
3 Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
140E-5 Series 27
SEN00158-02 50 Disassembly and assembly
28 140E-5 Series
50 Disassembly and assembly SEN00158-02
140E-5 Series 29
SEN00158-02 50 Disassembly and assembly
30 140E-5 Series
50 Disassembly and assembly SEN00158-02
8) Install cylinder head assembly (2) and a When not using tool J, make marks
tighten mounting bolts (1) and auxiliary (a) and (b) on the bolts and head with
bolts. paint, then tighten the bolts by 90°
2 Mounting bolt: (+30°/0).
Molybdenum disulfide lubricant (LM-P) a After tightening bolts 1 – 6, tighten
bolt 7.
3 Bolt 7:
66.6 ± 7.4 Nm {6.8 ± 0.8 kgm}
3 Mounting bolt:
a Tighten the mounting bolts according
to the following procedure.
1st time:
18. Crosshead
137 – 157 Nm {14 – 16 kgm}
Install crosshead (1).
2nd time:
a Adjust the crosshead according to the fol-
284 – 294 Nm {29.0 – 30.0 kgm}
lowing procedure.
3rd time:
1] Loosen the locknut and return the
Using tool J, tighten the bolt by
adjustment screw.
90° (+30°/0).
2] Holding the top of the crosshead
lightly, tighten the adjustment screw.
3] After the adjustment screw touches
the valve stem, tighten it further by
20°.
4] Tighten the locknut at this point.
3 Locknut:
58.7 ± 5.9 Nm {6.0 ± 0.6 kgm}
140E-5 Series 31
SEN00158-02 50 Disassembly and assembly
32 140E-5 Series
50 Disassembly and assembly SEN00158-02
1) Secure common rail (1) temporarily with a If sleeve nut (5) does not catch the
special bolts (2). threads, press its end with a small rod,
2) Fit O-ring (4) to high-pressure pipe sleeve etc. toward the injector and turn the span-
(3). Matching them to the injector connec- ner.
tor, tighten sleeve nut (5) and sleeve nut
(6) on the common rail side temporarily.
(Tighten the sleeve nuts temporarily in the
order of No. 4, No. 5, No. 2, No. 3, No. 1,
and No. 6.)
2 O-ring: Engine oil (EO30)
3) Tighten special bolts (2) permanently.
3 Special bolt:
59 – 74 Nm {6.0 – 7.5 kgm}
140E-5 Series 33
SEN00158-02 50 Disassembly and assembly
13) Tighten clamps and brackets (15), (16), 23. Adjusting valve clearance
(17), (18), (19) and (20) of bracket side a Adjust the clearance between the cross-
permanently. head and rocker arm to the following
value.
a Valve clearance (when cold)
Unit: mm
Air intake valve Exhaust valve
0.35 ± 0.02 0.57 ± 0.02
34 140E-5 Series
50 Disassembly and assembly SEN00158-02
140E-5 Series 35
SEN00158-02 50 Disassembly and assembly
26. Rear oil seal 1) Set the large inside diameter side (b) of
a Check the Teflon seal (Laydown lip seal) plastic inside cylinder (3) to the end of
by checking the wear of the crankshaft crankshaft (4).
and replace it with the “standard seal” or a Extremely take care not to mistake
“sleeved seal”. the direction of the plastic inside cylin-
a If the shaft is worn to the degree of luster der.
(If wear which you feel with your finger is
less than 10 mm) and does not have any
flaw, install the standard seal. In other
cases, install the sleeved seal.
a The left one in the following figure is the
standard seal and the right one is the
sleeved seal.
36 140E-5 Series
50 Disassembly and assembly SEN00158-02
4) Tighten the 3 bolts evenly to press fit seal 1) Set sleeve/seal (2) to tool N2.
(1) until the end of tool N1 reaches the 2 Inside of sleeve:
end of crankshaft (4). Gasket sealant (LG-7)
a First, tighten tool N1 until bolt N3 (45
mm) stops, then tighten N4 (25 mm).
a Press fitted depth of rear seal
13.2 ± 0.2 mm from crankshaft end.
a When press fitting the seal, take care
not to damage the lip of oil seal with
the tool set, etc.
a After press fitting the seal, remove the
red sealant layer from its periphery.
140E-5 Series 37
SEN00158-02 50 Disassembly and assembly
27. Flywheel
Using eyebolt [1] (12 mm, P = 1.75), sling fly-
wheel (1) and install it to the crankshaft and
tighten the mounting bolts.
a When installing the flywheel, match the
dowel pin of the crankshaft to the hole of
the flywheel.
a Take care not to bring the flywheel in con-
tact with the speed sensor.
2 Threaded portion and seat of bolt:
Engine oil (EO30)
4 Flywheel: 60 kg
a After installing the flywheel, measure its
facial runout and radial runout with dial
gauge [1].
q Radial runout: Max. 0.30 mm
q Facial runout: Max. 0.30 mm
38 140E-5 Series
50 Disassembly and assembly SEN00158-02
140E-5 Series 39
SEN00158-02 50 Disassembly and assembly
40 140E-5 Series
50 Disassembly and assembly SEN00158-02
140E-5 Series 41
SEN00158-02 50 Disassembly and assembly
42 140E-5 Series
50 Disassembly and assembly SEN00158-02
37. Air intake connector assembly 38. Oil filler and electric priming pump cover
1) Install joint housing (2) to bracket (1). 1) Install oil filler (1).
2) Install venturi nozzle, air heater (3) and a Tighten fuel tube clamp (2), too.
connector (4) to joint housing (2). 2) Install clamp (3).
a Direct the terminal of the air heater 3) Install electric priming pump cover (4).
toward the original direction. (The
direction of the terminal depends on
the applicable machines.)
140E-5 Series 43
SEN00158-02 50 Disassembly and assembly
44 140E-5 Series
50 Disassembly and assembly SEN00158-02
140E-5 Series 45
SEN00158-02 50 Disassembly and assembly
3) Fit the gasket and install lubrication tube 47. Front plate
(5) and 4 clamps (4). Fit the gasket to the air intake connector and
3 Tube joint bolt: sling and install front plate (1).
4
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
Bracket: 20 kg
4) Install wiring harness (3).
46 140E-5 Series
50 Disassembly and assembly SEN00158-02
51. Air cleaner bracket and wiring harness a Clean and degrease the engine and the
1) Install air cleaner bracket (2). parts around it in advance so that you can
a The type of the bracket depends on test it easily for fuel leakage.
the applicable machines. 1) Spray color checker (developer) over the
4 Air cleaner bracket: 30 kg fuel supply pump, common rail, fuel injec-
2) Install wiring harness clamp (1). tor, 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) Check the fuel piping and devices for fuel
leakage.
a Check mainly around the high-pres-
sure circuit parts coated with the color
checker for fuel leakage.
a If any fuel leakage is detected, repair
it and check again from step 2).
4) Run the engine at low idle.
5) Check the fuel piping and devices for fuel
leakage.
a Check mainly around the high-pres-
sure circuit parts coated with the color
3) After assembling, check the installing con- checker for fuel leakage.
dition of the wiring harness clamp. a If any fuel leakage is detected, repair
it and check again from step 2).
52. Tightening torque for sensor 6) Run the engine at high idle.
If a sensor is replaced, tighten the new sensor 7) Check the fuel piping and devices for fuel
to the following torque. leakage.
a Check mainly around the high-pres-
Sensor name Tightening torque
sure circuit parts coated with the color
NE 4.9 – 7.9 Nm {0.5 – 0.8 kgm} checker for fuel leakage.
Fuel temperature 23 ± 3 Nm {2.3 ± 0.3 kgm} a If any fuel leakage is detected, repair
Boost pressure 5.5 ± 0.5 Nm {0.56 ± 0.05 kgm} it and check again from step 2).
Intake air temperature 23 ± 3 Nm {2.3 ± 0.3 kgm} 8) Run the engine at high idle and load it.
Coolant temperature 23 ± 3 Nm {2.3 ± 0.3 kgm}
a When checking while the components
to be checked are mounted on the
Engine oil pressure 23 ± 3 Nm {2.3 ± 0.3 kgm}
machine, stall the torque converter or
Atmospheric pressure 4.5 ± 0.5 Nm {0.45 ± 0.05 kgm} relieve the hydraulic pump.
Fuel pressure Never disassemble.
140E-5 Series 47
SEN00158-02 50 Disassembly and assembly
48 140E-5 Series
50 Disassembly and assembly SEN00158-02
140E-5 Series 49
SEN00158-02
© 2007 KOMATSU
All Rights Reserved
Printed in Japan 03-07 (01)
50
SEN00159-02
140E-5 Series
140E-5 Series 1
SEN00159-02 50 Disassembly and assembly
2. Rotate the crankshaft forward and set interme- 6. Remove the clamp and fuel tubes (10) and (11)
diate point (a) between stamped “2/5 TOP” and and then disconnect fuel tubes (12) and (13)
“3/4 TOP” on damper (2) to pointer (3). and fuel hose (14). [*3]
a At this time, check that the forcing tap of
the drive gear is set to the bolt hole at the 7. Remove the clamp and oil tubes (15) and (16).
top of cover (1). [*4]
(If not, rotate the crankshaft 1 more turn.)
a At this point, the key of the shaft is turned 8. Remove the splash prevention cover, clamps
clockwise by 15° from the top. (17), (18), (19), and bracket (20), and then
remove high-pressure tube (21). [*5]
2 140E-5 Series
50 Disassembly and assembly SEN00159-02
[*2]
3 Sleeve nut of EGR oil tube (4):
43 – 47 Nm {4.4 – 4.8 kgm}
[*3]
3 Joint bolt of fuel tube (12) (Pump side):
14.8 – 19.6 Nm {1.5 – 2.0 kgm}
Joint bolt of fuel tube (13):
(Pump side)
14.8 – 19.6 Nm {1.5 – 2.0 kgm}
(Common rail side)
17.7 – 22.6 Nm {1.8 – 2.3 kgm}
10. Set tool P to the drive gear, tighten center bolt Joint bolt of fuel tubes (10) and (11):
of P, and remove gear (25) from the shaft. (Pump side)
14.8 – 19.6 Nm {1.5 – 2.0 kgm}
11. Remove mounting bolts (23) which have been
left and remove supply pump assembly (22). [*4]
a If tool P is removed, the gear falls down. 3 Joint bolt of oil tubes (15) and (16):
Accordingly, keep it installed until the (Pump side)
pump is installed. 7.9 – 12.7 Nm {0.8 – 1.3 kgm}
(Cylinder block side)
9.8 – 12.7 Nm {1.0 – 1.3 kgm}
[*5]
1) Tighten fuel tube (21) with the hand first,
and then tighten it permanently.
3 Sleeve nut:
(Pump side)
39.2 – 49.0 Nm {4.0 – 5.0 kgm}
(Common rail side)
39.2 – 58.8 Nm {4.0 – 6.0 kgm}
2) Tighten clamps (17), (18), and (19) with
the hand first, and then tighten them per-
manently.
a Tighten clamps permanently in the
order of (17), (18) and (19).
3 Clamp mounting bolt:
9.8 ± 1 Nm {1 ± 0.1 kgm}
3) Direct the notch of the splash prevention
cover on the supply pump side toward the
block and direct that on the common rail
side down.
140E-5 Series 3
SEN00159-02 50 Disassembly and assembly
Removal and installation of fuel 4. Remove fuel filters (1) and oil filters (2). [*2]
supply pump unit (EGR-less) 1
5. Remove oil filler (3) and electric priming pump
Removal cover (4). [*3]
1. Remove cover (1).
4 140E-5 Series
50 Disassembly and assembly SEN00159-02
7. Remove sensor connectors (10), (11) and (12). 14. Remove mounting bolts (32) and remove
bracket (33) from supply pump assembly (31).
8. Remove the scatter prevention cover bracket a Leave bolts (32) tightened by 2 – 3
(13). threads to prevent the pump from falling
down.
9. Remove clamps (14), (15) and (16) and high-
pressure pipes (17) and (18). [*5]
140E-5 Series 5
SEN00159-02 50 Disassembly and assembly
Installation [*7]
q Carry out installation in the reverse order to 3
[*5]
1) Tighten fuel high-pressure tubes (17), (18)
with the hand first, and then tighten them
permanently.
3 Sleeve nut:
(Pump side)
39.2 – 49.0 Nm {4.0 – 5.0 kgm}
(Common rail side)
39.2 – 58.8 Nm {4.0 – 6.0 kgm}
2) Tighten clamps (14), (15), and (16) with
the hand first, and then tighten them per-
manently.
a Tighten clamps permanently in the
order of (14), (15) and (16).
3 Clamp mounting bolt:
9.8 ± 1 Nm {1 ± 0.1 kgm}
3) Direct the notch of the splash prevention
cover on the supply pump side toward the
block and direct that on the common rail
side down.
[*6]
3 Clamps (21), (22) and (23) mounting bolt:
9.8 ± 1 Nm {1 ± 0.1 kgm}
6 140E-5 Series
50 Disassembly and assembly SEN00159-02
Installation
a Check the Teflon seal (Laydown lip seal) by
checking the wear of the crankshaft and
replace it with the “standard seal” or “sleeved
seal”.
a If the crankshaft is worn to the degree of luster
(If wear which you feel with your finger is less
than 10 mm) and does not have any flaw, install
the standard seal. In other cases, install the
sleeved seal.
a The left one in the following figure is the stan-
dard seal and the right one is the sleeved seal.
140E-5 Series 7
SEN00159-02 50 Disassembly and assembly
Procedure for installing standard seal 2) Hold the metal ring of rear oil seal (1) with both
a Before installing the rear oil seal, check that hands and push it in firmly.
the end corners and lip sliding surfaces of 3) After pushing in the rear oil seal, remove plas-
crankshaft (4) are free from flaw, burr, and rust tic inside cylinder (3).
of the housing. a When removing the inside cylinder, take
a When installing rear oil seal (1), do not apply care not to damage the seal lip.
oil or grease to the crankshaft and seal lip (a).
Wipe off the oil from the crankshaft.
a Never remove inside plastic cylinder (3) of the
standard spare seal before installing the seal.
8 140E-5 Series
50 Disassembly and assembly SEN00159-02
Procedure for installing sleeved seal 2) Set the sleeve of the seal to the end of the
a Before installing the rear oil seal, check that crankshaft, and then tighten the 3 bolts evenly
the end corners and lip sliding surfaces of the to press fit sleeve (1) and rear oil seal (2) until
crankshaft are free from flaw, burr, and rust of the end of tool N2 reaches the end of crank-
the housing. shaft (4).
a When installing the rear oil seal, do not apply a First, tighten tool N2 until bolt N3 (45 mm)
oil or grease to the crankshaft, sleeve (1), and stops, then tighten bolt N4 (25 mm).
seal lip (a). Wipe off the oil from the shaft.
a Handle the rear oil seal and sleeve as an
assembly and never separate them from each
other.
140E-5 Series 9
SEN00159-02 50 Disassembly and assembly
10 140E-5 Series
50 Disassembly and assembly SEN00159-02
2) Hold the metal ring of front oil seal (1) with both
hands and push it in evenly, passing it over the
large inside diameter side of the plastic inside
cylinder.
3) After pushing in the front oil seal (1), remove
plastic inside cylinder (2).
a When removing the inside cylinder, take
care not to damage the seal lip.
140E-5 Series 11
SEN00159-02
© 2007 KOMATSU
All Rights Reserved
Printed in Japan 03-07 (01)
12