8 0 53 MB
SEN00074-16
ENGINE
140E
-5
SERIES
SEN00076-16
ENGINE 1SHOP MANUAL
140E-5 Series
00 Index and foreword
1
Index Composition of shop manual .......................................................................................................................... 2 Table of contents ............................................................................................................................................. 3
140E-5 Series
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SEN00076-16
00 Index and foreword
Composition of shop manual
1
The contents of this shop manual are shown together with Form No. in a list. Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly. The marks shown to the right of Form No. denote the following: Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.) Note 2: This shop manual can be supplied for each Form No. Note 3: To file this shop manual in the special binder for management, handle it as follows: • Place a divider on the top of each section in the file after matching the Tub No. with No. indicated next to each Section Name shown in the table below: • File overview and other materials in sections in the order shown below and utilize them accordingly. Section Title
Form Number
Shop Manual, contents binder, binder label and tabs ............................................................ SEN00074-16 00 Index and foreword ......................................................................................................... SEN00075-16 Index ............................................................................................................................... SEN00076-16 q Foreword and general information .................................................................................. SEN00077-07 01 Specification.................................................................................................................... SEN00078-07 Specification and technical data...................................................................................... SEN00079-07 q 10 Structure, function and maintenance standard ............................................................... SEN00080-08 Structure, function and maintenance standard, Part 1.................................................... SEN00081-08 q Structure, function and maintenance standard, Part 2.................................................... SEN00082-06 q 20 Standard value table ....................................................................................................... SEN00083-07 Standard service value table........................................................................................... SEN00147-07 q 30 Testing and adjusting ...................................................................................................... SEN00148-05 Testing and adjusting ...................................................................................................... SEN00149-05 40 Troubleshooting .............................................................................................................. SEN00150-06 General information on troubleshooting.......................................................................... SEN00151-04 Troubleshooting of mechanical system (S-mode)........................................................... SEN00152-03 Troubleshooting of electrical system (E-mode), Part 1 ................................................... SEN00153-03 Troubleshooting of electrical system (E-mode), Part 2 ................................................... SEN00154-02 50 Disassembly and assembly ............................................................................................ SEN00155-07 General information on disassembly and assembly ....................................................... SEN00156-05 Disassembly and assembly, Part 1 (with EGR) .............................................................. SEN00157-05 Disassembly and assembly, Part 2 (EGR-less) .............................................................. SEN00158-05 Disassembly and assembly, Part 3 ................................................................................. SEN00159-04 90 Repair and replacement of parts..................................................................................... SEN05197-02 Information related to repair and replacement ................................................................ SEN05198-00 Cylinder head.................................................................................................................. SEN05199-02 Cylinder block ................................................................................................................. SEN05200-01
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140E-5 Series
00 Index and foreword
SEN00076-16
Table of contents
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00 Index and foreword Index SEN00076-16 Composition of shop manual ................................................................................................... 2 Table of contents ..................................................................................................................... 3 Foreword and general information SEN00077-07 Safety notice............................................................................................................................ 2 How to read the shop manual.................................................................................................. 7 Explanation of terms for maintenance standard ...................................................................... 9 Handling of electric equipment and hydraulic component ....................................................... 11 Handling of connectors newly used for engines ...................................................................... 20 How to read electric wire code ................................................................................................ 23 Precautions when carrying out operation ................................................................................ 26 Method of disassembling and connecting push-pull type coupler ........................................... 29 Standard tightening torque table.............................................................................................. 32 Conversion table...................................................................................................................... 36 01 Specification Specification and technical data SEN00079-07 Outline ..................................................................................................................................... 2 Specifications........................................................................................................................... 6 General view............................................................................................................................ 24 Weight table............................................................................................................................. 61 Engine performance curves..................................................................................................... 65 10 Structure, function and maintenance standard Structure, function and maintenance standard, Part 1 SEN00081-08 Air intake and exhaust unit ...................................................................................................... 3 Air cleaner ............................................................................................................................... 5 Turbocharger ........................................................................................................................... 8 Aftercooler ............................................................................................................................... 19 Muffler...................................................................................................................................... 20 EGR system ............................................................................................................................ 25 Cylinder head .......................................................................................................................... 32 Cylinder block .......................................................................................................................... 36 Cylinder liner............................................................................................................................ 39 Main moving parts ................................................................................................................... 40 Crankshaft ............................................................................................................................... 42 Camshaft ................................................................................................................................. 43 Cam follower and push rod...................................................................................................... 44 Piston, piston ring and piston pin............................................................................................. 46 Connecting rod ........................................................................................................................ 48 Flywheel and flywheel housing................................................................................................ 49 Vibration damper ..................................................................................................................... 52 Timing gear.............................................................................................................................. 54 Valve system ........................................................................................................................... 58 Valve and valve guide.............................................................................................................. 60 Rocker arm and shaft .............................................................................................................. 62 Crosshead and guide .............................................................................................................. 63 Structure, function and maintenance standard, Part 2 SEN00082-06 Lubrication system ...................................................................................................................... 4 Lubrication system diagram..................................................................................................... 4 Oil pump .................................................................................................................................. 8 EGR oil pump .......................................................................................................................... 9 Oil filter .................................................................................................................................... 10 Oil cooler ................................................................................................................................. 12 140E-5 Series
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00 Index and foreword
Fuel system ................................................................................................................................. CRI system diagram ................................................................................................................ Outline of CRI system.............................................................................................................. Fuel piping ............................................................................................................................... Fuel cooler ............................................................................................................................... Fuel filter .................................................................................................................................. Priming pump........................................................................................................................... Electric priming pump .............................................................................................................. Engine controller cooler ........................................................................................................... Cooling system............................................................................................................................ Cooling system diagram .......................................................................................................... Water pump ............................................................................................................................. Thermostat............................................................................................................................... Corrosion resistor .................................................................................................................... Cooling fan drive...................................................................................................................... Accessories ................................................................................................................................. Front PTO ................................................................................................................................ Electrical equipment .................................................................................................................... Alternator ................................................................................................................................. Starting motor .......................................................................................................................... Starting aid............................................................................................................................... Engine controller......................................................................................................................
14 14 16 38 42 43 46 47 48 49 49 54 57 58 60 63 63 65 65 76 78 79
20 Standard value table Standard service value table SEN00147-07 Standard service value table for testing, adjusting, and troubleshooting ................................. 2 Running-in standard and performance test standard .............................................................. 19 30 Testing and adjusting Testing and adjusting SEN00149-05 Testing and adjusting (with EGR) ................................................................................................ 3 Testing and adjusting tools list ................................................................................................. 3 Sketches of special tools ......................................................................................................... 5 Testing air boost pressure........................................................................................................ 6 Testing exhaust temperature ................................................................................................... 7 Adjusting valve clearance ........................................................................................................ 8 Testing compression pressure ................................................................................................. 9 Testing blow-by pressure ......................................................................................................... 11 Testing engine oil pressure ...................................................................................................... 12 Testing EGR valve and bypass valve drive oil pressure .......................................................... 13 Handling fuel system parts ...................................................................................................... 14 Releasing residual pressure in fuel system ............................................................................. 14 Testing fuel pressure................................................................................................................ 15 Reduced cylinder mode operation ........................................................................................... 16 No-injection cranking ............................................................................................................... 16 Testing fuel return rate and leakage ........................................................................................ 17 Bleeding air from fuel circuit .................................................................................................... 20 Testing fuel system for leakage ............................................................................................... 22 Testing and adjusting alternator belt tension ........................................................................... 23 Testing and adjusting fan belt tension...................................................................................... 24 Handling controller high-voltage circuit.................................................................................... 25 Testing and adjusting (EGR-less)................................................................................................ 26 Testing and adjusting tools list ................................................................................................. 26 Sketches of special tools ......................................................................................................... 28 Testing air boost pressure........................................................................................................ 29 Testing exhaust temperature ................................................................................................... 30 Adjusting valve clearance ........................................................................................................ 31
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Testing compression pressure................................................................................................. Testing blow-by pressure......................................................................................................... Testing engine oil pressure...................................................................................................... Handling fuel system parts ...................................................................................................... Releasing residual pressure in fuel system ............................................................................. Testing fuel pressure ............................................................................................................... Reduced cylinder mode operation........................................................................................... No-injection cranking ............................................................................................................... Testing fuel return rate and leakage ........................................................................................ Bleeding air from fuel circuit .................................................................................................... Testing fuel system for leakage ............................................................................................... Testing and adjusting alternator belt tension ........................................................................... Testing and adjusting fan belt tension ..................................................................................... Handling controller high-voltage circuit....................................................................................
32 34 35 36 36 37 38 38 39 42 44 45 46 47
40 Troubleshooting General information on troubleshooting SEN00151-04 Points to remember when troubleshooting .............................................................................. 2 Method of displaying trouble diagnosis lamps (Method of displaying error code) ................... 3 Error codes and failure codes list ............................................................................................ 5 Information in troubleshooting table ........................................................................................ 10 Connection table for connector pin numbers ........................................................................... 12 T- branch box and T- branch adapter table ............................................................................. 48 Troubleshooting of mechanical system (S-mode) SEN00152-03 Troubleshooting of mechanical system (S-mode) ....................................................................... 4 Method of using troubleshooting charts................................................................................... 4 S-1 Starting performance is poor ............................................................................................. 8 S-2 Engine does not start ........................................................................................................ 10 S-3 Engine does not pick up smoothly .................................................................................... 14 S-4 Engine stops during operations ........................................................................................ 15 S-5 Engine does not rotate smoothly ...................................................................................... 16 S-6 Engine lacks output (or lacks power) ................................................................................ 17 S-7 Exhaust smoke is black (incomplete combustion) ............................................................ 18 S-8 Oil consumption is excessive (or exhaust smoke is blue)................................................. 20 S-9 Oil becomes contaminated quickly ................................................................................... 21 S-10 Fuel consumption is excessive ....................................................................................... 22 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down).............................. 23 S-12 Oil pressure drops........................................................................................................... 24 S-13 Oil level rises (Entry of coolant/fuel) ............................................................................... 25 S-14 Coolant temperature becomes too high (overheating).................................................... 27 S-15 Abnormal noise is made ................................................................................................. 28 S-16 Vibration is excessive ..................................................................................................... 29 Troubleshooting of electrical system (E-mode), Part 1 SEN00153-03 Troubleshooting of electrical system (E-mode), Part 1 ............................................................... 3 Troubleshooting method for disconnecting wiring harness of pressure sensor system .......... 3 E-1 Code [111/CA111] Engine Controller Internal Failure........................................................ 6 E-2 Code [115/CA115] Eng. Ne and Bkup Speed Sensor Error .............................................. 7 E-3 Code [122/CA122] Charge (boost) Air Press Sensor High Error ...................................... 8 E-4 Code [123/CA123] Charge (boost) Air Press Sensor Low Error....................................... 12 E-5 Code [131/CA131] Throttle Sensor High Error ................................................................. 16 E-6 Code [132/CA132] Throttle Sensor Low Error .................................................................. 20 E-7 Code [135/CA135] Oil Press. Sensor High Error .............................................................. 22 E-8 Code [141/CA141] Oil Press. Sensor Low Error............................................................... 24 E-9 Code [144/CA144] Coolant Temp. Sensor High Error ...................................................... 26 E-10 Code [145/CA145] Coolant Temp. Sensor Low Error ..................................................... 28 E-11 Code [153/CA153] Charge (boost) Air Temp. Sensor High Error.................................... 30 E-12 Code [154/CA154] Charge (boost) Air Temp. Sensor Low Error .................................... 32
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E-13 Code [187/CA187] Sensor Sup. 2 Volt. Low Error .......................................................... 34 E-14 Code [221/CA221] Ambient Air Press. Sensor High Error .............................................. 38 E-15 Code [222/CA222] Ambient Air Press. Sensor Low Error............................................... 40 E-16 Code [227/CA227] Sensor Sup. 2 Volt. High Error ......................................................... 42 E-17 Code [234/CA234] Eng. Overspeed................................................................................ 42 E-18 Code [238/CA238] Ne Speed Sensor Sup. Volt. Error .................................................... 44 E-19 Code [263/CA263] Fuel Temp. Sensor High Error .......................................................... 46 E-20 Code [265/CA265] Fuel Temp. Sensor Low Error........................................................... 48 E-21 Code [271/CA271] PCV1 Short Error.............................................................................. 50 E-22 Code [272/CA272] PCV1 Open Error ............................................................................. 52 E-23 Code [273/CA273] PCV2 Short Error.............................................................................. 54 E-24 Code [274/CA274] PCV2 Open Error ............................................................................. 56 E-25 Code [322/CA322] Injector #1 System Open/Short Error ............................................... 58 E-26 Code [323/CA323] Injector #5 System Open/Short Error ............................................... 60 E-27 Code [324/CA324] Injector #3 System Open/Short Error ............................................... 62 E-28 Code [325/CA325] Injector #6 System Open/Short Error ............................................... 64 E-29 Code [331/CA331] Injector #2 System Open/Short Error ............................................... 66 E-30 Code [332/CA332] Injector #4 System Open/Short Error ............................................... 68 E-31 Code [342/CA342] Engine Controller Data Matching Error............................................. 70 E-32 Code [351/CA351] INJ. Drive Circuit Error...................................................................... 72 E-33 Code [352/CA352] Sensor Sup. 1 Volt. Low Error .......................................................... 74 E-34 Code [386/CA386] Sensor Sup. 1 Volt. High Error ......................................................... 75 E-35 Code [431/CA431] Idle Validation Switch Error............................................................... 78 E-36 Code [432/CA432] Idle Validation Process Error ............................................................ 80 E-37 Code [441/CA441] Supply Voltage Low Error ................................................................. 81 E-38 Code [442/CA442] Supply Voltage High Error ................................................................ 81 Troubleshooting of electrical system (E-mode), Part 2 SEN00154-02 Troubleshooting of electrical system (E-mode), Part 2................................................................ 3 E-39 Code [449/CA449] Rail Press. High Error 2.................................................................... 3 E-40 Code [451/CA451] Rail Press. Sensor High Error .......................................................... 4 E-41 Code [452/CA452] Rail Press. Sensor Low Error ........................................................... 7 E-42 Code [553/CA553] Rail Press. High Error 1.................................................................... 8 E-43 Code [554/CA554] Rail Press Sensor In Range Error .................................................... 9 E-44 Code [559/CA559] No-pressure Feed By Supply pump 1 .............................................. 10 E-45 Code [689/CA689] Eng. Ne Speed Sensor Error ............................................................ 14 E-46 Code [731/CA731] Eng. Bkup Speed Sensor Phase Error ............................................. 16 E-47 Code [757/CA757] All Engine Controller Data Lost Error ............................................... 16 E-48 Code [778/CA778] Eng. Bkup Speed Sensor Error ........................................................ 18 E-49 Code [1228/CA1228] EGR Valve Servo Error 1.............................................................. 21 E-50 Code [1625/CA1625] EGR Valve Servo Error 2.............................................................. 22 E-51 Code [1626/CA1626] Bypass Valve Solenoid Drive Short Circuit Error .......................... 23 E-52 Code [1627/CA1627] Bypass Valve Solenoid Drive Open Error ..................................... 25 E-53 Code [1628/CA1628] Bypass Valve Servo Error 1.......................................................... 26 E-54 Code [1629/CA1629] Bypass Valve Servo Error 2.......................................................... 27 E-55 Code [1631/CA1631] Bypass Valve Lift Sensor High Error............................................. 28 E-56 Code [1632/CA1632] Bypass Valve Lift Sensor Low Error ............................................. 30 E-57 Code [1633/CA1633] KOMNET Error ............................................................................. 30 E-58 Code [1642/CA1642] EGR Inlet Press Sensor Low Error............................................... 31 E-59 Code [1653/CA1653] EGR Inlet Press Sensor High Error .............................................. 32 E-60 Code [2185/CA2185] Throttle Sens. Sup. Volt. High Error ............................................. 34 E-61 Code [2186/CA2186] Throttle Sens. Sup. Volt. Low Error .............................................. 38 E-62 Code [2249/CA2249] No-pressure Feed By Supply pump 2 .......................................... 38 E-63 Code [2271/CA2271] EGR Valve Lift Sensor High Error................................................. 39 E-64 Code [2272/CA2272] EGR Valve Lift Sensor Low Error ................................................. 41 E-65 Code [2351/CA2351] EGR Valve Solenoid Drive Short Error ......................................... 42 E-66 Code [2352/CA2352] EGR Valve Solenoid Drive Open Error ......................................... 44 E-67 Code [2555/CA2555] Intake Air Heater Relay Open Error.............................................. 45 E-68 Code [2556/CA2556] Intake Air Heater Relay Short Error .............................................. 46
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E-69 Code [(143)/B@BAZG] Eng. Oil Press Low Torque Derate............................................ 48 E-70 Code [(146)/B@BCNS] Eng. Overheat........................................................................... 48 E-71 Code [(415)/B@BAZG] Eng. Oil Press. Low Speed Derate............................................ 49 50 Disassembly and assembly General information on disassembly and assembly SEN00156-05 General information on disassembly and assembly.................................................................... 2 How to read this manual.......................................................................................................... 2 Coating materials list ............................................................................................................... 4 Special tools list ....................................................................................................................... 7 Sketches of special tools ......................................................................................................... 8 Disassembly and assembly, Part 1 (with EGR) SEN00157-05 Disassembly and assembly, Part 1 (with EGR)........................................................................... 2 General disassembly of engine ............................................................................................... 2 General assembly of engine.................................................................................................... 20 Disassembly and assembly, Part 2 (EGR-less) SEN00158-05 Disassembly and assembly, Part 2 (EGR-less)........................................................................... 2 General disassembly of engine ............................................................................................... 2 General assembly of engine.................................................................................................... 18 Disassembly and assembly, Part 3 SEN00159-04 Disassembly and assembly, Part 3 ............................................................................................. 2 Removal and installation of fuel supply pump unit (with EGR) ................................................ 2 Removal and installation of fuel supply pump unit (EGR-less)................................................ 4 Replacement of oil seal of engine mounted on machine......................................................... 7 90 Repair and replacement of parts Information related to repair and replacement SEN05198-00 Flowchart ................................................................................................................................. 2 Special tool table ..................................................................................................................... 4 Special tool sketch................................................................................................................... 6 Cylinder head SEN05199-02 Part names related to cylinder head........................................................................................ 2 Testing and inspection of cylinder head................................................................................... 3 Pressure test of cylinder head ................................................................................................. 5 Replacement of valve guide .................................................................................................... 5 Replacement of valve seat insert ............................................................................................ 6 Replacement of crosshead guide ............................................................................................ 13 Repair of cylinder head mounting face by grinding ................................................................. 14 Repair of valve by grinding ...................................................................................................... 15 Cylinder block SEN05200-01 Part names related to cylinder block ....................................................................................... 3 Testing and inspection of cylinder block .................................................................................. 4 Method of checking main bearing metal inside diameter with alignment bar .......................... 6 Part names related to crankshaft............................................................................................. 7 Testing and inspection of crankshaft ....................................................................................... 8 Part names related to connecting rod...................................................................................... 9 Testing and inspection of connecting rod ................................................................................ 10 Replacement of flywheel ring gear .......................................................................................... 11 Replacement of crankshaft gear.............................................................................................. 12 Replacement of camshaft gear................................................................................................ 13 Replacement of main bearing metal cap ................................................................................. 14 Replacement of connecting rod small end bushing................................................................. 16 Replacement of cam bushing .................................................................................................. 17 Repair of cylinder block top by grinding................................................................................... 19 Repair of counterbore by grinding ........................................................................................... 20 Check and identification after repair by grinding...................................................................... 22 140E-5 Series
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Gasket sealant application procedure ..................................................................................... Repair standard for cylinder liner O-ring .................................................................................. Replacement of engine rear seal............................................................................................. Replacement of wear sleeve (when sleeve is installed) .......................................................... Repair of crankshaft by grinding .............................................................................................. Improvement of surface roughness of crankshaft journal........................................................
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140E-5 Series
SEN00076-16
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SEN00076-16
KOMATSU 140E-5 Series engine Form No. SEN00076-16
© 2012 KOMATSU All Rights Reserved Printed in Japan 12-12 (01)
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SEN00077-07
ENGINE 1SHOP MANUAL
140E-5 Series
00 Index and foreword
1
Foreword and general information Safety notice ................................................................................................................................................... 2 How to read the shop manual ......................................................................................................................... 7 Explanation of terms for maintenance standard ............................................................................................. 9 Handling of electric equipment and hydraulic component .............................................................................11 Handling of connectors newly used for engines ........................................................................................... 20 How to read electric wire code...................................................................................................................... 23 Precautions when carrying out operation...................................................................................................... 26 Method of disassembling and connecting push-pull type coupler................................................................. 29 Standard tightening torque table ................................................................................................................... 32 Conversion table ........................................................................................................................................... 36
140E-5 Series
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SEN00077-07
00 Index and foreword
Safety notice
(Rev. 2008/08) 1
Important safety notice Proper service and repair are extremely important for safe machine operation. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe. Some of these techniques require the use of tools specially designed by Komatsu for the specific purpose. To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation. 1.
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General precautions k Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully before operating the machine. In addition, read this manual and understand its contents before starting the work. 1) Before carrying out any greasing or repairs, read all the safety labels stuck to the machine. For the locations of the safety labels and detailed explanation of precautions, see the Operation and Maintenance Manual. 2) Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt, water, or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working. 3) When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. q Always wear safety glasses when hitting parts with a hammer. q Always wear safety glasses when grinding parts with a grinder, etc. 4) When carrying out any operation with 2 or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR warning signs in the operator's compartment. 5) Only qualified workers must carry out work and operation which require license or qualification. 6) Keep all tools in good condition, learn the correct way to use them, and use the proper ones of them. Before starting work, thoroughly check the tools, machine, forklift, service car, etc.
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If welding repairs are needed, always have a trained and experienced welder carry out the work. When carrying out w elding work, alw ays wear welding gloves, apron, shielding goggles, cap and other clothes suited for welding work. Before starting work, warm up your body thoroughly to start work under good condition. Avoid continuing work for long hours and take rests at proper intervals to keep your body in good condition. Take rests in specified safe places.
Safety points 1 Good arrangement 2 Correct work clothes 3 Following work standard 4 Making and checking signs 5
Prohibition of operation and handling by unlicensed workers
6 Safety check before starting work 7
Wearing protective goggles (for cleaning or grinding work)
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Wearing shielding goggles and protectors (for welding work)
9 Good physical condition and preparation 10
Precautions against work which you are not used to or you are used to too much
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Preparations for work 1) Before adding oil or making any repairs, park the machine on a hard and level ground, and apply the parking brake and block the wheels or tracks to prevent the machine from moving. 2) Before starting work, lower the work equipment (blade, ripper, bucket, etc.) to the ground. If this is not possible, insert the lock pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them. 3) When disassembling or assembling, support the machine with blocks, jacks, or stands before starting work. 4) Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the m a c h i n e . N e v e r j u m p o n o r o ff t h e machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.
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Precautions during work 1) Before disconnecting or removing components of the oil, water, or air circuits, first release the pressure completely from the circuit. When removing the oil filler cap, a drain plug, or an oil pressure pickup plug, loosen it slowly to prevent the oil from spurting out. 2) The coolant and oil in the circuits are hot when the engine is stopped, so be careful not to get scalded. Wait for the oil and coolant to cool before carrying out any work on the oil or water circuits. 3) Before starting work, stop the engine. When working on or around a rotating part, in particular, stop the engine. When checking the machine without stopping the engine (measuring oil pressure, revolving speed, temperature, etc.), take extreme care not to get rolled or caught in rotating parts or moving parts. 4) Before starting work, remove the leads from the battery. Always remove the lead from the negative (–) terminal first. 5) When raising a heavy component (heavier than 25 kg), use a hoist or crane. Before starting work, check that the slings (wire ropes, chains, and hooks) are free from damage. Always use slings which have ample capacity and install them to proper places. Operate the hoist or crane slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane.
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When removing a cover which is under internal pressure or under pressure from a spring, always leave 2 bolts in diagonal positions. Loosen those bolts gradually and alternately to release the pressure, and then remove the cover. When removing components, be careful not to break or damage the electrical wiring. Damaged wiring may cause electrical fires. When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips onto the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip and can even start fires. As a general rule, do not use gasoline to wash parts. Do not use it to clean electrical parts, in particular. Be sure to assemble all parts again in their original places. Replace any damaged parts and parts which must not be reused with new parts. When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is operated. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits. In addition, check t h a t c o n n e c t i n g pa r ts a r e c o r r e c t l y installed. When assembling or installing parts, always tighten them to the specified torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly. When aligning 2 holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. When measuring hydraulic pressure, check that the measuring tools are correctly assembled. Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates suddenly, so never let anyone stand at either end of the track. If the engine is operated for a long time in a place which is not ventilated well, you may suffer from gas poisoning. Accordingly, open the windows and doors to ventilate well.
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Precautions for sling work and making signs 1) Only one appointed worker must make signs and co-workers must communicate with each other frequently. The appointed sign maker must make specified signs clearly at a place where he is well seen from the operator's seat and where he can see the working condition easily. The sign maker must always stand in front of the load and guide the operator safely. q Do not stand under the load. q Do not step on the load. 2) Check the slings before starting sling work. 3) Keep putting on gloves during sling work. (Put on leather gloves, if available.) 4) Measure the weight of the load by the eye and check its center of gravity. 5) Use proper sling according to the weight of the load and method of slinging. If too thick wire ropes are used to sling a light load, the load may slip and fall. 6) Do not sling a load with 1 wire rope alone. If it is slung so, it may rotate and may slip out of the rope. Install 2 or more wire ropes symmetrically. k Slinging with 1 rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident. 7) Limit the hanging angle to 60°, as a rule. Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with 2 or more ropes, the force subjected to each rope will increase with the hanging angle. The table below shows the variation of allowable load in kN {kg} when hoisting is made with 2 ropes, each of which is allowed to sling up to 9.8 kN {1,000 kg} vertically, at various hanging angles. When the 2 ropes sling a load vertically, up to 19.6 kN {2,000 kg} of total weight can be suspended. This weight is reduced to 9.8 kN {1,000 kg} when the 2 ropes make a hanging angle of 120°. If the 2 ropes sling a 19.6 kN {2,000 kg} load at a lifting angle of 150°, each of them is subjected to a force as large as 39.2 kN {4,000 kg}.
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When installing wire ropes to an angular load, apply pads to protect the wire ropes. If the load is slippery, apply proper material to prevent the wire rope from slipping. 9) Use the specified eyebolts and fix wire ropes, chains, etc. to them with shackles, etc. 10) Apply wire ropes to the middle portion of the hook. q Slinging near the tip of the hook may cause the rope to slip off the hook during hoisting. The hook has the maximum strength at the middle portion.
11) Do not use twisted or kinked wire ropes. 12) When lifting up a load, observe the following. q Wind in the crane slowly until wire ropes are stretched. When settling the wire ropes with the hand, do not grasp them but press them from above. If you grasp them, your fingers may be caught. q After the wire ropes are stretched, stop the crane and check the condition of the slung load, wire ropes, and pads.
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If the load is unstable or the wire rope or chains are twisted, lower the load and lift it up again. q Do not lift up the load slantingly. 13) When lifting down a load, observe the following. q When lifting down a load, stop it temporarily at 30 cm above the floor, and then lower it slowly. q Check that the load is stable, and then remove the sling. q Remove kinks and dirt from the wire ropes and chains used for the sling work, and put them in the specified place.
SEN00077-07
13) If the hoist stops because of a power failure, turn the power switch OFF. When turning on a switch which was turned OFF by the electric shock prevention earth leakage breaker, check that the devices related to that switch are not in operation state. 14) If you find an obstacle around the hoist, stop the operation. 15) After finishing the work, stop the hoist at the specified position and raise the hook to at least 2 m above the floor. Do not leave the sling installed to the hook.
q
5.
6.
Precautions for using mobile crane a Read the Operation and Maintenance Manual of the crane carefully in advance and operate the crane safely. Precautions for using overhead hoist crane k When raising a heavy part (heavier than 25 kg), use a hoist, etc. In Disassembly and assembly, the weight of a part heavier than 25 kg is indicated after the mark of 4. 1) Before starting work, inspect the wire ropes, brake, clutch, controller, rails, over wind stop device, electric shock prevention earth leakage breaker, crane collision prevention device, and power application warning lamp, and check safety. 2) Observe the signs for sling work. 3) Operate the hoist at a safe place. 4) Check the direction indicator plates (east, west, south, and north) and the directions of the control buttons without fail. 5) Do not sling a load slantingly. Do not move the crane while the slung load is swinging. 6) Do not raise or lower a load while the crane is moving longitudinally or laterally. 7) Do not drag a sling. 8) When lifting up a load, stop it just after it leaves the ground and check safety, and then lift it up. 9) Consider the travel route in advance and lift up a load to a safe height. 10) Place the control switch on a position where it will not be an obstacle to work and passage. 11) After operating the hoist, do not swing the control switch. 12) Remember the position of the main switch so that you can turn off the power immediately in an emergency.
140E-5 Series
7.
Selecting wire ropes 1) Select adequate ropes depending on the weight of parts to be hoisted, referring to the table below.
Wire ropes (Standard “Z” twist ropes without galvanizing) (JIS G3525, No. 6, Type 6X37-A) Nominal Allowable load diameter of rope mm kN ton 10 8.8 0.9 12 12.7 1.3 14 17.3 1.7 16 22.6 2.3 18 28.6 2.9 20 35.3 3.6 25 55.3 5.6 30 79.6 8.1 40 141.6 14.4 50 221.6 22.6 60 318.3 32.4
a
The allowable load is one-sixth of the breaking strength of the rope used (Safety coefficient: 6).
5
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8.
Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit 1) Disconnection k For the environment, the air conditioner of this machine uses the refrigerant (air conditioner gas: R134a) which has fewer factors of the depletion of the ozone layer. However, it does not mean that you may discharge the refrigerant into the atmosphere as it is. Be sure to recover the refrigerant when disconnecting the refrigerant gas circuit and then reuse it. a Ask professional traders for collecting and filling operation of refrigerant (R134a). a Never release the refrigerant (R134a) to the atmosphere. k If the refrigerant gas gets in your eyes or contacts your skin, you may lose your sight and your skin may be frozen. Accordingly, put on safety glasses, safety gloves and safety clothes when recovering or adding the refrigerant. Refrigerant gas must be recovered and added by a qualified person. 2)
6
00 Index and foreword a
Example of O-ring (Fitted to every joint of hoses and tubes)
a
For tightening torque, see the precautions for installation in each section of "Disassembly and assembly".
Connection 1] When installing the air conditioner circuit hoses and tubes, take care that dirt, dust, water, etc. will not enter them. 2] When connecting the air conditioner hoses and tubes, check that O-rings (1) are fitted to their joints. 3] Check that each O-ring is not damaged or deteriorated. 4] When connecting the refrigerant piping, apply compressor oil for refrigerant (R134a) (DENSO: ND-OIL8, VA L E O T H E R M A L S Y S T E M S : ZXL100PG (equivalent to PAG46)) to its O-rings.
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How to read the shop manual q q q
1.
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1
Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one of them is required, consult KOMATSU distributors. Materials and specifications are subject to change without notice. Shop manuals are divided into the “Chassis volume” and “Engine volume”. For the engine unit, see the engine volume of the engine model mounted on the machine. Composition of shop manual This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections. 00. Index and foreword This section explains the shop manuals list, table of contents, safety, and basic information. 01. Specification This section explains the specifications of the machine. 10. Structure, function and maintenance standard This section explains the structure, function, and maintenance standard values of each component. The structure and function sub-section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. The maintenance standard sub-section explains the criteria and remedies for disassembly and service. 20. Standard value table This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting. 30. Testing and adjusting This section explains measuring instruments and measuring methods for testing and adjusting, and method of adjusting each part. The standard values and judgement criteria for testing and adjusting are explained in Testing and adjusting. 40. Troubleshooting This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also explained in the Chassis volume and Engine volume. In this case, see the Chassis volume. 50. Disassembly and assembly This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque and quantity and weight of coating material, oil, grease, and coolant necessary for the work are also explained. 90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume) q Chassis volume This section gives hydraulic circuit diagrams and electrical circuit diagrams. q Engine volume This section explains the method of reproducing, repairing, and replacing parts.
2.
Revision and distribution Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most up-to-date information before you start any work.
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7
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3.
4.
00 Index and foreword
Filing method File by the brochures in the correct order of the form number printed in the shop manual composition table. q
Revised edition mark When a manual is revised, the ones and tens digits of the form number of each brochure is increased by 1. (Example: 00, 01, 02 …)
q
Revisions Revised brochures are shown in the shop manual composition table.
Symbols Important safety and quality portions are marked with the following symbols so that the shop manual will be used practically. Symbol
Item
k
Safety
a
Caution
Special technical precautions or other precautions for preserving standards are necessary when performing work.
4
Weight
Weight of parts of component or parts. Caution necessary when selecting hoisting wire, or when working posture is important, etc.
3
Tightening torque
2
Coat
5
Oil, coolant
6
Drain
Remarks Special safety precautions are necessary when performing work.
Places that require special attention for tightening torque during assembly. Places to be coated with adhesives, etc. during assembly. Places where oil, etc. must be added, and capacity. Places where oil, etc. must be drained, and quantity to be drained.
5.
Units In this shop manual, the units are indicated with International System of units (SI). For reference, conventionally used Gravitational System of units is indicated in parentheses { }.
8
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Explanation of terms for maintenance standard
1
The maintenance standard chapter explains the criteria for replacing or reusing products and parts in the machine maintenance work. The following terms are used to explain the criteria. 1.
Standard size and tolerance q To be accurate, the finishing size of parts is a little different from one to another. q To specify a finishing size of a part, a temporary standard size is set and an allowable difference from that size is indicated. q The above size set temporarily is called the “standard size” and the range of difference from the standard size is called the “tolerance”. q The tolerance with the symbols of + or – is indicated on the right side of the standard size. Example: Standard size 120
Tolerance –0.022 –0.126
a
The tolerance may be indicated in the text and a table as [standard size (upper limit of tolerance/lower limit of tolerance)]. Example) 120 (–0.022/–0.126)
q
Usually, the size of a hole and the size of the shaft to be fitted to that hole are indicated by the same standard size and different tolerances of the hole and shaft. The tightness of fit is decided by the tolerance. Indication of size of rotating shaft and hole and relationship drawing of them
q
Example: Standard size 60
140E-5 Series
Tolerance Shaft Hole –0.030 +0.046 –0.076 +0
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2.
Standard clearance and standard value q The clearance made when new parts are assembled is called the “standard clearance“, which is indicated by the range from the minimum clearance to the maximum clearance. q When some parts are repaired, the clearance is generally adjusted to the standard clearance. q A value of performance and function of new products or equivalent is called the “standard value“, which is indicated by a range or a target value. q When some parts are repaired, the value of performance/function is set to the standard value.
3.
Standard interference q When the diameter of a hole of a part shown in the given standard size and tolerance table is smaller than that of the mating shaft, the difference between those diameters is called the “interference”. q The range (A – B) from the difference (A) between the minimum size of the shaft and the maximum size of the hole to the difference (B) between the maximum size of the shaft and the minimum size of the hole is the “standard interference”. q After repairing or replacing some parts, measure the size of their hole and shaft and check that the interference is in the standard range.
4.
Repair limit and allowable value or allowable dimension q The size of a part changes because of wear and deformation while it is used. The limit of changed size is called the “repair limit”. q If a part is worn to the repair limit, it must be replaced or repaired. q The performance and function of a product lowers while it is used. A value which the product can be used without causing a problem is called the “allowable value” or “allowable dimension”. q If a product is worn to the allowable value, it must be checked or repaired. Since the permissible value is estimated from various tests or experiences in most cases, however, it must be judged after considering the operating condition and customer's requirement.
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5.
Clearance limit Parts can be used until the clearance between them is increased to a certain limit. The limit at which those parts cannot be used is called the “clearance limit”. q If the clearance between the parts exceeds the clearance limit, they must be replaced or repaired. q
6.
Interference limit The allowable maximum interference between the hole of a part and the shaft of another part to be assembled is called the “interference limit”. q The interference limit shows the repair limit of the part of smaller tolerance. q If the interference between the parts exceeds the interference limit, they must be replaced or repaired. q
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00 Index and foreword
Handling of electric equipment and hydraulic component
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1
To maintain the performance of the machine over a long period, and to prevent failures or other troubles before they occur, correct “operation“, “maintenance and inspection“, “troubleshooting“, and “repairs” must be carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at improving the quality of repairs. For this purpose, it gives sections on “Handling electric equipment” and “Handling hydraulic equipment” (particularly gear oil and hydraulic oil).
Points to remember when handling electric equipment 1. Handling wiring harnesses and connectors Wiring harnesses consist of wiring connecting one component to another component, connectors used for connecting and disconnecting one wire from another wire, and protectors or tubes used for protecting the wiring. Compared with other electrical components fitted in boxes or cases, wiring harnesses are more likely to be affected by the direct effects of rain, water, heat, or vibration. Furthermore, during inspection and repair operations, they are frequently removed and installed again, so they are likely to suffer deformation or damage. For this reason, it is necessary to be extremely careful when handling wiring harnesses. 2.
Main failures occurring in wiring harness 1) Defective contact of connectors (defective contact between male and female) Problems with defective contact are likely to occur because the male connector is not properly inserted into the female connector, or because one or both of the connectors is deformed or the position is not correctly aligned, or because there is corrosion or oxidization of the contact surfaces. The corroded or oxidized contact surfaces may become shiny again (and contact may become normal) by connecting and disconnecting the connector about 10 times. 2)
Defective crimping or soldering of connectors The pins of the male and female connectors are in contact at the crimped terminal or soldered portion, but if there is excessive force brought to bear on the wiring, the plating at the joint will peel and cause improper connection or breakage.
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12
3)
Disconnections in wiring If the wiring is held and the connectors are pulled apart, or components are lifted with a crane with the wiring still connected, or a heavy object hits the wiring, the crimping of the connector may separate, or the soldering may be damaged, or the wiring may be broken.
4)
High-pressure water entering connector The connector is designed to make it difficult for water to enter (drip-proof structure), but if high-pressure water is sprayed directly on the connector, water may enter the connector, depending on the direction of the water jet. Accordingly, take care not to splash water over the connector. The connector is designed to prevent water from entering, but at the same time, if water does enter, it is difficult for it to be drained. Therefore, if water should get into the connector, the pins will be short-circuited by the water, so if any water gets in, immediately dry the connector or take other appropriate action before passing electricity through it.
5)
Oil or dirt stuck to connector If oil or grease are stuck to the connector and an oil film is formed on the mating surface between the male and female pins, the oil will not let the electricity pass, so there will be defective contact. If there is oil or grease stuck to the connector, wipe it off with a dry cloth or blow it dry with compressed air and spray it with a contact restorer. a When wiping the mating portion of the connector, be careful not to use excessive force or deform the pins. a If there is oil or water in the compressed air, the contacts will become even dirtier, so remove the oil and water from the compressed air completely before cleaning with compressed air.
00 Index and foreword
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00 Index and foreword
3.
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Removing, installing, and drying connectors and wiring harnesses 1) Disconnecting connectors 1] Hold the connectors when disconnecting. When disconnecting the connectors, hold the connectors. For connectors held by a screw, loosen the screw fully, then hold the male and female connectors in each hand and pull apart. For connectors which have a lock stopper, press down the stopper with your thumb and pull the connectors apart. a Never pull with one hand. 2] q
When removing from clips Both of the connector and clip have stoppers, which are engaged with each other when the connector is installed.
q
When removing a connector from a clip, pull the connector in a parallel direction to the clip for removing stoppers. a If the connector is twisted up and down or to the left or right, the housing may break.
3]
Action to take after removing connectors After removing any connector, cover it with a vinyl bag to prevent any dust, dirt, oil, or water from getting in the connector portion. a If the machine is left disassembled for a long time, it is particularly easy for improper contact to occur, so always cover the connector.
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13
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2)
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00 Index and foreword
Connecting connectors 1] Check the connector visually. Check that there is no oil, dirt, or water stuck to the connector pins (mating portion). Check that there is no deformation, defective contact, corrosion, or damage to the connector pins. Check that there is no damage or breakage to the outside of the connector. a If there is any oil, water, or dirt stuck to the connector, wipe it off with a dry cloth. If any water has got inside the connector, warm the inside of the wiring with a dryer, but be careful not to make it too hot as this will cause short circuits. a If there is any damage or breakage, replace the connector. 2] Fix the connector securely. Align the position of the connector correctly, and then insert it securely. For connectors with the lock stopper, push in the connector until the stopper clicks into position. 3] Correct any protrusion of the boot and any misalignment of the wiring harness. For connectors fitted with boots, correct any protrusion of the boot. In addition, if the wiring harness is misaligned, or the clamp is out of position, adjust it to its correct position. a If the connector cannot be corrected easily, remove the clamp and adjust the position. q If the connector clamp has been removed, be sure to return it to its original position. Check also that there are no loose clamps.
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3)
Heavy duty wire connector (DT 8-pole, 12pole) Disconnection (Left of figure) While pressing both sides of locks (a) and (b), pull out female connector (2). Connection (Right of figure) 1] Push in female connector (2) horizontally until the lock clicks. Arrow: 1) 2] Since locks (a) and (b) may not be set completely, push in female connector (2) while moving it up and down until the locks are set normally. Arrow: 1), 2), 3) a Right of figure: Lock (a) is pulled down (not set completely) and lock (b) is set completely. (1): Male connector (2): Female connector (a), (b): Locks
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q
Disconnection
q
Connection (Example of incomplete setting of (a))
15
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4)
16
00 Index and foreword
Drying wiring harness If there is any oil or dirt on the wiring harness, wipe it off with a dry cloth. Avoid washing it in water or using steam. If the connector must be washed in water, do not use high-pressure water or steam directly on the wiring harness. If water gets directly on the connector, do as follows. 1] Disconnect the connector and wipe off the water with a dry cloth. a If the connector is blown dry with compressed air, there is the risk that oil in the air may cause defective contact, so remove all oil and water from the compressed air before blowing with air. 2] Dry the inside of the connector with a dryer. If water gets inside the connector, use a dryer to dry the connector. a Hot air from the dryer can be used, but regulate the time that the hot air is used in order not to make the connector or related parts too hot, as this will cause deformation or damage to the connector. 3] Carry out a continuity test on the connector. After drying, leave the wiring harness disconnected and carry out a continuity test to check for any short circuits between pins caused by water. a After completely drying the conn e c t o r, b l o w i t w i t h c o n ta c t restorer and reassemble.
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4.
Handling controller 1) The controller contains a microcomputer and electronic control circuits. These control all of the electronic circuits on the machine, so be extremely careful when handling the controller. 2) Do not place objects on top of the controller. 3) Cover the control connectors with tape or a vinyl bag. Never touch the connector contacts with your hand. 4) During rainy weather, do not leave the controller in a place where it is exposed to rain. 5) Do not place the controller on oil, water, or soil, or in any hot place, even for a short time. (Place it on a suitable dry stand). 6) Precautions when carrying out arc welding When carrying out arc welding on the body, disconnect all wiring harness connectors connected to the controller. Fit an arc welding ground close to the welding point.
5.
Points to remember when troubleshooting electric circuits 1) Always turn the power OFF before disconnecting or connecting connectors. 2) Before carrying out troubleshooting, check that all the related connectors are properly inserted. a Disconnect and connect the related connectors several times to check. 3) Always connect any disconnected connectors before going on to the next step. a If the power is turned ON with the connectors still disconnected, unnecessary abnormality displays will be generated. 4) When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or current), move the related wiring and connectors several times and check that there is no change in the reading of the tester. a If there is any change, there is probably defective contact in that circuit.
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Points to remember when handling hydraulic equipment With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt (foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling hydraulic equipment, it is necessary to be particularly careful.
1.
Be careful of the operating environment. Avoid adding hydraulic oil, replacing filters, or repairing the machine in rain or high winds, or places where there is a lot of dust.
2.
Disassembly and maintenance work in the field If disassembly or maintenance work is carried out on hydraulic equipment in the field, there is danger of dust entering the equipment. It is also difficult to check the performance after repairs, so it is desirable to use unit exchange. Disassembly and maintenance of hydraulic equipment should be carried out in a specially prepared dustproof workshop, and the performance should be checked with special test equipment.
3.
Sealing openings After any piping or equipment is removed, the openings should be sealed with caps, tapes, or vinyl bags to prevent any dirt or dust from entering. If the opening is left open or is blocked with a rag, there is danger of dirt entering or of the surrounding area being made dirty by leaking oil so never do this. Do not simply drain oil out onto the ground, but collect it and ask the customer to dispose of it, or take it back with you for disposal.
4.
Do not let any dirt or dust get in during refilling operations Be careful not to let any dirt or dust get in when refilling with hydraulic oil. Always keep the oil filler and the area around it clean, and also use clean pumps and oil containers. If an oil cleaning device is used, it is possible to filter out the dirt that has collected during storage, so this is an even more effective method.
18
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5.
Change hydraulic oil when the temperature is high When hydraulic oil or other oil is warm, it flows easily. In addition, the sludge can also be drained out easily from the circuit together with the oil, so it is best to change the oil when it is still warm. When changing the oil, as much as possible of the old hydraulic oil must be drained out. (Drain the oil from the hydraulic tank; also drain the oil from the filter and from the drain plug in the circuit.) If any old oil is left, the contaminants and sludge in it will mix with the new oil and will shorten the life of the hydraulic oil.
6.
Flushing operations After disassembling and assembling the equipment, or changing the oil, use flushing oil to remove the contaminants, sludge, and old oil from the hydraulic circuit. Normally, flushing is carried out twice: primary flushing is carried out with flushing oil, and secondary flushing is carried out with the specified hydraulic oil.
7.
Cleaning operations After repairing the hydraulic equipment (pump, control valve, etc.) or when running the machine, carry out oil cleaning to remove the sludge or contaminants in the hydraulic oil circuit. The oil cleaning equipment is used to remove the ultra fine (about 3 m) particles that the filter built in the hydraulic equipment cannot remove, so it is an extremely effective device.
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Handling of connectors newly used for engines a
1.
Mainly, following engines are object for following connectors. q 95E-5 q 107E-1 q 114E-3 q 125E-5 q 140E-5 q 170E-5 q 12V140E-3 Slide lock type (FRAMATOME-3, FRAMATOME-2) q 95 – 170, 12V140 engines q Various pressure sensors and NE speed sensor Examples) Intake air pressure sensor in intake manifold: PIM (125, 170, 12V140 engines) Oil pressure sensor: POIL (125, 170, 12V140 engines) Oil pressure switch (95, 107, 114 engines) Ne speed sensor of flywheel housing: NE (95 – 170, 12V140 engines) Ambient pressure sensor: PAMB (125, 170, 12V140 engines)
2.
1
Pull lock type (PACKARD-2) 95 – 170, 12V140 engines q Various temperature sensors Example) Intake air temperature sensor in intake manifold: TIM Fuel temperature sensor: TFUEL Oil temperature sensor: TOIL Coolant temperature sensor: TWTR, etc. Disconnect the connector by pulling lock (B) (on the wiring harness side) of connector (2) outward.
q
Disconnect connector (1) according to the following procedure. 1) Slide lock (L1) to the right. 2) While pressing lock (L2), pull out connector (1) toward you. a Even if lock (L2) is pressed, connector (1) cannot be pulled out toward you, if part A does not float. In this case, float part A with a small screwdriver while press lock (L2), and then pull out connector (1) toward you.
20
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3.
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Push lock type q 95, 107, 114 engines Example) Fuel pressure sensor in common rail (BOSCH-03) Disconnect connector (3) according to the following procedure. 1) While pressing lock (C), pull out connector (3) in the direction of the arrow. q
q
114 engine
q
107, 114 engines Example) Intake air pressure/temperature sensor in intake manifold (SUMITOMO-04)
3)
While pressing lock (D), pull out connector (4) in the direction of the arrow.
107 engine
a
2)
If the lock is on the underside, use flat-head screwdriver [1] since you cannot insert your fingers. While pressing up lock (C) of the connector with flat-head screwdriver [1], pull out connector (3) in the direction of the arrow.
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21
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q
4)
95, 125 – 170, 12V140 engines While pressing lock (E) of the connector, pull out connector (5) in the direction of the arrow. Example) Fuel pressure sensor in common rail: PFUEL etc. (AMP-3)
00 Index and foreword
4.
Turn-housing type (Round green connector) 140 engine Example) Intake air pressure sensor in intake manifold (CANNON-04): PIM etc.
q
1)
Disconnect connector (6) according to the following procedure. 1] Turn housing (H1) in the direction of the arrow. a When connector is unlocked, housing (H1) becomes heavy to turn. 2] Pull out housing (H1) in the direction of the arrow. a Housing (H1) is left on the wiring harness side.
2)
Connect the connector according to the following procedure. 1] Insert the connector to the end, while setting its groove. 2] Turn housing (H1) in the direction of the arrow until it “clicks”.
Example) Injection pressure control valve of fuel supply pump: PCV (SUMITOMO-2)
Example) Speed sensor of fuel supply pump: G (SUMITOMO-3) a Pull the connector straight up.
22
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How to read electric wire code a
1
The information about the wires unique to each machine model is described in Troubleshooting section, Relational information of troubleshooting.
In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by symbols. The electric wire code is helpful in understanding the electric circuit diagram. Example: AEX
0.85
L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nominal No. of 0.85 Indicates color of wire by color code. Color codes are shown in Table 3. Indicates size of wire by nominal No. Size (Nominal No.) is shown in Table 2. Indicates type of wire by symbol. Type, symbol, and material of wire are shown in Table 1. (Since AV and AVS are classified by size (nominal No.), they are not indicated.)
1.
Type, symbol, and material AV and AVS are different in only thickness and outside diameter of the cover. AEX is similar to AV in thickness and outside diameter of AEX and different from AV and AVS in material of the cover.
(Table 1) Type Low-voltage wire for automobile Thin-cover low-voltage wire for automobile
Symbol AV
AVS
Heat-resistant low-voltAEX age wire for automobile
140E-5 Series
Material Conductor Insulator Conductor
Annealed copper for electric appliance Soft polyvinyl chloride Annealed copper for electric appliance
Insulator
Soft polyvinyl chloride
Conductor
Annealed copper for electric appliance Heat-resistant crosslinked polyethylene
Insulator
Using temperature range (°C)
Example of use General wiring (Nominal No. 5 and above)
–30 to +60 General wiring (Nominal No. 3 and below) General wiring in extremely –50 to +110 cold district, wiring at high-temperature place
23
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2.
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Dimensions
(Table 2) Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5 Number of strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32 eter of strand Conductor Sectional 0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23 area (mm2) d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0 AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 – CovAV Standard – – – – – – – 4.6 er D AEX Standard 2.0 2.2 2.7 3.0 3.1 – 3.8 4.6
Nominal No. Number of strands/Diameter of strand Conductor Sectional area (mm2) d (approx.) AVS Standard CovAV Standard er D AEX Standard
8
15
20
30
40
50
60
85
100
50/0.45
84/0.45
41/0.80
70/0.80
85/0.80
7.95
13.36
20.61
35.19
42.73
54.29
63.84
84.96
109.1
3.7 – 5.5 5.3
4.8 – 7.0 7.0
6.0 – 8.2 8.2
8.0 – 10.8 10.8
8.6 – 11.4 11.4
9.8 – 13.0 13.0
10.4 – 13.6 13.6
12.0 – 16.0 16.0
13.6 – 17.6 17.6
108/0.80 127/0.80 169/0.80 217/0.80
“f” of nominal No. denotes flexible”.
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3.
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Color codes table
(Table 3) Color Code B Br BrB BrR BrW BrY Ch Dg G GB GL Gr GR GW GY L LB Lg LgB LgR
Color of wire
Color Code LgW LgY LR LW LY O P R RB RG RL RW RY Sb Y YB YG YL YR YW
Black Brown Brown & Black Brown & Red Brown & White Brown & Yellow Charcoal Dark green Green Green & Black Green & Blue Gray Green & Red Green & White Green & Yellow Blue Blue & Black Light green Light green & Black Light green & Red
Color of wire Light green & White Light green & Yellow Blue & Red Blue & White Blue & Yellow Orange Pink Red Red & Black Red & Green Red & Blue Red & White Red & Yellow Sky Blue Yellow Yellow & Black Yellow &Green Yellow & Blue Yellow & Red Yellow & White
Remarks: In a color code consisting of 2 colors, the first color is the color of the background and the second color is the color of the marking. Example: “GW” means that the background is Green and marking is White.
4.
Types of circuits and color codes
(Table 4) Type of wire Charge Ground Start Light Instrument Signal Type of circuit
Others
140E-5 Series
AVS or AV R B R RW Y G L Br Lg O Gr P Sb Dg Ch
AEX
–
R B R D Y G L
–
–
WG
–
–
–
–
–
–
–
–
–
– –
–
–
–
–
–
RB YR GW LW BrW LgR
RY YB GR LR BrR LgY
RG YG GY LY BrY LgB
RL YL GB LB BrB LgW
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
YW GL
– –
Gr Br – –
25
SEN00077-07
00 Index and foreword
Precautions when carrying out operation
1
[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general precautions given below when carrying out the operation.] 1. q q q q q q q q q q
a
Precautions when carrying out removal work If the coolant contains antifreeze, dispose of it correctly. After disconnecting hoses or tubes, cover them or fit plugs to prevent dirt or dust from entering. When draining oil, prepare a container of adequate size to catch the oil. Confirm the match marks showing the installation position, and make match marks in the necessary places before removal to prevent any mistake when assembling. To prevent any excessive force from being applied to the wiring, always hold the connectors when disconnecting the connectors. Do not pull the wires. Fit wires and hoses with tags to show their installation position to prevent any mistake when installing. Check the number and thickness of the shims, and keep in a safe place. When raising components, be sure to use lifting equipment of ample strength. When using forcing screws to remove any components, tighten the forcing screws uniformly in turn. Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from entering after removal. Precautions when handling piping during disassembly Fit the following plugs into the piping after disconnecting it during disassembly operations. 1) Face seal type hoses and tubes Nominal number 02 03 04 05 06 10 12 2)
26
Sleeve nut (elbow end)
07376-70210 07376-70315 07376-70422 07376-70522 07376-70628 07376-71034 07376-71234
02789-20210 02789-20315 02789-20422 02789-20522 02789-20628 07221-21034 07221-21234
Split flange type hoses and tubes Nominal number 04 05
3)
Plug (nut end)
Flange (hose end)
Sleeve head (tube end)
Split flange
07379-00400 07379-00500
07378-10400 07378-10500
07371-30400 07371-30500
If the part is not under hydraulic pressure, the following corks can be used. Nominal number
Part Number
06 08 10 12 14 16 18 20 22 24
07049-00608 07049-00811 07049-01012 07049-01215 07049-01418 07049-01620 07049-01822 07049-02025 07049-02228 07049-02430
Dimensions D d L 6 5 8 8 6.5 11 10 8.5 12 12 10 15 14 11.5 18 16 13.5 20 18 15 22 20 17 25 22 18.5 28 24 20 30
27
07049-02734
27
22.5
34
140E-5 Series
00 Index and foreword
2. q q q q q q q q q q q q q
a
a 3.
SEN00077-07
Precautions when carrying out installation work Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque. Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any. Replace all gaskets, O-rings, cotter pins, and lock plates with new parts. Bend the cotter pins and lock plates securely. When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion with 2 – 3 drops of adhesive. When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is no dirt or damage, then coat uniformly with gasket sealant. Clean all parts, and correct any damage, dents, burrs, or rust. Coat rotating parts and sliding parts with engine oil. When press fitting parts, coat the surface with anti-friction compound (LM-P). After fitting snap rings, check that the snap ring is fitted securely in the ring groove. When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect securely. When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align the direction of the hook. When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side. When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other hydraulic equipment removed for repair, always bleed the air as follows: 1) Start the engine and run at low idle. 2) Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times, stopping the cylinder 100 mm from the end of its stroke. 3) Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke. 4) After doing this, run the engine at normal speed. When using the machine for the first time after repair or long storage, follow the same procedure. Precautions when completing the operation 1) Refilling with coolant, oil and grease q If the coolant has been drained, tighten the drain valve, and add coolant to the specified level. Run the engine to circulate the coolant through the system. Then check the coolant level again. q If the hydraulic equipment has been removed and installed again, add engine oil to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again. q If the piping or hydraulic equipment have been removed, always bleed the air from the system after reassembling the parts. a For details, see Testing and adjusting, “Bleeding air”. q Add the specified amount of grease (molybdenum disulphide grease) to the work equipment parts. 2) Checking cylinder head and manifolds for looseness Check the cylinder head and intake and exhaust manifold for looseness. If any part is loosened, retighten it. q For the tightening torque, see “Disassembly and assembly”. 3) Checking engine piping for damage and looseness Intake and exhaust system Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for air suction and exhaust gas leakage. If any part is loosened or damaged, retighten or repair it. Cooling system Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for coolant leakage. If any part is loosened or damaged, retighten or repair it. Fuel system Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel leakage. If any part is loosened or damaged, retighten or repair it.
140E-5 Series
27
SEN00077-07
4)
5)
28
00 Index and foreword
Checking muffler and exhaust pipe for damage and looseness 1] Visually check the muffler, exhaust pipe and their mounting parts for a crack and damage. If any part is damaged, replace it. 2] Check the mounting bolts and nuts of the muffler, exhaust pipe and their mounting parts for looseness. If any bolt or nut is loosened, retighten it. Checking muffler function Check the muffler for abnormal sound and sound different from that of a new muffler. If any abnormal sound is heard, repair the muffler, referring to “Troubleshooting” and “Disassembly and assembly”.
140E-5 Series
00 Index and foreword
SEN00077-07
Method of disassembling and connecting push-pull type coupler k k
1
Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to release the residual pressure from the hydraulic tank. Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out when the hose is disconnected. Accordingly, prepare an oil receiving container.
Type 1 1.
Disconnection 1) Hold adapter (1) and push hose joint (2) into mating adapter (3). (Fig. 1) a The adapter can be pushed in about 3.5 mm. a Do not hold rubber cap portion (4). 2) After hose joint (2) is pushed into adapter (3), press rubber cap portion (4) against adapter (3) until it clicks. (Fig. 2) 3) Hold hose adapter (1) or hose (5) and pull it out. (Fig. 3) a Since some hydraulic oil flows out, prepare an oil receiving container.
2.
Connection 1) Hold hose adapter (1) or hose (5) and insert it in mating adapter (3), aligning them with each other. (Fig. 4) a Do not hold rubber cap portion (4). 2) After inserting the hose in the mating adapter perfectly, pull it back to check its connecting condition. (Fig. 5) a When the hose is pulled back, the rubber cap portion moves toward the hose about 3.5 mm. This does not indicate abnormality, however.
140E-5 Series
29
SEN00077-07
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Type 2 1.
Disconnection 1) Hold the tightening portion and push body (7) straight until sliding prevention ring (6) contacts contact surface (a) of the hexagonal portion at the male end. (Fig. 6) 2) While holding the condition of Step 1), turn lever (8) to the right (clockwise). (Fig. 7) 3) While holding the condition of Steps 1) and 2), pull out whole body (7) to disconnect it. (Fig. 8)
2.
Connection q Hold the tightening portion and push body (7) straight until sliding prevention ring (6) contacts contact surface (a) of the hexagonal portion at the male end. (Fig. 9)
30
140E-5 Series
00 Index and foreword
SEN00077-07
Type 3 1.
Disconnection 1) Hold the tightening portion and push body (9) straight until sliding prevention ring (8) contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 10) 2) While holding the condition of Step 1), push cover (10) straight until it contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 11) 3) While holding the condition of Steps 1) and 2), pull out whole body (9) to disconnect it. (Fig. 12)
2.
Connection q Hold the tightening portion and push body (9) straight until the sliding prevention ring contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 13)
140E-5 Series
31
SEN00077-07
00 Index and foreword
Standard tightening torque table 1.
1
Table of tightening torques for bolts and nuts a Unless there are special instructions, tighten metric nuts and bolts to the torque below. a
The following table applies to the bolts in Fig. A.
Thread diameter of bolt mm 6 8 10 12 14 16 18 20 22 24 27 30 33 36 39 a
Tightening torque Nm 11.8 – 14.7 27 – 34 59 – 74 98 – 123 157 – 196 245 – 309 343 – 427 490 – 608 662 – 829 824 – 1,030 1,180 – 1,470 1,520 – 1,910 1,960 – 2,450 2,450 – 3,040 2,890 – 3,630
kgm 1.2 – 1.5 2.8 – 3.5 6.0 – 7.5 10.0 – 12.5 16 – 20 25 – 31.5 35 – 43.5 50 – 62 67.5 – 84.5 84 – 105 120 – 150 155 – 195 200 – 250 250 – 310 295 – 370
The following table applies to the bolts in Fig. B.
Thread diameter of bolt mm 6 8 10 12 a Fig. A
Width across flats mm 10 13 17 19 22 24 27 30 32 36 41 46 50 55 60
Width across flats mm 10 12 14 17
Tightening torque Nm kgm 5.9 – 9.8 0.6 – 1.0 13.7 – 23.5 1.4 – 2.4 34.3 – 46.1 3.5 – 4.7 74.5 – 90.2 7.6 – 9.2 a Fig. B
Remarks: The widths across flats against the thread diameters of flanged bolts (marks with "*") in Fig. A are the ones indicated in the table for bolts shown in Fig. B. (Values of tightening torques shown in the table for Fig. A are applied.)
32
140E-5 Series
00 Index and foreword
2.
Table of tightening torques for split flange bolts a Unless there are special instructions, tighten split flange bolts to the torque below.
Thread diameter of bolt mm 10 12 16
3.
Width across flats mm 14 17 22
Tightening torque Nm 59 – 74 98 – 123 235 – 285
kgm 6.0 – 7.5 10.0 – 12.5 23.5 – 29.5
Table of tightening torques for O-ring boss piping joints a Unless there are special instructions, tighten O-ring boss piping joints to the torque below. Thread diameter mm 14 20 24 33 42
Nominal No. 02 03,04 05,06 10,12 14
4.
SEN00077-07
Width across flats mm
Tightening torque Nm {kgm} Range Target 35 – 63 { 3.5 – 6.5} 44 { 4.5} 84 – 132 { 8.5 – 13.5} 103 {10.5} Varies depending on type of connec- 128 – 186 {13.0 – 19.0} 157 {16.0} tor. 363 – 480 {37.0 – 49.0} 422 {43.0} 746 – 1,010 {76.0 – 103} 883 {90.0}
Table of tightening torques for O-ring boss plugs a Unless there are special instructions, tighten O-ring boss plugs to the torque below. Nominal No. 08 10 12 14 16 18 20 24 30 33 36 42 52
Thread diameter mm 8 10 12 14 16 18 20 24 30 33 36 42 52
140E-5 Series
Width across flats mm 14 17 19 22 24 27 30 32 32 – 36 – –
Tightening torque Nm {kgm} Range Target 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75} 9.81 – 12.74 {1.0 – 1.3} 11.27 {1.15} 14.7 – 19.6 {1.5 – 2.0} 17.64 {1.8} 19.6 – 24.5 {2.0 – 2.5} 22.54 {2.3} 24.5 – 34.3 {2.5 – 3.5} 29.4 {3.0} 34.3 – 44.1 {3.5 – 4.5} 39.2 {4.0} 44.1 – 53.9 {4.5 – 5.5} 49.0 {5.0} 58.8 – 78.4 {6.0 – 8.0} 68.6 {7.0} 93.1 – 122.5 { 9.5 – 12.5} 107.8 {11.0} 107.8 – 147.0 {11.0 – 15.0} 127.4 {13.0} 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5} 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5} 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0}
33
SEN00077-07
5.
00 Index and foreword
Table of tightening torques for hoses (taper seal type and face seal type) a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the torque below. a Apply the following torque when the threads are coated (wet) with engine oil. Tightening torque Nm {kgm}
Nominal No. of hose
Width across flats
02
19
03 04 05 06 (10) (12) (14)
6.
22 24 27 32 36 41 46 55
Range 34 – 54 { 3.5 – 5.5} 34 – 63 { 3.5 – 6.5} 54 – 93 { 5.5 – 9.5} 59 – 98 { 6.0 – 10.0} 84 – 132 { 8.5 – 13.5} 128 – 186 {13.0 – 19.0} 177 – 245 {18.0 – 25.0} 177 – 245 {18.0 – 25.0} 197 – 294 {20.0 – 30.0} 246 – 343 {25.0 – 35.0}
Target
44 { 4.5} 74 { 7.5} 78 { 8.0} 103 {10.5} 157 {16.0} 216 {22.0} 216 {22.0} 245 {25.0} 294 {30.0}
Taper seal Thread size (mm) – 14 – 18 22 24 30 33 36 42
Face seal Nominal No. – Thread Number of diameter (mm) threads, type of (Reference) thread 9/16-18UN 14.3 – – 11/16-16UN 17.5 – – 13/16-16UN 20.6 1-14UNS 25.4 1-3/16-12UN 30.2 – – – – – –
Table of tightening torques for face seal joints a Tighten the face seal joints (sleeve nut type) made of plated steel pipes for low pressure service to be used for engines etc. to the torque shown in the following table. a Apply the following torque to the face seal joint while their threaded parts are coated with engine oil (wetted).
Outer diameter of pipe (mm)
Width across flats (mm)
8 10 12 15 (16) 22 (20)
19 22 24 (27) 30 (32) 36
Tightening torque Nm {kgm} Range
Target
14 – 16 {1.4 – 1.6} 24 – 27 {2.4 – 2.7} 43 – 47 {4.4 – 4.8} 60 – 68 {6.1 – 6.8} 90 – 95 {9.2 – 9.7}
15 {1.5} 25.5 {2.6} 45 {4.6} 64 {6.5} 92.5 {9.4}
Face seal Thread diameter Nominal No. – (mm) Number of threads, (Reference) type of thread 9/16-18UN 14.3 11/16-16UN 17.5 13/16-16UN 20.6 1-14UN 25.4 1-3/16-12UN 30.2
Reference: The face seal joints of the dimensions in ( ) are also used, depending on the specification.
7.
Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts) a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114 engine series to the torque below. Tightening torque Bolts and nuts
Thread size mm 6 8 10 12 14
34
Nm 10 ± 2 24 ± 4 43 ± 6 77 ± 12 —
kgm 1.02 ± 0.20 2.45 ± 0.41 4.38 ± 0.61 7.85 ± 1.22 —
140E-5 Series
00 Index and foreword
8.
Table of tightening torques for 102, 107 and 114 engine series (Eye joints) a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine series to the torque below. Thread size mm 6 8 10 12 14
9.
SEN00077-07
Tightening torque Nm 8±2 10 ± 2 12 ± 2 24 ± 4 36 ± 5
kgm 0.81 ± 0.20 1.02 ± 0.20 1.22 ± 0.20 2.45 ± 0.41 3.67 ± 0.51
Table of tightening torques for 102, 107 and 114 engine series (Taper screws) a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114 engine series to the torque below.
Material Thread size (inch) 1/16 1/8 1/4 3/8 1/2 3/4
140E-5 Series
Tightening torque In cast iron or steel In aluminum Nm kgm Nm kgm 15 ± 2 1.53 ± 0.20 5±1 0.51 ± 0.10 20 ± 2 2.04 ± 0.20 15 ± 2 1.53 ± 0.20 25 ± 3 2.55 ± 0.31 20 ± 2 2.04 ± 0.20 35 ± 4 3.57 ± 0.41 25 ± 3 2.55 ± 0.31 55 ± 6 5.61 ± 0.61 35 ± 4 3.57 ± 0.41 75 ± 8 7.65 ± 0.82 45 ± 5 4.59 ± 0.51
35
SEN00077-07
00 Index and foreword
Conversion table
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 1.
Convert 55 mm into inches. 1) Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a horizontal line from (A). 2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down from (B). 3) Take the point where the 2 lines cross as (C). This point (C) gives the value when converting from millimeters to inches. Therefore, 55 mm = 2.165 inches.
2.
Convert 550 mm into inches. 1) The number 550 does not appear in the table, so divide it by 10 (move the decimal point one place to the left) to convert it to 55 mm. 2) Carry out the same procedure as above to convert 55 mm to 2.165 inches. 3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
Millimeters to inches
(A)
36
(B)
0 10 20 30 40
0 0 0.394 0.787 1.181 1.575
1 0.039 0.433 0.827 1.220 1.614
2 0.079 0.472 0.866 1.260 1.654
3 0.118 0.512 0.906 1.299 1.693
4 0.157 0.551 0.945 1.339 1.732
50 60 70 80 90
1.969 2.362 2.756 3.150 3.543
2.008 2.402 2.795 3.189 3.583
2.047 2.441 2.835 3.228 3.622
2.087 2.480 2.874 3.268 3.661
2.126 2.520 2.913 3.307 3.701
5 0.197 0.591 0.984 1.378 1.772 (C) 2.165 2.559 2.953 3.346 3.740
6 0.236 0.630 1.024 1.417 1.811
7 0.276 0.669 1.063 1.457 1.850
2.205 2.598 2.992 3.386 3.780
2.244 2.638 3.032 3.425 3.819
1 mm = 0.03937 in 8 9 0.315 0.354 0.709 0.748 1.102 1.142 1.496 1.536 1.890 1.929 2.283 2.677 3.071 3.465 3.858
2.323 2.717 3.110 3.504 3.898
140E-5 Series
00 Index and foreword
SEN00077-07
Millimeters to inches
0 10 20 30 40
0 0 0.394 0.787 1.181 1.575
1 0.039 0.433 0.827 1.220 1.614
2 0.079 0.472 0.866 1.260 1.654
3 0.118 0.512 0.906 1.299 1.693
4 0.157 0.551 0.945 1.339 1.732
5 0.197 0.591 0.984 1.378 1.772
6 0.236 0.630 1.024 1.417 1.811
1 mm = 0.03937 in 7 8 9 0.276 0.315 0.354 0.669 0.709 0.748 1.063 1.102 1.142 1.457 1.496 1.536 1.850 1.890 1.929
50 60 70 80 90
1.969 2.362 2.756 3.150 3.543
2.008 2.402 2.795 3.189 3.583
2.047 2.441 2.835 3.228 3.622
2.087 2.480 2.874 3.268 3.661
2.126 2.520 2.913 3.307 3.701
2.165 2.559 2.953 3.346 3.740
2.205 2.598 2.992 3.386 3.780
2.244 2.638 3.032 3.425 3.819
1 kg = 2.2046 lb 6 7 8 9 13.23 15.43 17.64 19.84 35.27 37.48 39.68 41.89 57.32 59.53 61.73 63.93 79.37 81.57 83.78 85.98 101.41 103.62 105.82 108.03
2.283 2.677 3.071 3.465 3.858
2.323 2.717 3.110 3.504 3.898
Kilogram to pound
0 10 20 30 40
0 0 22.05 44.09 66.14 88.18
1 2.20 24.25 46.30 68.34 90.39
2 4.41 26.46 48.50 70.55 92.59
3 6.61 28.66 50.71 72.75 94.80
4 8.82 30.86 51.91 74.96 97.00
5 11.02 33.07 55.12 77.16 99.21
50 60 70 80 90
110.23 132.28 154.32 176.37 198.42
112.44 134.48 156.53 178.57 200.62
114.64 136.69 158.73 180.78 202.83
116.85 138.89 160.94 182.98 205.03
119.05 141.10 163.14 185.19 207.24
121.25 143.30 165.35 187.39 209.44
123.46 145.51 167.55 189.60 211.64
125.66 147.71 169.76 191.80 213.85
127.87 149.91 171.96 194.01 216.05
130.07 152.12 174.17 196.21 218.26
Liters to U.S. Gallons
0 10 20 30 40
0 1 2 0 0.264 0.528 2.642 2.906 3.170 5.283 5.548 5.812 7.925 8.189 8.454 10.567 10.831 11.095
3 0.793 3.434 6.076 8.718 11.359
4 1.057 3.698 6.340 8.982 11.624
1 l = 0.2642 U.S.Gal 5 6 7 8 9 1.321 1.585 1.849 2.113 2.378 3.963 4.227 4.491 4.755 5.019 6.604 6.869 7.133 7.397 7.661 9.246 9.510 9.774 10.039 10.303 11.888 12.152 12.416 12.680 12.944
50 60 70 80 90
13.209 15.850 18.492 21.134 23.775
14.001 16.643 19.285 21.926 24.568
14.265 16.907 19.549 22.190 24.832
14.529 17.171 19.813 22.455 25.096
140E-5 Series
13.473 16.115 18.756 21.398 24.040
13.737 16.379 19.020 21.662 24.304
14.795 17.435 20.077 22.719 25.361
15.058 17.700 20.341 22.983 25.625
15.322 17.964 20.605 23.247 25.889
15.586 18.228 20.870 23.511 26.153
37
SEN00077-07
00 Index and foreword
Liters to U.K. Gallons
0 10 20 30 40
0 0 2.200 4.399 6.599 8.799
1 0.220 2.420 4.619 6.819 9.019
2 0.440 2.640 4.839 7.039 9.239
3 0.660 2.860 5.059 7.259 9.459
4 0.880 3.080 5.279 7.479 9.679
5 1.100 3.300 5.499 7.699 9.899
50 60 70 80 90
10.998 13.198 15.398 17.598 19.797
11.281 13.418 15.618 17.818 20.017
11.438 13.638 15.838 18.037 20.237
11.658 13.858 16.058 18.257 20.457
11.878 14.078 16.278 18.477 20.677
12.098 14.298 16.498 18.697 20.897
1 l = 0.21997 U.K.Gal 6 7 8 9 1.320 1.540 1.760 1.980 3.520 3.740 3.950 4.179 5.719 5.939 6.159 6.379 7.919 8.139 8.359 8.579 10.119 10.339 10.559 10.778 12.318 14.518 16.718 18.917 21.117
12.528 14.738 16.938 19.137 21.337
12.758 14.958 17.158 19.357 21.557
12.978 15.178 17.378 19.577 21.777
kgm to ft.lb
0 10 20 30 40
0 0 72.3 144.7 217.0 289.3
1 7.2 79.6 151.9 224.2 296.6
2 14.5 86.8 159.1 231.5 303.8
3 21.7 94.0 166.4 238.7 311.0
4 28.9 101.3 173.6 245.9 318.3
5 36.2 108.5 180.8 253.2 325.5
6 43.4 115.7 188.1 260.4 332.7
1 kgm = 7.233 ft.lb 7 8 9 50.6 57.9 65.1 123.0 130.2 137.4 195.3 202.5 209.8 267.6 274.9 282.1 340.0 347.2 354.4
50 60 70 80 90
361.7 434.0 506.3 578.6 651.0
368.9 441.2 513.5 585.9 658.2
376.1 448.5 520.8 593.1 665.4
383.4 455.7 528.0 600.3 672.7
390.6 462.9 535.2 607.6 679.9
397.8 470.2 542.5 614.8 687.1
405.1 477.4 549.7 622.0 694.4
412.3 484.6 556.9 629.3 701.6
419.5 491.8 564.2 636.5 708.8
426.8 499.1 571.4 643.7 716.1
100 110 120 130 140
723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 160 170 180 190
1084.9 1157.3 1129.6 1301.9 1374.3
38
1092.2 1164.5 1236.8 1309.2 1381.5
1099.4 1171.7 1244.1 1316.4 1388.7
1106.6 1179.0 1251.3 1323.6 1396.0
1113.9 1186.2 1258.5 1330.9 1403.2
1121.1 1193.4 1265.8 1338.1 1410.4
1128.3 1200.7 1273.0 1345.3 1417.7
1135.6 1207.9 1280.1 1352.6 1424.9
1142.8 1215.1 1287.5 1359.8 1432.1
1150.0 1222.4 1294.7 1367.0 1439.4
140E-5 Series
00 Index and foreword
SEN00077-07
kg/cm2 to lb/in2
0 10 20 30 40
0 0 142.2 284.5 426.7 568.9
1 14.2 156.5 298.7 440.9 583.2
2 28.4 170.7 312.9 455.1 597.4
3 42.7 184.9 327.1 469.4 611.6
4 56.9 199.1 341.4 483.6 625.8
5 71.1 213.4 355.6 497.8 640.1
6 85.3 227.6 369.8 512.0 654.3
1 kg/cm2 = 14.2233 lb/in2 7 8 9 99.6 113.8 128.0 241.8 256.0 270.2 384.0 398.3 412.5 526.3 540.5 554.7 668.5 682.7 696.9
50 60 70 80 90
711.2 853.4 995.6 1,138 1,280
725.4 867.6 1,010 1,152 1,294
739.6 881.8 1,024 1,166 1,309
753.8 896.1 1,038 1,181 1,323
768.1 910.3 1,053 1,195 1,337
782.3 924.5 1,067 1,209 1,351
796.5 938.7 1,081 1,223 1,365
810.7 953.0 1,095 1,237 1,380
825.0 967.2 1,109 1,252 1,394
839.2 981.4 1,124 1,266 1,408
100 110 120 130 140
1,422 1,565 1,707 1,849 1,991
1,437 1,579 1,721 1,863 2,005
1,451 1,593 1,735 1,877 2,020
1,465 1,607 1,749 1,892 2,034
1,479 1,621 1,764 1,906 2,048
1,493 1,636 1,778 1,920 2,062
1,508 1,650 1,792 1,934 2,077
1,522 1,664 1,806 1,949 2,091
1,536 1,678 1,821 1,963 2,105
1,550 1,693 1,835 1,977 2,119
150 160 170 180 190
2,134 2,276 2,418 2,560 2,702
2,148 2,290 2,432 2,574 2,717
2,162 2,304 2,446 2,589 2,731
2,176 2,318 2,460 2,603 2,745
2,190 2,333 2,475 2,617 2,759
2,205 2,347 2,489 2,631 2,773
2,219 2,361 2,503 2,646 2,788
2,233 2,375 2,518 2,660 2,802
2,247 2,389 2,532 2,674 2,816
2,262 2,404 2,546 2,688 2,830
200 210 220 230 240
2,845 2,987 3,129 3,271 3,414
2,859 3,001 3,143 3,286 3,428
2,873 3,015 3,158 3,300 3,442
2,887 3,030 3,172 3,314 3,456
2,901 3,044 3,186 3,328 3,470
2,916 3,058 3,200 3,343 3,485
2,930 3,072 3,214 3,357 3,499
2,944 3,086 3,229 3,371 3,513
2,958 3,101 3,243 3,385 3,527
2,973 3,115 3,257 3,399 3,542
140E-5 Series
39
SEN00077-07
00 Index and foreword
Temperature Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vice versa is to enter the accompanying table in the center (boldface column) of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left. When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right.
°C
°F
°C
°F
°C
°F
°C
1°C = 33.8°F °F
–40.4 –37.2 –34.4 –31.7 –28.9
–40 –35 –30 –25 –20
–40.0 –31.0 –22.0 –13.0 –4.0
–11.7 –11.1 –10.6 –10.0 –9.4
11 12 13 14 15
51.8 53.6 55.4 57.2 59.0
7.8 8.3 8.9 9.4 10.0
46 47 48 49 50
114.8 116.6 118.4 120.2 122.0
27.2 27.8 28.3 28.9 29.4
81 82 83 84 85
177.8 179.6 181.4 183.2 185.0
–28.3 –27.8 –27.2 –26.7 –26.1
–19 –18 –17 –16 –15
–2.2 –0.4 1.4 3.2 5.0
–8.9 –8.3 –7.8 –7.2 –6.7
16 17 18 19 20
60.8 62.6 64.4 66.2 68.0
10.6 11.1 11.7 12.2 12.8
51 52 53 54 55
123.8 125.6 127.4 129.2 131.0
30.0 30.6 31.1 31.7 32.2
86 87 88 89 90
186.8 188.6 190.4 192.2 194.0
–25.6 –25.0 –24.4 –23.9 –23.3
–14 –13 –12 –11 –10
6.8 8.6 10.4 12.2 14.0
–6.1 –5.6 –5.0 –4.4 –3.9
21 22 23 24 25
69.8 71.6 73.4 75.2 77.0
13.3 13.9 14.4 15.0 15.6
56 57 58 59 60
132.8 134.6 136.4 138.2 140.0
32.8 33.3 33.9 34.4 35.0
91 92 93 94 95
195.8 197.6 199.4 201.2 203.0
–22.8 –22.2 –21.7 –21.1 –20.6
–9 –8 –7 –6 –5
15.8 17.6 19.4 21.2 23.0
–3.3 –2.8 –2.2 –1.7 –1.1
26 27 28 29 30
78.8 80.6 82.4 84.2 86.0
16.1 16.7 17.2 17.8 18.3
61 62 63 64 65
141.8 143.6 145.4 147.2 149.0
35.6 36.1 36.7 37.2 37.8
96 97 98 99 100
204.8 206.6 208.4 210.2 212.0
–20.0 –19.4 –18.9 –18.3 –17.8
–4 –3 –2 –1 0
24.8 26.6 28.4 30.2 32.0
–0.6 0 0.6 1.1 1.7
31 32 33 34 35
87.8 89.6 91.4 93.2 95.0
18.9 19.4 20.0 20.6 21.1
66 67 68 69 70
150.8 152.6 154.4 156.2 158.0
40.6 43.3 46.1 48.9 51.7
105 110 115 120 125
221.0 230.0 239.0 248.0 257.0
–17.2 –16.7 –16.1 –15.6 –15.0
1 2 3 4 5
33.8 35.6 37.4 39.2 41.0
2.2 2.8 3.3 3.9 4.4
36 37 38 39 40
96.8 98.6 100.4 102.2 104.0
21.7 22.2 22.8 23.3 23.9
71 72 73 74 75
159.8 161.6 163.4 165.2 167.0
54.4 57.2 60.0 62.7 65.6
130 135 140 145 150
266.0 275.0 284.0 293.0 302.0
–14.4 –13.9 –13.3 –12.8 –12.2
6 7 8 9 10
42.8 44.6 46.4 48.2 50.0
5.0 5.6 6.1 6.7 7.2
41 42 43 44 45
105.8 107.6 109.4 111.2 113.0
24.4 25.0 25.6 26.1 26.7
76 77 78 79 80
168.8 170.6 172.4 174.2 176.0
68.3 71.1 73.9 76.7 79.4
155 160 165 170 175
311.0 320.0 329.0 338.0 347.0
40
140E-5 Series
00 Index and foreword
140E-5 Series
SEN00077-07
41
SEN00077-07
KOMATSU 140E-5 Series engine Form No. SEN00077-07
© 2009 KOMATSU All Rights Reserved Printed in Japan 01-09 (01)
42
SEN00079-07
ENGINE 1SHOP MANUAL
140E-5 Series
01 Specification
1
Specification and technical data Outline............................................................................................................................................................. 2 Specifications .................................................................................................................................................. 6 General view ................................................................................................................................................. 24 Weight table .................................................................................................................................................. 61 Engine performance curves .......................................................................................................................... 65
140E-5 Series
1
SEN00079-07
01 Specification
Outline
1
1. Applicable machine Engine
SAA6D140E-5
2
Engine serial No.
Machine models PC600-8, PC600LC-8, PC600-8R, PC600LC-8R PC600-8E0, PC600LC-8E0, PC600-8R1, PC600LC-8R1, PC700-8E0, PC700LC-8E0 PC700-8R, PC700LC-8R, PC700LC-8R1 PC800-8, PC800SE-8, PC800LC-8 PC850-8, PC850SE-8 PC800-8R, PC800SE-8R, PC800LC-8R PC850-8R, PC850SE-8R PC800-8R1, PC800SE-8R1, PC800LC-8R1 PC850-8R1, PC850SE-8R1 PC800-8E0, PC800SE-8E0, PC800LC-8E0 PC850-8E0, PC850SE-8E0 D155AX-6, D155A-6 D275AX-5E0, D275A-5R WA500-6, WA500-6R HD325-7, HD405-7, HD325-7R, HD405-7R HM350-2, HM350-2R HM400-2, HM400-2R HM400-3M0, HM400-3R SDG400S-6B1 (HOKUETSU INDUSTRIES)
Hydraulic excavator Hydraulic excavator Hydraulic excavator Hydraulic excavator Hydraulic excavator Hydraulic excavator Hydraulic excavator Hydraulic excavator Hydraulic excavator Hydraulic excavator Hydraulic excavator Hydraulic excavator Hydraulic excavator Bulldozer Bulldozer Wheel loader Dump truck Articulated dump truck Articulated dump truck Articulated dump truck Generator
140E-5 Series
01 Specification
SEN00079-07
2. Outline of engine (With EGR) q
The 140E-5 engine is a high-performance and high-efficiency engine, which passed strict emission regulations (USA: EPA Regulations for 2006, EU: Regulations for 2006, Japan: Construction machinery regulations for 2006) and attained low fuel consumption, low noise, better exhaust gas color, and high acceleration performance. Accordingly, this newly developed engine is suitable as a power source of construction machinery and industrial machinery used for various purposes.
q
The 140E-5 engine is the successor to the 140E-3 engine. While it is an in-line 6-cylinder, water-cooled, common rail direct injection, 4stroke diesel engine similar to 140E-3, it is equipped with the cooled EGR system which is a new technology.
1)
2)
3)
The main components of the cooled EGR system are the EGR cooler of corrugated tube type made of newly developed special stainless steel and the EGR valve driven hydraulically and controlled electronically which KOMATSU developed by itself. The cooled EGR system secures the optimum EGR rate from the low-speed range to the high-speed range to attain both clean exhaust gas and low fuel consumption with the bypass assist circuit consisting of the venturi system and bypass valve which has the same function and structure as those of the EGR valve. The special EGR oil pump is employed to generate high oil pressure (1.47 MPa {15 kg/cm2}) as the drive power source of the EGR valve driven hydraulically and controlled electronically. The engine oil pump has sufficient delivery for the EGR valve and increased output of the engine. As a result, the reliability and durability of the engine are improved. While the 140E-3 engine has only 1 combination filter of high performance and high efficiency, the 140E-5 engine has 2 of the same filter to meet the requirements of the EGR system and high-dispersion oil and improve the ability to capture the soot in the oil. In addition, the recommended sub-materials for operation (oil and fuel) are changed to improve the reliability and durability of the engine.
140E-5 Series
4)
To secure the high output of the engine, the twin cooling nozzle to cool the piston employed for 140E-3 and after models is improved to increase the durability of the piston and lower the back side temperature of the piston. As a result, the lubricating oil on the piston is not exposed to high temperature, thus it is not deteriorated. Since the high-pressure fuel injection system controlled electronically is employed, less soot is produced and the draining interval of the oil is lengthened. (While the capacity of the oil pan is not changed, the oil replacement interval of 500 hours is secured.)
5)
The common rail high-pressure fuel injection system controlled electronically is employed for all of 140E-3 and after models. This system can inject the fuel at high pressure of 120 MPa {1,200 kg/cm2} from the low-speed range to the high-speed range. In addition, this system can control the form of injection most properly by electronic control according to the speed and load. The injection system of 140E-5 is further improved to employ multiple injections and increase the injection pressure up to 160 MPa {1,600 kg/cm2}. As a result, exhaust gas of the cleanest level in the world, good exhaust gas color, low fuel consumption, and low noise are realized simultaneously.
6)
As the injection pressure of the common rail injection system employed for the 140E-3 engine and after models is increased (from 120 to 160 MPa {from 1,200 to 1,600 kg/cm2}), the pressure resistance of the common rail, injector, and supply pump is improved for higher reliability.
7)
The main fuel filter of high efficiency and the pre-fuel filter are installed as standard so that the low grade fuel in the market (equivalent to Class NAS13) can be used. In addition, the delivery of the priming pump used to replace the filters is increased for higher serviceability.
8)
The high-quality piston made of cast iron which has been employed for the 140E-2 engine and after models is employed. This piston has a less coefficient of thermal expansion, a reentrant combustion chamber, and a shaker cooling gallery. As a result, clean exhaust gas, good exhaust gas color, and low fuel consumption are attained simultaneously, and high durability and reliability are also obtained.
3
SEN00079-07
9)
01 Specification
By using the above-mentioned high-pressure fuel injection system controlled electronically, the multiple injection and injection characteristics are set most properly to improve the startability and reduce the white exhaust smoke when the temperature is low.
10) Since the controller is mounted on the engine and equipped with the automatic high-altitude compensation function, the engine can be operated at high altitude without replacing the controller. As a result, the serviceability is improved. 11) The improved type of the KTR110 turbocharger manufactured by KOMATSU which has been employed for the 140E-2 engine and after models and which has high reliability and high performance is mounted. Besides; the efficiency of the blower impeller is heightened and the strength of its material is improved to obtain higher efficiency and pressure ratio. Since the design of the shaft is improved to increase the reliability, high performance is obtained from the low-speed range to the highspeed range. As a result, the engine has high performance and consumes less fuel and attains high reliability. 12) The cylinder block is changed partly to add the cooled EGR system. Since its overall length, overall width, and overall height are the same as before, however, its size is not increased.
4
140E-5 Series
01 Specification
SEN00079-07
(EGR-less) q
The 140E-5 engine is a high-performance and high-efficiency engine, which attained low fuel consumption and low noise. Accordingly, this newly developed engine is suitable as a power source of construction machinery and industrial machinery used for various purposes.
4)
As the injection pressure of the common rail injection system employed for the 140E-3 engine and after models is increased, the pressure resistance of the common rail, injector, and supply pump is improved for higher reliability.
q
The 140E-5 engine is the successor to the 140E-3 engine. While it is an in-line 6-cylinder, water-cooled, 4-stroke diesel engine, it is equipped with the common rail direct injection system.
5)
The main fuel filter of high efficiency and the pre-fuel filter are installed as standard so that the low grade fuel in the market can be used. In addition, the delivery of the priming pump used to replace the filters is increased for higher serviceability.
1)
While the 140E-3 engine has only 1 combination filter of high performance and high efficiency, the 140E-5 engine has 2 of the same filter to meet the requirements of the high-dispersion oil and improve the ability to capture the soot in the oil. In addition, the recommended sub-materials for operation (oil and fuel) are changed to improve the reliability and durability of the engine.
6)
The high-quality piston made of cast iron which has been employed for the 140E-2 engine and after models is employed. This piston has a less coefficient of thermal expansion, a reentrant combustion chamber, and a shaker cooling gallery. As a result, clean exhaust gas, good exhaust gas color, and low fuel consumption are attained simultaneously, and high durability and reliability are also obtained.
7)
By using the above-mentioned high-pressure fuel injection system controlled electronically, the multiple injection and injection characteristics are set most properly to improve the startability and reduce the white exhaust smoke when the temperature is low.
8)
Since the controller is mounted on the engine and equipped with the automatic high-altitude compensation function, the engine can be operated at high altitude without replacing the controller. As a result, the serviceability is improved.
9)
The improved type of the KTR110 turbocharger manufactured by KOMATSU which has been employed for the 140E-2 engine and after models and which has high reliability and high performance is mounted. Besides; the efficiency of the blower impeller is heightened and the strength of its material is improved to obtain higher efficiency and pressure ratio. Since the design of the shaft is improved to increase the reliability, high performance is obtained from the low-speed range to the highspeed range. As a result, the engine has high performance and consumes less fuel and attains high reliability.
2)
3)
To secure the high output of the engine, the twin cooling nozzle to cool the piston employed for 140E-3 and after models is improved to increase the durability of the piston and lower the back side temperature of the piston. As a result, the lubricating oil on the piston is not exposed to high temperature, thus it is not deteriorated. Since the high-pressure fuel injection system controlled electronically is employed, less soot is produced and the draining interval of the oil is lengthened. (While the capacity of the oil pan is not changed, the oil replacement interval of 500 hours is secured.) The common rail high-pressure fuel injection system controlled electronically is employed for all of 140E-3 and after models. This system can inject the fuel at high pressure of 120 MPa {1,200 kg/cm2} from the low-speed range to the high-speed range. In addition, this system can control the form of injection most properly by electronic control according to the speed and load. The injection system of 140E-5 is further improved to employ multiple injections and increase the injection pressure. As a result, exhaust gas of the cleanest level in the world, good exhaust gas color, low fuel consumption, and low noise are realized simultaneously.
140E-5 Series
5
SEN00079-07
01 Specification
Specifications
1 Engine name
SAA6D140E-5
Machine models
PC600-8, PC600LC-8 PC600-8E0, PC600LC-8E0 PC700-8E0, PC700LC-8E0
Number of cylinders – Bore × Stroke Total displacement Firing order
mm
Overall length
mm
1,494
Overall width
mm
1,151
Overall height (excluding exhaust pipe)
mm
1,467
Overall height (including exhaust pipe)
mm
1,863
Rated horsepower
kW{HP}/ min-1{rpm}
323 {433.3}/1,800 {1,800} (Gross)
Max. torque
Nm{kgm}/ min-1{rpm}
1,944 {198.4}/1,400 {1,400} (Gross)
Max. speed with no load (High idle speed)
min-1{rpm}
1,950 ± 50 {1,950 ± 50}
Min. speed with no load (Low idle speed)
min-1{rpm}
800 ± 25 {800 ± 25}
g/kW·h {g/HP·h}
209 {156}
Dry weight
kg
1,845
Fuel supply pump Governor
— —
DENSO ECD-U2 Electronic control type
Quantity of lubricating oil (refill capacity)
l
48 (40)
Quantity of coolant
l
24
Alternator Starting motor Battery
— — —
24V, 60A, 90A 24V, 11kW 12V, 170Ah × 2
Turbocharger Air compressor Others
— — —
KOMATSU KTR110L — With air-cooled aftercooler With cooled EGR
Performance
Dimensions
—
6 – 140 × 165 15.2 {15,230} 1–5–3–6–2–4
Fuel consumption ratio at rated point
6
l{cc}
140E-5 Series
01 Specification
SEN00079-07
1 Engine name
SAA6D140E-5
Machine models
PC600-8R, PC600LC-8R PC600-8R1, PC600LC-8R1 PC700-8R, PC700LC-8R, PC700LC-8R1
Number of cylinders – Bore × Stroke Total displacement Firing order
mm
Overall length
mm
1,482
Overall width
mm
1,191
Overall height (excluding exhaust pipe)
mm
1,467
Overall height (including exhaust pipe)
mm
1,863
Rated horsepower
kW{HP}/ min-1{rpm}
323 {433.3}/1,800 {1,800} (Gross)
Max. torque
Nm{kgm}/ min-1{rpm}
1,944 {198.4}/1,400 {1,400} (Gross)
Max. speed with no load (High idle speed)
min-1{rpm}
1,950 ± 50 {1,950 ± 50}
Min. speed with no load (Low idle speed)
min-1{rpm}
800 ± 25 {800 ± 25}
g/kW·h {g/HP·h}
205 {153}
Dry weight
kg
1,770
Fuel supply pump Governor
— —
DENSO ECD-U2 Electronic control type
Quantity of lubricating oil (refill capacity)
l
48 (40)
Quantity of coolant
l
24
Alternator Starting motor Battery
— — —
24V, 60A, 90A 24V, 11kW 12V, 170Ah × 2
Turbocharger Air compressor Others
— — —
KOMATSU KTR110L — With air-cooled aftercooler
Performance
Dimensions
—
6 – 140 × 165 15.2 {15,230} 1–5–3–6–2–4
Fuel consumption ratio at rated point
140E-5 Series
l{cc}
7
SEN00079-07
01 Specification
1 Engine name
SAA6D140E-5
Machine models
PC800-8, PC800SE-8, PC800LC-8, PC850-8, PC850SE-8 PC800-8E0, PC800SE-8E0, PC800LC-8E0, PC850-8E0, PC850SE-8E0
—
6 – 140 × 165 15.2 {15,230} 1–5–3–6–2–4
Overall length
mm
1,762
Overall width
mm
1,176
Overall height (excluding exhaust pipe)
mm
1,686
Overall height (including exhaust pipe)
mm
1,902
Rated horsepower
kW{HP}/ min-1{rpm}
370 {496.4}/1,800 {1,800} (Gross)
Max. torque
Nm{kgm}/ min-1{rpm}
2,195 {223.8}/1,350 {1,350} (Gross)
Max. speed with no load (High idle speed)
min-1{rpm}
1,980 ± 50 {1,980 ± 50}
Min. speed with no load (Low idle speed)
min-1{rpm}
825 ± 25 {825 ± 25}
g/kW·h {g/HP·h}
204 {152}
Dry weight
kg
1,920
Fuel supply pump Governor
— —
DENSO ECD-U2 Electronic control type
Quantity of lubricating oil (refill capacity)
l
58 (53)
Quantity of coolant
l
25 (In only engine)
Alternator Starting motor Battery
— — —
24V, 60A, 90A 24V, 11kW 12V, 170Ah × 2
Turbocharger Air compressor Others
— — —
KOMATSU KTR110L — With air-cooled aftercooler With cooled EGR
Performance
Dimensions
Number of cylinders – Bore × Stroke Total displacement Firing order
Fuel consumption ratio at rated point
8
mm l{cc}
140E-5 Series
01 Specification
SEN00079-07
1 Engine name
SAA6D140E-5
Machine models
PC800-8R, PC800SE-8R, PC800LC-8R, PC850-8R, PC850SE-8R PC800-8R1, PC800SE-8R1, PC800LC-8R1 PC850-8R1, PC850SE-8R1
—
6 – 140 × 165 15.2 {15,230} 1–5–3–6–2–4
Overall length
mm
1,718
Overall width
mm
1,176
Overall height (excluding exhaust pipe)
mm
1,686
Overall height (including exhaust pipe)
mm
1,902
Rated horsepower
kW{HP}/ min-1{rpm}
370 {496.4}/1,800 {1,800} (Gross)
Max. torque
Nm{kgm}/ min-1{rpm}
2,195 {223.8}/1,350 {1,350} (Gross)
Max. speed with no load (High idle speed)
min-1{rpm}
1,980 ± 50 {1,980 ± 50}
Min. speed with no load (Low idle speed)
min-1{rpm}
825 ± 25 {825 ± 25}
g/kW·h {g/HP·h}
204 {152}
Dry weight
kg
1,850
Fuel supply pump Governor
— —
DENSO ECD-U2 Electronic control type
Quantity of lubricating oil (refill capacity)
l
58 (53)
Quantity of coolant
l
25 (In only engine)
Alternator Starting motor Battery
— — —
24V, 60A, 90A 24V, 11kW 12V, 170Ah × 2
Turbocharger Air compressor Others
— — —
KOMATSU KTR110L — With air-cooled aftercooler
Performance
Dimensions
Number of cylinders – Bore × Stroke Total displacement Firing order
Fuel consumption ratio at rated point
140E-5 Series
mm l{cc}
9
SEN00079-07
01 Specification
1 Engine name
SAA6D140E-5
Machine models
D155AX-6
—
6 – 140 × 165 15.2 {15,230} 1–5–3–6–2–4
Overall length
mm
1,477
Overall width
mm
1,109
Overall height (excluding exhaust pipe)
mm
1,157
Overall height (including exhaust pipe)
mm
1,950
Rated horsepower
kW{HP}/ min-1{rpm}
268 {359.9}/1,900 {1,900} (Gross)
Max. torque
Nm{kgm}/ min-1{rpm}
1,834 {187}/1,300 {1,300} (Gross)
Max. speed with no load (High idle speed)
min-1{rpm}
2,100 (0/–50) {2,100 (0/–50)}
Min. speed with no load (Low idle speed)
min-1{rpm}
740 (+40/0) {740 (+40/0)}
g/kW·h {g/HP·h}
215 {160}
Dry weight
kg
1,800
Fuel supply pump Governor
— —
DENSO ECD-U2 Electronic control type
Quantity of lubricating oil (refill capacity)
l
45 (37)
Quantity of coolant
l
25 (In only engine)
Alternator Starting motor Battery
— — —
24V, 60A, 75A, 90A 24V, 11kW 12V, 170Ah × 2
Turbocharger Air compressor Others
— — —
KOMATSU KTR110L — With air-cooled aftercooler With cooled EGR
Performance
Dimensions
Number of cylinders – Bore × Stroke Total displacement Firing order
Fuel consumption ratio at rated point
10
mm l{cc}
140E-5 Series
01 Specification
SEN00079-07
1 Engine name
SAA6D140E-5
Machine models
D155A-6
—
6 – 140 × 165 15.2 {15,230} 1–5–3–6–2–4
Overall length
mm
1,461
Overall width
mm
1,109
Overall height (excluding exhaust pipe)
mm
1,157
Overall height (including exhaust pipe)
mm
1,950
Rated horsepower
kW{HP}/ min-1{rpm}
268 {359.9}/1,900 {1,900} (Gross)
Max. torque
Nm{kgm}/ min-1{rpm}
1,834 {187}/1,300 {1,300} (Gross)
Max. speed with no load (High idle speed)
min-1{rpm}
2,100 (0/–50) {2,100 (0/–50)}
Min. speed with no load (Low idle speed)
min-1{rpm}
740 (+40/0) {740 (+40/0)}
g/kW·h {g/HP·h}
215 {160}
Dry weight
kg
1,725
Fuel supply pump Governor
— —
DENSO ECD-U2 Electronic control type
Quantity of lubricating oil (refill capacity)
l
45 (37)
Quantity of coolant
l
25 (In only engine)
Alternator Starting motor Battery
— — —
24V, 60A, 75A, 90A 24V, 11kW 12V, 170Ah × 2
Turbocharger Air compressor Others
— — —
KOMATSU KTR110L — With air-cooled aftercooler
Performance
Dimensions
Number of cylinders – Bore × Stroke Total displacement Firing order
Fuel consumption ratio at rated point
140E-5 Series
mm l{cc}
11
SEN00079-07
01 Specification
1 Engine name
SAA6D140E-5
Machine models
D275AX-5E0
—
6 – 140 × 165 15.2 {15,230} 1–5–3–6–2–4
Overall length
mm
1,477
Overall width
mm
966
Overall height (excluding exhaust pipe)
mm
2,020
Overall height (including exhaust pipe)
mm
—
Rated horsepower
kW{HP}/ min-1{rpm}
337 {451.6}/2,000 {2,000} (Gross)
Max. torque
Nm{kgm}/ min-1{rpm}
2,030 {207}/1,400 {1,400} (Gross)
Max. speed with no load (High idle speed)
min-1{rpm}
2,200 ± 50 {2,200 ± 50}
Min. speed with no load (Low idle speed)
min-1{rpm}
700 ± 50 {700 ± 50}
g/kW·h {g/HP·h}
218 {162.3}
Dry weight
kg
1,869
Fuel supply pump Governor
— —
DENSO ECD-U2 Electronic control type
Quantity of lubricating oil (refill capacity)
l
58 (50)
Quantity of coolant
l
25 (In only engine)
Alternator Starting motor Battery
— — —
24V, 75A, 90A 24V, 11kW 12V, 170Ah × 2
Turbocharger Air compressor Others
— — —
KOMATSU KTR110L — With air-cooled aftercooler With cooled EGR
Performance
Dimensions
Number of cylinders – Bore × Stroke Total displacement Firing order
Fuel consumption ratio at rated point
12
mm l{cc}
140E-5 Series
01 Specification
SEN00079-07
1 Engine name
SAA6D140E-5
Machine models
D275A-5R
—
6 – 140 × 165 15.2 {15,230} 1–5–3–6–2–4
Overall length
mm
1,461
Overall width
mm
966
Overall height (excluding exhaust pipe)
mm
2,020
Overall height (including exhaust pipe)
mm
—
Rated horsepower
kW{HP}/ min-1{rpm}
337 {451.6}/2,000 {2,000} (Gross)
Max. torque
Nm{kgm}/ min-1{rpm}
2,030 {207}/1,400 {1,400} (Gross)
Max. speed with no load (High idle speed)
min-1{rpm}
2,200 ± 50 {2,200 ± 50}
Min. speed with no load (Low idle speed)
min-1{rpm}
700 ± 50 {700 ± 50}
g/kW·h {g/HP·h}
215 {160}
Dry weight
kg
1,800
Fuel supply pump Governor
— —
DENSO ECD-U2 Electronic control type
Quantity of lubricating oil (refill capacity)
l
58 (50)
Quantity of coolant
l
25 (In only engine)
Alternator Starting motor Battery
— — —
24V, 75A, 90A 24V, 11kW 12V, 170Ah × 2
Turbocharger Air compressor Others
— — —
KOMATSU KTR110L — With air-cooled aftercooler
Performance
Dimensions
Number of cylinders – Bore × Stroke Total displacement Firing order
Fuel consumption ratio at rated point
140E-5 Series
mm l{cc}
13
SEN00079-07
01 Specification
1 Engine name
SAA6D140E-5
Machine models
WA500-6
—
6 – 140 × 165 15.2 {15,230} 1–5–3–6–2–4
Overall length
mm
1,477
Overall width
mm
1,094
Overall height (excluding exhaust pipe)
mm
1,435
Overall height (including exhaust pipe)
mm
1,727
Rated horsepower
kW{HP}/ min-1{rpm}
266 {356.9}/1,900 {1,900} (Gross)
Max. torque
Nm{kgm}/ min-1{rpm}
1,803 {184}/1,250 {1,250} (Gross)
Max. speed with no load (High idle speed)
min-1{rpm}
2,150 ± 50 {2,150 ± 50}
Min. speed with no load (Low idle speed)
min-1{rpm}
700 ± 25 {700 ± 25}
g/kW·h {g/HP·h}
216.2 {161.3}
Dry weight
kg
1,750
Fuel supply pump Governor
— —
DENSO ECD-U2 Electronic control type
Quantity of lubricating oil (refill capacity)
l
45 (37)
Quantity of coolant
l
25
Alternator Starting motor Battery
— — —
24V, 75A, 90A 24V, 11kW 12V, 170Ah × 2
Turbocharger Air compressor Others
— — —
KOMATSU KTR110L — With air-cooled aftercooler With cooled EGR
Performance
Dimensions
Number of cylinders – Bore × Stroke Total displacement Firing order
Fuel consumption ratio at rated point
14
mm l{cc}
140E-5 Series
01 Specification
SEN00079-07
1 Engine name
SAA6D140E-5
Machine models
WA500-6R
—
6 – 140 × 165 15.2 {15,230} 1–5–3–6–2–4
Overall length
mm
1,461
Overall width
mm
1,094
Overall height (excluding exhaust pipe)
mm
1,435
Overall height (including exhaust pipe)
mm
1,727
Rated horsepower
kW{HP}/ min-1{rpm}
266 {356.9}/1,900 {1,900} (Gross)
Max. torque
Nm{kgm}/ min-1{rpm}
1,803 {184}/1,250 {1,250} (Gross)
Max. speed with no load (High idle speed)
min-1{rpm}
2,150 ± 50 {2,150 ± 50}
Min. speed with no load (Low idle speed)
min-1{rpm}
700 ± 25 {700 ± 25}
g/kW·h {g/HP·h}
211.4 {157.7}
Dry weight
kg
1,680
Fuel supply pump Governor
— —
DENSO ECD-U2 Electronic control type
Quantity of lubricating oil (refill capacity)
l
45 (37)
Quantity of coolant
l
25
Alternator Starting motor Battery
— — —
24V, 75A, 90A 24V, 11kW 12V, 170Ah × 2
Turbocharger Air compressor Others
— — —
KOMATSU KTR110L — With air-cooled aftercooler
Performance
Dimensions
Number of cylinders – Bore × Stroke Total displacement Firing order
Fuel consumption ratio at rated point
140E-5 Series
mm l{cc}
15
SEN00079-07
01 Specification
1 Engine name
SAA6D140E-5
Machine models
HD325-7, HD405-7
—
6 – 140 × 165 15.2 {15,230} 1–5–3–6–2–4
Overall length
mm
1,775
Overall width
mm
1,009
Overall height (excluding exhaust pipe)
mm
1,604
Overall height (including exhaust pipe)
mm
—
Rated horsepower
kW{HP}/ min-1{rpm}
386 {517.7}/2,000 {2,000} (Gross)
Max. torque
Nm{kgm}/ min-1{rpm}
2,170 {221.3}/1,400 {1,400} (Gross)
Max. speed with no load (High idle speed)
min-1{rpm}
2,300 ± 25 {2,300 ± 25}
Min. speed with no load (Low idle speed)
min-1{rpm}
725 ± 25 {725 ± 25}
g/kW·h {g/HP·h}
212 {158}
Dry weight
kg
1,810
Fuel supply pump Governor
— —
DENSO ECD-U2 Electronic control type
Quantity of lubricating oil (refill capacity)
l
58 (50)
Quantity of coolant
l
25 (In only engine)
Alternator Starting motor Battery
— — —
24V, 60A, 75A 24V, 11kW 12V, 170Ah × 2
Turbocharger Air compressor Others
— — —
KOMATSU KTR110L — With air-cooled aftercooler With cooled EGR
Performance
Dimensions
Number of cylinders – Bore × Stroke Total displacement Firing order
Fuel consumption ratio at rated point
16
mm l{cc}
140E-5 Series
01 Specification
SEN00079-07
1 Engine name
SAA6D140E-5
Machine models
HD325-7R, HD405-7R
—
6 – 140 × 165 15.2 {15,230} 1–5–3–6–2–4
Overall length
mm
1,775
Overall width
mm
1,009
Overall height (excluding exhaust pipe)
mm
1,604
Overall height (including exhaust pipe)
mm
—
Rated horsepower
kW{HP}/ min-1{rpm}
386 {517.7}/2,000 {2,000} (Gross)
Max. torque
Nm{kgm}/ min-1{rpm}
2,170 {221.3}/1,400 {1,400} (Gross)
Max. speed with no load (High idle speed)
min-1{rpm}
2,300 ± 25 {2,300 ± 25}
Min. speed with no load (Low idle speed)
min-1{rpm}
725 ± 25 {725 ± 25}
g/kW·h {g/HP·h}
207 {154}
Dry weight
kg
1,740
Fuel supply pump Governor
— —
DENSO ECD-U2 Electronic control type
Quantity of lubricating oil (refill capacity)
l
58 (50)
Quantity of coolant
l
25 (In only engine)
Alternator Starting motor Battery
— — —
24V, 60A, 75A 24V, 11kW 12V, 170Ah × 2
Turbocharger Air compressor Others
— — —
KOMATSU KTR110L — With air-cooled aftercooler
Performance
Dimensions
Number of cylinders – Bore × Stroke Total displacement Firing order
Fuel consumption ratio at rated point
140E-5 Series
mm l{cc}
17
SEN00079-07
01 Specification
1 Engine name
SAA6D140E-5
Machine models
HM350-2
—
6 – 140 × 165 15.2 {15,230} 1–5–3–6–2–4
Overall length
mm
1,724
Overall width
mm
1,250
Overall height (excluding exhaust pipe)
mm
1,496
Overall height (including exhaust pipe)
mm
—
Rated horsepower
kW{HP}/ min-1{rpm}
304 {407.2}/2,000 {2,000} (Gross)
Max. torque
Nm{kgm}/ min-1{rpm}
1,991 {203}/1,400 {1,400} (Gross)
Max. speed with no load (High idle speed)
min-1{rpm}
2,200 (+50/0) {2,200 (+50/0)}
Min. speed with no load (Low idle speed)
min-1{rpm}
725 ± 25 {725 ± 25}
g/kW·h {g/HP·h}
223 {166}
Dry weight
kg
1,820
Fuel supply pump Governor
— —
DENSO ECD-U2 Electronic control type
Quantity of lubricating oil (refill capacity)
l
58 (50)
Quantity of coolant
l
25 (In only engine)
Alternator Starting motor Battery
— — —
24V, 60A, 75A 24V, 11kW 12V 170Ah × 2
Turbocharger Air compressor Others
— — —
KOMATSU KTR110L — With air-cooled aftercooler With cooled EGR
Performance
Dimensions
Number of cylinders – Bore × Stroke Total displacement Firing order
Fuel consumption ratio at rated point
18
mm l{cc}
140E-5 Series
01 Specification
SEN00079-07
1 Engine name
SAA6D140E-5
Machine models
HM350-2R
—
6 – 140 × 165 15.2 {15,230} 1–5–3–6–2–4
Overall length
mm
1,724
Overall width
mm
1,250
Overall height (excluding exhaust pipe)
mm
1,496
Overall height (including exhaust pipe)
mm
—
Rated horsepower
kW{HP}/ min-1{rpm}
304 {407.2}/2,000 {2,000} (Gross)
Max. torque
Nm{kgm}/ min-1{rpm}
1,991 {203}/1,400 {1,400} (Gross)
Max. speed with no load (High idle speed)
min-1{rpm}
2,200 (+50/0) {2,200 (+50/0)}
Min. speed with no load (Low idle speed)
min-1{rpm}
725 ± 25 {725 ± 25}
g/kW·h {g/HP·h}
222 {165}
Dry weight
kg
1,750
Fuel supply pump Governor
— —
DENSO ECD-U2 Electronic control type
Quantity of lubricating oil (refill capacity)
l
58 (50)
Quantity of coolant
l
25 (In only engine)
Alternator Starting motor Battery
— — —
24V, 60A, 75A 24V, 11kW 12V 170Ah × 2
Turbocharger Air compressor Others
— — —
KOMATSU KTR110L — With air-cooled aftercooler
Performance
Dimensions
Number of cylinders – Bore × Stroke Total displacement Firing order
Fuel consumption ratio at rated point
140E-5 Series
mm l{cc}
19
SEN00079-07
01 Specification
1 Engine name
SAA6D140E-5
Machine models
HM400-2, HM400-3M0
—
6-140 × 165 15.2 {15,230} 1–5–3–6–2–4
Overall length
mm
1,724
Overall width
mm
1,250
Overall height (excluding exhaust pipe)
mm
1,496
Overall height (including exhaust pipe)
mm
—
Rated horsepower
kW{HP}/ min-1{rpm}
338 {452.6}/2,000 {2,000} (Gross)
Max. torque
Nm{kgm}/ min-1{rpm}
2,089 {213}/1,400 {1,400} (Gross)
Max. speed with no load (High idle speed)
min-1{rpm}
2,200 (+50/0) {2,200 (+50/0)}
Min. speed with no load (Low idle speed)
min-1{rpm}
725 ± 25 {725 ± 25}
g/kW·h {g/HP·h}
213 {159}
Dry weight
kg
1,820
Fuel supply pump Governor
— —
DENSO ECD-U2 Electronic control type
Quantity of lubricating oil (refill capacity)
l
58 (50)
Quantity of coolant
l
25 (In only engine)
Alternator Starting motor Battery
— — —
24V, 60A, 75A 24V, 11kW 12V, 170Ah × 2
Turbocharger Air compressor Others
— — —
KOMATSU KTR110L — With air-cooled aftercooler With cooled EGR
Performance
Dimensions
Number of cylinders – Bore × Stroke Total displacement Firing order
Fuel consumption ratio at rated point
20
mm l{cc}
140E-5 Series
01 Specification
SEN00079-07
1 Engine name
SAA6D140E-5
Machine models
HM400-2R, HM400-3R
—
6-140 × 165 15.2 {15,230} 1–5–3–6–2–4
Overall length
mm
1,724
Overall width
mm
1,250
Overall height (excluding exhaust pipe)
mm
1,496
Overall height (including exhaust pipe)
mm
—
Rated horsepower
kW{HP}/ min-1{rpm}
338 {452.6}/2,000 {2,000} (Gross)
Max. torque
Nm{kgm}/ min-1{rpm}
2,089 {213}/1,400 {1,400} (Gross)
Max. speed with no load (High idle speed)
min-1{rpm}
2,200 (+50/0) {2,200 (+50/0)}
Min. speed with no load (Low idle speed)
min-1{rpm}
725 ± 25 {725 ± 25}
g/kW·h {g/HP·h}
218 {162}
Dry weight
kg
1,750
Fuel supply pump Governor
— —
DENSO ECD-U2 Electronic control type
Quantity of lubricating oil (refill capacity)
l
58 (50)
Quantity of coolant
l
25 (In only engine)
Alternator Starting motor Battery
— — —
24V, 60A, 75A 24V, 11kW 12V, 170Ah × 2
Turbocharger Air compressor Others
— — —
KOMATSU KTR110L — With air-cooled aftercooler
Performance
Dimensions
Number of cylinders – Bore × Stroke Total displacement Firing order
Fuel consumption ratio at rated point
140E-5 Series
mm l{cc}
21
SEN00079-07
01 Specification
1 Engine name
SAA6D140E-5
Machine models
SDG400S-6B1 (HOKUETSU INDUSTRIES GENERATOR)
—
6 – 140 × 165 15.2 {15,230} 1–5–3–6–2–4
Overall length
mm
1,785
Overall width
mm
1,242
Overall height (excluding exhaust pipe)
mm
1,523
Overall height (including exhaust pipe)
mm
—
Rated horsepower
kW{HP}/ min-1{rpm}
357 {478}/1,800 {1,800} (Net)
Max. torque
Nm{kgm}/ min-1{rpm}
— —
Max. speed with no load (High idle speed)
min-1{rpm}
—
Min. speed with no load (Low idle speed)
min-1{rpm}
—
g/kW·h {g/HP·h}
222 {163}
Dry weight
kg
1,950
Fuel supply pump Governor
— —
DENSO ECD-U2 Electronic control type
Quantity of lubricating oil (refill capacity)
l
82 (73)
Quantity of coolant (with radiator)
l
53
Alternator Starting motor Battery
— — —
24V, 35A 24V, 7.5kW —
Turbocharger Air compressor Others
— — —
KOMATSU KTR110L — With air-cooled aftercooler With cooled EGR
Performance
Dimensions
Number of cylinders – Bore × Stroke Total displacement Firing order
Fuel consumption ratio at rated point
22
mm l{cc}
140E-5 Series
01 Specification
140E-5 Series
SEN00079-07
23
SEN00079-07
General view
01 Specification
1
SAA6D140E-5 (Left side view of engine) Machine model: PC600-8, PC600LC-8
a
The shape is subject to machine models.
1. 2.
Center of crankshaft Rear face of flywheel housing
24
140E-5 Series
01 Specification
SEN00079-07
SAA6D140E-5 (Front view of engine) Machine model: PC600-8, PC600LC-8
a
The shape is subject to machine models.
1. 2.
Center of crankshaft Center of cylinder liner
140E-5 Series
25
SEN00079-07
01 Specification
SAA6D140E-5 (Left side view of engine) Machine model: PC600-8R, PC600LC-8R
a a
The shape is subject to machine models. Corrosion resistor-less, Single cartridge and Manual priming pump are set for some models. (See the PC700-8R, PC700LC-8R.)
1. 2.
Center of crankshaft Rear face of flywheel housing
26
140E-5 Series
01 Specification
SEN00079-07
SAA6D140E-5 (Front view of engine) Machine model: PC600-8R, PC600LC-8R
a a
The shape is subject to machine models. Corrosion resistor-less, Single cartridge and Manual priming pump are set for some models. (See the PC700-8R, PC700LC-8R.)
1. 2.
Center of crankshaft Center of cylinder liner
140E-5 Series
27
SEN00079-07
01 Specification
SAA6D140E-5 (Left side view of engine) Machine model: PC600-8E0, PC600LC-8E0, PC700-8E0, PC700LC-8E0
a
The shape is subject to machine models.
1. 2.
Center of crankshaft Rear face of flywheel housing
28
140E-5 Series
01 Specification
SEN00079-07
SAA6D140E-5 (Front view of engine) Machine model: PC600-8E0, PC600LC-8E0, PC700-8E0, PC700LC-8E0
a
The shape is subject to machine models.
1. 2.
Center of crankshaft Center of cylinder liner
140E-5 Series
29
SEN00079-07
01 Specification
SAA6D140E-5 (Left side view of engine) Machine model: PC600-8R1, PC600LC-8R1, PC700-8R, PC700LC-8R, PC700LC-8R1
a
The shape is subject to machine models.
1. 2.
Center of crankshaft Rear face of flywheel housing
30
140E-5 Series
01 Specification
SEN00079-07
SAA6D140E-5 (Front view of engine) Machine model: PC600-8R1, PC600LC-8R1, PC700-8R, PC700LC-8R, PC700LC-8R1
a
The shape is subject to machine models.
1. 2.
Center of crankshaft Center of cylinder liner
140E-5 Series
31
SEN00079-07
01 Specification
SAA6D140E-5 (Left side view of engine) Machine model: PC800-8, PC800SE-8, PC800LC-8, PC850-8, PC850SE-8 PC800-8E0, PC800SE-8E0, PC800LC-8E0, PC850-8E0, PC850SE-8E0
a
The shape is subject to machine models.
1. 2.
Center of crankshaft Rear face of flywheel housing
32
140E-5 Series
01 Specification
SEN00079-07
SAA6D140E-5 (Front view of engine) Machine model: PC800-8, PC800SE-8, PC800LC-8, PC850-8, PC850SE-8 PC800-8E0, PC800SE-8E0, PC800LC-8E0, PC850-8E0, PC850SE-8E0
a
The shape is subject to machine models.
1. 2.
Center of crankshaft Center of cylinder liner
140E-5 Series
33
SEN00079-07
01 Specification
SAA6D140E-5 (Left side view of engine) Machine model: PC800-8R, PC800SE-8R, PC800LC-8R, PC850-8R, PC850SE-8R
a
The shape is subject to machine models.
1. 2.
Center of crankshaft Rear face of flywheel housing
34
140E-5 Series
01 Specification
SEN00079-07
SAA6D140E-5 (Front view of engine) Machine model: PC800-8R, PC800SE-8R, PC800LC-8R, PC850-8R, PC850SE-8R
a
The shape is subject to machine models.
1. 2.
Center of crankshaft Center of cylinder liner
140E-5 Series
35
SEN00079-07
01 Specification
SAA6D140E-5 (Left side view of engine) Machine model: PC800-8R1, PC800SE-8R1, PC800LC-8R1, PC850-8R1, PC850SE-8R1
a
The shape is subject to machine models.
1. 2.
Center of crankshaft Rear face of flywheel housing
36
140E-5 Series
01 Specification
SEN00079-07
SAA6D140E-5 (Front view of engine) Machine model: PC800-8R1, PC800SE-8R1, PC800LC-8R1, PC850-8R1, PC850SE-8R1
a
The shape is subject to machine models.
1. 2.
Center of crankshaft Center of cylinder liner
140E-5 Series
37
SEN00079-07
01 Specification
SAA6D140E-5 (Left side view of engine) Machine model: D275AX-5E0
a
The shape is subject to machine models.
1. 2.
Center of crankshaft Rear face of flywheel housing
38
140E-5 Series
01 Specification
SEN00079-07
SAA6D140E-5 (Front view of engine) Machine model: D275AX-5E0
a
The shape is subject to machine models.
1. 2.
Center of crankshaft Center of cylinder liner
140E-5 Series
39
SEN00079-07
01 Specification
SAA6D140E-5 (Left side view of engine) Machine model: D275A-5R
a
The shape is subject to machine models.
1. 2.
Center of crankshaft Rear face of flywheel housing
40
140E-5 Series
01 Specification
SEN00079-07
SAA6D140E-5 (Front view of engine) Machine model: D275A-5R
a
The shape is subject to machine models.
1. 2.
Center of crankshaft Center of cylinder liner
140E-5 Series
41
SEN00079-07
01 Specification
SAA6D140E-5 (Left side view of engine) Machine model: WA500-6
a
The shape is subject to machine models.
1. 2.
Center of crankshaft Rear face of flywheel housing
42
140E-5 Series
01 Specification
SEN00079-07
SAA6D140E-5 (Front view of engine) Machine model: WA500-6
a
The shape is subject to machine models.
1. 2.
Center of crankshaft Center of cylinder liner
140E-5 Series
43
SEN00079-07
01 Specification
SAA6D140E-5 (Left side view of engine) Machine model: WA500-6R
a
The shape is subject to machine models.
1. 2.
Center of crankshaft Rear face of flywheel housing
44
140E-5 Series
01 Specification
SEN00079-07
SAA6D140E-5 (Front view of engine) Machine model: WA500-6R
a
The shape is subject to machine models.
1. 2.
Center of crankshaft Center of cylinder liner
140E-5 Series
45
SEN00079-07
01 Specification
SAA6D140E-5 (Left side view of engine) Machine model: HD325-7, HD405-7
a
The shape is subject to machine models.
1. 2.
Center of crankshaft Rear face of flywheel housing
46
140E-5 Series
01 Specification
SEN00079-07
SAA6D140E-5 (Front view of engine) Machine model: HD325-7, HD405-7
a
The shape is subject to machine models.
1. 2.
Center of crankshaft Center of cylinder liner
140E-5 Series
47
SEN00079-07
01 Specification
SAA6D140E-5 (Left side view of engine) Machine model: HD325-7R, HD405-7R
a
The shape is subject to machine models.
1. 2.
Center of crankshaft Rear face of flywheel housing
48
140E-5 Series
01 Specification
SEN00079-07
SAA6D140E-5 (Front view of engine) Machine model: HD325-7R, HD405-7R
a
The shape is subject to machine models.
1. 2.
Center of crankshaft Center of cylinder liner
140E-5 Series
49
SEN00079-07
01 Specification
SAA6D140E-5 (Left side view of engine) Machine model: HM350-2, HM400-2
a
The shape is subject to machine models.
1. 2.
Center of crankshaft Rear face of flywheel housing
50
140E-5 Series
01 Specification
SEN00079-07
SAA6D140E-5 (Front view of engine) Machine model: HM350-2, HM400-2
a
The shape is subject to machine models.
1. 2.
Center of crankshaft Center of cylinder liner
140E-5 Series
51
SEN00079-07
01 Specification
SAA6D140E-5 (Left side view of engine) Machine model: HM350-2R, HM400-2R
a
The shape is subject to machine models.
1. 2.
Center of crankshaft Rear face of flywheel housing
52
140E-5 Series
01 Specification
SEN00079-07
SAA6D140E-5 (Front view of engine) Machine model: HM350-2R, HM400-2R
a
The shape is subject to machine models.
1. 2.
Center of crankshaft Center of cylinder liner
140E-5 Series
53
SEN00079-07
01 Specification
SAA6D140E-5 (Left side view of engine) Machine model: HM400-3M0
a
The shape is subject to machine models.
1. 2.
Center of crankshaft Rear face of flywheel housing
54
140E-5 Series
01 Specification
SEN00079-07
SAA6D140E-5 (Front view of engine) Machine model: HM400-3M0
a
The shape is subject to machine models.
1. 2.
Center of crankshaft Center of cylinder liner
140E-5 Series
55
SEN00079-07
01 Specification
SAA6D140E-5 (Left side view of engine) Machine model: HM400-3R
a
The shape is subject to machine models.
1. 2.
Center of crankshaft Rear face of flywheel housing
56
140E-5 Series
01 Specification
SEN00079-07
SAA6D140E-5 (Front view of engine) Machine model: HM400-3R
a
The shape is subject to machine models.
1. 2.
Center of crankshaft Center of cylinder liner
140E-5 Series
57
SEN00079-07
01 Specification
SAA6D140E-5 (Left side view of engine) Machine model: SDG400S-6B1 (HOKUETSU INDUSTRIES GENERATOR)
a
The shape is subject to machine models.
1. 2.
Center of crankshaft Rear face of flywheel housing
58
140E-5 Series
01 Specification
SEN00079-07
SAA6D140E-5 (Front view of engine) Machine model: SDG400S-6B1 (HOKUETSU INDUSTRIES GENERATOR)
a
The shape is subject to machine models.
1. 2.
Center of crankshaft Center of cylinder liner
140E-5 Series
59
SEN00079-07
01 Specification
Dimensions table
1 Unit: mm
Engine
Machine model
Dimension of each part C
D
E
F
1,494 1,863
441
227
143
920
1,155 1,151
PC600-8E0, PC600LC-8E0 1,412 1,867 PC700-8E0, PC700LC-8E0
444
227
143
920
1,155 1,061
PC600-8R, PC600LC-8R PC600-8R1, PC600LC-8R1, 1,482 1,863 PC700-8R, PC700LC-8R PC700LC-8R1
411
227
143
920
1,155 1,151
PC800-8, PC800LC-8, PC800SE-8, PC850-8, PC850SE-8, PC800-8E0, PC800LC-8E0, PC800SE-8E0, PC850-8E0, 1,350 1,902 PC850SE-8E0, PC800-8R, PC800LC-8R, PC800SE-8R, PC850-8R, PC850SE-8R SAA6D140E-5 PC800-8R1, PC800LC-8R1, PC800SE-8R1, PC850-8R1, PC850SE-8R1
594
196
196
PC600-8, PC600LC-8
A
B
G
H
1,000 1,185 1,176
D155AX-6, D155A-6
1,477 1,950
419
14
14
918
1,090 1,109
D275AX-5E0
1,505 2,178
542
15
15
794
966
1,135
D275A-5R
1,461 2,178
542
15
15
794
966
1,180
WA500-6
1,477 1,727
419
150
150
815
945
1,094
WA500-6R
1,465 1,727
419
150
150
815
945
1,094
HD325-7, HD405-7, HD325-7R, HD405-7R
1,775 1,604
542
80
80
875
HM350-2, HM350-2R, HM400-2, HM400-2R
1,724 1,496
542
147
147
815
945
1,250
HM400-3M0
1,477 1,509
542
147
147
815
945
1,112
HM400-3R
1,451 1,509
542
147
147
815
945
1,112
SDG400S-6B1 (HOKUETSU INDUSTRIES GENERATOR)
1,785 1,523
403
213
213
877
956
1,242
1,005 1,025
a These dimensions are given for reference when the engine is set on a test bench.
60
140E-5 Series
01 Specification
SEN00079-07
Weight table
1
(With EGR) No.
Unit: kg 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
3
Cylinder block assembly
Cylinder block, bearing, cap, cylinder liner
4
Front cover
5
6
60
Oil pan
Flywheel assembly
480
Flywheel ring gear
PC800-8, PC800SE-8, PC800LC-8 PC850-8, PC850SE-8 PC800-8E0, PC800SE-8E0, PC800LC-8E0 PC850-8E0, PC850SE-8E0
36
PC600-8, PC600LC-8 PC600-8E0, PC600LC-8E0 PC700-8E0, PC700LC-8E0 D155AX-6 WA500-6
30
D275AX-5E0 HD325-7, HD405-7 HM350-2, HM400-2 HM400-3M0
28
SDG400S-6B1 (HOKUETSU INDUSTRIES GENERATOR)
62
PC600-8, PC600LC-8 PC800-8, PC800SE-8, PC800LC-8 PC850-8, PC850SE-8 PC800-8E0, PC800SE-8E0, PC800LC-8E0 PC850-8E0, PC850SE-8E0 D155AX-6 D275AX-5E0 WA500-6
60
HD325-7, HD405-7 HM350-2, HM400-2 HM400-3M0
47
SDG400S-6B1 (HOKUETSU INDUSTRIES GENERATOR)
123
65 7
Flywheel housing assembly
8
Crankshaft assembly
Crankshaft, crank gear
136
9
Camshaft assembly
Camshaft, cam gear, thrust plate
20
10
Piston and connecting rod assembly
Piston, piston ring, piston pin, connecting rod
11
Oil pump
7
12
Fuel supply pump
13
13
Water pump
18
140E-5 Series
SDG400S-6B1 (HOKUETSU INDUSTRIES GENERATOR)
63
11 × 6
61
SEN00079-07
01 Specification
Unit: kg No.
14
Item
Alternator
Main parts
SAA6D140E-5
24V, 35A
8
24V, 50A
11
24V, 60A
11
24V, 75A
12.5
24V, 90A
19
24V, 7.5kW
15.5
24V, 11kW
18
15
Starting motor
16
EGR oil pump
6
17
EGR valve
10
18
Bypass valve
10
19
EGR cooler
10
62
140E-5 Series
01 Specification
SEN00079-07
(EGR-less) No.
Unit: kg Item
Main parts
SAA6D140E-5
1
Turbocharger
KOMATSU KTR110L
24 (Air-cooled) / 28 (Water-cooled)
2
Cylinder head assembly
Cylinder head, valve, valve spring
23 × 6
3
Cylinder block assembly
Cylinder block, bearing, cap, cylinder liner
4
Front cover
5
6
60
Oil pan
Flywheel assembly
480
Flywheel ring gear
PC800-8R, PC800SE-8R, PC800LC-8R PC850-8R, PC850SE-8R PC800-8R1, PC800SE-8R1 PC800LC-8R1 PC850-8R1, PC850SE-8R1
36
PC600-8R, PC600LC-8R PC600-8R1, PC600LC-8R1 PC700-8R, PC700LC-8R PC700LC-8R1 D155A-6 WA500-6R
30
D275A-5R HD325-7R, HD405-7R HM350-2R, HM400-2R HM400-3R
28
PC600-8R, PC600LC-8R PC600-8R1, PC600LC-8R1 PC700LC-8R1 PC800-8R, PC800SE-8R, PC800LC-8R PC850-8R, PC850SE-8R PC800-8R1, PC800SE-8R1 PC800LC-8R1 PC850-8R1, PC850SE-8R1 D155A-6 D275A-5R WA500-6R
60
HD325-7R, HD405-7R HM350-2R, HM400-2R HM400-3R
47
7
Flywheel housing assembly
8
Crankshaft assembly
Crankshaft, crank gear
136
9
Camshaft assembly
Camshaft, cam gear, thrust plate
20
10
Piston and connecting rod assembly
Piston, piston ring, piston pin, connecting rod
11
Oil pump
7
12
Fuel supply pump
13
13
Water pump
18
140E-5 Series
65
11 × 6
63
SEN00079-07
01 Specification
Unit: kg No.
14
15
64
Item
Alternator
Starting motor
Main parts
SAA6D140E-5
24V, 35A
8
24V, 50A
11
24V, 60A
11
24V, 75A
12.5
24V, 90A
19
24V, 11kW
18
140E-5 Series
01 Specification
SEN00079-07
Engine performance curves Engine
SAA6D140E-5
140E-5 Series
Engine serial No.
1 Machine model
Page
PC600-8, PC600-8R, PC600LC-8, PC600LC-8R PC600-8E0, PC600-8R1, PC600LC-8E0, PC600LC-8R1, PC700-8E0, PC700LC-8E0, PC700-8R, PC700LC-8R, PC700LC-8R1
66
PC800-8, PC800LC-8, PC800-8R, PC800LC-8R PC800SE-8, PC800SE-8R PC850-8, PC850-8R PC850SE-8, PC850SE-8R PC800-8E0, PC800SE-8E0, PC800LC-8E0, PC850-8E0, PC850SE-8E0 PC800-8R1, PC800SE-8R1 PC800LC-8R1 PC850-8R1, PC850SE-8R1
67
D155AX-6, D155A-6
68
D275AX-5E0, D275A-5R
69
WA500-6, WA500-6R
70
HD325-7, HD325-7R HD405-7, HD405-7R
71
HM350-2, HM350-2R
72
HM400-2, HM400-2R HM400-3M0, HM400-3R
73
65
SEN00079-07
01 Specification
SAA6D140E-5 (Machine model: PC600-8, PC600LC-8, PC600-8R, PC600LC-8R, PC6008E0, PC600LC-8E0, PC600-8R1, PC600LC-8R1, PC700-8E0, PC700LC-8E0, PC700-8R, PC700LC-8R, PC700LC-8R1) Rated horsepower: 323 kW {433.3 HP}/1,800 min-1 {1,800 rpm} (Gross) Max. torque: 1,944 Nm {198.4 kgm}/1,400 min-1 {1,400 rpm} (Gross)
66
140E-5 Series
01 Specification
SEN00079-07
SAA6D140E-5 (Machine model: PC800-8, PC800SE-8, PC850-8, PC850SE-8, PC800LC-8, PC800-8E0, PC800SE-8E0, PC850-8E0, PC850SE-8E0, PC800LC-8E0, PC800-8R, PC800SE-8R, PC800LC-8R, PC850-8R, PC850SE-8R, PC8008R1, PC800SE-8R1, PC800LC-8R1, PC850-8R1, PC850SE-8R1) Rated horsepower: 370 kW {496.4 HP}/1,800 min-1 {1,800 rpm} (Gross) Max. torque: 2,195 Nm {223.8 kgm}/1,350 min-1 {1,350 rpm} (Gross)
140E-5 Series
67
SEN00079-07
01 Specification
SAA6D140E-5 (Machine model: D155AX-6, D155A-6) Rated horsepower: 268 kW {359.9 HP}/1,900 min-1 {1,900 rpm} (Gross) Max. torque: 1,834 Nm {187 kgm}/1,300 min-1 {1,300 rpm} (Gross)
68
140E-5 Series
01 Specification
SEN00079-07
SAA6D140E-5 (Machine model: D275AX-5E0, D275A-5R) Rated horsepower: 337 kW {451.6 HP}/2,000 min-1 {2,000 rpm} (Gross) Max. torque: 2,030 Nm {207 kgm}/1,400 min-1 {1,400 rpm} (Gross)
140E-5 Series
69
SEN00079-07
01 Specification
SAA6D140E-5 (Machine model: WA500-6, WA500-6R) Rated horsepower: 266 kW {356.9 HP}/1,900 min-1 {1,900 rpm} (Gross) Max. torque: 1,803 Nm {184 kgm}/1,250 min-1 {1,250 rpm} (Gross)
70
140E-5 Series
01 Specification
SEN00079-07
SAA6D140E-5 (Machine model: HD325-7, HD405-7, HD325-7R, HD405-7R) Rated horsepower: 386 kW {517.7 HP}/2,000 min-1 {2,000 rpm} (Gross) Max. torque: 2,170 Nm {221.3 kgm}/1,400 min-1 {1,400 rpm} (Gross)
140E-5 Series
71
SEN00079-07
01 Specification
SAA6D140E-5 (Machine model: HM350-2, HM350-2R) Rated horsepower: 304 kW {407.2 HP}/2,000 min-1 {2,000 rpm} (Gross) Max. torque: 1,991 Nm {203 kgm}/1,400 min-1 {1,400 rpm} (Gross)
72
140E-5 Series
01 Specification
SEN00079-07
SAA6D140E-5 (Machine model: HM400-2, HM400-2R, HM400-3M0, HM400-3R) Rated horsepower: 338 kW {452.6 HP}/2,000 min-1 {2,000 rpm} (Gross) Max. torque: 2,089 Nm {213 kgm}/1,400 min-1 {1,400 rpm} (Gross)
140E-5 Series
73
SEN00079-07
KOMATSU 140E-5 Series engine Form No. SEN00079-07
© 2012 KOMATSU All Rights Reserved Printed in Japan 12-12 (01)
74
SEN00081-08
ENGINE 1SHOP MANUAL
140E-5 Series
10 Structure, function and maintenance standard
1
Structure, function and maintenance standard, Part 1 Air intake and exhaust unit.............................................................................................................................. 3 Air cleaner....................................................................................................................................................... 5 Turbocharger................................................................................................................................................... 8 Aftercooler..................................................................................................................................................... 19 Muffler ........................................................................................................................................................... 20 EGR system.................................................................................................................................................. 25 Cylinder head................................................................................................................................................ 32 Cylinder block ............................................................................................................................................... 36 Cylinder liner ................................................................................................................................................. 39 Main moving parts......................................................................................................................................... 40 Crankshaft..................................................................................................................................................... 42
140E-5 Series
1
SEN00081-08
10 Structure, function and maintenance standard
Camshaft....................................................................................................................................................... 43 Cam follower and push rod ........................................................................................................................... 44 Piston, piston ring and piston pin .................................................................................................................. 46 Connecting rod.............................................................................................................................................. 48 Flywheel and flywheel housing ..................................................................................................................... 49 Vibration damper ........................................................................................................................................... 52 Timing gear ................................................................................................................................................... 54 Valve system ................................................................................................................................................. 58 Valve and valve guide ................................................................................................................................... 60 Rocker arm and shaft.................................................................................................................................... 62 Crosshead and guide .................................................................................................................................... 63
2
140E-5 Series
10 Structure, function and maintenance standard
Air intake and exhaust unit
SEN00081-08
1
SAA6D140E-5 (Left side view of engine)
a
The above illustration shows the engine for PC600-8.
A:
Air intake unit (Between air-cooled aftercooler and air intake manifold)
1. 2. 3.
Electrical intake air heater (ribbon heater) Diffuser Air intake manifold
140E-5 Series
3
SEN00081-08
10 Structure, function and maintenance standard
SAA6D140E-5 (Right side view of engine)
a
The above illustration shows the engine for PC600-8.
A: B: C:
To EGR cooler To turbocharger From bypass valve
1. 2. 3.
Exhaust manifold (rear) Exhaust manifold (center) Exhaust manifold (front)
4
140E-5 Series
10 Structure, function and maintenance standard
Air cleaner
SEN00081-08
1
ERB type [Air cleaner of automatic exhaust gas discharge type (radial seal type)]
a
The shape is subject to machine models.
A: B: C:
Air inlet To turbocharger (intake air) To muffler (dust)
1. 2. 3. 4.
Pre-cleaner Air cleaner casing Outer element Inner element
Engine
Machine model
Type
D155AX-6, D155A-6, Komaclone, multi-cyclone SAA6D140E-5 D275AX-5E0 (ERB type) D275A-5R
140E-5 Series
Method of discharging dust from pre-cleaner
Number of elements
Automatic discharge (Exhaust ejector)
Inner cylinder: 1, Outer cylinder: 1
5
SEN00081-08
10 Structure, function and maintenance standard
FRG type [Air cleaner of cyclone pack type with evacuator valve (radial seal type)]
a
The shape is subject to machine models.
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Inlet Outlet Guide vane Primary element Safety element Evacuator valve Dust pan Guide plate (sleeve) Body Element
6
140E-5 Series
10 Structure, function and maintenance standard
Engine
Machine model
SEN00081-08
Type
PC600-8, PC600-8R, PC600LC-8, PC600LC-8R PC600-8E0, PC600-8R1, PC600LC-8E0, PC600LC-8R1, PC700-8E0, PC700LC-8E0, PC700-8R, PC700LC-8R, PC700LC-8R1 PC800-8, PC800LC-8, PC800-8R, PC800LC-8R PC800SE-8, PC800SE-8R PC850-8, PC850-8R FRG PC850SE-8, PC850SE-8R SAA6D140E-5 (radial seal type) PC800-8E0, PC800LC-8E0, PC800SE-8E0, PC850-8E0, PC850SE-8E0 PC800-8R1, PC800LC-8R1, PC800SE-8R1, PC850-8R1, PC850SE-8R1 WA500-6, WA500-6R HD325-7, HD325-7R HD405-7, HD405-7R HM350-2, HM350-2R, HM400-2, HM400-2R HM400-3M0, HM400-3R Structure q The size of the body is reduced from the conventional type without changing the diameter of the element. q Since the inlet is set in the tangential direction, air is given sufficient centrifugal force by the simple spiral guide vane, not by the guide plate.
140E-5 Series
Evacuator valve
Number of elements
Automatic discharge
Inner cylinder: 1, Outer cylinder: 1
Operation q Air containing dust is sucked in vertically through inlet (1) and the dust is separated by the centrifugal effect of guide vane (3). q More than 99.9% of the dust is removed by primary element (4) and clean air is sucked in the engine through safety element (5) and outlet (2). q The dust and water separated by guide vane (3) swirl along the inside wall of body (9) and enter evacuator valve (6) and then are discharged out automatically.
7
SEN00081-08
Turbocharger
10 Structure, function and maintenance standard
1
(With EGR) Air-cooled type Model: KTR110L PC600-8, PC600LC-8, PC600-8E0, PC600LC-8E0, PC700-8E0, PC700LC-8E0, HD325-7, HD405-7, WA500-6, HM350-2, HM400-2, HM400-3M0, SDG400S-6B1 (HOKUETSU INDUSTRIES GENERATOR)
8
140E-5 Series
10 Structure, function and maintenance standard
A: B: C: D: E: F:
Intake air inlet Intake air outlet Exhaust gas inlet Exhaust gas outlet Oil inlet Oil outlet
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
Blower housing V-band Diffuser plate Center housing Shroud Turbine housing Blower impeller Seal ring Bearing metal Journal bearing Seal ring Turbine impeller
SEN00081-08
Specifications Model: KOMATSU KTR110L (air-cooled) Overall length: 308 mm Overall width: 305 mm Overall height: 287 mm Weight: 24 kg
140E-5 Series
9
SEN00081-08
10 Structure, function and maintenance standard
(EGR-less) Air-cooled type Model: KTR110L PC600-8R, PC600-8R1, PC600LC-8R, PC600LC-8R1, PC700-8R, PC700LC-8R, PC700LC-8R1, HD3257R, HD405-7R, WA500-6R, HM350-2R, HM400-2R, HM400-3R
10
140E-5 Series
10 Structure, function and maintenance standard
A: B: C: D: E: F:
Intake air inlet Intake air outlet Exhaust gas inlet Exhaust gas outlet Oil inlet Oil outlet
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
Blower housing V-band Diffuser plate Center housing Shroud Turbine housing Blower impeller Seal ring Bearing metal Journal bearing Seal ring Turbine impeller
SEN00081-08
Specifications Model: KOMATSU KTR110L (air-cooled) Overall length: 308 mm Overall width: 305 mm Overall height: 287 mm Weight: 24 kg
140E-5 Series
11
SEN00081-08
10 Structure, function and maintenance standard
(With EGR) Water-cooled type Model: KTR110L PC800-8, PC800LC-8, PC800SE-8, PC850-8, PC850SE-8, PC800-8E0, PC800LC-8E0, PC800SE-8E0, PC850-8E0, PC850SE-8E0, D155AX-6, D275AX-5E0
12
140E-5 Series
10 Structure, function and maintenance standard
A: B: C: D: E: F: G:
SEN00081-08
Intake air inlet Intake air outlet Exhaust gas inlet Exhaust gas outlet Oil inlet Oil outlet Coolant
1. 2. 3. 4.
Blower housing V-band Diffuser plate Center housing (water-cooled center housing: standard for D275AX, D155AX and PC800, and optional for other machine models) 5. Shroud 6. Turbine housing 7. Blower impeller 8. Seal ring 9. Bearing metal 10. Journal bearing 11. Seal ring 12. Turbine impeller Specifications Model: KOMATSU KTR110L (water-cooled) Overall length: 308 mm Overall width: 305 mm Overall height: 287 mm Weight: 28 kg
140E-5 Series
13
SEN00081-08
10 Structure, function and maintenance standard
(EGR-less) Water-cooled type Model: KTR110L PC800-8R, PC800LC-8R, PC800SE-8R, PC850-8R, PC850SE-8R, PC800-8R1, PC800LC-8R1, PC800SE8R1, PC850-8R1, PC850SE-8R1, D155A-6, D275A-5R
14
140E-5 Series
10 Structure, function and maintenance standard
A: B: C: D: E: F: G:
SEN00081-08
Intake air inlet Intake air outlet Exhaust gas inlet Exhaust gas outlet Oil inlet Oil outlet Coolant
1. 2. 3. 4.
Blower housing V-band Diffuser plate Center housing (water-cooled center housing: standard for D275A, D155A and PC800, and optional for other machine models) 5. Shroud 6. Turbine housing 7. Blower impeller 8. Seal ring 9. Bearing metal 10. Journal bearing 11. Seal ring 12. Turbine impeller Specifications Model: KOMATSU KTR110L (water-cooled) Overall length: 308 mm Overall width: 305 mm Overall height: 287 mm Weight: 28 kg
140E-5 Series
15
SEN00081-08
10 Structure, function and maintenance standard
Model: KTR110L
a
16
The above illustration shows the air-cooled turbocharger.
140E-5 Series
10 Structure, function and maintenance standard
SEN00081-08
Unit: mm No.
Check item
1
End play (play in axial direction)
2
Radial play (play in radial direction)
3
Clearance between blower housing and impeller
140E-5 Series
Criteria
Remedy
Standard
Repair limit
0.08 to 0.13
0.18
0.43 to 0.68
0.84
Clearance limit (min.): 0.14
Replace thrust parts Replace bearing parts Replace bearing parts
17
SEN00081-08
10 Structure, function and maintenance standard
Turbocharger mounting
a a
The above illustration shows the engine for PC600-8. The shape is subject to machine models.
A: B:
Intake air inlet Intake air (between turbocharger and air-cooled aftercooler)
1. 2.
Muffler Turbocharger
18
140E-5 Series
10 Structure, function and maintenance standard
Aftercooler
SEN00081-08
1
Air-cooled type SAA6D140E-5 (HD325-7, HD325-7R, HD405-7, HD405-7R)
a
The shape is subject to machine models.
a.
Inlet/Outlet of intake air (between turbocharger and air intake manifold)
1. 2. 3. 4.
Tank Side support Tube Fin
140E-5 Series
19
SEN00081-08
Muffler
10 Structure, function and maintenance standard
1
For PC600-8, PC600-8R, PC600LC-8, PC600LC-8R, PC600-8E0, PC600-8R1, PC600LC-8E0, PC600LC8R1, PC700-8E0, PC700-8R,PC700LC-8E0, PC700LC-8R, PC700LC-8R1
A: B: C:
20
Exhaust gas inlet (from turbocharger) Exhaust gas outlet Water drain
140E-5 Series
10 Structure, function and maintenance standard
SEN00081-08
For PC800-8, PC800SE-8, PC850-8, PC850SE-8, PC800LC-8, WA500-6, PC800-8R, PC800SE-8R, PC850-8R, PC850SE-8R, PC800LC-8R, WA500-6R
A: B: C:
Exhaust gas inlet (from turbocharger) Exhaust gas outlet Water drain
140E-5 Series
21
SEN00081-08
10 Structure, function and maintenance standard
For PC800-8E0, PC800SE-8E0, PC800LC-8E0, PC850-8E0, PC850SE-8E0 PC800-8R1, PC800SE-8R1, PC800LC-8R1, PC850-8R1, PC850SE-8R1
A: B: C:
22
Exhaust gas inlet (from turbocharger) Exhaust gas outlet Water drain
140E-5 Series
10 Structure, function and maintenance standard
SEN00081-08
For D155AX-6, D155A-6
A: B: C: D:
Exhaust gas inlet (from turbocharger) Exhaust gas outlet Water drain From air cleaner (dust)
140E-5 Series
23
SEN00081-08
10 Structure, function and maintenance standard
For D275AX-5E0, D275A-5R
A: B: C: D:
24
Exhaust gas inlet (from turbocharger) Exhaust gas outlet Water drain From air cleaner (dust)
140E-5 Series
10 Structure, function and maintenance standard
EGR system
No.
SEN00081-08
1
Component part
Function
EGR valve 1 (driven hydraulically)
• Controls the gas flow from the exhaust system to the air intake system. • Since the exhaust pressure (PEX) is higher than the boost pressure (PIN), the exhaust gas flows to the air intake valve.
2 Bypass valve
• Opens the bypass valve when the boost pressure (PIN) is higher than the exhaust pressure (PEX). • Makes the intake air flow to the exhaust side to increase the exhaust pressure so that the exhaust gas will be returned to the air intake side easily.
3 EGR cooler
• Lowers the exhaust temperature and returns the exhaust gas to the air intake side.
4 Venturi system
• Generates negative pressure with the venturi effect and takes in the exhaust gas.
5 Each sensor
• Controls the EGR according to the operating condition. • Troubleshoots the system.
Features q The exhaust gas is kept clean by sensing each part of the EGR circuit and controlling the EGR rate according to the operating condition. q Since the EGR circuit is monitored and troubleshooted, a serious trouble is prevented.
140E-5 Series
25
SEN00081-08
a
26
10 Structure, function and maintenance standard
The above illustration shows the engine for D155AX-6.
140E-5 Series
10 Structure, function and maintenance standard
1. 2. 3. 4. 5. 6. 7. 8. 9.
SEN00081-08
EGR valve Bypass valve EGR cooler Venturi system EGR valve position sensor Bypass valve position sensor Bypass piping EGR piping EGR oil pump
Operation q The engine controller outputs signals for opening EGR valve (1) most properly according to the load on the engine to attain both clean exhaust gas and low fuel consumption. q If EGR valve (1) opens, a part of the exhaust gas (EGR gas) flows from the exhaust manifold through EGR piping (8) to EGR cooler (3). q The exhaust gas cooled by EGR cooler (3) flows through EGR valve (1) and mixes with the intake air in venturi system (4), and then flows in the air intake manifold. q In the operating range where the boost pressure is higher than the exhaust pressure on the high load side, the EGR gas does not flow to the air intake side easily. At this time, the engine controller opens bypass valve (2). q If bypass valve (2) opens, the intake air flows through bypass piping (7). As a result, the exhaust pressure rises and more EGR gas mixes with the intake air.
140E-5 Series
27
SEN00081-08
10 Structure, function and maintenance standard
EGR valve and bypass valve
A: B: C: D:
Oil inlet Oil outlet EGR gas passage (EGR valve) Boost air passage (bypass valve)
Function q The EGR valve controls the EGR gas. q This valve is driven hydraulically and its opening ratio is controlled electronically. Operation q The oil pressure (engine oil) of 1.47 MPa {15 kg/cm2} supplied to oil inlet (A) is reduced by oil pressure control valve (2). q Hydraulic piston (5) generates pressing force from the reduced oil pressure. q The control oil pressure can be changed with the drive current of solenoid (3).
28
1. 2. 3. 4. 5. 6. 7.
Stick prevention device Oil pressure control valve Solenoid Position sensor Hydraulic piston Spring Valve
q
Valve (7) is closed by spring (6) but pushed open by hydraulic piston (5) to an opening ratio in proportion to the control oil pressure. The valve opening ratio is sensed with position sensor (4) installed to hydraulic piston (5) and set to the specified opening ratio by controlling the solenoid current. The bypass valve assists the EGR gas by increasing the exhaust pressure. The structure and operation of the EGR bypass valve are the same as those of the EGR valve.
q
q q
140E-5 Series
10 Structure, function and maintenance standard
SEN00081-08
EGR cooler
A: B: C:
EGR gas inlet EGR gas outlet Coolant inlet
1.
Heat exchange tube (corrugated tube)
D: E:
Coolant outlet Air bleeder
Function q The EGR cooler cools the high-temperature EGR gas taken out of the exhaust gas to increase the gas density, or the EGR efficiency. Structure q The EGR cooler is a multi-tube heat exchanger. When the high-temperature EGR gas flows through heat exchange tube (1), it is cooled by the coolant flowing outside of the tube. q Heat exchange tube (1) is made of corrosionresistant stainless steel and corrugated to increase the cooling efficiency.
140E-5 Series
29
SEN00081-08
10 Structure, function and maintenance standard
Venturi system
A: B:
Air inlet EGR gas inlet
1. 2. 3.
Venturi nozzle Throat Diffuser
Structure q The EGR gas and intake air mix together in the venturi system. q The venturi system consists of throat (2), venturi nozzle (1), and diffuser (3). Operation q The boost pressure increased by the turbocharger is set negative temporarily with the venturi effect of the throat to take the EGR gas into the intake air through venturi nozzle (1). q When the mixture of the EGR gas and intake air flows through diffuser (3), its pressure is increased again to the normal level and then it flows in the intake manifold.
30
140E-5 Series
10 Structure, function and maintenance standard
140E-5 Series
SEN00081-08
31
SEN00081-08
Cylinder head
a
32
10 Structure, function and maintenance standard
1
The shape is subject to machine models.
140E-5 Series
10 Structure, function and maintenance standard
A: B: C: D:
Intake air Exhaust gas To fuel tank To radiator
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Rocker cover bolt Cylinder head bolt Air bleeding pipe from coolant Fuel spill pipe Rocker cover Cylinder head Injector connector Injector assembly Injector holder mounting bolt Injector holder retainer
SEN00081-08
Specifications Cylinder head q Direct injection type q 4-valve type q Split-type 1-cylinder, 1-head q Centralized cooling system for valve bridge and injector q Cylinder head bolt: Plastic-region tightening Valve seat q Valve seat inserts are press fitted to both intake and exhaust valves Rocker cover O-ring seal
q
Injector q Installation: Dry type (without sleeve)
140E-5 Series
33
SEN00081-08
a
10 Structure, function and maintenance standard
Tighten the cylinder head mounting bolts in the order of (1) to (7).
Unit: mm
No.
Check item
1
Strain of cylinder head mounting face
2
Projection of nozzle
3
Tightening torque for cylinder head mounting bolt (Apply molybdenum disulfide or engine oil to threaded part)
Criteria
Remedy
Tolerance
Repair limit
0 to 0.06
0.09
Engine
Standard
SAA6D140E-5
2.3 to 2.9
Bolt No.
(1) to (6)
Target(Nm{kgm})
1st stage
137 to 157{14 to 16} Tighten in order shown above. If 289{29.5} 284 to 294{29 to 30} there are 5 punch Retighten 90 deg. 90(+30/0) deg. marks, replace bolt.
2nd stage 3rd stage —
Range(Nm{kgm})
147{15}
68.6{7}
58.8 to 73.5{6 to 7.5}
Target(Nm{kgm})
Range(Nm{kgm})
4
Tightening torque for injector holder mounting bolt
66.7{6.8}
58.8 to 73.5{6 to 7.5}
5
Tightening torque for fuel injection pipe
37.3{3.8}
34.3 to 40.2{3.5 to 4.1}
6
Tightening torque for head cover mounting bolt
32.4{3.3}
29.4 to 34.3{3.0 to 3.5}
34
Replace nozzle or gasket
Procedure
(7)
a
Correct by grinding or replace
Retighten
Do not use a cylinder head mounting bolt more than 5 times. Each time the bolt is used, make a punch mark on its head.
140E-5 Series
10 Structure, function and maintenance standard
140E-5 Series
SEN00081-08
35
SEN00081-08
Cylinder block
36
10 Structure, function and maintenance standard
1
140E-5 Series
10 Structure, function and maintenance standard
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
SEN00081-08
Front cover Cylinder block Cylinder liner Clevis seal Liner O-ring (water) Liner O-ring (oil) Thrust bearing metal Main bearing metal Main bearing metal cap Main bearing metal cap bolt Front oil seal Piston cooling nozzle (front side) Piston cooling nozzle (rear side)
Specifications Cylinder block q Crankshaft section: 7 bearings q Camshaft section: High cam type, 7 bearings q Main cap bolt: Plastic-region tightening Front seal q Single lip with dust seal (lay-down seal) Piston cooling With piston cooling nozzle (2 pieces for each cylinder)
q
Cylinder liner q Wet type q Machining on inside: Plateau honing Soft nitriding process Liner ring Upper: Clevis seal q Middle: O-ring (ethylene-propylene rubber) q Lower: O-ring (silicone rubber) q
140E-5 Series
37
SEN00081-08
10 Structure, function and maintenance standard
Unit: mm
No. 1
Check item
Remedy
Tolerance
Repair limit
0 to 0.09
0.135
Standard dimension
Tolerance
127
+0.018 –0.006
3.5
–0.010 –0.010
Strain of cylinder head mounting face Diameter of main bearing metal mounting hole
2
Criteria
Thickness of main bearing metal Roundness of mounting hole
Repair limit: 0.005 Standard dimension
Tolerance
Repair limit
120
+0.038 –0.006
120.15
Diameter of cam bushing mounting hole
69
+0.030 +0.030
—
5
Inside diameter of cam bushing
65
+0.040 +0.040
65.15
6
Level difference between underside faces of cylinder block and front cover
7
Tightening torque for main cap mounting bolt (Apply engine oil to threads)
3
Inside diameter of main bearing metal
4
8 a
38
Tightening torque for crank pulley mounting bolt
Repair limit: 0.14
Correct by grinding or replace Replace main bearing metal cap
Replace bearing metal
Replace bearing metal Correct or replace block Replace cam bushing Reassemble
Procedure
Target(Nm{kgm})
Range(Nm{kgm})
1st stage
118{12}
108 to 127{11 to 13}
2nd stage
235{24}
230 to 240{23.5 to 24.5}
3rd stage
Retighten 90 deg.
90(+30/0) deg.
—
275{28}
245 to 309{25 to 31.5}
Retighten
Do not use a main cap mounting bolt more than 5 times. Each time the bolt is used, make a punch mark on its head. 140E-5 Series
10 Structure, function and maintenance standard
Cylinder liner
SEN00081-08
1
Unit: mm
No. 1
Check item
Criteria
Projection of cylinder liner
2
Standard dimension
Tolerance
Repair limit
S
140
+0.020 +0.020
140.12
L
140
+0.040 +0.021
140.14
Roundness of inside of cylinder liner
Repair limit: 0.02
Cylindricality of inside of cylinder liner
Repair limit: 0.02
Outside diameter of cylinder liner
3
4 Interference of cylinder liner and block
5
Outside diameter of cylinder liner (at O-ring) Clearance between cylinder liner and block (at O-ring)
140E-5 Series
Replace cylinder liner
Standard dimension
Tolerance
170.2
–0.10 –0.10
Clearance between cylinder liner and block Outside diameter of cylinder liner
Replace cylinder liner or cylinder block
Permissible range: 0.07 to 0.15 Rank
Inside diameter of cylinder liner
Remedy
Standard clearance: 0 to 0.163 Standard dimension
Tolerance
161.2
+0.090 +0.050
Standard interference
Interference limit
0.02 to 0.12
Min. 0.02
Standard size
Tolerance
158
–0.073 –0.103
Standard clearance: 0.024 to 0.089
Replace cylinder liner or block Replace cylinder liner
Replace or correct cylinder liner or block
Replace cylinder liner Replace cylinder liner or block
39
SEN00081-08
Main moving parts
a
The shape is subject to machine models.
1. 2. 3. 4. 5. 6. 7. 8.
Piston (FCD piston) Piston pin Connecting rod bushing Top ring Second ring Oil ring Connecting rod Connecting rod cap
40
10 Structure, function and maintenance standard
1
9. 10. 11. 12. 13. 14. 15. 16.
Connecting rod cap bolt Connecting rod bearing metal Crank gear (number of teeth: 36) Key (crank gear) Crankshaft Vibration damper Pin (flange) Flange
140E-5 Series
10 Structure, function and maintenance standard
Specifications Crankshaft:
Piston:
SEN00081-08
Closed die forging Journal, fillet Induction hardening Special thin ductile cast iron (FCD piston) Re-entrant piston
Connecting rod: Closed die forging Cap bolt is screw type, installed by plastic-region tightening, with lubricating oil hole. Piston rings
Top ring (1):
Double-side keystone, inner cut, barrel face, hard chromium-plated
Second ring (2): Double-side keystone, inner cut, taper face, hard chromium-plated Oil ring (3):
140E-5 Series
M-shaped steel, with expander, nitrided surface
coil
41
SEN00081-08
10 Structure, function and maintenance standard
Crankshaft
1
Unit: mm
No. 1
Check item
Criteria
End play
Standard value
Repair limit
0.140 to 0.315
0.50
Standard dimension
Outside diameter of main journal
2
3
0.25 US
119.75
0.50 US
119.50
0.75 US
119.25
119.13
1.00 US
119.00
118.88
Clearance of crank pin journal
4
a
42
Bend of crankshaft
119.88 119.63 –0.050 –0.068
119.38
Standard
Repair limit
0 to 0.009
0.020
Standard clearance
Allowable clearance
0.044 to 0.106
0.27 Tolerance
STD
90
89.88
89.75
89.63
0.50 US
89.50
0.75 US
89.25
–0.050 –0.068
89.38 89.13
89.00 Standard
Use undersize journal or replace
Replace main bearing metal
Repair limit
0.25 US
1.00 US Roundness
Repair limit
120
Standard dimension
Outside diameter of crank pin journal
Tolerance
Replace thrust bearing metal or use oversize metal
STD
Roundness
Clearance of main journal
Remedy
Use undersize journal or replace
88.88 Repair limit
0 to 0.009
0.020
Standard clearance
Allowable clearance
0.042 to 0.110
0.24
Standard clearance
Repair limit
Coaxiallity of all main journals: Max. 0.150
0.20
Coaxiallity of adjacent journals: Max. 0.050
0.10
Replace connecting rod bearing metal
Use undersize crankshaft or replace
US: Undersize
140E-5 Series
10 Structure, function and maintenance standard
Camshaft
SEN00081-08
1
Unit: mm
No. 1
Check item
Criteria Standard
Repair limit
0.1 to 0.25
0.36
Standard dimension
Tolerance
65
–0.016 –0.036
Standard clearance
Allowable clearance
0.016 to 0.096
0.15
End play
Outside diameter of camshaft journal
2 Clearance of camshaft journal
3 4
Bend of camshaft
Height of cam
140E-5 Series
Remedy Replace thrust plate
Replace camshaft
Replace cam bushing
Repair limit: 0.03 (Overall swing of indicator) Cam
Standard dimension
Tolerance
Repair limit
Intake
55.48
±0.1
55.08
Exhaust
55.75
±0.1
55.35
Replace camshaft
43
SEN00081-08
10 Structure, function and maintenance standard
Cam follower and push rod
1
Unit: mm
No.
Check item
Repair limit
22
–0.021 –0.034
21.92
Diameter of cam follower shaft hole
22
+0.021 +0.021
22.07
Outside diameter of cam roller
31.7
+0.05 +0.02
31.50
Inside diameter of cam roller
12.7
+0.038 +0.013
12.78
12.63
±0.006
1
3
Remedy
Tolerance
Diameter of cam follower shaft
2
Criteria Standard dimension
Diameter of cam roller pin
12.56
Standard dimension
Tolerance
12.7
–0.20 –0.20 –0.20 –0.20
4
Diameter of push rod ball end
5
Diameter of push rod socket end
13.4
6
Bend of push rod
Repair limit: 0.3 (Overall swing of indicator)
44
Replace
140E-5 Series
10 Structure, function and maintenance standard
140E-5 Series
SEN00081-08
45
SEN00081-08
Piston, piston ring and piston pin
46
10 Structure, function and maintenance standard
1
140E-5 Series
10 Structure, function and maintenance standard
SEN00081-08
Unit: mm
No.
Check item
Criteria Rank Standard dimension
1
Outside diameter of piston
Thickness of piston ring
Width of piston ring groove
2 to 4 Clearance between piston ring and piston ring groove
Closed gap of piston ring
Outside diameter of piston pin
5
Diameter of piston pin hole Clearance between piston pin and piston
a a
Remedy
Tolerance
Repair limit
140
–0.120 –0.135
139.830
L
140
–0.105 –0.120
139.845
No.
Measuring point
Standard dimension
Tolerance
2
No. 1 ring
2.9
–0.015 –0.035
3
No. 2 ring
2.41
–0.010 –0.035
4
Oil ring
4
–0.010 –0.030
2
No. 1 ring
Judge using groove wear gauge (*1)
3
No. 2 ring
Judge using groove wear gauge (*2)
4
Oil ring
No.
Measuring point
2
No. 1 ring
3
No. 2 ring
4
Oil ring
0.035 to 0.060
0.14
2
No. 1 ring
0.42 to 0.57 (Tension 16.5 to 23.5N {1.68 to 2.40kg})
2.0
3
No. 2 ring (Identification: 2RN white mark)
1.15 to 1.30 (Tension 16.2 to 24.2N {1.65 to 2.47kg})
1.8
4
Oil ring
0.30 to 0.50 (Tension 84.5 to 111.7N {8.61 to 11.39kg})
1.0
S
Replace piston
Replace piston ring
Replace piston
+0.040 +0.025
4
Standard clearance Allowable clearance Judge using groove wear gauge
Standard dimension
Tolerance
52
–0.006 –0.006
52
+0.045 +0.035
Standard clearance
Allowable clearance
0.035 to 0.051
0.10
Replace piston or piston ring
Replace piston ring or cylinder liner
Replace piston pin
Replace piston Replace piston or piston pin
*1: Part No. (groove wear gauge) 795-901-1150 *2: Part No. (groove wear gauge) 795-901-1130
140E-5 Series
47
SEN00081-08
10 Structure, function and maintenance standard
Connecting rod
1
Unit: mm
No.
1
Check item Inside diameter of connecting rod small end bushing (Ream after press fitting)
Criteria
Remedy
Standard dimension
Tolerance
Repair limit
52
+0.049 +0.030
52.09
Clearance between connecting rod small end bushing and piston pin
Standard clearance
Allowable clearance
0.030 to 0.055
0.11
Diameter of connecting rod small end bushing mounting hole
Standard dimension
Tolerance
2
57.4
+0.030 +0.030
3
Inside diameter of connecting rod large end bearing metal
4
5
6
—
a
48
Replace bushing (Spare is half worked) Replace bushing or piston pin Replace connecting rod
Standard dimension
Tolerance
Repair limit
90
+0.042 –0.008
90.15
Diameter of connecting rod large end bearing metal mounting hole (Before measuring, tighten connecting rod cap mounting bolt to specified torque)
95
+0.026 –0.004
—
Replace connecting rod
Thickness of connecting rod bearing metal
2.5
+0.002 –0.008
—
Replace bearing metal
Parallelism and twist of connecting rod
Tightening torque for connecting rod cap mounting bolt (Apply engine oil to bolt threads and nut seat) Weight of connecting rod
Item
Standard
Repair limit
Parallelism a
0.20
0.25
Twist b
0.30
0.35
Dimension c
264
—
Procedure
Target(Nm{kgm})
Range(Nm{kgm})
1st stage
127.5{13}
117.7 to 132.4 {12.5 to 13.5}
2nd stage
Retighten 90 deg.
90(+30/0) deg.
Replace bearing metal
Replace connecting rod
Retighten
Permissible range: Dispersion of weight of connecting rods in one engine Replace must not exceed 154 g.
Do not use a connecting rod cap mounting bolt more than 5 times. Each time the bolt is used, make a punch mark on its head.
140E-5 Series
10 Structure, function and maintenance standard
Flywheel and flywheel housing
a
The shape is subject to machine models.
1. 2. 3. 4. 5. 6.
Rear seal Ring gear Flywheel Engine speed sensor (for monitor) Flywheel housing Engine speed sensor (NE sensor for engine control)
140E-5 Series
SEN00081-08
1
49
SEN00081-08
a
Tighten the flywheel mounting bolts with an impact wrench in the 1st stage and then tighten them with a torque wrench in the 2nd stage.
A: B:
Tightening order of flywheel mounting bolts Tightening order of flywheel housing mounting bolts
50
10 Structure, function and maintenance standard
140E-5 Series
10 Structure, function and maintenance standard
SEN00081-08
Unit: mm
No.
Check item
Criteria
1
Facial runout of flywheel housing
Repair limit: 0.20
2
Radial runout of flywheel housing
Repair limit: 0.20
3
Facial runout of flywheel
Repair limit: 0.20
4
Radial runout of flywheel
Repair limit: 0.13 Target(Nm{kgm})
Range(Nm{kgm})
5
Tightening torque for flywheel Procedure housing mounting bolt 1st stage (Apply engine oil to bolt threads 2nd stage and seat surface)
191{19.5}
147 to 235{15 to 24}
275{28.0}
245 to 309{25 to 31.5}
Tightening torque for flywheel Procedure mounting bolt 1st stage (Apply engine oil to bolt threads 2nd stage and seat surface)
Target(Nm{kgm})
Range(Nm{kgm})
118{12}
113 to 123{11.5 to 12.5}
Retighten 90 deg.
90(+30/0) deg.
6
a
Remedy
Reassemble
Tighten in order shown in above figure Tighten and retighten in order shown in above figure
Do not use a flywheel mounting bolt more than 5 times. Each time the bolt is used, make a punch mark on its head.
140E-5 Series
51
SEN00081-08
Vibration damper
a
The shape is subject to machine models.
1. 2. 3. 4. 5. 6.
Adapter Pin (between adapter and crankshaft pulley) Vibration damper Bolt (between adapter and vibration damper) Bolt (between crankshaft and adapter) Pin (between adapter and vibration damper)
52
10 Structure, function and maintenance standard
1
140E-5 Series
10 Structure, function and maintenance standard
140E-5 Series
SEN00081-08
53
SEN00081-08
Timing gear
10 Structure, function and maintenance standard
1
(With EGR)
a
54
The shape is subject to machine models.
140E-5 Series
10 Structure, function and maintenance standard
A: B: C:
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
SEN00081-08
Timing mark [Between crank gear and main idler gear (large)] Timing mark [Between main idler gear (small) and fuel supply pump drive gear] Timing mark [Between main idler gear (small) and cam gear] Water pump drive gear (Number of teeth: 23) Sub idler gear (Number of teeth: 42) Main idler gear (large) (Number of teeth: 60) Main idler gear (small) (Number of teeth: 40) Cam gear (Number of teeth: 48) Air compressor pulley drive gear (Number of teeth: 14) Fuel supply pump drive gear (Number of teeth: 48) EGR oil pump drive gear (Number of teeth: 22) Crank gear (Number of teeth: 36) Oil pump drive gear (Number of teeth: 20) Unit: mm
No. 11
Check item
Clearance between main idler gear bushing and shaft
12
Clearance between sub idler gear bushing and shaft
13
End play of main idler gear
14
End play of sub idler gear
Criteria Standard dimension
Position
—
Backlash of each gear
140E-5 Series
Tolerance
Remedy Standard clearance
Allowable clearance
+0.034 +0.009
0.025 to 0.063
0.20
+0.055 +0.055
0.016 to 0.084
0.20
Shaft
Hole
56
–0.016 –0.029
56
–0.016 –0.029 Standard
Repair limit
0.06 to 0.24
0.4
0.11 to 0.23
0.4
Measuring point
Standard
15
Crank gear and main idler gear (large) 0.028 to 0.312
16
Main idler gear (small) and fuel supply 0.016 to 0.278 pump gear
17
Main idler gear (small) and cam gear
0.016 to 0.278
18
Main idler gear (large) and sub idler gear
0.028 to 0.313
19
Sub idler gear and oil pump drive gear 0.080 to 0.417
20
Sub idler gear and water pump drive gear
0.095 to 0.346
21
Cam gear and air conditioner drive gear
0.118 to 0.369
22
Fuel supply pump gear and EGR oil pump drive gear
0.118 to 0.369
Replace bushing
Replace thrust bearing
Repair limit
Replace 0.6
55
SEN00081-08
10 Structure, function and maintenance standard
(EGR-less)
a
56
The shape is subject to machine models.
140E-5 Series
10 Structure, function and maintenance standard
A: B: C:
1. 2. 3. 4. 5. 6. 7. 8. 9.
SEN00081-08
Timing mark [Between crank gear and main idler gear (large)] Timing mark [Between main idler gear (small) and fuel supply pump drive gear] Timing mark [Between main idler gear (small) and cam gear] Water pump drive gear (Number of teeth: 23) Sub idler gear (Number of teeth: 42) Main idler gear (large) (Number of teeth: 60) Main idler gear (small) (Number of teeth: 40) Cam gear (Number of teeth: 48) Air compressor pulley drive gear (Number of teeth: 14) Fuel supply pump drive gear (Number of teeth: 48) Crank gear (Number of teeth: 36) Oil pump drive gear (Number of teeth: 20) Unit: mm
No. 10
Check item
Clearance between main idler gear bushing and shaft
11
Clearance between sub idler gear bushing and shaft
12
End play of main idler gear
13
End play of sub idler gear
Criteria Standard dimension
Position
—
Backlash of each gear
140E-5 Series
Tolerance
Remedy Standard clearance
Allowable clearance
+0.034 +0.009
0.025 to 0.063
0.20
+0.055 +0.055
0.016 to 0.084
0.20
Shaft
Hole
56
–0.016 –0.029
56
–0.016 –0.029 Standard
Repair limit
0.06 to 0.24
0.4
0.11 to 0.23
0.4
Measuring point
Standard
14
Crank gear and main idler gear (large) 0.141 to 0.425
15
Main idler gear (small) and fuel supply 0.129 to 0.391 pump gear
16
Main idler gear (small) and cam gear
0.129 to 0.391
17
Main idler gear (large) and sub idler gear
0.141 to 0.425
18
Sub idler gear and oil pump drive gear 0.080 to 0.417
19
Sub idler gear and water pump drive gear
0.095 to 0.346
20
Cam gear and air conditioner drive gear
0.118 to 0.369
Replace bushing
Replace thrust bearing
Repair limit
Replace 0.6
57
SEN00081-08
Valve system
58
10 Structure, function and maintenance standard
1
140E-5 Series
10 Structure, function and maintenance standard
A:
Lubricating oil inlet
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.
Cam gear (Number of teeth: 48) Thrust plate Camshaft Cam roller Cam roller pin Cam follower shaft Cam follower Push rod Rocker arm shaft Locknut Rocker arm adjustment screw Rocker arm Crosshead adjustment screw Locknut Crosshead Valve retainer Outer valve spring Inner valve spring Air intake valve Valve guide Spring seat Exhaust valve
SEN00081-08
Valve timing
Specifications Camshaft: Drawn steel bar (turning) Journal and cam sections: Induction hardening
140E-5 Series
59
SEN00081-08
Valve and valve guide
60
10 Structure, function and maintenance standard
1
140E-5 Series
10 Structure, function and maintenance standard
SEN00081-08
Unit: mm
No. 1
Check item
Sinking distance of valve
Criteria Valve
Standard dimension
Tolerance
Repair limit
Intake
0
±0.10
0.70
Exhaust
0
±0.10
Valve
2
3
Remedy
Thickness of valve lip
0.70
Standard dimension
Repair limit
Intake
2.4
1.9
Exhaust
2.15
1.75
Valve
Standard dimension
Tolerance
Intake
30 deg.
±15 min.
Exhaust
45 deg.
±15 min.
Intake
10
–0.045 –0.060
Exhaust
10
–0.074 –0.089
Before head is press fitted
10
+0.019 +0.001
Standard dimension
Tolerance
Valve seat angle
Diameter of valve stem
4
After head is press fitted
Clearance between valve guide and stem Bend of valve stem
5
+0.008 –0.009 (Press fitted part)
Inside diameter of valve guide 10
+0.011 –0.009 (Other than press fitted part)
Valve
Standard clearance
Allowable clearance
Intake
0.036 to 0.068
0.22
Exhaust
0.065 to 0.097
0.24
Repair limit: 0.02 (Overall swing of indicator in 100)
Driving height of valve guide
Standard
Tolerance
22.0
±0.2
Spring
Standard dimension
Repair limit
Outer
81.7
—
Inner
72.0
—
Spring Installed length
Standard installed load(N{kg})
Allowable installed load(N{kg}) 377.3 {38.5} 192.1 {19.6}
Free length of valve spring
6 Installed load of valve spring
Perpendicularity of valve spring
140E-5 Series
Outer
51.0
424.3±21.6 {43.3±2.2}
Inner
46.0
215.6±10.8 {22.0±1.1}
Replace valve or valve seat
Replace valve
Correct or replace valve or valve seat
Replace valve
Replace valve guide
Replace valve or valve guide Replace valve Correct
Replace valve spring
Repair limit: 2 deg. (both sides)
61
SEN00081-08
10 Structure, function and maintenance standard
Rocker arm and shaft
1
Unit: mm
No.
Check item Diameter of rocker arm shaft
1
3
62
Valve clearance (when cold)
Tightening torque for locknut of rocker arm adjustment screw
Remedy Tolerance
32.0
±0.0065
32.0
+0.087 +0.035
Standard clearance
Allowable clearance
0.0285 to 0.0935
0.13
Inside diameter of rocker arm bushing Clearance between rocker arm shaft and rocker arm
2
Criteria Standard dimension
Valve
Standard
Tolerance
Intake
0.35
±0.02
Exhaust
0.57
±0.02
Target(Nm{kgm})
Range(Nm{kgm})
58.8{6}
52.9 to 64.7{5.4 to 6.6}
Replace rocker arm shaft Replace rocker arm Replace rocker arm shaft or rocker arm
Adjust
Tighten
140E-5 Series
10 Structure, function and maintenance standard
Crosshead and guide
SEN00081-08
1
Unit: mm
No. 1
Check item Depth of crosshead stem receiver Inside diameter of crosshead
Criteria
Remedy
Standard dimension
Tolerance
Repair limit
6.2
+0.3 +0.3
6.61
11.04
±0.02
11.17
2
Outside diameter of crosshead guide
11
+0.011 +0.011
10.95
3
Projection of crosshead guide
49.0
±0.25
—
140E-5 Series
Replace
Correct
63
SEN00081-08
KOMATSU 140E-5 Series engine Form No. SEN00081-08
© 2012 KOMATSU All Rights Reserved Printed in Japan 12-12 (01)
64
SEN00082-06
ENGINE 1SHOP MANUAL
140E-5 Series
10 Structure, function and maintenance standard
1
Structure, function and maintenance standard, Part 2 Lubrication system .......................................................................................................................................... 4 Lubrication system diagram ................................................................................................................. 4 Oil pump............................................................................................................................................... 8 EGR oil pump....................................................................................................................................... 9 Oil filter ............................................................................................................................................... 10 Oil cooler ............................................................................................................................................ 12 Fuel system................................................................................................................................................... 14 CRI system diagram........................................................................................................................... 14 Outline of CRI system ........................................................................................................................ 16 Fuel piping.......................................................................................................................................... 38 Fuel cooler ......................................................................................................................................... 42
140E-5 Series
1
SEN00082-06
10 Structure, function and maintenance standard
Fuel filter............................................................................................................................................. 43 Priming pump ..................................................................................................................................... 46 Electric priming pump......................................................................................................................... 47 Engine controller cooler...................................................................................................................... 48 Cooling system.............................................................................................................................................. 49 Cooling system diagram..................................................................................................................... 49 Water pump ........................................................................................................................................ 54 Thermostat ......................................................................................................................................... 57 Corrosion resistor ............................................................................................................................... 58 Cooling fan drive ................................................................................................................................ 60 Accessories................................................................................................................................................... 63 Front PTO........................................................................................................................................... 63 Electrical equipment...................................................................................................................................... 65 Alternator............................................................................................................................................ 65 Starting motor ..................................................................................................................................... 76 Starting aid ......................................................................................................................................... 78 Engine controller ................................................................................................................................ 79
2
140E-5 Series
10 Structure, function and maintenance standard
140E-5 Series
SEN00082-06
3
SEN00082-06
10 Structure, function and maintenance standard
Lubrication system
1
Lubrication system diagram
1
(With EGR)
a
4
The layout of the oil filter, shapes of the oil pan and piping, etc. are subject to machine models. 140E-5 Series
10 Structure, function and maintenance standard
SEN00082-06
W: Coolant 1. Oil pan 2. Oil strainer 3. Oil pump 4. Oil pump relief valve 5. Oil cooler 6. Thermo-valve 7. Oil filter 8. Safety valve 9. Crankshaft 10. Piston cooling nozzle 11. Piston 12. Camshaft 13. Cam follower 14. Rocker arm 15. Air intake valve and exhaust valve 16. Timing gear 17. Turbocharger 18. Fuel supply pump 19. EGR oil pump 20. EGR oil pump relief valve 21. EGR valve 22. Bypass valve 23. Main gallery 24. Oil filter clogging switch (for SDG400S-6B1)
140E-5 Series
5
SEN00082-06
10 Structure, function and maintenance standard
(EGR-less)
a
6
The layout of the oil filter, shapes of the oil pan and piping, etc. are subject to machine models.
140E-5 Series
10 Structure, function and maintenance standard
SEN00082-06
W: Coolant 1. Oil pan 2. Oil strainer 3. Oil pump 4. Oil pump relief valve 5. Oil cooler 6. Thermo-valve 7. Oil filter 8. Safety valve 9. Crankshaft 10. Piston cooling nozzle 11. Piston 12. Camshaft 13. Cam follower 14. Rocker arm 15. Air intake valve and exhaust valve 16. Timing gear 17. Turbocharger 18. Fuel supply pump 19. Main gallery
140E-5 Series
7
SEN00082-06
10 Structure, function and maintenance standard
Oil pump
1
A: From oil pan B: To oil cooler C: Rotation direction D: Pump mounting face
Specifications Oil pump Type: Gear pump Revolving speed: Engine speed × 1.8
1. Pump cover 2. Drive gear 3. Pump body 4. Pump drive gear (Number of teeth: 20) 5. Driven gear 6. Main relief valve 7. Main valve spring 8. Sub relief valve 9. Sub valve spring
Main relief valve Cracking pressure:
8
600 ± 50 kPa {6.0 ± 0.5 kg/cm2} Sub relief valve Cracking pressure: 1,000 ± 50 kPa {10.0 ± 0.5 kg/cm2}
140E-5 Series
10 Structure, function and maintenance standard
SEN00082-06
EGR oil pump
A: From main gallery B: To EGR valve and bypass valve C: Rotation direction 1. Pump cover 2. Drive gear 3. Pump body 4. Driven gear 5. Pump drive gear (Number of teeth: 22) 6. Main relief valve 7. Main valve spring 8. Sub-relief valve 9. Sub-valve spring
140E-5 Series
1
Specifications Oil pump Type: Gear pump Revolving speed: Engine speed × 1.09 Main relief valve Cracking pressure: 1,430 ± 100 kPa {14.6 ± 1.0 kg/cm2} Sub-relief valve Cracking pressure: 1,800 ± 150 kPa {18.4 ± 1.5 kg/cm2}
9
SEN00082-06
10 Structure, function and maintenance standard
Oil filter
1
Except SDG400S-6B1 (HOKUETSU INDUSTRIES GENERATOR)
a
The shape is subject to machine models.
A: Oil inlet B: Oil outlet 1. Safety valve 2. Filter head 3. Cartridge
10
Specifications Oil filter Filtration area: 0.44 m2 (full flow) Safety valve Cracking pressure: 343 ± 19.6 kPa {3.5 ± 0.2 kg/cm2}
140E-5 Series
10 Structure, function and maintenance standard
SEN00082-06
For SDG400S-6B1 (HOKUETSU INDUSTRIES GENERATOR)
a
The shape is subject to machine models.
A: Oil inlet B: Oil outlet 1. Safety valve 2. Filter head 3. Cartridge 4. Clogging switch
Specifications Oil filter Filtration area: 0.44 m2 (full flow) Safety valve Cracking pressure: 343 ± 19.6 kPa {3.5 ± 0.2 kg/cm2} Clogging switch q Operating differential pressure: +0.4 2 147 +39 +0 kPa {1.5 +0 kg/cm } q Contact type: NO (Normal Open)
140E-5 Series
11
SEN00082-06
10 Structure, function and maintenance standard
Oil cooler
1
a
12
The shape is subject to machine models.
140E-5 Series
10 Structure, function and maintenance standard
SEN00082-06
A: Oil inlet B: Oil outlet C: Coolant inlet 1. Oil cooler cover 2. Cooler element SAA6D140E-5: 15 layers 3. Thermo-valve 4. Thermo-valve spring 5. Thermo-valve cover Specifications Oil cooler thermo-valve Opening temperature: 85 ± 1.5°C Full opening temperature: 100°C Lift at full opening: 8 mm Oil cooler Heat dissipation surface area SAA6D140E-5: 1.23 m2 Heat exchange rate SAA6D140E-5: Min. 39,800 kcal/h Unit: mm
No.
Check item
Criteria
Remedy
Lift of thermostat at full opening Min. 8 mm (Before checking, leave valve in oil of 100°C for 4 to 5 minutes)
6
Opening/Closing of thermostat
140E-5 Series
Check that valve closes fully when its temperature is lowered from 100°C Replace for full opening to 85°C. (Before checking valve, leave it in oil for 4 to 5 minutes)
13
SEN00082-06
10 Structure, function and maintenance standard
Fuel system
1
CRI system diagram
1
(With EGR)
a
CRI is an abbreviation for common rail injection.
1. NE speed sensor 2. Engine controller 3. Injector 4. Fuel cooler 5. Fuel tank 6. Pre-fuel filter 7. Main fuel filter 8. Overflow valve 9. Fuel supply pump 9A. PCV 9B. High-pressure pump
14
9C. Priming pump (sub) 9D. Feed pump 9E. Relief valve 9F. Bkup speed sensor (G sensor) 10. Common rail 11. High-pressure injection pipe 12. Flow damper 13. Pressure limiter 14. Priming pump (main) 15. Engine controller cooler
140E-5 Series
10 Structure, function and maintenance standard
SEN00082-06
(EGR-less)
a
CRI is an abbreviation for common rail injection.
1. NE speed sensor 2. Engine controller 3. Injector 4. Fuel cooler 5. Fuel tank 6. Pre-fuel filter 7. Main fuel filter (double cartridges) a Single cartridge is set for some models. 8. Overflow valve 9. Fuel supply pump 9A. PCV 9B. High-pressure pump 140E-5 Series
9C. Priming pump 9D. Feed pump 9E. Relief valve 9F. Bkup speed sensor (G sensor) 10. Common rail 11. High-pressure injection pipe 12. Flow damper 13. Pressure limiter 14. Electric priming pump a Manual priming pump is set for some models. 15. Engine controller cooler
15
SEN00082-06
10 Structure, function and maintenance standard
Outline of CRI system Outline q The CRI system checks the condition of the engine (engine speed, accelerator angle, coolant temperature, etc.) with sensors. q The microcomputer of the CRI system controls the fuel injection rate, fuel injection timing, fuel injection pressure, etc. totally to operate the engine under the best condition. q The CRI system has a diagnosis function and an alarm function, with which the computer of the system checks the main component parts and notifies the operator of detected failures. q In addition, the CRI system has a failsafe function which stops the engine when a certain parts fail and a backup function which continues the operation by changing the control method in such a case. q The CRI system has the same basic structure as the current Tier 2 engine. q The maximum service pressure is heightened. (120 MPa {1,200 kg/cm2} 160 MPa {1,600 kg/cm2})
1 1. Fuel system
Configuration The CRI system is divided by the function into the fuel system and control system.
q
q
q
16
The fuel system distributes the high-pressure fuel supplied by the fuel supply pump to the cylinders through the common rail. The solenoid valve in the injector opens and closes the nozzle needle valve to start and finish injection.
140E-5 Series
10 Structure, function and maintenance standard
SEN00082-06
2. Control system
a
Parts marked with * (2 places) are installed to only the engines with EGR.
q
The engine controller calculates and controls the energizing timing and energizing period of the injector with the signals from the sensors installed to the machine to inject proper quantity of fuel in proper timing. The control system is roughly divided by the electric parts into the sensors, computer, and actuators.
q
140E-5 Series
17
SEN00082-06
10 Structure, function and maintenance standard
Structure and operation of CRI system
q
q
q
q
q
q
q
q
18
The CRI system consists of the fuel supply pump, common rail, injector, engine controller to control them, and sensors. The fuel supply pump generates fuel pressure in the common rail. The fuel pressure is controlled by the fuel discharge rate of the supply pump. The discharge rate is controlled by turning on and off the PCV (pressure control valve) of the fuel supply pump according to the electric signals from the engine controller. The common rail receives the pressurized fuel from the fuel supply pump and distributes it to the cylinders. The fuel pressure is sensed by the common rail fuel pressure sensor installed to the common rail. A feedback control is applied so that the actual fuel pressure will match to the command pressure set according to the engine speed and the load on the engine. The fuel pressure in the common rail is applied to the nozzle side of the injector and to the control chamber through the fuel injection pipe of each cylinder. The injector controls the fuel injection rate and fuel injection timing by turning on and off the TWV (2-way solenoid valve).
q
q
q
1
If the TWV is turned on (energized), the fuel circuit is so changed that the high-pressure fuel in the control chamber will flow through the orifice. As a result, the needle valve is raised to start fuel injection by the nozzle cracking pressure of the high-pressure fuel on the nozzle side. If the TWV is turned off (de-energized), the fuel circuit is so changed that the high-pressure fuel will be applied to the control chamber through the orifice. As a result, the needle valve lowers and finishes fuel injection. Accordingly, the fuel injection timing and fuel injection rate are controlled respectively by the timing to turn on the TWV and the length of the turn-on time of the TWV.
140E-5 Series
10 Structure, function and maintenance standard
SEN00082-06
Structure and operation of component parts
1
1. Fuel supply pump
1. 3-head cam 2. Overflow valve 3. Drive gear 4. No. 1 high-pressure pump 5. PCV (pressure control valve)
6. No. 2 high-pressure pump 7. Priming pump 8. Feed pump 9. Gear for Bkup speed sensor (G sensor)
Outline q The fuel supply pump consists of priming pump (7), feed pump (8), and high-pressure pumps (4) and (6). q The function of the fuel supply pump is to generate common rail fuel pressure by controlling the fuel delivery.
q
Structure High-pressure pumps (4) and (6) have the pressure feed systems similar to those of the conventional in-line fuel injection pump and the PCVs (pressure control valves) for each cylinder to control the fuel delivery. q By employing the 3-head cam, the necessary number of the cylinders of high-pressure pumps (4) and (6) is reduced to 1/3 of the engine cylinders. q
140E-5 Series
q q
q
Since the number of the times of feeding fuel to the common rail is the same as the number of the times of fuel injection, the common rail fuel pressure is smooth and stable. The fuel fed by high-pressure pumps (4) and (6) to the common rail is divided as follows. No. 1 high-pressure pump (on the drive gear side) (4) compensates for drop in the common rail fuel pressure caused by fuel injection into the No. 1, 3, and 5 cylinders. No. 2 high-pressure pump (on the feed pump side) (6) compensates for drop in the common rail fuel pressure caused by fuel injection into the No. 2, 4, and 6 cylinders.
19
SEN00082-06
10 Structure, function and maintenance standard
Operation
q
q
q
q
20
(A): During the lowering stroke of the plunger, the PCV is open and the low-pressure fuel is sucked in the plunger chamber through the PCV. (B): While the PCV is not energized and is open after the plunger starts the rising stroke, the sucked fuel is returned through the PCV without being pressurized. (C): If the PCV is energized and closed in the timing for the necessary delivery, the return passage is closed and the pressure in the plunger chamber rises. Accordingly, the fuel is fed through the delivery valve (check valve) to the common rail. That is, the quantity of the fuel corresponding to the plunger lift after the PCV is closed is the delivery. The delivery is changed and the common rail fuel pressure is controlled by changing the opening timing of the PCV. (D): After the cam passes the maximum lift point, the plunger starts the lowering stroke and the pressure in it lowers. At this time, the delivery valve closes to stop feeding the fuel. Since the PCV is deenergized, it opens and the low-pressure fuel is sucked in the plunger chamber, or the state of (A) starts again.
140E-5 Series
10 Structure, function and maintenance standard
1) PCV (pressure control valve) q The PCV adjusts the fuel delivery from the fuel supply pump to adjust the common rail fuel pressure. The delivery from the fuel supply pump to the common rail is decided by the timing of energizing the PCV.
140E-5 Series
SEN00082-06
2) Feed pump q The feed pump built in the fuel supply pump assembly draws the fuel from the fuel tank and sends it through the fuel filter to the high-pressure pump chamber. q The outer and inner rotors of the feed pump are rotated by the camshaft. q The fuel is sucked in on the suction side and discharged on the delivery side according to the increase and decrease of the spaces between the outer and inner rotors.
21
SEN00082-06
10 Structure, function and maintenance standard
2. Common rail Structure q Common rail (4) distributes the high-pressure fuel from the high-pressure pump to the injectors of the cylinders. q Common rail (4) is equipped with common rail fuel pressure sensor (2), flow dampers (1), and pressure limiter (3). q The fuel injection pipes are connected to flow dampers (1) to send the high-pressure fuel to the injectors. q The piping of the pressure limiter (3) is returned to the fuel tank.
When fuel is stopped q If the fuel flows out abnormally because of a burst of the piping, etc., piston (2) moves to the right stroke end. q The tip of piston (2) contacts seat (b) to stop the fuel. q Once the fuel is stopped, piston (2) does not return to the initial position until the engine is stopped.
1) Flow damper Function q The flow dampers damp the pressure pulses in the high pressure piping and supply the fuel to the injectors with stable pressure. q If excessive fuel flows out, the flow dampers block the fuel passage to prevent abnormal outflow of the fuel. q If the fuel flows out abnormally, high pressure is applied to the piston, which moves to the right until it reaches the seat to stop the fuel. Operation When fuel is not injected q Piston (2) is in contact with stopper (1) (initial position). q The fuel for static leakage is supplied through orifice (a) of piston (2) and clearance in the sliding parts. When fuel is injected The fuel pressure is applied to piston (2), which compresses spring (3) and moves to the right. q The fuel for static leakage is supplied through orifice (a) of piston (2) and clearance in the sliding parts. q
22
140E-5 Series
10 Structure, function and maintenance standard
2) Pressure limiter q If abnormally high pressure is generated, the pressure limiter opens to release that pressure. q If the common rail fuel pressure reaches about 200 MPa {2,040 kg/cm2}, the pressure limiter operates (opens). q If the common rail fuel pressure lowers to 30 MPa {310 kg/cm2}, the pressure limiter resets itself (closes) to maintain the pressure. q Under the normal condition, the pressure limiter does not reset itself (close) until the engine is stopped.
SEN00082-06
3) Common rail fuel pressure sensor q The common rail fuel pressure sensor is installed to the common rail to sense the fuel pressure. q This sensor is a semiconductor pressure sensor, which utilizes the phenomenon that the electric resistance of silicon changes according to pressure applied to it.
1. Ball 2. Housing 3. Spring 4. Guide 5. Body
140E-5 Series
23
SEN00082-06
10 Structure, function and maintenance standard
3. Injector
Outline q The function of the injector is to inject the highpressure fuel from the common rail into each combustion chamber of the engine in the optimum timing, by the optimum quantity, at the optimum injection rate, and under the optimum spray condition. q The TWV (2-way solenoid valve) controls the start and finish of fuel injection by controlling the pressure in the control chamber. q The orifice limits the opening speed of the nozzle and controls the fuel injection rate. q The hydraulic piston transmits the force generated by the pressure in the control chamber to the needle valve of the nozzle. q The nozzle sprays the fuel.
24
140E-5 Series
10 Structure, function and maintenance standard
SEN00082-06
Structure
1. Inlet connector 2. Terminal 3. Upper body 4. Solenoid 5. Valve body 6. Orifice (out) q
7. Orifice (in) 8. Pressure control chamber 9. Control piston 10. Spring 11. Pressure pin 12. Nozzle assembly
The injector consists of the nozzle section, orifice to control the fuel injection rate, hydraulic piston section, and 2-way solenoid valve section.
140E-5 Series
25
SEN00082-06
10 Structure, function and maintenance standard
A: No fuel injection B: Start of fuel injection
C: Finish of fuel injection D: From common rail
1. Nozzle 2. Control piston 3. Orifice (in) 4. Orifice (out)
5. Valve body 6. Solenoid 7. Spring 8. Pressure control chamber
Operation 1) No fuel injection (A) q While solenoid (6) is not energized, valve body (5) is pressed down by spring (7). q Since the high-pressure fuel is applied from the common rail to pressure control chamber (8), nozzle (1) is closed and the fuel is not injected.
3) Finish of fuel injection (C) q If solenoid (6) is de-energized, valve body (5) is lowered by spring (7) and the fuel passage is closed. q At this time, the high-pressure fuel in the common rail is applied to pressure control chamber (8) suddenly and nozzle (1) is closed quickly, fuel injection is finished sharply.
2) Start of fuel injection (B) If solenoid (6) is energized, valve body (5) is pulled up by the electromagnetic force and the fuel passage is opened. q Since the fuel in pressure control chamber (8) flows out through orifices (3) and (4), nozzle (1) rises and fuel injection pump starts. q The fuel injection rate is increased gradually by the function of orifices (3) and (4). q If solenoid (6) is kept energized, the fuel injection rate is increased to the maximum. q
26
140E-5 Series
10 Structure, function and maintenance standard
SEN00082-06
Electric circuit diagram
k
Since high voltage (65 V) is applied to the wiring harnesses connected to the engine controller, COMMON 1 and COMMON 2 of the supply pump, and TWV #1 to #6 of the injector, take care not get an electric shock.
140E-5 Series
27
SEN00082-06
28
10 Structure, function and maintenance standard
140E-5 Series
10 Structure, function and maintenance standard
SEN00082-06
Various controls
a
Parts marked with * (3 places) are installed to only the engines with EGR.
q
The CRI system controls the fuel injection rate and fuel injection timing more properly than the mechanical governor or timer of the conventional fuel injection pump. For the control of the system, calculations necessary to the engine controller are performed fr om th e si gn als se nt fr om the s en so rs installed to the engine and machine. The energizing timing and energizing period of the injector are so controlled that the optimum quantity of fuel will be injected in the optimum timing.
q
q
2. Fuel injection timing control function q
3. Fuel injection pressure control function (Common rail fuel pressure control function) q
1. Fuel injection rate control function q
The fuel injection rate control function is employed instead of the function of the conventional governor. It controls the fuel injection according to the signals of engine speed and accelerator angle so that the fuel injection rate will be most proper.
140E-5 Series
The fuel injection timing control function is employed instead of the function of the conventional timer. It controls the fuel injection timing most properly from the engine speed and fuel injection rate.
q
The fuel injection pressure control function (common rail fuel pressure control function) is a function of measuring the fuel pressure with the common rail fuel pressure sensor and feeding it back to the engine controller to control the delivery of the fuel supply pump. This function performs pressure feedback control so that the fuel injection pressure will be the same as the optimum value (command value) set according to the engine speed and fuel injection rate.
29
SEN00082-06
10 Structure, function and maintenance standard
4. Various sensors and relays
a a a
30
Nos. 1 to 13 in the above illustration correspond to title Nos. 1) to 13). The above illustration shows the engine for HD325-7. Parts *1, *3 and *4 are installed to only the engines with EGR.
140E-5 Series
10 Structure, function and maintenance standard
140E-5 Series
SEN00082-06
31
SEN00082-06
1) EGR inlet pressure sensor (with EGR) q
This sensor is used to sense the EGR pressure.
10 Structure, function and maintenance standard
2) Fuel temperature sensor q
q
q
32
The fuel temperature sensor senses the fuel temperature and sends it to the engine controller. The sensor unit is a thermistor the resistance of which changes according to the temperature. The engine controller applies voltage to the thermistor and senses the temperature by the voltage divided by the resistance in the computer and the resistance of the thermistor.
The following graph shows the output characteristics of the EGR inlet pressure sensor.
140E-5 Series
10 Structure, function and maintenance standard
SEN00082-06
3) EGR valve position sensor (with EGR) 4) Bypass valve position sensor (with EGR) q
These sensors sense the opening and closing positions of the EGR valve and bypass valve.
1. EGR and bypass valve position sensors q
The following graph shows the output characteristics of the position sensor.
140E-5 Series
33
SEN00082-06
5) Engine controller
10 Structure, function and maintenance standard
7) Atmospheric pressure sensor This sensor is used to correct altitude. (with EGR)
q
6) NE speed sensor (crank angle sensor) q q
If the signal hole made on the flywheel passes the sensor, the magnetic line of force changes. If the magnetic line of force changes, the output of the Hall element sensor changes linearly and it is converted into pulse of 0 to 5 V by the wave form shaping circuit in the sensor, and then output.
A: Pressure inlet B: Mounting screw: M5 Tightening torque: 4.1 to 9.5 Nm {0.4 to 1.0 kgm} q
34
The following graph shows the output characteristics of the atmospheric pressure sensor.
140E-5 Series
10 Structure, function and maintenance standard
SEN00082-06
(EGR-less)
10) Bkup speed sensor (G sensor) (Cylinder No. sensor) q
q
q
q
Similarly to the NE speed sensor, this sensor utilizes the pulses of 0 – 5 V generated by the change of the magnetic line of force crossing the sensor unit. The disc gear installed to the central part of the camshaft of the high-pressure pump has teeth (cut parts) around it at intervals of 120 degree. In addition to the above teeth, one more tooth is installed. Accordingly, 7 pulses are generated every 2 revolutions of the engine. The standard pulse of the No. 1 cylinder is recognized by the combination of the NE speed sensor pulse and Bkup speed sensor pulse.
A: Pressure inlet B: Mounting screw: M5 Tightening torque: 4.5 ± 0.5 Nm {0.46 ± 0.05 kgm} q
The following graph shows the output characteristics of the atmospheric pressure sensor.
8) Common rail pressure sensor 9) Oil pressure sensor
140E-5 Series
35
SEN00082-06
11) Charge pressure sensor
10 Structure, function and maintenance standard
(EGR-less)
This sensor is used to sense the charge pressure (boost pressure). (with EGR)
q
1. Sensor 2. O-ring q
The following graph shows the output characteristics of the charge pressure sensor.
A: Mounting screw: M6 Tightening torque: 5.5 ± 0.5 Nm {0.56 ± 0.05 kgm} 1. Sensor 2. O-ring q
36
The following graph shows the output characteristics of the charge pressure sensor.
140E-5 Series
10 Structure, function and maintenance standard
12) Charge temperature sensor q
q
The charge temperature sensor senses the intake air temperature (boost temperature) and sends it to the engine controller. The sensor unit is a thermistor the resistance of which changes according to the temperature. The engine controller applies voltage to the thermistor and senses the temperature by the voltage divided by the resistance in the computer and the resistance of the thermistor.
140E-5 Series
SEN00082-06
13) Coolant temperature sensor q
q
The coolant temperature sensor senses the coolant temperature and sends it to the engine controller. The sensor unit is a thermistor the resistance of which changes according to the temperature. The engine controller applies voltage to the thermistor and senses the temperature by the voltage divided by the resistance in the computer and the resistance of the thermistor.
37
SEN00082-06
10 Structure, function and maintenance standard
Fuel piping
1
(with EGR)
a a
The above illustration shows the engine for PC600-8. The shape is subject to machine models.
Specifications Fuel supply pump Manufacturer: DENSO CORPORATION Model: DENSO ECD-U2 Lubrication method: Forced lubrication with engine oil
38
A: Fuel inlet B: To engine controller cooler C: To main fuel filter D: From main fuel filter E: To injector F: Return fuel (between overflow valve and main fuel tank) G: Return fuel (between injector and main fuel tank) H: Engine oil (to fuel supply pump)
140E-5 Series
10 Structure, function and maintenance standard
a a
SEN00082-06
The above illustration shows the engine for PC600-8. The shape is subject to machine models.
1. Fuel injection pipe (No. 1 cylinder) 2. Fuel injection pipe (No. 2 cylinder) 3. Fuel injection pipe (No. 3 cylinder) 4. Fuel injection pipe (No. 4 cylinder) 5. Fuel injection pipe (No. 5 cylinder) 6. Fuel injection pipe (No. 6 cylinder) 7. Common rail 8. Fuel return pipe 9. Priming pump (sub) 10. Feed pump
140E-5 Series
11. Oil inlet pipe (for pump lubricating oil) 12. Fuel supply pump 13. Drive gear (Number of teeth: 48) 14. Overflow valve 15. PCV 16. Priming pump (main) 17. Pre-fuel filter 18. Main fuel filter
39
SEN00082-06
10 Structure, function and maintenance standard
(EGR-less)
a a
The above illustration shows the engine for D275A-5R. The shape is subject to machine models.
Specifications Fuel supply pump Manufacturer: DENSO CORPORATION Model: DENSO ECD-U2 Lubrication method: Forced lubrication with engine oil
40
A: Fuel inlet B: To engine controller cooler C: To main fuel filter D: From main fuel filter E: To injector F: Return fuel (between overflow valve and main fuel tank) G: Return fuel (between injector and main fuel tank) H: Engine oil (to fuel supply pump)
140E-5 Series
10 Structure, function and maintenance standard
a a
SEN00082-06
The above illustration shows the engine for D275A-5R. The shape is subject to machine models.
1. Fuel injection pipe (No. 1 cylinder) 2. Fuel injection pipe (No. 2 cylinder) 3. Fuel injection pipe (No. 3 cylinder) 4. Fuel injection pipe (No. 4 cylinder) 5. Fuel injection pipe (No. 5 cylinder) 6. Fuel injection pipe (No. 6 cylinder) 7. Common rail 8. Fuel return pipe 9. Priming pump 10. Feed pump
140E-5 Series
11. Oil inlet pipe (for pump lubricating oil) 12. Fuel supply pump 13. Drive gear (Number of teeth: 48) 14. Overflow valve 15. PCV 16. Electric priming pump a Manual priming pump is set for some models. (See the "with EGR".) 17. Pre-fuel filter 18. Main fuel filter (double cartridges) a Single cartridge is set for some models. 19. Air bleeding valve for electric priming pump
41
SEN00082-06
Fuel cooler
10 Structure, function and maintenance standard
1
(installed on the machine)
a
The shape is subject to machine models.
A: From fuel tank B: To fuel supply pump 1. Mount bracket 2. Core Specifications Cooling method: Cooling with air Type of core: Drawn cup, 23 layers Heat dissipation surface area: 2.12 m2
42
140E-5 Series
10 Structure, function and maintenance standard
Fuel filter
SEN00082-06
1
Main fuel filter (with EGR)
a
The shape is subject to machine models.
A: Fuel inlet B: Fuel outlet 1. Air bleeding plug 2. Filter head 3. Cartridge (single cartridge) Specifications Filtration area: 1.06 m2
140E-5 Series
43
SEN00082-06
10 Structure, function and maintenance standard
(EGR-less)
a
The shape is subject to machine models.
A: Fuel inlet B: Fuel outlet 1. Air bleeding plug 2. Filter head 3. Cartridge (double cartridges) a Single cartridge is set for some models. Specifications Filtration area: 1.06 m2 x 2
44
140E-5 Series
10 Structure, function and maintenance standard
SEN00082-06
Pre-fuel filter
a
The shape is subject to machine models.
A: Fuel inlet B: Fuel outlet 1. Air bleeding plug 2. Filter head 3. Cartridge Specifications Filtration area: 1.06 m2 with water separator
140E-5 Series
45
SEN00082-06
10 Structure, function and maintenance standard
Priming pump
1
(with EGR)
1. Spring 2. Cover 3. Shaft 4. Bushing 5. Diaphragm 6. Diaphragm cover 7. Body 8. Check valve
46
9. Valve stopper 10. Packing 11. Check valve body 12. Lever pin 13. E-ring 14. Washer 15. Bolt 16. Lever
140E-5 Series
10 Structure, function and maintenance standard
Electric priming pump
SEN00082-06
1
(EGR-less) a
Manual priming pump is set for some models (see the"with EGR")
A: Fuel IN B: Fuel OUT 1. Connector 2. Vibration prevention rubber
140E-5 Series
47
SEN00082-06
Engine controller cooler
10 Structure, function and maintenance standard
1
A: Fuel IN (from feed pump of fuel supply pump) B: Fuel OUT (main fuel filter) 1. Engine controller 2. Engine controller cooler Outline q The fuel is circulated as refrigerant through engine controller cooler (2) to prevent engine controller (1) from overheating.
48
140E-5 Series
10 Structure, function and maintenance standard
SEN00082-06
Cooling system
1
Cooling system diagram
1
SAA6D140E-5 (For construction machinery) 1. Hydraulic cooling fan (With EGR) (PC600-8, PC600LC-8, PC600-8E0, PC600LC-8E0, PC700-8E0, PC700LC-8E0, PC8008, PC800SE-8, PC850-8, PC850SE-8, PC800LC-8, PC800-8E0, PC800SE-8E0, PC8508E0, PC850SE-8E0, PC800LC-8E0, D155AX-6, D275AX-5E0, WA500-6, HM400-3M0)
A: Oil inlet B: Oil outlet C: Exhaust gas inlet D: Exhaust gas outlet 1. Radiator 2. Thermostat 3. Oil cooler 4. Water pump 5. EGR cooler
140E-5 Series
6. Corrosion resistor a Corrosion resistor is not set for some models. 7. Hydraulic cooling fan 8. Hydraulic fan motor
49
SEN00082-06
10 Structure, function and maintenance standard
2. Hydraulic cooling fan (EGR-less) (PC600-8R, PC600LC-8R, PC600-8R1, PC600LC-8R1, PC700-8R, PC700LC-8R, PC700LC-8R1, PC800-8R, PC800LC-8R, PC800SE-8R, PC850-8R, PC850SE-8R, PC800-8R1, PC800LC-8R1, PC800SE-8R1, PC850-8R1, PC850SE-8R1, D155A-6, D275A-5R, WA500-6R, HM400-3R)
A: Oil inlet B: Oil outlet 1. Radiator 2. Thermostat 3. Oil cooler 4. Water pump 5. Corrosion resistor a Corrosion resistor is not set for some models. 6. Hydraulic cooling fan 7. Hydraulic fan motor
50
140E-5 Series
10 Structure, function and maintenance standard
SEN00082-06
3. Engine-driven cooling fan (With EGR) (HD325-7, HD405-7, HM350-2, HM400-2, SDG400S-6B1 (HOKUETSU INDUSTRIES GENERATOR))
A: Oil inlet B: Oil outlet C: Exhaust gas inlet D: Exhaust gas outlet 1. Radiator 2. Thermostat 3. Oil cooler 4. Water pump 5. EGR cooler 6. Corrosion resistor a Corrosion resistor is not set for some models. 7. Engine-driven cooling fan
140E-5 Series
51
SEN00082-06
10 Structure, function and maintenance standard
4. Engine-driven cooling fan (EGR-less) (HD325-7R, HD405-7R, HM350-2R, HM400-2R)
A: Oil inlet B: Oil outlet 1. Radiator 2. Thermostat 3. Oil cooler 4. Water pump 5. Corrosion resistor a Corrosion resistor is not set for some models. 6. Engine-driven cooling fan
52
140E-5 Series
10 Structure, function and maintenance standard
140E-5 Series
SEN00082-06
53
SEN00082-06
Water pump
10 Structure, function and maintenance standard
1
SAA6D140E-5
a
54
The shape is subject to machine models.
140E-5 Series
10 Structure, function and maintenance standard
SEN00082-06
A: From radiator B: To oil cooler C: Rotation direction D: Pump mounting face 1. Alternator drive pulley 2. Oil seal 3. Ball bearing 4. Pump shaft 5. Water pump drive gear (Number of teeth: 23) 6. Pump body 7. Water seal 8. Impeller 9. Pump cover Specifications Type: Centrifugal type driven with gear Speed: Engine speed × 1.56 Delivery: 785 l/min Total head: Min. 18.5 m Unit: mm
No. 10
Check item Interference between impeller and shaft
Criteria Standard dimension
Remedy
Tolerance
Standard interference
Shaft
Hole
16
–0.082 –0.095
–0.120 –0.150
0.025 to 0.068
11
Interference between drive gear and shaft
28
+0.015 +0.002
–0.023 –0.055
0.025 to 0.070 Replace
12
Interference between flange and shaft
25
+0.015 +0.002
–0.023 –0.053
0.025 to 0.068
13 14
Clearance between impeller and body Wear of water seal ring
140E-5 Series
Standard clearance: 0.6 to 0.9 (including end play) Limits of size: 1.5
55
SEN00082-06
10 Structure, function and maintenance standard
Water pump mounting
1
SAA6D140E-5
a a
The above illustration shows the engine for PC600-8. The shape is subject to machine models.
A: To radiator inlet (coolant) B: From thermostat (coolant) C: From radiator outlet (coolant) D: To each part of engine through oil cooler (coolant) E: From oil pump (oil) F: To each part of engine (oil) 1. Oil cooler 2. Thermostat housing 3. Water pump
56
140E-5 Series
10 Structure, function and maintenance standard
SEN00082-06
Thermostat
a
1
The shape is subject to machine models.
A: To radiator inlet B: From radiator outlet 1. Thermostat housing 2. Thermostat
Specifications Opening temperature: 76.5 ± 2°C Full opening temperature: 90°C Lift at full opening: Min. 9 mm
Unit: mm
No.
Check item Lift of thermostat at full opening
3
Criteria Min. 9 mm (Before checking, leave valve in water of 90°C for 4 to 5 minutes) Check that valve closes fully when its temperature is lowered from 90°C
Opening/Closing of thermostat
140E-5 Series
Remedy
Replace
for full opening to 76.5°C. (Before checking valve, leave it in water for 4 to 5 minutes)
57
SEN00082-06
10 Structure, function and maintenance standard
Corrosion resistor
a a
The shape is subject to machine models. Corrosion resistor is not set for some models.
A: Coolant inlet B: Coolant outlet 1. Head 2. Cartridge 3. Element 4. Inhibitor (solid anti-corrosion agent) 5. Spring 6. Stop valve
58
1
Specifications Filtration area Quantity of anti-corrosion agent
0.13m2
0.19m2
0.37m2
400g
600g
1,000g
140E-5 Series
10 Structure, function and maintenance standard
SEN00082-06
Corrosion resistor mounting
a a
The shape is subject to machine models. Corrosion resistor is not set for some models.
1. Tube (return from corrosion resistor) 2. Corrosion resistor head 3. Corrosion resistor cartridge 4. Tube (to corrosion resistor)
140E-5 Series
59
SEN00082-06
10 Structure, function and maintenance standard
Cooling fan drive
1
Mounting (Adjustment bolt type) SAA6D140E-5 [HD325-7, HD405-7, HM350-2, HM400-2, HD325-7R, HD405-7R, HM350-2R, HM400-2R, SDG400S-6B1 (HOKUETSU INDUSTRIES GENERATOR)]
a
The shape is subject to machine models.
1. Crankshaft pulley 2. Tension pulley 3. Adjustment bolt
4. Fan belt 5. Fan pulley
Outside diameter of pulley Unit: mm Engine
SAA6D140E-5
60
Machine model
Crankshaft pulley
Tension pulley
Fan pulley
HD325-7, HD405-7, HD325-7R, HD405-7R
166
120
322
HM350-2, HM350-2R
166
120
262
HM400-2, HM400-2R
166
120
262
SDG400S-6B1 (HOKUETSU INDUSTRIES GENERATOR)
203
120
277
140E-5 Series
10 Structure, function and maintenance standard
SEN00082-06
Tension pulley SAA6D140E-5 [HD325-7, HD405-7, HM350-2, HM400-2, HD325-7R, HD405-7R, HM350-2R, HM400-2R, SDG400S-6B1 (HOKUETSU INDUSTRIES GENERATOR)]
a
The shape is subject to machine models.
1. Tension pulley 2. Spacer 3. Ball bearing 4. Tension shaft 5. Oil seal 6. Adjustment bolt 7. Bracket
140E-5 Series
61
SEN00082-06
10 Structure, function and maintenance standard
Fan mounting case SAA6D140E-5 [HD325-7, HD405-7, HM350-2, HM400-2, HD325-7R, HD405-7R, HM350-2R, HM400-2R, SDG400S-6B1 (HOKUETSU INDUSTRIES GENERATOR)]
a
The shape is subject to machine models.
1. Fan pulley hub 2. Ball bearing 3. Shaft 4. Case
62
140E-5 Series
10 Structure, function and maintenance standard
SEN00082-06
Accessories
1
Front PTO
1
a
The shape is subject to machine models.
1. Shaft 2. Pulley 3. Oil seal 4. Bearing (2 pieces) 5. Housing 6. O-ring 7. Gear (Number of teeth: 14) 8. Snap ring 9. Sleeve
140E-5 Series
63
SEN00082-06
10 Structure, function and maintenance standard
Front PTO mounting
a
The shape is subject to machine models.
1. Front PTO (for driving air conditioner compressor) 2. O-ring
64
140E-5 Series
10 Structure, function and maintenance standard
SEN00082-06
Electrical equipment
1
Alternator
1
1. Alternator with built-in regulator (open type, 35 A)
a
The shape is subject to machine models.
1. Alternator 2. Alternator pulley 3. Terminal B 4. Terminal E 5. Terminal R
140E-5 Series
6. Internal electric circuit diagram 6A. Field coil 6B. Regulator
65
SEN00082-06
10 Structure, function and maintenance standard
2. Alternator with built-in regulator (open type, 50 A)
a
The shape is subject to machine models.
1. Alternator 2. Alternator pulley 3. Terminal B 4. Terminal E 5. Terminal R
66
6. Internal electric circuit diagram 6A. Field coil 6B. Initial excitation resistor 6C. Regulator
140E-5 Series
10 Structure, function and maintenance standard
SEN00082-06
3. Alternator with built-in regulator (open type, 50 A)
a
The shape is subject to machine models.
1. Alternator 2. Alternator pulley 3. Terminal B 4. Terminal E 5. Terminal R
140E-5 Series
6. Internal electric circuit diagram 6A. Stator 6B. Regulator
67
SEN00082-06
10 Structure, function and maintenance standard
4. Alternator with built-in regulator (open type, 60 A)
a
The shape is subject to machine models.
1. Alternator 2. Alternator pulley 3. Terminal B 4. Terminal E 5. Terminal R
68
6. Internal electric circuit diagram 6A. Field coil 6B. Initial excitation resistor 6C. Regulator
140E-5 Series
10 Structure, function and maintenance standard
Engine
Machine model
Type
Specification
Open type (brushless) manufactured by NIKKO DENKI
24V, 60A
PC800-8, PC800LC-8, PC800-8R, PC800LC-8R, PC800SE-8, PC800SE-8R PC850-8, PC850-8R, PC850SE-8, PC850SE-8R Open type (brushless) PC800-8E0, PC800SE-8E0, manufactured by NIKKO DENKI PC850-8E0, PC850SE-8E0, PC800LC-8E0 PC800-8R1, PC800SE-8R1 PC850-8R1, PC850SE-8R1 PC800LC-8R1
24V, 60A
D155AX-6, D155A-6
Open type (brushless) manufactured by NIKKO DENKI
24V, 60A
HD325-7, HD325-7R HD405-7, HD405-7R
Open type (brushless) manufactured by NIKKO DENKI
24V, 60A
HM350-2, HM350-2R HM400-2, HM400-2R HM400-3M0, HM400-3R
Open type (brushless) manufactured by NIKKO DENKI
24V, 60A
PC600-8, PC600LC-8, PC600-8R, PC600LC-8R, PC600-8E0, PC600LC-8E0, PC600-8R1, PC600LC-8R1, PC700-8E0, PC700LC-8E0, PC700-8R, PC700LC-8R, PC700LC-8R1
SAA6D140E-5
SEN00082-06
140E-5 Series
Outside diameter Weight (kg) of pulley (mm)
69
SEN00082-06
10 Structure, function and maintenance standard
5. Alternator with built-in regulator (open type, 75 A)
a
The shape is subject to machine models.
1. Alternator 2. Alternator pulley 3. Terminal B 4. Terminal E 5. Terminal R Engine
SAA6D140E-5
70
Machine model
6. Internal electric circuit diagram 6A. Stator 6B. Regulator
Type
Specification
D155AX-6, D155A-6 (If equipped)
Open type (brushless) manufactured by SAWAFUJI DENKI
24V, 75A
D275AX-5E0, D275A-5R
Open type (brushless) manufactured by SAWAFUJI DENKI
24V, 75A
WA500-6, WA500-6R
Open type (brushless) manufactured by SAWAFUJI DENKI
24V, 75A
HD325-7, HD325-7R HD405-7, HD405-7R (If equipped)
Open type (brushless) manufactured by SAWAFUJI DENKI
24V, 75A
HM350-2, HM350-2R Open type (brushless) manufactured HM400-2, HM400-2R HM400-3M0, HM400-3R by SAWAFUJI DENKI (If equipped)
24V, 75A
Outside diameter of pulley (mm)
Weight (kg)
140E-5 Series
10 Structure, function and maintenance standard
140E-5 Series
SEN00082-06
71
SEN00082-06
10 Structure, function and maintenance standard
6. Alternator with built-in regulator (open type, 90 A)
a
The shape is subject to machine models.
1. Alternator 2. Alternator pulley 3. Terminal B 4. Terminal E 5. Terminal R
72
6. Internal electric circuit diagram 6A. Field coil 6B. Initial excitation resistor 6C. Regulator
140E-5 Series
10 Structure, function and maintenance standard
Engine
SAA6D140E-5
Machine model PC600-8, PC600LC-8, PC600-8R, PC600LC-8R, PC600-8E0, PC600LC-8E0, PC600-8R1, PC600LC-8R1, PC700-8E0, PC700LC-8E0, PC700-8R, PC700LC-8R, PC700LC-8R1 (If equipped) PC800-8, PC800LC-8, PC800-8R, PC800LC-8R, PC800SE-8, PC800SE-8R PC850-8, PC850-8R PC850SE-8, PC850SE-8R PC800-8E0, PC800SE-8E0, PC850-8E0, PC850SE-8E0, PC800LC-8E0 PC800-8R1, PC800SE-8R1 PC850-8R1, PC850SE-8R1 PC800LC-8R1 (If equipped) D155AX-6, D155A-6 (If equipped) D275AX-5E0, D275A-5R (If equipped) WA500-6, WA500-6R (If equipped)
140E-5 Series
SEN00082-06
Type
Specification
Open type (brushless) manufactured by NIKKO DENKI
24V, 90A
Open type (brushless) manufactured by NIKKO DENKI
24V, 90A
Open type (brushless) manufactured by NIKKO DENKI Open type (brushless) manufactured by NIKKO DENKI Open type (brushless) manufactured by NIKKO DENKI
Outside diameter Weight (kg) of pulley (mm)
24V, 90A 24V, 90A 24V, 90A
73
SEN00082-06
10 Structure, function and maintenance standard
Alternator mounting
a
The shape is subject to machine models.
a: Outside diameter of alternator pulley: 85 mm b: Outside diameter of alternator drive pulley: 132 mm 1. Alternator 2. Adjustment rod 3. Nut (2 pieces) 4. Plate 5. Cover 6. V-belt (2 pieces) 7. Spacer
74
140E-5 Series
10 Structure, function and maintenance standard
140E-5 Series
SEN00082-06
75
SEN00082-06
10 Structure, function and maintenance standard
Starting motor
1
For 7.5kW (for SDG400S-6B1 (HOKUETSU INDUSTRIES GENERATOR))
a
The shape is subject to machine models.
E: To chassis ground R: To alternator terminal R S: To starting switch terminal C
5. Terminal C 6. Safety relay 7. External connection diagram (2-pole connector type) 7A. Safety relay section 7B. Starting motor section 8. Jump start prohibition label 9. Jump start prevention cover
1. Pinion gear 2. Starting motor assembly 3. Magnetic switch 4. Terminal B Engine
Machine model
SDG400S-6B1 (HOKUETSU SAA6D140E-5 INDUSTRIES GENERATOR)
76
Type
Specification
Number of pinion teeth
Weight (kg)
Type of connector
Water-resistant, oil-resistant type manufactured by NIKKO DENKI
24V, 7.5kW
12
15.5
DT
140E-5 Series
10 Structure, function and maintenance standard
SEN00082-06
For 11kW (except SDG400S-6B1 (HOKUETSU INDUSTRIES GENERATOR))
a
The shape is subject to machine models.
E: To chassis ground R: To alternator terminal R S: To starting switch terminal C
5. Terminal C 6. Safety relay 7. External connection diagram (2-pole connector type) 7A. Safety relay section 7B. Starting motor section 8. Jump start prohibition label 9. Jump start prevention cover
1. Pinion gear 2. Starting motor assembly 3. Magnetic switch 4. Terminal B Engine SAA6D140E-5
Machine model All machines
140E-5 Series
Type
Specification
Number of pinion teeth
Weight (kg)
Type of connector
Water-resistant, oil-resistant type manufactured by NIKKO DENKI
24V, 11kW
12
18
DT
77
SEN00082-06
Starting aid
10 Structure, function and maintenance standard
1
Electric heater For SAA6D140E-5
a
The shape is subject to machine models.
1. Body 2. Heater coil 3. Terminal 4. Connection diagram
78
Specifications Type of heater: Electrical intake air heater q Rated voltage: 22 V (DC) q Load current: 175 A
140E-5 Series
10 Structure, function and maintenance standard
Engine controller
SEN00082-06
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. Unified specifications of engine controller Engine controller CM850 developed by the cooperation between KOMATSU and CUMMINS is employed.
q
140E-5 Series
79
SEN00082-06
KOMATSU 140E-5 Series engine Form No. SEN00082-06
© 2012 KOMATSU All Rights Reserved Printed in Japan 12-12 (01)
80
SEN00147-07
ENGINE 1SHOP MANUAL
140E-5 Series
20 Standard value table
1
Standard service value table Standard service value table for testing, adjusting, and troubleshooting ........................................................ 2 Running-in standard and performance test standard.................................................................................... 19
140E-5 Series
1
SEN00147-07
20 Standard value table
Air intake and exhaust system
Performance Category
Standard service value table for testing, adjusting, and troubleshooting
Body Lubrication system Cooling system
SAA6D140E-5
Machine models
D155AX-6 Unit
Standard value for new machine
Repair limit
Max. speed with no load
rpm
2,100(0/–50)
2,100(0/–50)
Min. speed with no load
rpm
740(+40/0)
740(+40/0)
Necessary speed for starting
At 0°C (without starting aid)
rpm
Min. 110
—
At –20°C (with starting aid)
rpm
Min. 85
—
Air intake resistance
Whole speed range
kPa {mmH2O}
Max. 3.73 {Max. 380}
7.47 {762}
Air boost pressure
At rated horsepower
kPa {mmHg}
Min. 117 {Min. 880}
100 {750}
Exhaust pressure
At rated horsepower
kPa {mmHg}
Min. 127 {Min. 950}
108 {810}
Exhaust temperature
Whole speed range (20°C)
°C
660
700
% (Bosch index)
Max. 25 (Max. 2.5)
35 (3.5)
At rated horsepower
Bosch index
Max. 1.5
2.5
At high idle
Bosch index
Max. 1.0
2.0
Intake valve
mm
0.35
—
Exhaust valve
mm
0.57
—
At low idle
MPa {kg/cm2}
Min. 1.18 {Min. 12}
Min. 1.18 {Min. 12}
At high idle
MPa {kg/cm2}
Min. 1.43 {Min. 14.6}
Min. 1.43 {Min. 14.6}
Compression pressure
Engine oil temperature: 40 to 60°C Engine speed: 200 to 250 rpm
MPa {kg/cm2}
Min. 4.1 {Min. 42}
2.8 {29}
Blow-by pressure
At rated horsepower Engine coolant temperature: Min. 70°C
kPa {mmH2O}
Max. 2.94 {Max. 300}
3.92 {400}
Min. 0.34 {Min. 3.5}
0.21 {2.1}
Oil pressure
At rated horsepower MPa Engine oil temperature: SAE0W30EOS 2 } {kg/cm SAE5W40EOS Min. 80°C SAE10W30DH At low idle SAE15W40DH MPa Engine oil temperature: SAE30DH {kg/cm2} Min. 80°C
Min. 0.10 {Min. 1.0}
0.08 {0.8}
Item
Speed
Measurement conditions
At sudden acceleration (Low High) Exhaust gas color
Valve clearance
EGR valve and bypass valve drive oil pressure
2
Engine
Oil temperature
Whole speed range
°C
90 to 110
120
Oil consumption
Ratio to fuel consumption at continuous rated horsepower
%
Max. 0.15
0.3
Function of radiator pressure valve
Cracking pressure (Differential pressure)
kPa {kg/cm2}
—
—
Fan speed
At rated speed
rpm
Hydraulically driven on machine side
Fan belt tension
Deflection under finger pressure of 98 N {10 kg}
mm
Hydraulically driven on machine side
Alternator belt tension
Deflection under finger pressure of 98 N {10 kg}
mm
13 to 16
13 to 16
140E-5 Series
Air intake and exhaust system
Performance Category
20 Standard value table
Body Lubrication system
Engine
SAA6D140E-5
Machine models
D155A-6 Unit
Standard value for new machine
Repair limit
Max. speed with no load
rpm
2,100(0/–50)
2,100(0/–50)
Min. speed with no load
rpm
740(+40/0)
740(+40/0)
Necessary speed for starting
At 0°C (without starting aid)
rpm
Min. 110
—
At –20°C (with starting aid)
rpm
Min. 85
—
Air intake resistance
Whole speed range
kPa {mmH2O}
Max. 3.73 {Max. 380}
7.47 {762}
Air boost pressure
At rated horsepower
kPa {mmHg}
Min. 85 {Min. 640}
72 {540}
Exhaust pressure
At rated horsepower
kPa {mmHg}
Min. 92 {Min. 690}
77 {580}
Exhaust temperature
Whole speed range (20°C)
°C
670
720
% (Bosch index)
Max. 30 (Max. 3.0)
40 (4.0)
At rated horsepower
Bosch index
Max. 1.5
2.5
At high idle
Bosch index
Max. 1.0
2.0
Item
Speed
Measurement conditions
At sudden acceleration (Low High) Exhaust gas color
Valve clearance
Cooling system
SEN00147-07
Intake valve
mm
0.35
—
Exhaust valve
mm
0.57
—
Compression pressure
Engine oil temperature: 40 to 60°C Engine speed: 200 to 250 rpm
MPa {kg/cm2}
Min. 4.1 {Min. 42}
2.8 {29}
Blow-by pressure
At rated horsepower Engine coolant temperature: Min. 70°C
kPa {mmH2O}
Max. 2.94 {Max. 300}
3.92 {400}
Min. 0.34 {Min. 3.5}
0.21 {2.1}
Oil pressure
At rated horsepower MPa Engine oil temperature: SAE0W30EOS {kg/cm2} SAE5W40EOS Min. 80°C SAE10W30DH At low idle SAE15W40DH MPa Engine oil temperature: SAE30DH {kg/cm2} Min. 80°C
Min. 0.10 {Min. 1.0}
0.08 {0.8}
Oil temperature
Whole speed range
°C
90 to 110
120
Oil consumption
Ratio to fuel consumption at continuous rated horsepower
%
Max. 0.15
0.3
Function of radiator pressure valve
Cracking pressure (Differential pressure)
kPa {kg/cm2}
—
—
Fan speed
At rated speed
rpm
Hydraulically driven on machine side
Fan belt tension
Deflection under finger pressure of 98 N {10 kg}
mm
Hydraulically driven on machine side
Alternator belt tension
Deflection under finger pressure of 98 N {10 kg}
mm
140E-5 Series
13 to 16
13 to 16
3
Air intake and exhaust system
Performance Category
SEN00147-07
Body Lubrication system Cooling system
Engine
SAA6D140E-5
Machine models
D275AX-5E0 Unit
Standard value for new machine
Repair limit
rpm
2,200 ± 50
2,200 ± 50
Min. speed with no load
rpm
700 ± 50
700 ± 50
Necessary speed for starting
At 0°C (without starting aid)
rpm
Min. 110
—
At –20°C (with starting aid)
rpm
Min. 85
—
Air intake resistance
Whole speed range
kPa {mmH2O}
Max. 3.73 {Max. 380}
7.47 {762}
Air boost pressure
At rated horsepower
kPa {mmHg}
Min. 169 {Min. 1,270}
144 {1,080}
Exhaust pressure
At rated horsepower
kPa {mmHg}
Min. 169 {Min. 1,270}
144 {1,080}
Exhaust temperature
Whole speed range (20°C)
Item
Speed
Measurement conditions Max. speed with no load
°C
Max. 620
670
% (Bosch index)
Max. 25 (Max. 2.5)
35 (3.5)
At rated horsepower
Bosch index
Max. 1.5
2.5
At high idle
Bosch index
Max. 1.0
2.0
Intake valve
mm
0.35
—
At sudden acceleration (Low High) Exhaust gas color
Valve clearance
mm
0.57
—
At low idle
MPa {kg/cm2}
Min. 1.18 {Min. 12}
Min. 1.18 {Min. 12}
At high idle
MPa {kg/cm2}
Min. 1.43 {Min. 14.6}
Min. 1.43 {Min. 14.6}
Compression pressure
Engine oil temperature: 40 to 60°C Engine speed: 200 to 250 rpm
MPa {kg/cm2}
Min. 4.1 {Min. 42}
2.8 {29}
Blow-by pressure
At rated horsepower Engine coolant temperature: Min. 70°C
kPa {mmH2O}
Max. 2.94 {Max. 300}
3.92 {400}
Min. 0.34 {Min. 3.5}
0.21 {2.1}
Oil pressure
At rated horsepower SAE0W30EOS MPa Engine oil temperature: {kg/cm2} SAE5W40EOS Min. 80°C SAE10W30DH At low idle SAE15W40DH MPa Engine oil temperature: SAE30DH {kg/cm2} Min. 80°C
Min. 0.10 {Min. 1.0}
0.08 {0.8}
EGR valve and bypass valve drive oil pressure
4
20 Standard value table
Exhaust valve
Oil temperature
Whole speed range
°C
90 to 110
120
Oil consumption
Ratio to fuel consumption at continuous rated horsepower
%
Max. 0.15
0.3
Function of radiator pressure valve
Cracking pressure (Differential pressure)
kPa {kg/cm2}
—
—
Fan speed
At rated speed
rpm
Hydraulically driven on machine side
Fan belt tension
Deflection under finger pressure of 98 N {10 kg}
mm
Hydraulically driven on machine side
Alternator belt tension
Deflection under finger pressure of 98 N {10 kg}
mm
13 to 16
13 to 16
140E-5 Series
Air intake and exhaust system
Performance Category
20 Standard value table
Body Lubrication system
Engine
SAA6D140E-5
Machine models
D275A-5R Unit
Standard value for new machine
Repair limit
Max. speed with no load
rpm
2,200 ± 50
2,200 ± 50
Min. speed with no load
rpm
700 ± 50
700 ± 50
Necessary speed for starting
At 0°C (without starting aid)
rpm
Min. 110
—
At –20°C (with starting aid)
rpm
Min. 85
—
Air intake resistance
Whole speed range
kPa {mmH2O}
Max. 3.73 {Max. 380}
7.47 {762}
Air boost pressure
At rated horsepower
kPa {mmHg}
Min. 116 {Min. 870}
99 {740}
Exhaust pressure
At rated horsepower
kPa {mmHg}
Min. 116 {Min. 870}
99 {740}
Exhaust temperature
Whole speed range (20°C)
°C
Max. 670
720
% (Bosch index)
Max. 40 (Max. 4.0)
50 (5.0)
At rated horsepower
Bosch index
Max. 1.5
2.5
At high idle
Bosch index
Max. 1.0
2.0
Intake valve
mm
0.35
—
Exhaust valve
mm
0.57
—
Item
Speed
Measurement conditions
At sudden acceleration (Low High) Exhaust gas color
Valve clearance
Cooling system
SEN00147-07
Compression pressure
Engine oil temperature: 40 to 60°C Engine speed: 200 to 250 rpm
MPa {kg/cm2}
Min. 4.1 {Min. 42}
2.8 {29}
Blow-by pressure
At rated horsepower Engine coolant temperature: Min. 70°C
kPa {mmH2O}
Max. 2.94 {Max. 300}
3.92 {400}
Min. 0.34 {Min. 3.5}
0.21 {2.1}
Oil pressure
At rated horsepower SAE0W30EOS MPa Engine oil temperature: {kg/cm2} SAE5W40EOS Min. 80°C SAE10W30DH At low idle SAE15W40DH MPa Engine oil temperature: SAE30DH {kg/cm2} Min. 80°C
Min. 0.10 {Min. 1.0}
0.08 {0.8}
Oil temperature
Whole speed range
°C
90 to 110
120
Oil consumption
Ratio to fuel consumption at continuous rated horsepower
%
Max. 0.15
0.3
Function of radiator pressure valve
Cracking pressure (Differential pressure)
kPa {kg/cm2}
—
—
Fan speed
At rated speed
rpm
Hydraulically driven on machine side
Fan belt tension
Deflection under finger pressure of 98 N {10 kg}
mm
Hydraulically driven on machine side
Alternator belt tension
Deflection under finger pressure of 98 N {10 kg}
mm
140E-5 Series
13 to 16
13 to 16
5
Air intake and exhaust system
Performance Category
SEN00147-07
Item
Speed Necessary speed for starting
Body Lubrication system Cooling system
Engine
SAA6D140E-5
Machine models
PC600-8, PC600LC-8 PC600-8E0, PC600LC-8E0 PC700-8E0, PC700LC-8E0 Unit
Standard value for new machine
Repair limit
Max. speed with no load
rpm
1,950 ± 50
1,950 ± 50
Min. speed with no load
rpm
800 ± 25
800 ± 25
At 0°C (without starting aid)
rpm
Min. 110
—
Measurement conditions
At –20°C (with starting aid)
rpm
Min. 85
—
Max. 3.73 {Max. 380}
7.47 {762}
Air intake resistance
Whole speed range
kPa {mmH2O}
Air boost pressure
At rated horsepower
kPa {mmHg}
Min. 147 {Min. 1,100}
125 {940}
Exhaust pressure
At rated horsepower
kPa {mmHg}
Min. 145 {Min. 1,090}
128 {930}
Exhaust temperature
Whole speed range (20°C)
°C
Max. 650
700
% (Bosch index)
Max. 25 (Max. 2.5)
35 (3.5)
At rated horsepower
Bosch index
Max. 1.5
2.5
At high idle
Bosch index
Max. 1.0
2.0
Intake valve
mm
0.35
—
Exhaust valve
mm
0.57
—
At low idle
MPa {kg/cm2}
Min. 1.18 {Min. 12}
Min. 1.18 {Min. 12}
At high idle
MPa {kg/cm2}
Min. 1.43 {Min. 14.6}
Min. 1.43 {Min. 14.6}
Compression pressure
Engine oil temperature: 40 to 60°C Engine speed: 200 to 250 rpm
MPa {kg/cm2}
Min. 4.1 {Min. 42}
2.8 {29}
Blow-by pressure
At rated horsepower Engine coolant temperature: Min. 70°C
kPa {mmH2O}
Max. 2.94 {Max. 300}
3.92 {400}
Min. 0.34 {Min. 3.5}
0.21 {2.1}
Oil pressure
At rated horsepower SAE0W30EOS MPa Engine oil temperature: {kg/cm2} SAE5W40EOS Min. 80°C SAE10W30DH At low idle SAE15W40DH MPa Engine oil temperature: {kg/cm2} SAE30DH Min. 80°C
Min. 0.10 {Min. 1.0}
0.08 {0.8}
At sudden acceleration (Low High) Exhaust gas color
Valve clearance
EGR valve and bypass valve drive oil pressure
6
20 Standard value table
Oil temperature
Whole speed range
°C
90 to 110
120
Oil consumption
Ratio to fuel consumption at continuous rated horsepower
%
Max. 0.15
0.3
Function of radiator pressure valve
Cracking pressure (Differential pressure)
kPa {kg/cm2}
—
—
Fan speed
At rated speed
rpm
Hydraulically driven on machine side
Fan belt tension
Deflection under finger pressure of 98 N {10 kg}
mm
Hydraulically driven on machine side
Alternator belt tension
Deflection under finger pressure of 98 N {10 kg}
mm
13 to 16
13 to 16
140E-5 Series
Air intake and exhaust system
Performance Category
20 Standard value table
Body Lubrication system
Engine
SAA6D140E-5
Machine models
PC600-8R, PC600LC-8R, PC600-8R1, PC600LC-8R1, PC700-8R, PC700LC-8R, PC700LC-8R1 Unit
Standard value for new machine
Repair limit
rpm
1,950 ± 50
1,950 ± 50
Min. speed with no load
rpm
800 ± 25
800 ± 25
Necessary speed for starting
At 0°C (without starting aid)
rpm
Min. 110
—
At –20°C (with starting aid)
rpm
Min. 85
—
Air intake resistance
Whole speed range
kPa {mmH2O}
Max. 3.73 {Max. 380}
7.47 {762}
Air boost pressure
At rated horsepower
kPa {mmHg}
Min. 120 {Min. 900}
102 {760}
Exhaust pressure
At rated horsepower
kPa {mmHg}
Min. 116 {Min. 870}
99 {740}
Exhaust temperature
Whole speed range (20°C)
°C
Max. 700
750
% (Bosch index)
Max. 30 (Max. 3.0)
40 (4.0)
At rated horsepower
Bosch index
Max. 1.5
2.5
At high idle
Bosch index
Max. 1.0
2.0
Item
Speed
Measurement conditions Max. speed with no load
At sudden acceleration (Low High) Exhaust gas color
Valve clearance
Cooling system
SEN00147-07
Intake valve
mm
0.35
—
Exhaust valve
mm
0.57
—
Compression pressure
Engine oil temperature: 40 to 60°C Engine speed: 200 to 250 rpm
MPa {kg/cm2}
Min. 4.1 {Min. 42}
2.8 {29}
Blow-by pressure
At rated horsepower Engine coolant temperature: Min. 70°C
kPa {mmH2O}
Max. 2.94 {Max. 300}
3.92 {400}
Min. 0.34 {Min. 3.5}
0.21 {2.1}
Oil pressure
At rated horsepower SAE0W30EOS MPa Engine oil temperature: {kg/cm2} SAE5W40EOS Min. 80°C SAE10W30DH At low idle SAE15W40DH MPa Engine oil temperature: SAE30DH {kg/cm2} Min. 80°C
Min. 0.10 {Min. 1.0}
0.08 {0.8}
Oil temperature
Whole speed range
°C
90 to 110
120
Oil consumption
Ratio to fuel consumption at continuous rated horsepower
%
Max. 0.15
0.3
Function of radiator pressure valve
Cracking pressure (Differential pressure)
kPa {kg/cm2}
—
—
Fan speed
At rated speed
rpm
Hydraulically driven on machine side
Fan belt tension
Deflection under finger pressure of 98 N {10 kg}
mm
Hydraulically driven on machine side
Alternator belt tension
Deflection under finger pressure of 98 N {10 kg}
mm
140E-5 Series
13 to 16
13 to 16
7
Air intake and exhaust system
Performance Category
SEN00147-07
Body Lubrication system Cooling system
Engine
SAA6D140E-5
Machine models
PC800-8, PC800SE-8, PC800LC-8 PC850-8, PC850SE-8 PC800-8E0, PC800SE-8E0, PC800LC-8E0 PC850-8E0, PC850SE-8E0 Unit
Standard value for new machine
Repair limit
rpm
1,980 ± 50
1,980 ± 50
Min. speed with no load
rpm
825 ± 25
825 ± 25
Necessary speed for starting
At 0°C (without starting aid)
rpm
Min. 110
—
At –20°C (with starting aid)
rpm
Min. 85
—
Air intake resistance
Whole speed range
kPa {mmH2O}
Max. 3.73 {Max. 380}
7.47 {762}
Air boost pressure
At rated horsepower
kPa {mmHg}
Min. 184 {Min. 1,380}
157 {1,180}
Exhaust pressure
At rated horsepower
kPa {mmHg}
Min. 172 {Min. 1,290}
147 {1,100}
Exhaust temperature
Whole speed range (20°C)
°C
Max. 650
700
% (Bosch index)
Max. 25 (Max. 2.5)
35 (3.5)
At rated horsepower
Bosch index
Max. 1.5
2.5
At high idle
Bosch index
Max. 1.0
2.0
Intake valve
mm
0.35
—
Exhaust valve
mm
0.57
—
At low idle
MPa {kg/cm2}
Min. 1.18 {Min. 12}
Min. 1.18 {Min. 12}
At high idle
MPa {kg/cm2}
Min. 1.43 {Min. 14.6}
Min. 1.43 {Min. 14.6}
Compression pressure
Engine oil temperature: 40 to 60°C Engine speed: 200 to 250 rpm
MPa {kg/cm2}
Min. 4.1 {Min. 42}
2.8 {29}
Blow-by pressure
At rated horsepower kPa Engine coolant temperature: Min. 70°C {mmH2O}
Max. 2.94 {Max. 300}
3.92 {400}
Min. 0.34 {Min. 3.5}
0.21 {2.1}
Oil pressure
At rated horsepower SAE0W30EOS MPa Engine oil temperature: SAE5W40EOS {kg/cm2} Min. 80°C SAE10W30DH At low idle SAE15W40DH MPa Engine oil temperature: 2 } {kg/cm SAE30DH Min. 80°C
Min. 0.10 {Min. 1.0}
0.08 {0.8}
Item
Speed
Measurement conditions Max. speed with no load
At sudden acceleration (Low High) Exhaust gas color
Valve clearance
EGR valve and bypass valve drive oil pressure
8
20 Standard value table
Oil temperature
Whole speed range
°C
90 to 110
120
Oil consumption
Ratio to fuel consumption at continuous rated horsepower
%
Max. 0.15
Max. 0.3
Function of radiator pressure valve
Cracking pressure (Differential pressure)
kPa {kg/cm2}
—
—
Fan speed
At rated speed
rpm
Hydraulically driven on machine side
Fan belt tension
Deflection under finger pressure of 98 N {10 kg}
mm
Hydraulically driven on machine side
Alternator belt tension
Deflection under finger pressure of 98 N {10 kg}
mm
13 to 16
13 to 6
140E-5 Series
Air intake and exhaust system
Performance Category
20 Standard value table
Body Lubrication system
Engine
SAA6D140E-5
Machine models
PC800-8R, PC800SE-8R, PC800LC-8R PC850-8R, PC850SE-8R PC800-8R1, PC800SE-8R1, PC800LC-8R1, PC850-8R1, PC850SE-8R1 Unit
Standard value for new machine
Repair limit
Max. speed with no load
rpm
1,980 ± 50
1,980 ± 50
Min. speed with no load
rpm
825 ± 25
825 ± 25
Necessary speed for starting
At 0°C (without starting aid)
rpm
Min. 110
—
At –20°C (with starting aid)
rpm
Min. 85
—
Air intake resistance
Whole speed range
kPa {mmH2O}
Max. 3.73 {Max. 380}
7.47 {762}
Air boost pressure
At rated horsepower
kPa {mmHg}
Min. 128 {Min. 960}
108 {810}
Exhaust pressure
At rated horsepower
kPa {mmHg}
Min. 113 {Min. 850}
96 {720}
Exhaust temperature
Whole speed range (20°C)
°C
Max. 700
750
% (Bosch index)
Max. 30 (Max. 3.0)
40 (4.0)
At rated horsepower
Bosch index
Max. 1.5
2.5
At high idle
Bosch index
Max. 1.0
2.0
Item
Speed
Measurement conditions
At sudden acceleration (Low High) Exhaust gas color
Valve clearance
Cooling system
SEN00147-07
Intake valve
mm
0.35
—
Exhaust valve
mm
0.57
—
MPa {kg/cm2}
Min. 4.1 {Min. 42}
2.8 {29}
Max. 2.94 {Max. 300}
3.92 {400}
Min. 0.34 {Min. 3.5}
0.21 {2.1}
Min. 0.10 {Min. 1.0}
0.08 {0.8}
Compression pressure
Engine oil temperature: 40 to 60°C Engine speed: 200 to 250 rpm
Blow-by pressure
At rated horsepower kPa Engine coolant temperature: Min. 70°C {mmH2O}
Oil pressure
At rated horsepower SAE0W30EOS MPa Engine oil temperature: SAE5W40EOS {kg/cm2} Min. 80°C SAE10W30DH At low idle SAE15W40DH MPa Engine oil temperature: {kg/cm2} SAE30DH Min. 80°C
Oil temperature
Whole speed range
°C
90 to 110
120
Oil consumption
Ratio to fuel consumption at continuous rated horsepower
%
Max. 0.15
Max. 0.3
Function of radiator pressure valve
Cracking pressure (Differential pressure)
kPa {kg/cm2}
—
—
Fan speed
At rated speed
rpm
Hydraulically driven on machine side
Fan belt tension
Deflection under finger pressure of 98 N {10 kg}
mm
Hydraulically driven on machine side
Alternator belt tension
Deflection under finger pressure of 98 N {10 kg}
mm
140E-5 Series
13 to 16
13 to 6
9
Air intake and exhaust system
Performance Category
SEN00147-07
Body Lubrication system Cooling system
Engine
SAA6D140E-5
Machine models
WA500-6 Unit
Standard value for new machine
Repair limit
Max. speed with no load
rpm
2,150 ± 50
2,150 ± 50
Min. speed with no load
rpm
700 ± 25
700 ± 25
Necessary speed for starting
At 0°C (without starting aid)
rpm
Min. 110
—
At –20°C (with starting aid)
rpm
Min. 85
—
Air intake resistance
Whole speed range
kPa {mmH2O}
Max. 3.73 {Max. 380}
7.47 {762}
Air boost pressure
At rated horsepower
kPa {mmHg}
Min. 116 {Min. 870}
89 {670}
Exhaust pressure
At rated horsepower
kPa {mmHg}
Min. 121 {Min. 910}
91 {680}
Exhaust temperature
Whole speed range (20°C)
°C
Max. 650
700
% (Bosch index)
Max. 25 (Max. 2.5)
35 (3.5)
At rated horsepower
Bosch index
Max. 1.5
2.5
At high idle
Bosch index
Max. 1.0
2.0
Intake valve
mm
0.35
—
Exhaust valve
mm
0.57
—
At low idle
MPa {kg/cm2}
Min. 1.18 {Min. 12}
Min. 1.18 {Min. 12}
At high idle
MPa {kg/cm2}
Min. 1.43 {Min. 14.6}
Min. 1.43 {Min. 14.6}
Compression pressure
Engine oil temperature: 40 to 60°C Engine speed: 200 to 250 rpm
MPa {kg/cm2}
Min. 4.1 {Min. 42}
2.8 {29}
Blow-by pressure
At rated horsepower kPa Engine coolant temperature: Min. 70°C {mmH2O}
Max. 2.94 {Max. 300}
3.92 {400}
Min. 0.34 {Min. 3.5}
0.21 {2.1}
Oil pressure
At rated horsepower MPa Engine oil temperature: SAE0W30EOS {kg/cm2} SAE5W40EOS Min. 80°C SAE10W30DH At low idle SAE15W40DH MPa Engine oil temperature: SAE30DH {kg/cm2} Min. 80°C
Min. 0.10 {Min. 1.0}
0.08 {0.8}
Item
Speed
Measurement conditions
At sudden acceleration (Low High) Exhaust gas color
Valve clearance
EGR valve and bypass valve drive oil pressure
10
20 Standard value table
Oil temperature
Whole speed range
°C
90 to 110
120
Oil consumption
Ratio to fuel consumption at continuous rated horsepower
%
Max. 0.15
0.3
Function of radiator pressure valve
Cracking pressure (Differential pressure)
kPa {kg/cm2}
—
—
Fan speed
At rated speed
rpm
Hydraulically driven on machine side
Fan belt tension
Deflection under finger pressure of 98 N {10 kg}
mm
Hydraulically driven on machine side
Alternator belt tension
Deflection under finger pressure of 98 N {10 kg}
mm
13 to 16
13 to 16
140E-5 Series
Air intake and exhaust system
Performance Category
20 Standard value table
Item
Speed Necessary speed for starting
Body Lubrication system
Engine
SAA6D140E-5
Machine models
WA500-6R Unit
Standard value for new machine
Repair limit
Max. speed with no load
rpm
2,150 ± 50
2,150 ± 50
Min. speed with no load
rpm
700 ± 25
700 ± 25
At 0°C (without starting aid)
rpm
Min. 110
—
At –20°C (with starting aid)
rpm
Min. 85
—
Measurement conditions
Air intake resistance
Whole speed range
kPa {mmH2O}
Max. 3.73 {Max. 380}
7.47 {762}
Air boost pressure
At rated horsepower
kPa {mmHg}
Min. 89 {Min. 670}
76 {570}
Exhaust pressure
At rated horsepower
kPa {mmHg}
Min. 101 {Min. 760}
85 {640}
Exhaust temperature
Whole speed range (20°C)
°C
Max. 670
720
% (Bosch index)
Max. 40 (Max. 4.0)
50 (5.0)
At rated horsepower
Bosch index
Max. 1.5
2.5
At high idle
Bosch index
Max. 1.0
2.0
Intake valve
mm
0.35
—
Exhaust valve
mm
0.57
—
At sudden acceleration (Low High) Exhaust gas color
Valve clearance
Cooling system
SEN00147-07
Compression pressure
Engine oil temperature: 40 to 60°C Engine speed: 200 to 250 rpm
MPa {kg/cm2}
Min. 4.1 {Min. 42}
2.8 {29}
Blow-by pressure
At rated horsepower Engine coolant temperature: Min. 70°C
kPa {mmH2O}
Max. 2.94 {Max. 300}
3.92 {400}
Min. 0.34 {Min. 3.5}
0.21 {2.1}
Oil pressure
At rated horsepower MPa Engine oil temperature: SAE0W30EOS 2 } {kg/cm SAE5W40EOS Min. 80°C SAE10W30DH At low idle SAE15W40DH MPa Engine oil temperature: SAE30DH {kg/cm2} Min. 80°C
Min. 0.10 {Min. 1.0}
0.08 {0.8}
Oil temperature
Whole speed range
°C
90 to 110
120
Oil consumption
Ratio to fuel consumption at continuous rated horsepower
%
Max. 0.15
0.3
Function of radiator pressure valve
Cracking pressure (Differential pressure)
kPa {kg/cm2}
—
—
Fan speed
At rated speed
rpm
Hydraulically driven on machine side
Fan belt tension
Deflection under finger pressure of 98 N {10 kg}
mm
Hydraulically driven on machine side
Alternator belt tension
Deflection under finger pressure of 98 N {10 kg}
mm
140E-5 Series
13 to 16
13 to 16
11
Air intake and exhaust system
Performance Category
SEN00147-07
Item
Speed Necessary speed for starting
Body Lubrication system Cooling system
Engine
SAA6D140E-5
Machine models
HD325-7 HD405-7 Unit
Standard value for new machine
Repair limit
Max. speed with no load
rpm
2,300 ± 25
2,300 ± 25
Min. speed with no load
rpm
725 ± 25
725 ± 25
At 0°C (without starting aid)
rpm
Min. 110
—
At –20°C (with starting aid)
rpm
Min. 85
—
Max. 3.73 {Max. 380}
7.47 {762}
Measurement conditions
Air intake resistance
Whole speed range
kPa {mmH2O}
Air boost pressure
At rated horsepower
kPa {mmHg}
Min. 183 {Min. 1,370}
156 {1,170}
Exhaust pressure
At rated horsepower
kPa {mmHg}
Min. 163 {Min. 1,220}
139 {1,040}
Exhaust temperature
Whole speed range (20°C)
°C
Max. 650
700
% (Bosch index)
Max. 25 (Max. 2.5)
35 (3.5)
At rated horsepower
Bosch index
Max. 1.5
2.5
At high idle
Bosch index
Max. 1.0
2.0
Intake valve
mm
0.35
—
Exhaust valve
mm
0.57
—
At low idle
MPa {kg/cm2}
Min. 1.18 {Min. 12}
Min. 1.18 {Min. 12}
At high idle
MPa {kg/cm2}
Min. 1.43 {Min. 14.6}
Min. 1.43 {Min. 14.6}
Compression pressure
Engine oil temperature: 40 to 60°C Engine speed: 200 to 250 rpm
MPa {kg/cm2}
Min. 4.1 {Min. 42}
2.8 {29}
Blow-by pressure
At rated horsepower kPa Engine coolant temperature: Min. 70°C {mmH2O}
Max. 2.94 {Max. 300}
3.92 {400}
Min. 0.34 {Min. 3.5}
0.21 {2.1}
Oil pressure
At rated horsepower SAE0W30EOS MPa Engine oil temperature: SAE5W40EOS {kg/cm2} Min. 80°C SAE10W30DH At low idle SAE15W40DH MPa Engine oil temperature: {kg/cm2} SAE30DH Min. 80°C
Min. 0.10 {Min. 1.0}
0.08 {0.8}
At sudden acceleration (Low High) Exhaust gas color
Valve clearance
EGR valve and bypass valve drive oil pressure
12
20 Standard value table
Oil temperature
Whole speed range
°C
90 to 110
120
Oil consumption
Ratio to fuel consumption at continuous rated horsepower
%
Max. 0.15
0.3
Function of radiator pressure valve
Cracking pressure (Differential pressure)
kPa {kg/cm2}
—
—
Fan speed
At rated speed
rpm
1,020 ± 30
1,020 ± 30
Fan belt tension
Deflection under finger pressure of 98 N {10 kg}
mm
13 to 15 (when new)
17 to 19 (when retightened)
Alternator belt tension
Deflection under finger pressure of 98 N {10 kg}
mm
13 to 16
13 to 16
140E-5 Series
Air intake and exhaust system
Performance Category
20 Standard value table
Item
Speed Necessary speed for starting
Body Lubrication system
Engine
SAA6D140E-5
Machine models
HD325-7R HD405-7R Unit
Standard value for new machine
Repair limit
Max. speed with no load
rpm
2,300 ± 25
2,300 ± 25
Min. speed with no load
rpm
725 ± 25
725 ± 25
At 0°C (without starting aid)
rpm
Min. 110
—
At –20°C (with starting aid)
rpm
Min. 85
—
Max. 3.73 {Max. 380}
7.47 {762}
Measurement conditions
Air intake resistance
Whole speed range
kPa {mmH2O}
Air boost pressure
At rated horsepower
kPa {mmHg}
Min. 135 {Min. 1,010}
115 {860}
Exhaust pressure
At rated horsepower
kPa {mmHg}
Min. 121 {Min. 910}
103 {770}
Exhaust temperature
Whole speed range (20°C)
°C
Max. 680
730
% (Bosch index)
Max. 40 (Max. 4.0)
50 (5.0)
At rated horsepower
Bosch index
Max. 1.5
2.5
At high idle
Bosch index
Max. 1.0
2.0
Intake valve
mm
0.35
—
Exhaust valve
mm
0.57
—
At sudden acceleration (Low High) Exhaust gas color
Valve clearance
Cooling system
SEN00147-07
Compression pressure
Engine oil temperature: 40 to 60°C Engine speed: 200 to 250 rpm
MPa {kg/cm2}
Min. 4.1 {Min. 42}
2.8 {29}
Blow-by pressure
At rated horsepower Engine coolant temperature: Min. 70°C
kPa {mmH2O}
Max. 2.94 {Max. 300}
3.92 {400}
Min. 0.34 {Min. 3.5}
0.21 {2.1}
Oil pressure
At rated horsepower SAE0W30EOS MPa Engine oil temperature: SAE5W40EOS {kg/cm2} Min. 80°C SAE10W30DH At low idle SAE15W40DH MPa Engine oil temperature: 2 } {kg/cm SAE30DH Min. 80°C
Min. 0.10 {Min. 1.0}
0.08 {0.8}
Oil temperature
Whole speed range
°C
90 to 110
120
Oil consumption
Ratio to fuel consumption at continuous rated horsepower
%
Max. 0.15
0.3
Function of radiator pressure valve
Cracking pressure (Differential pressure)
kPa {kg/cm2}
—
—
Fan speed
At rated speed
rpm
1,020 ± 30
1,020 ± 30
Fan belt tension
Deflection under finger pressure of 98 N {10 kg}
mm
13 to 15 (when new)
17 to 19 (when retightened)
Alternator belt tension
Deflection under finger pressure of 98 N {10 kg}
mm
13 to 16
13 to 16
140E-5 Series
13
Air intake and exhaust system
Performance Category
SEN00147-07
Body Lubrication system Cooling system
Engine
SAA6D140E-5
Machine models
HM350-2 Unit
Standard value for new machine
Repair limit
Max. speed with no load
rpm
2,200(+50/0)
2,200(+50/0)
Min. speed with no load
rpm
725 ± 25
725 ± 25
Necessary speed for starting
At 0°C (without starting aid)
rpm
Min. 110
—
At –20°C (with starting aid)
rpm
Min. 85
—
Air intake resistance
Whole speed range
kPa {mmH2O}
Max. 3.73 {Max. 380}
7.47 {762}
Air boost pressure
At rated horsepower
kPa {mmHg}
Min. 145 {Min. 1,090}
124 {930}
Exhaust pressure
At rated horsepower
kPa {mmHg}
Min. 148 {Min. 1,110}
127 {950}
Exhaust temperature
Whole speed range (20°C)
°C
Max. 620
670
% (Bosch index)
Max. 25 (Max. 2.5)
35 (3.5)
At rated horsepower
Bosch index
Max. 1.5
2.5
At high idle
Bosch index
Max. 1.0
2.0
Intake valve
mm
0.35
—
Exhaust valve
mm
0.57
—
At low idle
MPa {kg/cm2}
Min. 1.18 {Min. 12}
Min. 1.18 {Min. 12}
At high idle
MPa {kg/cm2}
Min. 1.43 {Min. 14.6}
Min. 1.43 {Min. 14.6}
Compression pressure
Engine oil temperature: 40 to 60°C Engine speed: 200 to 250 rpm
MPa {kg/cm2}
Min. 4.1 {Min. 42}
2.8 {29}
Blow-by pressure
At rated horsepower kPa Engine coolant temperature: Min. 70°C {mmH2O}
Max. 2.94 {Max. 300}
3.92 {400}
Min. 0.34 {Min. 3.5}
0.21 {2.1}
Oil pressure
At rated horsepower SAE0W30EOS MPa Engine oil temperature: SAE5W40EOS {kg/cm2} Min. 80°C SAE10W30DH At low idle SAE15W40DH MPa Engine oil temperature: {kg/cm2} SAE30DH Min. 80°C
Min. 0.10 {Min. 1.0}
0.08 {0.8}
Item
Speed
Measurement conditions
At sudden acceleration (Low High) Exhaust gas color
Valve clearance
EGR valve and bypass valve drive oil pressure
14
20 Standard value table
Oil temperature
Whole speed range
°C
90 to 110
120
Oil consumption
Ratio to fuel consumption at continuous rated horsepower
%
Max. 0.15
0.3
Function of radiator pressure valve
Cracking pressure (Differential pressure)
kPa {kg/cm2}
—
—
Fan speed
At rated speed
rpm
1,256 ± 38
1,256 ± 38
Fan belt tension
Deflection under finger pressure of 98 N {10 kg}
mm
13 to 15 (when new)
17 to 19 (when retightened)
Alternator belt tension
Deflection under finger pressure of 98 N {10 kg}
mm
13 to 16
13 to 16
140E-5 Series
Air intake and exhaust system
Performance Category
20 Standard value table
Body Lubrication system
Engine
SAA6D140E-5
Machine models
HM350-2R Unit
Standard value for new machine
Repair limit
Max. speed with no load
rpm
2,200(+50/0)
2,200(+50/0)
Min. speed with no load
rpm
725 ± 25
725 ± 25
Necessary speed for starting
At 0°C (without starting aid)
rpm
Min. 110
—
At –20°C (with starting aid)
rpm
Min. 85
—
Air intake resistance
Whole speed range
kPa {mmH2O}
Max. 3.73 {Max. 380}
7.47 {762}
Air boost pressure
At rated horsepower
kPa {mmHg}
Min. 98 {Min. 730}
83 {620}
Exhaust pressure
At rated horsepower
kPa {mmHg}
Min. 104 {Min. 780}
88 {660}
Exhaust temperature
Whole speed range (20°C)
°C
Max. 670
720
% (Bosch index)
Max. 40 (Max. 4.0)
50 (5.0)
At rated horsepower
Bosch index
Max. 1.5
2.5
At high idle
Bosch index
Max. 1.0
2.0
Intake valve
mm
0.35
—
Exhaust valve
mm
0.57
—
Item
Speed
Measurement conditions
At sudden acceleration (Low High) Exhaust gas color
Valve clearance
Cooling system
SEN00147-07
Compression pressure
Engine oil temperature: 40 to 60°C Engine speed: 200 to 250 rpm
MPa {kg/cm2}
Min. 4.1 {Min. 42}
2.8 {29}
Blow-by pressure
At rated horsepower Engine coolant temperature: Min. 70°C
kPa {mmH2O}
Max. 2.94 {Max. 300}
3.92 {400}
Min. 0.34 {Min. 3.5}
0.21 {2.1}
Oil pressure
At rated horsepower SAE0W30EOS MPa Engine oil temperature: {kg/cm2} SAE5W40EOS Min. 80°C SAE10W30DH At low idle SAE15W40DH MPa Engine oil temperature: {kg/cm2} SAE30DH Min. 80°C
Min. 0.10 {Min. 1.0}
0.08 {0.8}
Oil temperature
Whole speed range
°C
90 to 110
120
Oil consumption
Ratio to fuel consumption at continuous rated horsepower
%
Max. 0.15
0.3
Function of radiator pressure valve
Cracking pressure (Differential pressure)
kPa {kg/cm2}
—
—
Fan speed
At rated speed
rpm
1,256 ± 38
1,256 ± 38
Fan belt tension
Deflection under finger pressure of 98 N {10 kg}
mm
13 to 15 (when new)
17 to 19 (when retightened)
Alternator belt tension
Deflection under finger pressure of 98 N {10 kg}
mm
13 to 16
13 to 16
140E-5 Series
15
Air intake and exhaust system
Performance Category
SEN00147-07
Body Lubrication system Cooling system
Engine
SAA6D140E-5
Machine models
HM400-2, HM400-3M0 Unit
Standard value for new machine
Repair limit
Max. speed with no load
rpm
2,200(+50/0)
2,200(+50/0)
Min. speed with no load
rpm
725 ± 25
725 ± 25
Necessary speed for starting
At 0°C (without starting aid)
rpm
Min. 110
—
At –20°C (with starting aid)
rpm
Min. 85
—
Air intake resistance
Air intake resistance
kPa {mmH2O}
Max. 3.73 {Max. 380}
7.47 {762}
Air boost pressure
At rated horsepower
kPa {mmHg}
Min. 160 {Min. 1,200}
136 {1,020}
Exhaust pressure
At rated horsepower
kPa {mmHg}
Min. 163 {Min. 1,220}
139 {1,040}
Exhaust temperature
Whole speed range (20°C)
°C
Max. 650
700
% (Bosch index)
Max. 25 (Max. 2.5)
35 (3.5)
At rated horsepower
Bosch index
Max. 1.5
2.5
At high idle
Bosch index
Max. 1.0
2.0
Intake valve
mm
0.35
—
Exhaust valve
mm
0.57
—
At low idle
MPa {kg/cm2}
Min. 1.18 {Min. 12}
Min. 1.18 {Min. 12}
At high idle
MPa {kg/cm2}
Min. 1.43 {Min. 14.6}
Min. 1.43 {Min. 14.6}
Compression pressure
Engine oil temperature: 40 to 60°C Engine speed: 200 to 250 rpm
MPa {kg/cm2}
Min. 4.1 {Min. 42}
2.8 {29}
Blow-by pressure
At rated horsepower kPa Engine coolant temperature: Min. 70°C {mmH2O}
Max. 2.94 {Max. 300}
3.92 {400}
Min. 0.34 {Min. 3.5}
0.21 {2.1}
Oil pressure
At rated horsepower SAE0W30EOS MPa Engine oil temperature: SAE5W40EOS {kg/cm2} Min. 80°C SAE10W30DH At low idle MPa SAE15W40DH Engine oil temperature: {kg/cm2} SAE30DH Min. 80°C
Min. 0.10 {Min. 1.0}
0.08 {0.8}
Item
Speed
Measurement conditions
At sudden acceleration (Low High) Exhaust gas color
Valve clearance
EGR valve and bypass valve drive oil pressure
16
20 Standard value table
Oil temperature
Whole speed range
°C
90 to 110
120
Oil consumption
Ratio to fuel consumption at continuous rated horsepower
%
Max. 0.15
0.3
Function of radiator pressure valve
Cracking pressure (Differential pressure)
kPa {kg/cm2}
—
—
Fan speed
At rated speed
rpm
Hydraulically driven on machine side
Fan belt tension
Deflection under finger pressure of 98 N {10 kg}
mm
Hydraulically driven on machine side
Alternator belt tension
Deflection under finger pressure of 98 N {10 kg}
mm
13 to 16
13 to 16
140E-5 Series
Air intake and exhaust system
Performance Category
20 Standard value table
Body Lubrication system
Engine
SAA6D140E-5
Machine models
HM400-2R, HM400-3R Unit
Standard value for new machine
Repair limit
Max. speed with no load
rpm
2,200(+50/0)
2,200(+50/0)
Min. speed with no load
rpm
725 ± 25
725 ± 25
Necessary speed for starting
At 0°C (without starting aid)
rpm
Min. 110
—
At –20°C (with starting aid)
rpm
Min. 85
—
Air intake resistance
Air intake resistance
kPa {mmH2O}
Max. 3.73 {Max. 380}
7.47 {762}
Air boost pressure
At rated horsepower
kPa {mmHg}
Min. 111 {Min. 830}
94 {700}
Exhaust pressure
At rated horsepower
kPa {mmHg}
Min. 115 {Min. 860}
98 {730}
Exhaust temperature
Whole speed range (20°C)
°C
Max. 670
720
% (Bosch index)
Max. 40 (Max. 4.0)
50 (5.0)
At rated horsepower
Bosch index
Max. 1.5
2.5
At high idle
Bosch index
Max. 1.0
2.0
Intake valve
mm
0.35
—
Exhaust valve
mm
0.57
—
Item
Speed
Measurement conditions
At sudden acceleration (Low High) Exhaust gas color
Valve clearance
Cooling system
SEN00147-07
Compression pressure
Engine oil temperature: 40 to 60°C Engine speed: 200 to 250 rpm
MPa {kg/cm2}
Min. 4.1 {Min. 42}
2.8 {29}
Blow-by pressure
At rated horsepower Engine coolant temperature: Min. 70°C
kPa {mmH2O}
Max. 2.94 {Max. 300}
3.92 {400}
Min. 0.34 {Min. 3.5}
0.21 {2.1}
Oil pressure
At rated horsepower SAE0W30EOS MPa Engine oil temperature: SAE5W40EOS {kg/cm2} Min. 80°C SAE10W30DH At low idle MPa SAE15W40DH Engine oil temperature: {kg/cm2} SAE30DH Min. 80°C
Min. 0.10 {Min. 1.0}
0.08 {0.8}
Oil temperature
Whole speed range
°C
90 to 110
120
Oil consumption
Ratio to fuel consumption at continuous rated horsepower
%
Max. 0.15
0.3
Function of radiator pressure valve
Cracking pressure (Differential pressure)
kPa {kg/cm2}
—
—
Fan speed
At rated speed
rpm
Hydraulically driven on machine side
Fan belt tension
Deflection under finger pressure of 98 N {10 kg}
mm
Hydraulically driven on machine side
Alternator belt tension
Deflection under finger pressure of 98 N {10 kg}
mm
140E-5 Series
13 to 16
13 to 16
17
SEN00147-07
20 Standard value table
Engine
SAA6D140E-5 SDG400S-6B1
Air intake and exhaust system
Performance Category
Machine models
Item
Speed
Body Lubrication system Cooling system
Unit
Standard value for new machine
Repair limit
Max. speed with no load
rpm
1,890 ± 50
1,890 ± 50
Min. speed with no load
rpm
875 ± 25
875 ± 25
Measurement conditions
Necessary speed for starting
At 0°C (without starting aid)
rpm
Min. 110
—
At –20°C (with starting aid)
rpm
Min. 85
—
Air intake resistance
Whole speed range
kPa {mmH2O}
Max. 3.73 {Max. 380}
7.47 {762}
Air boost pressure
At rated horsepower
kPa {mmHg}
Min. 207 {Min. 1,550}
171 {1,280}
Exhaust pressure
At rated horsepower
kPa {mmHg}
Min. 185 {Min. 1,390}
153 {1,150}
Exhaust temperature
Whole speed range (20°C)
°C
Max. 670
700
% (Bosch index)
— (—)
— (—)
At rated horsepower
Bosch index
Max. 1.5
2.5
At high idle
Bosch index
Max. 1.0
2.0
Intake valve
mm
0.35
—
Exhaust valve
mm
0.57
—
At low idle
MPa {kg/cm2}
Min. 1.18 {Min. 12}
Min. 1.18 {Min. 12}
At high idle
MPa {kg/cm2}
Min. 1.43 {Min. 14.6}
Min. 1.43 {Min. 14.6}
Compression pressure
Engine oil temperature: 40 to 60°C Engine speed: 200 to 250 rpm
MPa {kg/cm2}
Min. 4.1 {Min. 42}
2.8 {29}
Blow-by pressure
At rated horsepower Engine coolant temperature: Min. 70°C
kPa {mmH2O}
Max. 2.94 {Max. 300}
3.92 {400}
Min. 0.34 {Min. 3.5}
0.21 {2.1}
Oil pressure
At rated horsepower MPa Engine oil temperature: SAE0W30EOS 2 } {kg/cm SAE5W40EOS Min. 80°C SAE10W30DH At low idle SAE15W40DH MPa Engine oil temperature: SAE30DH {kg/cm2} Min. 80°C
Min. 0.10 {Min. 1.0}
0.08 {0.8}
At sudden acceleration (Low High) Exhaust gas color
Valve clearance
EGR valve and bypass valve drive oil pressure
18
(HOKUETSU INDUSTRIES GENERATOR)
Oil temperature
Whole speed range
°C
90 to 110
120
Oil consumption
Ratio to fuel consumption at continuous rated horsepower
%
Max. 0.15
0.3
Function of radiator pressure valve
Cracking pressure (Differential pressure)
kPa {kg/cm2}
—
—
Fan speed
At rated speed
rpm
1,329 ± 40
1,329 ± 40
Fan belt tension
Deflection under finger pressure of 98 N {10 kg}
mm
13 to 15 (When new)
17 to 19
Alternator belt tension
Deflection under finger pressure of 98 N {10 kg}
mm
13 to 16
13 to 16
140E-5 Series
20 Standard value table
SEN00147-07
Running-in standard and performance test standard
1
Running-in standard Engine
SAA6D140E-5
Machine models
D155AX-6 Procedure
Item
1
2
3
4
5
Running time
min.
1
3
6
8
2
Speed
rpm
740
1,197
1,501
1,729
1,900
Dynamometer load
N{kg}
0{0}
747{76}
1,192{122}
1,552{158}
1,883{192}
Output
kW{HP}
0{0}
67{90}
134{181}
201{270}
268{360}
a a
This table shows the values when the fan is not installed. The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Performance test standard Engine
SAA6D140E-5
Machine models
D155AX-6
Test item
Rated horsepower
Max. torque
High idle speed
Low idle speed
Specification value (Gross value)
—
Speed
rpm
1,900
1,300
2,100(0/–50)
740(+40/0)
Dynamometer load
N {kg}
1,823 to 1,940 {186 to 198}
2,460 to 2,607 {251 to 266}
—
—
Output (Gross value)
kW {HP}
260 to 277 {349 to 371}
—
—
—
Torque (Gross value)
Nm {kgm}
—
1,758 to 1,868 {179.4 to 190.6}
—
—
Fuel consumption
sec/300cc
Min. 16.0
—
—
—
Coolant temperature
°C
70 to 90
70 to 90
70 to 90
70 to 90
Lubricating oil temperature
°C
90 to 110
90 to 110
90 to 110
80 to 110
Lubricating oil pressure
kPa {kg/cm2}
340 to 490 {3.5 to 5.0}
340 to 490 {3.5 to 5.0}
340 to 490 {3.5 to 5.0}
Min. 120 {Min. 1.2}
Exhaust temperature
°C
Max. 650
Max. 650
—
—
a a a a a a
268 kW/1,900 rpm 1,834 Nm/1,300 rpm 2,100(0/–50) rpm {359.9 HP/1,900 rpm} {187 kgm/1,300 rpm}
740(+40/0) rpm
This table shows the standard values obtained by using the JIS correction coefficients. Since the output and torque in this table are the standard values when the fan is not installed, they are different from the specification values. This table shows the standard values when the air cleaner and the muffler are installed and no load is applied to the alternator. The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long. Use ASTM No.1 or No. 2 diesel fuel as fuel. Use SAE15W-40 as lubricating oil.
140E-5 Series
19
SEN00147-07
20 Standard value table
Running-in standard Engine
SAA6D140E-5
Machine models
D155A-6 Procedure
Item
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 a
This table shows the values when the fan is not installed. The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Performance test standard Engine
SAA6D140E-5
Machine models
D155A-6
Test item
Rated horsepower
Max. torque
High idle speed
Specification value (Gross value)
—
Speed
rpm
1,900
1,300
2,100(0/–50)
740(+40/0)
Dynamometer load
N {kg}
1,823 to 1,940 {186 to 198}
2,482 to 2,635 {253 to 269}
—
—
Output (Gross value)
kW {HP}
260 to 277 {349 to 371}
—
—
—
Torque (Gross value)
Nm {kgm}
—
1,778 to 1,888 {181.4 to 192.6}
—
—
Fuel consumption
sec/300cc
Min. 16.0
—
—
—
Coolant temperature
°C
70 to 90
70 to 90
70 to 90
70 to 90
Lubricating oil temperature
°C
90 to 110
90 to 110
90 to 110
80 to 110
Lubricating oil pressure
kPa {kg/cm2}
340 to 490 {3.5 to 5.0}
340 to 490 {3.5 to 5.0}
340 to 490 {3.5 to 5.0}
Min. 120 {Min. 1.2}
Exhaust temperature
°C
Max. 670
Max. 670
—
—
a a a a a a
20
268 kW/1,900 rpm 1,834 Nm/1,300 rpm 2,100(0/–50) rpm {359.9 HP/1,900 rpm} {187 kgm/1,300 rpm}
Low idle speed 740(+40/0) rpm
This table shows the standard values obtained by using the JIS correction coefficients. Since the output and torque in this table are the standard values when the fan is not installed, they are different from the specification values. This table shows the standard values when the air cleaner and the muffler are installed and no load is applied to the alternator. The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long. Use ASTM No.1 or No. 2 diesel fuel as fuel. Use SAE15W-40 as lubricating oil.
140E-5 Series
20 Standard value table
SEN00147-07
Running-in standard Engine
SAA6D140E-5
Machine models
D275AX-5E0 Procedure
Item
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 a
This table shows the values when the fan is not installed. The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Performance test standard Engine
SAA6D140E-5
Machine models
D275AX-5E0
Test item
Rated horsepower
Max. torque
Low idle speed
2,200 ± 50 rpm
700 ± 50 rpm
Specification value (Gross value)
—
Speed
rpm
2,000
1,400
2,200 ± 50
700 ± 50
Dynamometer load
N {kg}
2,177 to 2,314 {222.0 to 236.0}
2,753 to 2,917 {280.7 to 297.5}
—
—
Output (Gross value)
kW {HP}
327 to 347 {438 to 465}
—
—
—
Torque (Gross value)
Nm {kgm}
—
1,970 to 2,087 {201 to 213}
—
—
Fuel consumption
sec/300cc
Min. 12.8
—
—
—
Coolant temperature
°C
70 to 90
70 to 90
70 to 90
70 to 90
Lubricating oil temperature
°C
90 to 110
90 to 110
90 to 110
90 to 110
Lubricating oil pressure
kPa {kg/cm2}
340 to 490 {3.5 to 5.0}
340 to 490 {3.5 to 5.0}
340 to 490 {3.5 to 5.0}
Min. 120 {Min. 1.2}
Exhaust temperature
°C
Max. 650
Max. 650
—
—
a a a a a a
337 kW/2,000 rpm 2,030 Nm/1,400 rpm {451.6 HP/2,000 rpm} {207 kgm/1,400 rpm}
High idle speed
This table shows the standard values obtained by using the JIS correction coefficients. Since the output and torque in this table are the standard values when the fan is not installed, they are different from the specification values. This table shows the standard values when the air cleaner and the muffler are installed and no load is applied to the alternator. The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long. Use ASTM No.1 or No. 2 diesel fuel as fuel. Use SAE15W-40 as lubricating oil.
140E-5 Series
21
SEN00147-07
20 Standard value table
Running-in standard Engine
SAA6D140E-5
Machine models
D275A-5R Procedure
Item
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 a
This table shows the values when the fan is not installed. The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Performance test standard Engine
SAA6D140E-5
Machine models
D275A-5R
Test item
Rated horsepower
Max. torque
Low idle speed
2,200 ± 50 rpm
700 ± 50 rpm
Specification value (Gross value)
—
Speed
rpm
2,000
1,400
2,200 ± 50
700 ± 50
Dynamometer load
N {kg}
2,177 to 2,314 {222.0 to 236.0}
2,753 to 2,917 {280.7 to 297.5}
—
—
Output (Gross value)
kW {HP}
327 to 347 {438 to 465}
—
—
—
Torque (Gross value)
Nm {kgm}
—
1,970 to 2,087 {201 to 213}
—
—
Fuel consumption
sec/300cc
Min. 12.8
—
—
—
Coolant temperature
°C
70 to 90
70 to 90
70 to 90
70 to 90
Lubricating oil temperature
°C
90 to 110
90 to 110
90 to 110
90 to 110
Lubricating oil pressure
kPa {kg/cm2}
340 to 490 {3.5 to 5.0}
340 to 490 {3.5 to 5.0}
340 to 490 {3.5 to 5.0}
Min. 120 {Min. 1.2}
Exhaust temperature
°C
Max. 670
Max. 670
—
—
a a a a a a
22
337 kW/2,000 rpm 2,030 Nm/1,400 rpm {451.6 HP/2,000 rpm} {207 kgm/1,400 rpm}
High idle speed
This table shows the standard values obtained by using the JIS correction coefficients. Since the output and torque in this table are the standard values when the fan is not installed, they are different from the specification values. This table shows the standard values when the air cleaner and the muffler are installed and no load is applied to the alternator. The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long. Use ASTM No.1 or No. 2 diesel fuel as fuel. Use SAE15W-40 as lubricating oil.
140E-5 Series
20 Standard value table
SEN00147-07
Running-in standard Engine
SAA6D140E-5
Machine models
PC600-8, PC600LC-8, PC600-8E0, PC600LC-8E0 PC700-8E0, PC700LC-8E0 Procedure
Item
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 a
This table shows the values when the fan is not installed. The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Performance test standard Engine
SAA6D140E-5
Machine models
PC600-8, PC600LC-8, PC600-8E0, PC600LC-8E0 PC700-8E0, PC700LC-8E0
Test item
Rated horsepower
Max. torque
High idle speed
Low idle speed
Specification value (Gross value)
—
323 kW/1,800 rpm {433.3 HP/ 1,800 rpm}
1,944Nm/1,400rpm {198.4 kgm/ 1,400 rpm}
1,950 ± 50 rpm
800 ± 25 rpm
Speed
rpm
1,800
1,400
1,950 ± 50
800 ± 25
Dynamometer load
N {kg}
2,323 to 2,470 {237 to 252}
2,626 to 2,793 {268 to 285}
—
—
Output (Gross value)
kW {HP}
313 to 333 {420 to 447}
—
—
—
Torque (Gross value)
Nm {kgm}
—
1,882 to 1,999 {192 to 204}
—
—
Fuel consumption
sec/300cc
Min. 13.8
—
—
—
Coolant temperature
°C
70 to 90
70 to 90
70 to 90
70 to 90
Lubricating oil temperature
°C
90 to 110
90 to 110
90 to 110
80 to 110
Lubricating oil pressure
kPa {kg/cm2}
340 to 490 {3.5 to 5.0}
340 to 490 {3.5 to 5.0}
340 to 490 {3.5 to 5.0}
Min. 120 {Min. 1.2}
Exhaust temperature
°C
Max. 650
Max. 650
—
—
a a a a a a
This table shows the standard values obtained by using the JIS correction coefficients. Since the output and torque in this table are the standard values when the fan is not installed, they are different from the specification values. This table shows the standard values when the air cleaner and the muffler are installed and no load is applied to the alternator. The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long. Use ASTM No.1 or No. 2 diesel fuel as fuel. Use SAE15W-40 as lubricating oil.
140E-5 Series
23
SEN00147-07
20 Standard value table
Running-in standard Engine
SAA6D140E-5
Machine models
PC600-8R, PC600LC-8R, PC600-8R1, PC600LC-8R1, PC700-8R, PC700LC-8R, PC700LC-8R1 Procedure
Item
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 a
This table shows the values when the fan is not installed. The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Performance test standard Engine
SAA6D140E-5
Machine models
PC600-8R, PC600LC-8R, PC600-8R1, PC600LC-8R1, PC700-8R, PC700LC-8R, PC700LC-8R1
Test item
Rated horsepower
Max. torque
High idle speed
Low idle speed
Specification value (Gross value)
—
323 kW/1,800 rpm {433.3 HP/ 1,800 rpm}
1,944Nm/1,400rpm {198.4 kgm/ 1,400 rpm}
1,950 ± 50 rpm
800 ± 25 rpm
Speed
rpm
1,800
1,400
1,950 ± 50
800 ± 25
Dynamometer load
N {kg}
2,323 to 2,470 {237 to 252}
2,626 to 2,793 {268 to 285}
—
—
Output (Gross value)
kW {HP}
313 to 333 {420 to 447}
—
—
—
Torque (Gross value)
Nm {kgm}
—
1,882 to 1,999 {192 to 204}
—
—
Fuel consumption
sec/300cc
Min. 13.8
—
—
—
Coolant temperature
°C
70 to 90
70 to 90
70 to 90
70 to 90
Lubricating oil temperature
°C
90 to 110
90 to 110
90 to 110
80 to 110
Lubricating oil pressure
kPa {kg/cm2}
340 to 490 {3.5 to 5.0}
340 to 490 {3.5 to 5.0}
340 to 490 {3.5 to 5.0}
Min. 120 {Min. 1.2}
Exhaust temperature
°C
Max. 700
Max. 700
—
—
a a a a a a
24
This table shows the standard values obtained by using the JIS correction coefficients. Since the output and torque in this table are the standard values when the fan is not installed, they are different from the specification values. This table shows the standard values when the air cleaner and the muffler are installed and no load is applied to the alternator. The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long. Use ASTM No.1 or No. 2 diesel fuel as fuel. Use SAE15W-40 as lubricating oil.
140E-5 Series
20 Standard value table
SEN00147-07
Running-in standard Engine
SAA6D140E-5
Machine models
PC800-8, PC800SE-8, PC800LC-8, PC850-8, PC850SE-8 PC800-8E0, PC800SE-8E0, PC800LC-8E0, PC850-8E0, PC850SE-8E0 Procedure
Item
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 a
This table shows the values when the fan is not installed. The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Performance test standard Engine
SAA6D140E-5
Machine models
PC800-8, PC800SE-8, PC800LC-8, PC850-8, PC850SE-8 PC800-8E0, PC800SE-8E0, PC800LC-8E0, PC850-8E0, PC850SE-8E0
Test item
Rated horsepower
Max. torque
High idle speed
Low idle speed
Specification value (Gross value)
—
370 kW/1,800 rpm {496.4 HP/ 1,800 rpm}
2,195 Nm/1,350 rpm {223.8 kgm/ 1,350 rpm}
1,980 ± 50 rpm
825 ± 25 rpm
Speed
rpm
1,800
1,350
1,980 ± 50
825 ± 25
Dynamometer load
N {kg}
2,550 to 2,690 {260 to 274}
2,930 to 3,100 {299 to 316}
—
—
Output (Gross value)
kW {HP}
359 to 381 {481 to 512}
—
—
—
Torque (Gross value)
Nm {kgm}
—
2,126 to 2,264 {217 to 231}
—
—
Fuel consumption
sec/300cc
Min. 12.3
—
—
—
Coolant temperature
°C
70 to 90
70 to 90
70 to 90
70 to 90
Lubricating oil temperature
°C
90 to 110
90 to 110
90 to 110
80 to 110
Lubricating oil pressure
kPa {kg/cm2}
340 to 490 {3.5 to 5.0}
340 to 490 {3.5 to 5.0}
340 to 490 {3.5 to 5.0}
Min. 120 {Min. 1.2}
Exhaust temperature
°C
Max. 650
Max. 650
—
—
a a a a a a
This table shows the standard values obtained by using the JIS correction coefficients. Since the output and torque in this table are the standard values when the fan is not installed, they are different from the specification values. This table shows the standard values when the air cleaner and the muffler are installed and no load is applied to the alternator. The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long. Use ASTM No.1 or No. 2 diesel fuel as fuel. Use SAE15W-40 as lubricating oil.
140E-5 Series
25
SEN00147-07
20 Standard value table
Running-in standard Engine
SAA6D140E-5
Machine models
PC800-8R, PC800SE-8R, PC800LC-8R, PC850-8R, PC850SE-8R PC800-8R1, PC800SE-8R1, PC800LC-8R1, PC850-8R1, PC850SE-8R1 Procedure
Item
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 a
This table shows the values when the fan is not installed. The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Performance test standard Engine
SAA6D140E-5
Machine models
PC800-8R, PC800SE-8R, PC800LC-8R, PC850-8R, PC850SE-8R PC800-8R1, PC800SE-8R1, PC800LC-8R1, PC850-8R1, PC850SE-8R1
Test item
Rated horsepower
Max. torque
High idle speed
Low idle speed
Specification value (Gross value)
—
370 kW/1,800 rpm {496.4 HP/ 1,800 rpm}
2,195 Nm/1,350 rpm {223.8 kgm/ 1,350 rpm}
1,980 ± 50 rpm
825 ± 25 rpm
Speed
rpm
1,800
1,350
1,980 ± 50
825 ± 25
Dynamometer load
N {kg}
2,550 to 2,690 {260 to 274}
2,969 to 3,162 {303 to 323}
—
—
Output (Gross value)
kW {HP}
359 to 381 {481 to 512}
—
—
—
Torque (Gross value)
Nm {kgm}
—
2,126 to 2,264 {217 to 231}
—
—
Fuel consumption
sec/300cc
Min. 12.3
—
—
—
Coolant temperature
°C
70 to 90
70 to 90
70 to 90
70 to 90
Lubricating oil temperature
°C
90 to 110
90 to 110
90 to 110
80 to 110
Lubricating oil pressure
kPa {kg/cm2}
340 to 490 {3.5 to 5.0}
340 to 490 {3.5 to 5.0}
340 to 490 {3.5 to 5.0}
Min. 120 {Min. 1.2}
Exhaust temperature
°C
Max. 700
Max. 700
—
—
a a a a a a
26
This table shows the standard values obtained by using the JIS correction coefficients. Since the output and torque in this table are the standard values when the fan is not installed, they are different from the specification values. This table shows the standard values when the air cleaner and the muffler are installed and no load is applied to the alternator. The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long. Use ASTM No.1 or No. 2 diesel fuel as fuel. Use SAE15W-40 as lubricating oil.
140E-5 Series
20 Standard value table
SEN00147-07
Running-in standard Engine
SAA6D140E-5
Machine models
WA500-6 Procedure
Item
1
2
3
4
5
Running time
min.
1
3
6
8
2
Speed
rpm
675
1,197
1,501
1,729
1,900
Dynamometer load
N{kg}
0{0}
712{73}
1,136{116}
1,479{151}
1,795{183}
Output
kW{HP}
0{0}
64{86}
128{172}
192{257}
266{357}
a a
This table shows the values when the fan is not installed. The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Performance test standard Engine
SAA6D140E-5
Machine models
WA500-6
Test item
Rated horsepower
Max. torque
Low idle speed
2,150 ± 50 rpm
700 ± 25 rpm
Specification value (Gross value)
—
Speed
rpm
1,900
1,250
2,150 ± 50
700 ± 25
Dynamometer load
N {kg}
1,744 to 1,852 {178 to 189}
2,440 to 2,597 {249 to 265}
—
—
Output (Gross value)
kW {HP}
248 to 263 {333 to 353}
—
—
—
Torque (Gross value)
Nm {kgm}
—
1,744 to 1,862 {178 to 190}
—
—
Fuel consumption
sec/300cc
Min. 16.8
—
—
—
Coolant temperature
°C
70 to 90
70 to 90
70 to 90
70 to 90
Lubricating oil temperature
°C
90 to 110
90 to 110
90 to 110
80 to 110
Lubricating oil pressure
kPa {kg/cm2}
340 to 490 {3.5 to 5.0}
340 to 490 {3.5 to 5.0}
340 to 490 {3.5 to 5.0}
Min. 120 {Min. 1.2}
Exhaust temperature
°C
Max. 650
Max. 650
—
—
a a a a a a
266 kW/1,900 rpm 1,803 Nm/1,250 rpm {357 HP/1,900 rpm} {184 kgm/1,250 rpm}
High idle speed
This table shows the standard values obtained by using the JIS correction coefficients. Since the output and torque in this table are the standard values when the fan is not installed, they are different from the specification values. This table shows the standard values when the air cleaner and the muffler are installed and no load is applied to the alternator. The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long. Use ASTM No.1 or No. 2 diesel fuel as fuel. Use SAE15W-40 as lubricating oil.
140E-5 Series
27
SEN00147-07
20 Standard value table
Running-in standard Engine
SAA6D140E-5
Machine models
WA500-6R Procedure
Item
1
2
3
4
5
Running time
min.
1
3
6
8
2
Speed
rpm
675
1,197
1,501
1,729
1,900
Dynamometer load
N{kg}
0{0}
712{73}
1,136{116}
1,479{151}
1,795{183}
Output
kW{HP}
0{0}
64{86}
128{172}
192{257}
266{357}
a a
This table shows the values when the fan is not installed. The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Performance test standard Engine
SAA6D140E-5
Machine models
WA500-6R
Test item
Rated horsepower
Max. torque
Low idle speed
2,150 ± 50 rpm
700 ± 25 rpm
Specification value (Gross value)
—
Speed
rpm
1,900
1,250
2,150 ± 50
700 ± 25
Dynamometer load
N {kg}
1,814 to 1,922 {185 to 196}
2,440 to 2,597 {249 to 265}
—
—
Output (Gross value)
kW {HP}
258 to 274 {346 to 368}
—
—
—
Torque (Gross value)
Nm {kgm}
—
1,744 to 1,862 {178 to 190}
—
—
Fuel consumption
sec/300cc
Min. 16.8
—
—
—
Coolant temperature
°C
70 to 90
70 to 90
70 to 90
70 to 90
Lubricating oil temperature
°C
90 to 110
90 to 110
90 to 110
80 to 110
Lubricating oil pressure
kPa {kg/cm2}
340 to 490 {3.5 to 5.0}
340 to 490 {3.5 to 5.0}
340 to 490 {3.5 to 5.0}
Min. 120 {Min. 1.2}
Exhaust temperature
°C
Max. 670
Max. 670
—
—
a a a a a a
28
266 kW/1,900 rpm 1,803 Nm/1,250 rpm {357 HP/1,900 rpm} {184 kgm/1,250 rpm}
High idle speed
This table shows the standard values obtained by using the JIS correction coefficients. Since the output and torque in this table are the standard values when the fan is not installed, they are different from the specification values. This table shows the standard values when the air cleaner and the muffler are installed and no load is applied to the alternator. The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long. Use ASTM No.1 or No. 2 diesel fuel as fuel. Use SAE15W-40 as lubricating oil.
140E-5 Series
20 Standard value table
SEN00147-07
Running-in standard Engine
SAA6D140E-5
Machine models
HD325-7 HD405-7 Procedure
Item
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 a
This table shows the values when the fan is not installed. The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Performance test standard Engine
SAA6D140E-5
Machine models
HD325-7 HD405-7
Test item
Rated horsepower
Max. torque
High idle speed
Low idle speed
2,300 ± 25 rpm
725 ± 25 rpm
Specification value (Gross value)
—
Speed
rpm
2,000
1,400
2,300 ± 25
725 ± 25
Dynamometer load
N {kg}
2,499 to 2,646 {255 to 270}
2,930 to 3,120 {299 to 318}
—
—
Output (Gross value)
kW {HP}
374 to 398 {502 to 533}
—
—
—
Torque (Gross value)
Nm {kgm}
—
2,100 to 2,230 {214 to 228}
—
—
Fuel consumption
sec/300cc
Min. 11.4
—
—
—
Coolant temperature
°C
70 to 90
70 to 90
70 to 90
70 to 90
Lubricating oil temperature
°C
90 to 110
90 to 110
90 to 110
80 to 110
Lubricating oil pressure
kPa {kg/cm2}
340 to 490 {3.5 to 5.0}
340 to 490 {3.5 to 5.0}
340 to 490 {3.5 to 5.0}
Min. 120 {Min. 1.2}
Exhaust temperature
°C
Max. 650
Max. 650
—
—
a a a a a
386 kW/2,000 rpm 2,170 Nm/1,400 rpm {517.7 HP/2,000 rpm} {221.3 kgm/1,400 rpm}
This table shows the standard values obtained by using the JIS correction coefficients. Since the output and torque in this table are the standard values when the fan is not installed, they are different from the specification values. This table shows the standard values when the air cleaner and the muffler are installed and no load is applied to the alternator. The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long. Use ASTM No.1 or No. 2 diesel fuel as fuel.
140E-5 Series
29
SEN00147-07
20 Standard value table
Running-in standard Engine
SAA6D140E-5
Machine models
HD325-7R HD405-7R Procedure
Item
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 a
This table shows the values when the fan is not installed. The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Performance test standard Engine
SAA6D140E-5
Machine models
HD325-7R HD405-7R
Test item
Rated horsepower
Max. torque
High idle speed
Low idle speed
2,300 ± 25 rpm
725 ± 25 rpm
Specification value (Gross value)
—
Speed
rpm
2,000
1,400
2,300 ± 25
725 ± 25
Dynamometer load
N {kg}
2,499 to 2,646 {255 to 270}
2,930 to 3,120 {299 to 318}
—
—
Output (Gross value)
kW {HP}
374 to 398 {502 to 533}
—
—
—
Torque (Gross value)
Nm {kgm}
—
2,100 to 2,230 {214 to 228}
—
—
Fuel consumption
sec/300cc
Min. 11.4
—
—
—
Coolant temperature
°C
70 to 90
70 to 90
70 to 90
70 to 90
Lubricating oil temperature
°C
90 to 110
90 to 110
90 to 110
80 to 110
Lubricating oil pressure
kPa {kg/cm2}
340 to 490 {3.5 to 5.0}
340 to 490 {3.5 to 5.0}
340 to 490 {3.5 to 5.0}
Min. 120 {Min. 1.2}
Exhaust temperature
°C
Max. 680
Max. 680
—
—
a a a a a a
30
386 kW/2,000 rpm 2,170 Nm/1,400 rpm {517.7 HP/2,000 rpm} {221.3 kgm/1,400 rpm}
This table shows the standard values obtained by using the JIS correction coefficients. Since the output and torque in this table are the standard values when the fan is not installed, they are different from the specification values. This table shows the standard values when the air cleaner and the muffler are installed and no load is applied to the alternator. The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long. Use ASTM No.1 or No. 2 diesel fuel as fuel. Use SAE15W-40 as lubricating oil.
140E-5 Series
20 Standard value table
SEN00147-07
Running-in standard Engine
SAA6D140E-5
Machine models
HM350-2 Procedure
Item
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 a
This table shows the values when the fan is not installed. The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Performance test standard Engine
SAA6D140E-5
Machine models
HM350-2
Test item
Rated horsepower
Max. torque
High idle speed
Specification value (Gross value)
—
Speed
rpm
2,000
1,400
2,200(+50/0)
725 ± 25
Dynamometer load
N {kg}
1,960 to 2,087 {200 to 213}
2,695 to 2,862 {275 to 292}
—
—
Output (Gross value)
kW {HP}
295 to 315 {395 to 419}
—
—
—
Torque (Gross value)
Nm {kgm}
—
1,931 to 2,048 {197 to 209}
—
—
Fuel consumption
sec/300cc
Min. 13.8
—
—
—
Coolant temperature
°C
70 to 90
70 to 90
70 to 90
70 to 90
Lubricating oil temperature
°C
90 to 110
90 to 110
90 to 110
80 to 110
Lubricating oil pressure
kPa {kg/cm2}
340 to 490 {3.5 to 5.0}
340 to 490 {3.5 to 5.0}
340 to 490 {3.5 to 5.0}
Min. 120 {Min. 1.2}
Exhaust temperature
°C
Max. 650
Max. 650
—
—
a a a a a a
304 kW/2,000 rpm 1,990 Nm/1,400 rpm 2,200(+50/0) rpm {407.2 HP/2,000 rpm} {203 kgm/1,400 rpm}
Low idle speed 725 ± 25 rpm
This table shows the standard values obtained by using the JIS correction coefficients. Since the output and torque in this table are the standard values when the fan is not installed, they are different from the specification values. This table shows the standard values when the air cleaner and the muffler are installed and no load is applied to the alternator. The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long. Use ASTM No.1 or No. 2 diesel fuel as fuel. Use SAE15W-40 as lubricating oil.
140E-5 Series
31
SEN00147-07
20 Standard value table
Running-in standard Engine
SAA6D140E-5
Machine models
HM350-2R Procedure
Item
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 a
This table shows the values when the fan is not installed. The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Performance test standard Engine
SAA6D140E-5
Machine models
HM350-2R
Test item
Rated horsepower
Max. torque
High idle speed
Specification value (Gross value)
—
Speed
rpm
2,000
1,400
2,200(+50/0)
725 ± 25
Dynamometer load
N {kg}
1,960 to 2,087 {200 to 213}
2,695 to 2,862 {275 to 292}
—
—
Output (Gross value)
kW {HP}
295 to 315 {395 to 419}
—
—
—
Torque (Gross value)
Nm {kgm}
—
1,931 to 2,048 {197 to 209}
—
—
Fuel consumption
sec/300cc
Min. 13.8
—
—
—
Coolant temperature
°C
70 to 90
70 to 90
70 to 90
70 to 90
Lubricating oil temperature
°C
90 to 110
90 to 110
90 to 110
80 to 110
Lubricating oil pressure
kPa {kg/cm2}
340 to 490 {3.5 to 5.0}
340 to 490 {3.5 to 5.0}
340 to 490 {3.5 to 5.0}
Min. 120 {Min. 1.2}
Exhaust temperature
°C
Max. 670
Max. 670
—
—
a a a a a a
32
304 kW/2,000 rpm 1,991 Nm/1,400 rpm 2,200(+50/0) rpm {407.2 HP/2,000 rpm} {203 kgm/1,400 rpm}
Low idle speed 725 ± 25 rpm
This table shows the standard values obtained by using the JIS correction coefficients. Since the output and torque in this table are the standard values when the fan is not installed, they are different from the specification values. This table shows the standard values when the air cleaner and the muffler are installed and no load is applied to the alternator. The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long. Use ASTM No.1 or No. 2 diesel fuel as fuel. Use SAE15W-40 as lubricating oil.
140E-5 Series
20 Standard value table
SEN00147-07
Running-in standard Engine
SAA6D140E-5
Machine models
HM400-2, HM400-3M0 Procedure
Item
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 a
This table shows the values when the fan is not installed. The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Performance test standard Engine
SAA6D140E-5
Machine models
HM400-2, HM400-3M0
Test item
Rated horsepower
Max. torque
High idle speed
Specification value (Gross value)
—
Speed
rpm
2,000
1,400
2,200(+50/0)
725 ± 25
Dynamometer load
N {kg}
2,185 to 2,313 {223 to 236}
2,832 to 2,999 {289 to 306}
—
—
Output (Gross value)
kW {HP}
327 to 348 {439 to 466}
—
—
—
Torque (Gross value)
Nm {kgm}
—
2,029 to 2,146 {207 to 219}
—
—
Fuel consumption
sec/300cc
Min. 13.0
—
—
—
Coolant temperature
°C
70 to 90
70 to 90
70 to 90
70 to 90
Lubricating oil temperature
°C
90 to 110
90 to 110
90 to 110
80 to 110
Lubricating oil pressure
kPa {kg/cm2}
340 to 490 {3.5 to 5.0}
340 to 490 {3.5 to 5.0}
340 to 490 {3.5 to 5.0}
Min. 120 {Min. 1.2}
Exhaust temperature
°C
Max. 650
Max. 650
—
—
a a a a a a
338 kW/2,000 rpm 2,090 Nm/1,400 rpm 2,200(+50/0) rpm {452.6 HP/2,000 rpm} {213 kgm/1,400 rpm}
Low idle speed 725 ± 25 rpm
This table shows the standard values obtained by using the JIS correction coefficients. Since the output and torque in this table are the standard values when the fan is not installed, they are different from the specification values. This table shows the standard values when the air cleaner and the muffler are installed and no load is applied to the alternator. The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long. Use ASTM No.1 or No. 2 diesel fuel as fuel. Use SAE15W-40 as lubricating oil.
140E-5 Series
33
SEN00147-07
20 Standard value table
Running-in standard Engine
SAA6D140E-5
Machine models
HM400-2R, HM400-3R Procedure
Item
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 a
This table shows the values when the fan is not installed. The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Performance test standard Engine
SAA6D140E-5
Machine models
HM400-2R, HM400-3R
Test item
Rated horsepower
Max. torque
High idle speed
Specification value (Gross value)
—
Speed
rpm
2,000
1,400
2,200(+50/0)
725 ± 25
Dynamometer load
N {kg}
2,185 to 2,313 {223 to 236}
2,832 to 2,999 {289 to 306}
—
—
Output (Gross value)
kW {HP}
327 to 348 {439 to 466}
—
—
—
Torque (Gross value)
Nm {kgm}
—
2,029 to 2,146 {207 to 219}
—
—
Fuel consumption
sec/300cc
Min. 13.0
—
—
—
Coolant temperature
°C
70 to 90
70 to 90
70 to 90
70 to 90
Lubricating oil temperature
°C
90 to 110
90 to 110
90 to 110
80 to 110
Lubricating oil pressure
kPa {kg/cm2}
340 to 490 {3.5 to 5.0}
340 to 490 {3.5 to 5.0}
340 to 490 {3.5 to 5.0}
Min. 120 {Min. 1.2}
Exhaust temperature
°C
Max. 670
Max. 670
—
—
a a a a a a
34
338 kW/2,000 rpm 2,090 Nm/1,400 rpm 2,200(+50/0) rpm {452.6 HP/2,000 rpm} {213 kgm/1,400 rpm}
Low idle speed 725 ± 25 rpm
This table shows the standard values obtained by using the JIS correction coefficients. Since the output and torque in this table are the standard values when the fan is not installed, they are different from the specification values. This table shows the standard values when the air cleaner and the muffler are installed and no load is applied to the alternator. The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long. Use ASTM No.1 or No. 2 diesel fuel as fuel. Use SAE15W-40 as lubricating oil.
140E-5 Series
20 Standard value table
SEN00147-07
Running-in standard Engine
SAA6D140E-5
Machine models
SDG400S-6B1 (HOKUETSU INDUSTRIES GENERATOR) Procedure
Item
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 a
This table shows the values when the fan is not installed. The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Performance test standard Engine
SAA6D140E-5
Machine models
SDG400S-6B1 (HOKUETSU INDUSTRIES GENERATOR)
Test item
Rated horsepower
Max. torque
High idle speed
Low idle speed
Specification value (Gross value)
—
371 kW/1,800 rpm {498 HP/1,800 rpm}
— —
1,890 ± 50 rpm
875 ± 25 rpm
Speed
rpm
1,800
—
1,890 ± 50
875 ± 25
Dynamometer load
N {kg}
2,695 to 2,813 {275 to 287}
— —
—
—
Output (Gross value)
kW {HP}
360 to 382 {483 to 512}
—
—
—
Torque (Gross value)
Nm {kgm}
—
—
—
—
Fuel consumption
sec/300cc
Min. 10.8
—
—
—
Coolant temperature
°C
70 to 90
—
70 to 90
70 to 90
Lubricating oil temperature
°C
90 to 110
—
90 to 110
80 to 110
Lubricating oil pressure
kPa {kg/cm2}
340 to 490 {3.5 to 5.0}
— {—}
340 to 490 {3.5 to 5.0}
Min. 120 {Min. 1.2}
Exhaust temperature
°C
Max. 670
—
—
—
a a a a a a
This table shows the standard values obtained by using the JIS correction coefficients. Since the output and torque in this table are the standard values when the fan is not installed, they are different from the specification values. This table shows the standard values when the air cleaner and the muffler are installed and no load is applied to the alternator. The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long. Use ASTM No.1 or No. 2 diesel fuel as fuel. Use SAE15W-40 as lubricating oil.
140E-5 Series
35
SEN00147-07
KOMATSU 140E-5 Series engine Form No. SEN00147-07
© 2012 KOMATSU All Rights Reserved Printed in Japan 12-12 (01)
36
SEN00149-05
ENGINE 1SHOP MANUAL
140E-5 Series
30 Testing and adjusting
1
Testing and adjusting Testing and adjusting (with EGR).................................................................................................................... 3 Testing and adjusting tools list ............................................................................................................. 3 Sketches of special tools...................................................................................................................... 5 Testing air boost pressure .................................................................................................................... 6 Testing exhaust temperature................................................................................................................ 7 Adjusting valve clearance .................................................................................................................... 8 Testing compression pressure ............................................................................................................. 9 Testing blow-by pressure ....................................................................................................................11 Testing engine oil pressure ................................................................................................................ 12 Testing EGR valve and bypass valve drive oil pressure .................................................................... 13 Handling fuel system parts ................................................................................................................. 14 Releasing residual pressure in fuel system........................................................................................ 14 Testing fuel pressure .......................................................................................................................... 15 Reduced cylinder mode operation ..................................................................................................... 16 No-injection cranking.......................................................................................................................... 16 Testing fuel return rate and leakage................................................................................................... 17
140E-5 Series
1
SEN00149-05
30 Testing and adjusting
Bleeding air from fuel circuit ............................................................................................................... 20 Testing fuel system for leakage .......................................................................................................... 22 Testing and adjusting alternator belt tension ...................................................................................... 23 Testing and adjusting fan belt tension ................................................................................................ 24 Handling controller high-voltage circuit .............................................................................................. 25 Testing and adjusting (EGR-less).................................................................................................................. 26 Testing and adjusting tools list............................................................................................................ 26 Sketches of special tools.................................................................................................................... 28 Testing air boost pressure .................................................................................................................. 29 Testing exhaust temperature .............................................................................................................. 30 Adjusting valve clearance................................................................................................................... 31 Testing compression pressure............................................................................................................ 32 Testing blow-by pressure.................................................................................................................... 34 Testing engine oil pressure................................................................................................................. 35 Handling fuel system parts ................................................................................................................. 36 Releasing residual pressure in fuel system........................................................................................ 36 Testing fuel pressure .......................................................................................................................... 37 Reduced cylinder mode operation...................................................................................................... 38 No-injection cranking.......................................................................................................................... 38 Testing fuel return rate and leakage ................................................................................................... 39 Bleeding air from fuel circuit ............................................................................................................... 42 Testing fuel system for leakage .......................................................................................................... 44 Testing and adjusting alternator belt tension ...................................................................................... 45 Testing and adjusting fan belt tension ................................................................................................ 46 Handling controller high-voltage circuit .............................................................................................. 47
2
140E-5 Series
30 Testing and adjusting
SEN00149-05
Testing and adjusting (with EGR) Testing and adjusting tools list Testing and adjusting item
Symbol
1
1
Part No.
Part name
Q'ty
Remarks
799-201-2202 Boost gauge kit
1
–101 – 200 kPa {–760 – 1,500 mmHg}
799-401-2220 Hose
1
I-coupler type (if necessary)
Testing air boost pressure
A
Testing exhaust temperature
B
799-101-1502 Digital thermometer
1
–99.9 – 1,299°C
Adjusting valve clearance
C
Commercially Clearance gauge available
1
Intake: 0.35 mm Exhaust: 0.57 mm
1 795-502-1590 Compression gauge
1
0 – 7 MPa {0 – 70 kg/cm2}
Testing compression pressure
D
795-471-1330 Adapter
1
6261-71-6150 Gasket
1
799-201-1504 Blow-by checker
1
0 – 5 kPa {0 – 500 mmH2O}
799-101-5002 Hydraulic tester
1
Pressure gauge: 2.5, 6, 40, 60 MPa {25, 60, 400, 600 kg/cm2}
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}
799-101-5002 Hydraulic tester
1
Pressure gauge: 2.5, 6, 40, 60 MPa {25, 60, 400, 600 kg/cm2}
790-261-1204 Digital hydraulic tester
1
Pressure gauge: 60 MPa {600 kg/cm2}
1
Pressure gauge: 1 MPa {10 kg/cm2}
795-471-1450 Adapter
1
8 × 1.25 mm o R1/8
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
3
Commercially Hose available
1
∅5mm × 2 – 3 m
H 4
Commercially Hose available
1
∅15mm × 2 – 3 m
5
Commercially Measuring cylinder available
1
6
Commercially Stopwatch available
1
Testing blow-by pressure Testing engine oil pressure Testing EGR valve and bypass valve drive oil pressure
2 E
F
1
1 Testing fuel pressure
G
2 799-401-2320 Gauge 3
Testing fuel return rate and leakage
140E-5 Series
For 140E-5
3
SEN00149-05
Testing and adjusting item
Troubleshooting for controllers, sensors, and actuators
30 Testing and adjusting
Symbol
J
Part No.
Part name
Q'ty
799-601-4130 T-adapter
— For Ne sensor
799-601-4330 Socket
— For Bkup sensor
799-601-4240 Socket
— For atmospheric pressure sensor
799-601-4250 Socket
— For boost pressure sensor
799-601-4180 T-adapter
— For EGR gas sensor
799-601-9420 T-adapter
— For common rail pressure
799-601-4150 T-adapter
— For oil pressure sensor
795-799-5540 T-adapter
— For boost temperature sensor
795-799-5530 T-adapter
—
For coolant temperature sensor For fuel temperature sensor
799-601-9020 T-adapter
—
For EGR valve solenoid For bypass valve solenoid
799-601-9030 T-adapter
—
For EGR valve stroke sensor For bypass valve stroke sensor
799-601-9430 T-adapter
— For supply pump PCV
799-601-9020 T-adapter
— For injector
799-601-4260 T-adapter
— For controller (4-pole)
799-601-4210 T-adapter
— For controller (50-pole)
799-601-4220 T-adapter
— For controller (60-pole)
799-601-9320 T-box
—
799-601-9310 Plate
—
799-601-4350 T-box
— For 60-pole type
Checking coolant temperature and oil temperature
—
799-101-1502 Digital thermometer
1
Checking voltage and resistance
—
Commercially Tester available
1
Removal and installation of engine coolant temperature sensor
Commercially Socket available
For 24-pole type
–99.9 – 1,299°C
1
21 mm deep socket (MITOLOY 4ML 21 or equivalent) Applicable engine serial No.: 530056-534132
1
19 mm deep socket (MITOLOY 4ML 19 or equivalent) Applicable engine serial No.: 534133 and up
— 795T-981-1010 Socket
4
Remarks
140E-5 Series
30 Testing and adjusting
Sketches of special tools
SEN00149-05
1
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches. Socket
140E-5 Series
5
SEN00149-05
30 Testing and adjusting
Testing air boost pressure a
Testing tools for air boost pressure
Symbol A k
a 1.
1
Part No.
Part name
799-201-2202
Boost gauge kit
799-401-2220
Hose
Be careful not to touch any hot part when removing or installing the testing tools. The test point is subject to machine models. Remove air boost pressure pickup plug (1) from the bottom of the air intake connector. 4.
2.
Install nipple [1] of boost gauge kit A and connect it to gauge [2].
3.
Run the engine at the rated output and test the air boost pressure. a When testing with the engine mounted on the machine, test on the condition described in the shop manual for the machine.
6
After finishing testing, remove the testing tools and return the removed parts. q Remove the gasket sealant remaining on the threads of the removed plug with a wire brush and apply new adhesive or gasket sealant to the plug before installing. 2 Plug: Adhesive (LT2) or gasket sealant (LG-5) 3 Plug: 6.9 – 14.7 Nm {0.7 – 1.5 kgm} (*1) 9.8 – 19.6 Nm {1.0 – 2.0 kgm} (*2) (*1): When air intake connector is made of iron. (*2): When air intake connector is made of aluminum.
140E-5 Series
30 Testing and adjusting
SEN00149-05
Testing exhaust temperature a
Testing tool for exhaust temperature
Symbol
Part No.
B
799-101-1502
k
a 1.
1
Part name Digital thermometer
Remove and install the testing tools after the exhaust manifold temperature has lowered. The test point is subject to machine models. Remove exhaust temperature pickup plug (1) from the bottom of the exhaust manifold. a You may measure at either front or rear plug.
2.
Install sensor [1] of digital thermometer B and connect it to thermometer [2].
3.
Run the engine and test the exhaust temperature in the whole speed range. a When testing with the engine mounted on the machine, test on the condition described in the shop manual for the machine.
140E-5 Series
4.
After finishing testing, remove the testing tools and return the removed parts. q Clean the thread of the removed plug and apply seizure prevention compound to the plug before installing. 2 Plug: Seizure prevention compound (LC-G) (NEVER-SEEZ (NEVER-SEEZ COMPOUND CO, LTD) or equivalent). 3 Plug: 2.9 – 5.9 Nm {0.3 – 0.6 kgm}
7
SEN00149-05
30 Testing and adjusting
Adjusting valve clearance a
Part No.
C
Commercially available
2.
8
3.
While fixing adjustment screw (3), loosen locknut (4). a After setting the No. 1 cylinder to the compression top dead center, adjust the valve clearance of the No. 1 cylinder.
4.
Insert clearance gauge C in the clearance between rocker arm (5) and crosshead (6) and adjust the valve clearance with adjustment screw (3). a With the clearance gauge inserted, turn the adjustment screw to a degree that you can move the thickness gauge lightly. a Valve clearance Intake valve: 0.35 mm, Exhaust valve: 0.57 mm
5.
While fixing adjustment screw (3), tighten locknut (4). 3 Locknut: 45.1 – 51.0 Nm {4.6 – 5.2 kgm} a After tightening the locknut, check the valve clearance again.
6.
After adjusting the No. 1 cylinder, rotate the crankshaft forward by 120° and adjust the clearance of each cylinder according the firing order. a Firing order: 1 – 5 – 3 – 6 – 2 – 4
7.
After finishing adjustment, return the removed parts. 3 Cylinder head cover mounting bolt: 29.4 – 34.3 Nm {3.0 – 3.5 kgm}
Adjusting tool for valve clearance
Symbol
1.
1
Part name Clearance gauge
Remove 6 cylinder head covers (1).
Rotate the crankshaft forward to bring the stamped “1.6TOP” line (a) of the damper to pointer (2) and set the No. 1 cylinder to the compression top dead center. a Rotate the crankshaft with the hexagonal part at the end of the water pump drive shaft. a When the No. 1 cylinder is at the compression top dead center, the rocker arm of the No. 1 cylinder can be moved by the valve clearance with the hand. If the rocker arm cannot be moved, rotate the crankshaft one more turn.
140E-5 Series
30 Testing and adjusting
SEN00149-05
Testing compression pressure a
Testing tools for compression pressure
Symbol 1 D
k
a
1.
1
2
Part No.
Part name
795-502-1590
Compression gauge
795-471-1330
Adapter
6261-71-6150
Gasket
When measuring the compression pressure, take care not to burn yourself on the exhaust manifold, muffler, etc. or get caught in a rotating part. Measure the compression pressure after the engine is warmed up (Engine oil temperature: 40 – 60°C).
4.
Install adapter D2 to the mounting hole on the injector and the compression gauge D1. a Fit the gasket to the adapter end without fail. a Fix the adapter with the injector holder. 3 Holder mounting bolt: 58.8 – 73.5 Nm {6.0 – 7.5 kgm} a Apply a little amount of engine oil to the connecting parts of the adapter and gauge so that air will not leak easily.
5.
Install rocker arm assembly (2) and adjust the valve clearance. 3 Rocker arm mounting bolt: 93 – 103 Nm {9.5 – 10.5 kgm} a See “Adjusting valve clearance.”
6.
Connect the INSITE (bench test tool) to the engine and set the engine in the no-injection cranking mode. a When inspecting with the engine mounted on the machine, set the engine in the noinjection cranking mode by operating the monitor panel. k If the engine is not set in the no-injection cranking mode, it will start and will be dangerous. Accordingly, be sure to set the engine in this mode.
Remove cylinder head cover (1) of the cylinder to be tested for compression pressure.
2.
Bring the cylinder to be tested to the compression top dead center and remove rocker arm assembly (2). a See “Adjusting valve clearance.”
3.
Disconnect fuel high-pressure tube (3) and injector wiring harness and remove injector (4). a Disconnect the terminal of the injector wiring harness on the injector side and the bracket on the rocker housing side and r e m o v e t h e i n j e c t o r w ir i n g h a r n e s s (Loosen the 2 terminal nuts alternately). a Pass a wire, etc. under the fuel path projected sideways and pull up the injector (Do not pry the injector top up).
140E-5 Series
9
SEN00149-05
7.
Rotate the engine with the starting motor and measure the compression pressure. a Read the pressure gauge pointer when it is stabilized.
8.
After finishing testing, remove the testing tools and return the removed parts. a Install the injector and fuel high-pressure tube according to the following procedure. 1) Push in injector (11) with the hand to assemble holder (12) temporarily. a Change the copper gasket and the O-ring for a new part. 2) Tighten bolt (13) and washer (14) temporarily. 2 Spherical part of washer: Engine oil 3) Tighten sleeve nut (15) of the fuel highpressure tube temporarily. 4) Tighten bolt (13) permanently. 3 Bolt: 58.8 – 73.5 Nm {6.0 – 7.5 kgm} 5) Tighten sleeve nut (15) permanently. 3 Sleeve nut: 39.2 – 49.0 Nm {4 – 5 kgm}
30 Testing and adjusting
a
Install the injector wiring harness according to the following procedure. 1) Install the injector wiring harness to the rocker arm housing and fix the connector side with the plate. 2) Fix the intermediate clamp with the clip. 3) Tighten the nut on the injector side. 3 Nut: 2 ± 0.2 Nm {0.2 ± 0.02 kgm} 4) Secure the clamp and spacer with the bolt. 3
a
Adjust the valve clearance. For details, see “Adjusting valve clearance.”
3
10
Rocker arm assembly mounting bolt: 93 – 103 Nm {9.5 – 10.5 kgm}
Cylinder head cover mounting bolt: 29.4 – 34.3 Nm {3.0 – 3.5 kgm}
140E-5 Series
30 Testing and adjusting
SEN00149-05
Testing blow-by pressure a
1
Testing tool for blow-by pressure
Symbol
Part No.
E
799-201-1504
Part name Blow-by checker
a
The test point is subject to machine models.
1.
Install nozzle [1] of blow-by checker E to the end of blow-by hose (1).
2.
Connect hose [2], and then connect it to gauge [3].
3.
Run the engine at the rated output and test the blow-by pressure. a When testing with the engine mounted on the machine, test on the condition described in the shop manual for the machine.
4.
After finishing testing, remove the testing tools and return the removed parts.
140E-5 Series
11
SEN00149-05
30 Testing and adjusting
Testing engine oil pressure a
Testing tools for engine oil pressure
Symbol F
1
1 2
Part No.
Part name
799-101-5002
Hydraulic tester
790-261-1204
Digital hydraulic tester
799-401-2320
Hydraulic tester
a
The test point is subject to machine models.
1.
Remove oil pressure pickup plug (1) from the cylinder block.
4.
2.
Install nipples [1] and [2] of hydraulic tester F1 and connect them to hydraulic tester F2. a Since the size of the plug hole is R1/4, quick nipple (799-101-5210) may be used.
3.
Run the engine at the rated output and low idle and test the oil pressure. a When testing with the engine mounted on the machine, test on the condition described in the shop manual for the machine.
12
After finishing testing, remove the testing tools and return the removed parts. q Remove the gasket sealant remaining on the threads of the removed plug with a wire brush and apply new adhesive or gasket sealant to the plug before installing. 2 Plug: Adhesive (LT2) or gasket sealant (LG-5) 3 Plug: 16.7 – 37.2 Nm {1.7 – 3.8 kgm}
140E-5 Series
30 Testing and adjusting
SEN00149-05
Testing EGR valve and bypass valve drive oil pressure a
Connect hydraulic tester [2] (Component part of tool F1) to the nipple.
4.
Start the engine and measure the oil pressure at low idle and high idle.
5.
After finishing measurement, remove the measuring instruments and return the removed parts. Remove the gasket sealant remaining on the threads of the removed plug with a wire brush and apply new adhesive or gasket sealant to the plug before installing. 2 Plug: Adhesive (LT2) or gasket sealant (LG-5) 3 Plug: 9.8 – 19.6 Nm {1.0 – 2.0 kgm}
1
Testing instrument for EGR valve and bypass valve drive oil pressure
Symbol F
3.
1
Part No.
Part name
799-101-5002
Hydraulic tester
790-261-1204
Digital hydraulic tester
a
The measuring point may be different from the following explanation, depending on each applicable machine.
1.
Remove oil pressure pickup plug (2) from the left side of timing gear cover (1).
2.
Install nipple [1] (Component part of tool F1: PT 1/8) to the hole from which the oil pressure pickup plug was removed.
q
140E-5 Series
13
SEN00149-05
Handling fuel system parts a
a
14
30 Testing and adjusting
1
Precautions for testing and maintaining fuel system The common rail fuel injection system (CRI) consists of more precise parts than the conventional fuel injection pump and nozzle. If foreign matter enters this system, it can cause a trouble. When testing and maintaining the fuel system, take care more than the past. If dust, etc. sticks to any part, wash that part thoroughly with clean fuel. Precautions for replacing fuel filter cartridge Be sure to use the Komatsu genuine fuel filter cartridge. Since the common rail fuel injection system (CRI) consists of more precise parts than the conventional fuel injection pump and nozzle, it employs a high-efficiency special filter to prevent foreign matter from entering it. If a filter other than the genuine one is used, the fuel system may have a trouble. Accordingly, never use such a filter.
Releasing residual pressure in fuel system a
a
a
k
1
Pressure is generated in the low-pressure circuit and high-pressure circuit of the fuel system while the engine is running. Low-pressure circuit: Feed pump – Fuel filter – Supply pump High-pressure circuit: Supply pump – Common rail – Injector The pressure in both low-pressure circuit and high-pressure circuit lowers to a safety level automatically 30 seconds after the engine is stopped. Before the fuel circuit is tested and its parts are removed, the residual pressure in the fuel circuit must be released completely. Accordingly, observe the following. Before testing the fuel system or removing its parts, wait at least 30 seconds after stopping the engine until the residual pressure in the fuel circuit is released. (Do not start the work just after stopping the engine since there is residual pressure.)
140E-5 Series
30 Testing and adjusting
SEN00149-05
Testing fuel pressure a
1 2 3
a k
1.
3.
Testing tools for fuel pressure
Symbol
G
1
Part No.
Part name
799-101-5002
Hydraulic tester
790-261-1204
Digital hydraulic tester
799-401-2320
Gauge
795-471-1450
Adapter
07005-00812
Gasket
Engine speed
Fuel pressure
High idle
0.15 – 0.3 MPa {1.5 – 3 kg/cm2}
Check the fuel pressure in only the low-pressure circuit from the feed pump via the fuel filter to the supply pump. Since the pressure in the high-pressure circuit from the supply pump through the common rail to the injector is very high, it cannot be measured. Remove fuel pressure pickup plug (1) from the fuel filter head.
4.
2.
Run the engine at high idle and measure the fuel pressure. a If the fuel pressure is in the following range, it is normal.
After finishing testing, remove the testing tools and return the removed parts. 3 Plug: 7.8 – 9.8 Nm {0.8 – 1.0 kgm}
Install adapter G3, 90° elbow [1] of hydraulic tester G1, and nipple [2] and connect them to gauge G2.
140E-5 Series
15
SEN00149-05
Reduced cylinder mode operation
30 Testing and adjusting
No-injection cranking a
a
1.
2.
3.
16
1
1
Reduced cylinder mode operation means to run the engine with the fuel injectors of 1 or more cylinders disabled electrically to reduce the number of effective cylinders. The purposes and effects of this operation are as follows. This operation is used to find out a cylinder which does not output power normally (or, combustion in it is abnormal). When a cylinder is selected for the reduced cylinder mode operation, if the engine speed and output do not change from the normal operation (all-cylinder operation), that cylinder has 1 or more defects. The possible defects are as follows. q Leakage of compression through cylinder head gasket q Defective injection q Defective piston, piston ring, or cylinder liner q Defective valve mechanism (Moving valve system) q Defect in electrical system Since the common rail fuel injection system controls the injector of each cylinder electronically, the operator can perform the reduced cylinder mode operation easily with switches to find out a defective cylinder. a Perform the reduced cylinder mode operation with the engine mounted on the machine or connected to INSITE (bench test tool). Before performing, see Testing method in the shop manual for the machine or INSITE (bench test tool).
q
a
No-injection cranking means to crank the engine with the starting motor while all the injections are stopped electrically. The purpose and effect of this operation are as follows. Before the engine is started after it or the machine has been stored for a long period, the no-injection cranking is performed to lubricate the engine parts and protect them from seizure. Perform the no-injection operation with the engine mounted on the machine or connected to INSITE (bench test tool). Before performing, see Testing method in the shop manual for the machine or INSITE (bench test tool).
140E-5 Series
30 Testing and adjusting
SEN00149-05
Testing fuel return rate and leakage
1
Type of engine having intake manifold equipped with return block
a
If the engine has the intake manifold equipped with the return block on it to return the fuel spilling from the injector to the fuel tank, test the fuel return rate and fuel leakage according to the following procedure (The figure shows the engine for D155AX-6).
a
Testing tools for fuel return rate and leakage
Symbol
H
a
Part No.
Part name
1
6151-51-8490
Spacer
2
6206-71-1770
Joint
3
Commercially available Hose
4
Commercially available Hose
5
Commercially available Measuring cylinder
6
Commercially available Stopwatch
1.
Preparation work 1) Remove tube (3) between common rail (1) and supply pump (2). 2) Insert spacer H1 on supply pump (2) side and tighten the removed joint bolt again. a Connect the return pipe to the fuel tank again, too. a Be sure to fit the gaskets to both ends of the spacer.
Prepare a receiving pan of about 20 l to receive the fuel flowing out during the test.
140E-5 Series
17
SEN00149-05
30 Testing and adjusting
a
3)
4)
2.
18
Insert joint H2 on common rail (1) side and tighten the removed joint bolt again. a Be sure to fit the gaskets to both ends of the joint. Connect test hose H3 to the end of joint H2. a Bind the connecting part of the test hose with a wire, etc. to prevent it from coming off. a The above is the preparation work for testing the leakage from the pressure limiter.
Testing leakage from pressure limiter 1) Lay test hose H3 so that it will not slacken and put its end in the receiving pan. 2) Connect INSITE (bench test tool) to the engine and set it so that it can check the engine speed. q Or set on the machine so that it can check the engine speed. 3) Start the engine and keep its speed to rated output. 4) After the engine speed is stabilized, test the leakage in 1 minute with measuring cylinder H5. a You may test for 20 seconds and judge by multiplying the result by 3.
5) 3.
If the leakage from the pressure limiter is in the following range, it is normal. Engine speed
Leakage (cc/min)
At rated output
Max. 10
After finishing testing, stop the engine.
Testing return rate from injector a Keep the hose on the pressure limiter side connected and keep its end in the receiving pan while testing the return rate from the injector. 1) Disconnect return hose (5) of return block (4) and connect test hose H4. a Stop the return hose with a plug, etc. and fix it to the fuel tank. Plug: 07376-70315 a Bind the connecting part of the test hose with a wire, etc. to prevent it from coming off. 2) Lay test hose H4 so that it will not slacken and put its end in the receiving pan.
3)
Connect INSITE (bench test tool) to the engine and set it so that it can check the engine speed. q Or set on the machine so that it can check the engine speed.
140E-5 Series
30 Testing and adjusting
4) 5)
6) 4.
SEN00149-05
Run the engine at the rated output. After the engine speed is stabilized, test the return rate in 1 minute with measuring cylinder H5. a You may test for 20 seconds and judge by multiplying the result by 3. a If the supply pump is not supplying fuel, the engine speed may not rise. In this case, record the engine speed, too, during the test. a If the return rate (spill) from the injector is in the following range, it is normal. Rated output speed (rpm)
Limit of return rate (spill) (cc/min)
1,600
960
1,700
1,020
1,800
1,080
1,900
1,140
2,000
1,200
After finishing testing, stop the engine.
Work after finishing testing After finishing all testing, remove the testing tools and return the removed parts. 3 Common rail pressure limiter joint bolt: 17.7 – 22.6 Nm {1.8 – 2.3 kgm} 3 Supply pump overflow joint bolt: 14.8 – 19.6 Nm {1.5 – 2.0 kgm}
140E-5 Series
19
SEN00149-05
Bleeding air from fuel circuit
a a
1.
20
30 Testing and adjusting
1
If fuel is used up or if a fuel circuit part is removed and installed, bleed air from the fuel circuit according to the following procedure. The locations of the fuel circuit parts are subject to machine models (The figure shows the engine for D155AX-6). Remove fuel pre-filter (1) and fill it with fuel. a Fill the fuel filter with clean fuel and take care that dirt will not enter it. a Check that the cap is fitted to part (a) (central hole) of the fuel pre-filter, and then add fuel through part (b) (holes around the central hole). a After filling the fuel pre-filter with fuel, remove the cap from part (a). a If clean fuel is not available, do not remove the fuel pre-filter but fill it with the fuel by operating priming pump (4). a Do not add fuel to fuel main filter (2) from outside.
2.
Install fuel pre-filter (1) to the filter head. a Apply engine oil thinly over the packing on the fuel pre-filter side. a After the packing of the fuel pre-filter touches the sealing face of the filter head, tighten the fuel pre-filter 3/4 turns.
140E-5 Series
30 Testing and adjusting
SEN00149-05
6.
3.
Remove air bleed plug (3) of the fuel main filter (2) and operate priming pump (4). a Operate the priming pump until the fuel flows out of the plug hole and install the plug. 3 Air bleed plug: 7.8 – 9.8 Nm {0.8 – 1.0 kgm}
4.
Remove air bleed plug (5) of the fuel main filter (2) and operate priming pump (4). a Operate the priming pump until the fuel flows out of the plug hole and install the plug. 3 Air bleed plug: 7.8 – 9.8 Nm {0.8 – 1.0 kgm}
5.
Loosen air bleeder (6) of the fuel supply pump and operate priming pump (4) 90 – 100 times. a Operate the priming pump until the fuel flows out of the air bleeder and tighten the air bleeder. Then, operate the priming pump several times more until it becomes heavy. 3 Air bleeder: 4.9 – 6.9 Nm {0.5 – 0.7 kgm}
140E-5 Series
Start the engine with the starting motor. a The air in the high-pressure circuit is bled automatically if the engine is cranked. a If the engine does not start, there may be still air in the low-pressure circuit. In this case, repeat the above procedure from step 3.
21
SEN00149-05
30 Testing and adjusting
Testing fuel system for leakage 1 k
a
9. Very high pressure is generated in the highpressure circuit of the fuel system. If fuel leaks while the engine is running, it is dangerous since it can catch fire. After testing the fuel system or removing its parts, test it for fuel leakage according to the following procedure. Clean and degrease the engine and the parts around it in advance so that you can test it easily for fuel leakage.
1.
Spray color checker (developer) over the fuel supply pump, common rail, fuel injector, and joints of the high-pressure piping.
2.
Run the engine at speed below 1,000 rpm and stop it after its speed is stabilized.
3.
Inspect the fuel piping and devices for fuel leakage. a Inspect mainly around the high-pressure circuit parts coated with the color checker for fuel leakage. a If any fuel leakage is detected, repair it and inspect again from step 1.
4.
Run the engine at low idle.
5.
Inspect the fuel piping and devices for fuel leakage. a Inspect mainly around the high-pressure circuit parts coated with the color checker for fuel leakage. a If any fuel leakage is detected, repair it and inspect again from step 1.
6.
Run the engine at high idle.
7.
Inspect the fuel piping and devices for fuel leakage. a Inspect mainly around the high-pressure circuit parts coated with the color checker for fuel leakage. a If any fuel leakage is detected, repair it and inspect again from step 1.
8.
Run the engine at high idle and load it. a When testing the engine mounted on the machine, stall the torque converter or relieve the oil from the hydraulic pump.
22
Inspect the fuel piping and devices for fuel leakage. a Inspect mainly around the high-pressure circuit parts coated with the color checker for fuel leakage. a If any fuel leakage is detected, repair it and inspect again from step 1. a If no fuel leakage is detected, inspection is completed.
140E-5 Series
30 Testing and adjusting
SEN00149-05
Testing and adjusting alternator belt tension 1 Testing Press the intermediate point of the belt between alternator pulley and drive pulley with a finger and measure deflection (a) of the belt. a Pressing force: Approx. 98 N {Approx. 10 kg} a Deflection (a): 13 – 16 mm (1 piece)
Adjusting a If the deflection is out of the standard range, adjust it according to the following procedure. 1.
Loosen mounting bolts (2), (3) and (4) of alternator (1), and then loosen locknut (5).
2.
Move alternator (1) with adjustment nut (6) to adjust the tension of belt (7).
3.
Tighten locknut (5), and then tighten mounting bolts (3), (2) and (1). a After adjusting, test the belt tension again.
140E-5 Series
23
SEN00149-05
Testing and adjusting fan belt tension
30 Testing and adjusting
1
Testing Press the intermediate point (at the arrow) of the belt (1) between fan pulley and crankshaft pulley with a finger and measure the deflection of the belt. a Check the belts one by one. a Pressing force: Approx. 98 N {Approx. 10 kg} a Deflection: 15 – 17 mm (When new) 19 – 21 mm (When retightened) Adjusting a If the deflection is out of the standard range, adjust it according to the following procedure. 1.
Loosen lock bolt of tension pulley (3).
2.
Move tension pulley (3) with adjustment bolt (2) to adjust the belt tension. a After adjusting, test the belt tension again.
3.
Tighten lock bolt of tension pulley (3).
24
140E-5 Series
30 Testing and adjusting
Handling controller high-voltage circuit 1.
Before disconnecting or connecting the connector between the engine controller and engine, be sure to turn the starting switch OFF.
2.
If the T-adapter is inserted in or connected to the connector between the engine controller and engine for troubleshooting, do not start the engine. a You may turn the starting switch to the OFF or ON position but must not turn it to the START position.
140E-5 Series
SEN00149-05
1
25
SEN00149-05
30 Testing and adjusting
Testing and adjusting (EGR-less)
1
Testing and adjusting tools list
1
Testing and adjusting item
Symbol
799-401-2220 Hose
1
I-coupler type (if necessary)
B
799-101-1502 Digital thermometer
1
–99.9 – 1,299°C
C
Commercially Clearance gauge available
1
Intake: 0.35 mm Exhaust: 0.57 mm
1 795-502-1590 Compression gauge
1
0 – 7 MPa {0 – 70 kg/cm2}
Adjusting valve clearance
D
795-471-1330 Adapter
1
6261-71-6150 Gasket
1
799-201-1504 Blow-by checker
1
0 – 5 kPa {0 – 500 mmH2O}
799-101-5002 Hydraulic tester
1
Pressure gauge: 2.5, 6, 40, 60 MPa {25, 60, 400, 600 kg/cm2}
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}
799-101-5002 Hydraulic tester
1
Pressure gauge: 2.5, 6, 40, 60 MPa {25, 60, 400, 600 kg/cm2}
790-261-1204 Digital hydraulic tester
1
Pressure gauge: 60 MPa {600 kg/cm2}
1
Pressure gauge: 1 MPa {10 kg/cm2}
795-471-1450 Adapter
1
8 × 1.25 mm o R1/8
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
3
Commercially Hose available
1
∅5mm × 2 – 3 m
H 4
Commercially Hose available
1
∅15mm × 2 – 3 m
5
Commercially Measuring cylinder available
1
6
Commercially Stopwatch available
1
Testing blow-by pressure
2 E
F
1
1 G
2 799-401-2320 Gauge 3
Testing fuel return rate and leakage
26
Remarks –101 – 200 kPa {–760 – 1,500 mmHg}
Testing exhaust temperature
Testing fuel pressure
Q'ty 1
A
Testing engine oil pressure
Part name
799-201-2202 Boost gauge kit
Testing air boost pressure
Testing compression pressure
Part No.
For 140E-5
140E-5 Series
30 Testing and adjusting
Testing and adjusting item
Troubleshooting for controllers, sensors, and actuators
Symbol
J
SEN00149-05
Part No.
Part name
Q'ty
799-601-4130 T-adapter
— For Ne sensor
799-601-4330 Socket
— For Bkup sensor
799-601-4240 Socket
— For atmospheric pressure sensor
799-601-4250 Socket
— For boost pressure sensor
799-601-9420 T-adapter
— For common rail pressure
799-601-4150 T-adapter
— For oil pressure sensor
795-799-5540 T-adapter
— For boost temperature sensor
795-799-5530 T-adapter
—
799-601-9430 T-adapter
— For supply pump PCV
799-601-9020 T-adapter
— For injector
799-601-4260 T-adapter
— For controller (4-pole)
799-601-4210 T-adapter
— For controller (50-pole)
799-601-4220 T-adapter
— For controller (60-pole)
799-601-9320 T-box
—
799-601-9310 Plate
—
799-601-4350 T-box
— For 60-pole type
Checking coolant temperature and oil temperature
—
799-101-1502 Digital thermometer
1
Checking voltage and resistance
—
Commercially Tester available
1
Removal and installation of engine coolant temperature sensor
Commercially Socket available
For coolant temperature sensor For fuel temperature sensor
For 24-pole type
–99.9 – 1,299°C
1
21 mm deep socket (MITOLOY 4ML 21 or equivalent) Applicable engine serial No.: 530056-534132
1
19 mm deep socket (MITOLOY 4ML 19 or equivalent) Applicable engine serial No.: 534133 and up
— 795T-981-1010 Socket
140E-5 Series
Remarks
27
SEN00149-05
Sketches of special tools
30 Testing and adjusting
1
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches. Socket
28
140E-5 Series
30 Testing and adjusting
SEN00149-05
Testing air boost pressure a
Testing tools for air boost pressure
Symbol A k
a 1.
1
Part No.
Part name
799-201-2202
Boost gauge kit
799-401-2220
Hose
Be careful not to touch any hot part when removing or installing the testing tools. The test point is subject to machine models. Remove air boost pressure pickup plug (1) from the bottom of the air intake connector. 4.
2.
Install nipple [1] of boost gauge kit A and connect it to gauge [2].
3.
Run the engine at the rated output and test the air boost pressure. a When testing with the engine mounted on the machine, test on the condition described in the shop manual for the machine.
140E-5 Series
After finishing testing, remove the testing tools and return the removed parts. q Remove the gasket sealant remaining on the threads of the removed plug with a wire brush and apply new adhesive or gasket sealant to the plug before installing. 2 Plug: Adhesive (LT2) or gasket sealant (LG-5) 3 Plug: 6.9 – 14.7 Nm {0.7 – 1.5 kgm} (*1) 9.8 – 19.6 Nm {1.0 – 2.0 kgm} (*2) (*1): When air intake connector is made of iron. (*2): When air intake connector is made of aluminum.
29
SEN00149-05
30 Testing and adjusting
Testing exhaust temperature a
1
Testing tool for exhaust temperature
Symbol
Part No.
B
799-101-1502
k
Part name Digital thermometer
a
Remove and install the testing tools after the exhaust manifold temperature has lowered. The test point is subject to machine models.
1.
Remove the heat insulation cover.
2.
Remove exhaust temperature pickup plug (1) from the bottom of the exhaust manifold.
3.
Install sensor [1] of digital thermometer B and connect it to thermometer [2].
4.
Run the engine and test the exhaust temperature in the whole speed range. a When testing with the engine mounted on the machine, test on the condition described in the shop manual for the machine.
30
5.
After finishing testing, remove the testing tools and return the removed parts. q Clean the thread of the removed plug and apply seizure prevention compound to the plug before installing. 2 Plug: Seizure prevention compound (LC-G) (NEVER-SEEZ (NEVER-SEEZ COMPOUND CO, LTD) or equivalent). 3 Plug: 2.9 – 5.9 Nm {0.3 – 0.6 kgm}
140E-5 Series
30 Testing and adjusting
SEN00149-05
Adjusting valve clearance a
Part No.
C
Commercially available
2.
3.
While fixing adjustment screw (3), loosen locknut (4). a After setting the No. 1 cylinder to the compression top dead center, adjust the valve clearance of the No. 1 cylinder.
4.
Insert clearance gauge C in the clearance between rocker arm (5) and crosshead (6) and adjust the valve clearance with adjustment screw (3). a With the clearance gauge inserted, turn the adjustment screw to a degree that you can move the thickness gauge lightly. a Valve clearance Intake valve: 0.35 mm, Exhaust valve: 0.57 mm
5.
While fixing adjustment screw (3), tighten locknut (4). 3 Locknut: 45.1 – 51.0 Nm {4.6 – 5.2 kgm} a After tightening the locknut, check the valve clearance again.
6.
After adjusting the No. 1 cylinder, rotate the crankshaft forward by 120° and adjust the clearance of each cylinder according the firing order. a Firing order: 1 – 5 – 3 – 6 – 2 – 4
7.
After finishing adjustment, return the removed parts. 3 Cylinder head cover mounting bolt: 29.4 – 34.3 Nm {3.0 – 3.5 kgm}
Adjusting tool for valve clearance
Symbol
1.
1
Part name Clearance gauge
Remove 6 cylinder head covers (1).
Rotate the crankshaft forward to bring the stamped “1.6TOP” line (a) of the damper to pointer (2) and set the No. 1 cylinder to the compression top dead center. a Rotate the crankshaft with the hexagonal part at the end of the water pump drive shaft. a When the No. 1 cylinder is at the compression top dead center, the rocker arm of the No. 1 cylinder can be moved by the valve clearance with the hand. If the rocker arm cannot be moved, rotate the crankshaft one more turn.
140E-5 Series
31
SEN00149-05
30 Testing and adjusting
Testing compression pressure a
Testing tools for compression pressure
Symbol 1 D
k
a
1.
1
2
Part No.
Part name
795-502-1590
Compression gauge
795-471-1330
Adapter
6261-71-6150
Gasket
When measuring the compression pressure, take care not to burn yourself on the exhaust manifold, muffler, etc. or get caught in a rotating part. Measure the compression pressure after the engine is warmed up (Engine oil temperature: 40 – 60°C).
Install adapter D2 to the mounting hole on the injector and the compression gauge D1. a Fit the gasket to the adapter end without fail. a Fix the adapter with the injector holder. 3 Holder mounting bolt: 58.8 – 73.5 Nm {6.0 – 7.5 kgm} a Apply a little amount of engine oil to the connecting parts of the adapter and gauge so that air will not leak easily.
5.
Install rocker arm assembly (2) and adjust the valve clearance. 3 Rocker arm mounting bolt: 93 – 103 Nm {9.5 – 10.5 kgm} a See “Adjusting valve clearance.”
6.
Connect the INSITE (bench test tool) to the engine and set the engine in the no-injection cranking mode. a When inspecting with the engine mounted on the machine, set the engine in the noinjection cranking mode by operating the monitor panel. k If the engine is not set in the no-injection cranking mode, it will start and will be dangerous. Accordingly, be sure to set the engine in this mode.
Remove cylinder head cover (1) of the cylinder to be tested for compression pressure.
2.
Bring the cylinder to be tested to the compression top dead center and remove rocker arm assembly (2). a See “Adjusting valve clearance.”
3.
Disconnect fuel high-pressure tube (3) and injector wiring harness and remove injector (4). a Disconnect the terminal of the injector wiring harness on the injector side and the bracket on the rocker housing side and r e m o v e t h e i n j e c t o r w ir i n g h a r n e s s (Loosen the 2 terminal nuts alternately). a Pass a wire, etc. under the fuel path projected sideways and pull up the injector (Do not pry the injector top up).
32
4.
140E-5 Series
30 Testing and adjusting
7.
Rotate the engine with the starting motor and measure the compression pressure. a Read the pressure gauge pointer when it is stabilized.
8.
After finishing testing, remove the testing tools and return the removed parts. a Install the injector and fuel high-pressure tube according to the following procedure. 1) Push in injector (11) with the hand to assemble holder (12) temporarily. a Change the copper gasket and the O-ring for a new part. 2) Tighten bolt (13) and washer (14) temporarily. 2 Spherical part of washer: Engine oil 3) Tighten sleeve nut (15) of the fuel highpressure tube temporarily. 4) Tighten bolt (13) permanently. 3 Bolt: 58.8 – 73.5 Nm {6.0 – 7.5 kgm} 5) Tighten sleeve nut (15) permanently. 3 Sleeve nut: 39.2 – 49.0 Nm {4 – 5 kgm}
SEN00149-05
a
Install the injector wiring harness according to the following procedure. 1) Install the injector wiring harness to the rocker arm housing and fix the connector side with the plate. 2) Fix the intermediate clamp with the clip. 3) Tighten the nut on the injector side. 3 Nut: 2 ± 0.2 Nm {0.2 ± 0.02 kgm} 4) Secure the clamp and spacer with the bolt. 3
a
Rocker arm assembly mounting bolt: 93 – 103 Nm {9.5 – 10.5 kgm}
Adjust the valve clearance. For details, see “Adjusting valve clearance.”
3
Cylinder head cover mounting bolt: 29.4 – 34.3 Nm {3.0 – 3.5 kgm}
140E-5 Series
33
SEN00149-05
30 Testing and adjusting
Testing blow-by pressure a
1
Testing tool for blow-by pressure
Symbol
Part No.
E
799-201-1504
Part name Blow-by checker
a
The test point is subject to machine models.
1.
Install nozzle [1] of blow-by checker E to the end of blow-by hose (1).
2.
Connect hose [2], and then connect it to gauge [3].
3.
Run the engine at the rated output and test the blow-by pressure. a When testing with the engine mounted on the machine, test on the condition described in the shop manual for the machine.
4.
After finishing testing, remove the testing tools and return the removed parts.
34
140E-5 Series
30 Testing and adjusting
SEN00149-05
Testing engine oil pressure a
Testing tools for engine oil pressure
Symbol F
1
1 2
Part No.
Part name
799-101-5002
Hydraulic tester
790-261-1204
Digital hydraulic tester
799-401-2320
Hydraulic tester
a
The test point is subject to machine models.
1.
Remove oil pressure pickup plug (1) from the cylinder block.
4.
2.
Install nipples [1] and [2] of hydraulic tester F1 and connect them to hydraulic tester F2. a Since the size of the plug hole is R1/4, quick nipple (799-101-5210) may be used.
3.
Run the engine at the rated output and low idle and test the oil pressure. a When testing with the engine mounted on the machine, test on the condition described in the shop manual for the machine.
140E-5 Series
After finishing testing, remove the testing tools and return the removed parts. q Remove the gasket sealant remaining on the threads of the removed plug with a wire brush and apply new adhesive or gasket sealant to the plug before installing. 2 Plug: Adhesive (LT2) or gasket sealant (LG-5) 3 Plug: 16.7 – 37.2 Nm {1.7 – 3.8 kgm}
35
SEN00149-05
Handling fuel system parts a
a
36
30 Testing and adjusting
1
Precautions for testing and maintaining fuel system The common rail fuel injection system (CRI) consists of more precise parts than the conventional fuel injection pump and nozzle. If foreign matter enters this system, it can cause a trouble. When testing and maintaining the fuel system, take care more than the past. If dust, etc. sticks to any part, wash that part thoroughly with clean fuel. Precautions for replacing fuel filter cartridge Be sure to use the Komatsu genuine fuel filter cartridge. Since the common rail fuel injection system (CRI) consists of more precise parts than the conventional fuel injection pump and nozzle, it employs a high-efficiency special filter to prevent foreign matter from entering it. If a filter other than the genuine one is used, the fuel system may have a trouble. Accordingly, never use such a filter.
Releasing residual pressure in fuel system a
a
a
k
1
Pressure is generated in the low-pressure circuit and high-pressure circuit of the fuel system while the engine is running. Low-pressure circuit: Feed pump – Fuel filter – Supply pump High-pressure circuit: Supply pump – Common rail – Injector The pressure in both low-pressure circuit and high-pressure circuit lowers to a safety level automatically 30 seconds after the engine is stopped. Before the fuel circuit is tested and its parts are removed, the residual pressure in the fuel circuit must be released completely. Accordingly, observe the following. Before testing the fuel system or removing its parts, wait at least 30 seconds after stopping the engine until the residual pressure in the fuel circuit is released. (Do not start the work just after stopping the engine since there is residual pressure.)
140E-5 Series
30 Testing and adjusting
SEN00149-05
Testing fuel pressure a
1 2 3
a k
1.
3.
Testing tools for fuel pressure
Symbol
G
1
Part No.
Part name
799-101-5002
Hydraulic tester
790-261-1204
Digital hydraulic tester
799-401-2320
Gauge
795-471-1450
Adapter
07005-00812
Gasket
Engine speed
Fuel pressure
High idle
0.15 – 0.3 MPa {1.5 – 3 kg/cm2}
Check the fuel pressure in only the low-pressure circuit from the feed pump via the fuel filter to the supply pump. Since the pressure in the high-pressure circuit from the supply pump through the common rail to the injector is very high, it cannot be measured. Remove fuel pressure pickup plug (1) from the fuel filter head. a Single cartridge is set for some models. 4.
2.
Run the engine at high idle and measure the fuel pressure. a If the fuel pressure is in the following range, it is normal.
After finishing testing, remove the testing tools and return the removed parts. 3 Plug: 7.8 – 9.8 Nm {0.8 – 1.0 kgm}
Install adapter G3, nipple [1] of hydraulic tester G1, and connect them to gauge G2.
140E-5 Series
37
SEN00149-05
30 Testing and adjusting
Reduced cylinder mode operation1
No-injection cranking
a
a
1.
2.
3.
38
Reduced cylinder mode operation means to run the engine with the fuel injectors of 1 or more cylinders disabled electrically to reduce the number of effective cylinders. The purposes and effects of this operation are as follows. This operation is used to find out a cylinder which does not output power normally (or, combustion in it is abnormal). When a cylinder is selected for the reduced cylinder mode operation, if the engine speed and output do not change from the normal operation (all-cylinder operation), that cylinder has 1 or more defects. The possible defects are as follows. q Leakage of compression through cylinder head gasket q Defective injection q Defective piston, piston ring, or cylinder liner q Defective valve mechanism (Moving valve system) q Defect in electrical system Since the common rail fuel injection system controls the injector of each cylinder electronically, the operator can perform the reduced cylinder mode operation easily with switches to find out a defective cylinder. a Perform the reduced cylinder mode operation with the engine mounted on the machine or connected to INSITE (bench test tool). Before performing, see Testing method in the shop manual for the machine or INSITE (bench test tool).
q
a
1
No-injection cranking means to crank the engine with the starting motor while all the injections are stopped electrically. The purpose and effect of this operation are as follows. Before the engine is started after it or the machine has been stored for a long period, the no-injection cranking is performed to lubricate the engine parts and protect them from seizure. Perform the no-injection operation with the engine mounted on the machine or connected to INSITE (bench test tool). Before performing, see Testing method in the shop manual for the machine or INSITE (bench test tool).
140E-5 Series
30 Testing and adjusting
SEN00149-05
Testing fuel return rate and leakage
1
Type of engine having intake manifold equipped with return block
a
If the engine has the intake manifold equipped with the return block on it to return the fuel spilling from the injector to the fuel tank, test the fuel return rate and fuel leakage according to the following procedure (The figure shows the engine for WA500-6R).
a
Testing tools for fuel return rate and leakage
Symbol
1 2 H
a
Part No.
Part name
6151-51-8490
Spacer
6206-71-1770
Joint
3
Commercially available Hose
4
Commercially available Hose
5
Commercially available Measuring cylinder
6
Commercially available Stopwatch
1.
Preparation work 1) Remove tube (3) between common rail (1) and supply pump (2). 2) Insert spacer H1 on supply pump (2) side and tighten the removed joint bolt again. a Connect the return pipe to the fuel tank again, too. a Be sure to fit the gaskets to both ends of the spacer.
Prepare a receiving pan of about 20 l to receive the fuel flowing out during the test.
140E-5 Series
39
SEN00149-05
30 Testing and adjusting
a
3)
4)
2.
40
Insert joint H2 on common rail (1) side and tighten the removed joint bolt again. a Be sure to fit the gaskets to both ends of the joint. Connect test hose H3 to the end of joint H2. a Bind the connecting part of the test hose with a wire, etc. to prevent it from coming off. a The above is the preparation work for testing the leakage from the pressure limiter.
Testing leakage from pressure limiter 1) Lay test hose H3 so that it will not slacken and put its end in the receiving pan. 2) Connect INSITE (bench test tool) to the engine and set it so that it can check the engine speed. q Or set on the machine so that it can check the engine speed. 3) Start the engine and keep its speed to rated output. 4) After the engine speed is stabilized, test the leakage in 1 minute with measuring cylinder H5. a You may test for 20 seconds and judge by multiplying the result by 3.
5) 3.
If the leakage from the pressure limiter is in the following range, it is normal. Engine speed
Leakage (cc/min)
At rated output
Max. 10
After finishing testing, stop the engine.
Testing return rate from injector a Keep the hose on the pressure limiter side connected and keep its end in the receiving pan while testing the return rate from the injector. 1) Disconnect return hose (5) of return block (4) and connect test hose H4. a Stop the return hose with a plug, etc. and fix it to the fuel tank. Plug: 07376-70315 a Bind the connecting part of the test hose with a wire, etc. to prevent it from coming off. 2) Lay test hose H4 so that it will not slacken and put its end in the receiving pan.
3)
Connect INSITE (bench test tool) to the engine and set it so that it can check the engine speed. q Or set on the machine so that it can check the engine speed.
140E-5 Series
30 Testing and adjusting
4) 5)
6) 4.
SEN00149-05
Run the engine at the rated output. After the engine speed is stabilized, test the return rate in 1 minute with measuring cylinder H5. a You may test for 20 seconds and judge by multiplying the result by 3. a If the supply pump is not supplying fuel, the engine speed may not rise. In this case, record the engine speed, too, during the test. a If the return rate (spill) from the injector is in the following range, it is normal. Rated output speed (rpm)
Limit of return rate (spill) (cc/min)
1,600
960
1,700
1,020
1,800
1,080
1,900
1,140
2,000
1,200
After finishing testing, stop the engine.
Work after finishing testing After finishing all testing, remove the testing tools and return the removed parts. 3 Common rail pressure limiter joint bolt: 17.7 – 22.6 Nm {1.8 – 2.3 kgm} 3 Supply pump overflow joint bolt: 14.8 – 19.6 Nm {1.5 – 2.0 kgm}
140E-5 Series
41
SEN00149-05
Bleeding air from fuel circuit
30 Testing and adjusting
1
4.
Reference: The electric priming pump switch is installed to the chassis. a a
a
Turn “ON” switch (3) of electric priming pump (2) installed to the chassis. a The electric priming pump operates and lamp (4) blinks.
Manual priming pump is set for some models. (See the "with EGR".) Bleed air from the fuel circuit in the following cases according to this procedure. q When the fuel filter is replaced q When fuel is used up q When the engine is started for the first time after the fuel piping or supply pump is replaced If the fuel filter was replaced, do not fill the main filter and prefilter with the fuel.
1.
Turn the starting switch to the “OFF” position.
2.
Check that the fuel valve on the fuel tank side is open.
a
3.
Turn lever (1) of the air bleeding piping to the parallel position with the piping to open the circuit valve.
a a k
The electric priming pump has a timer in it to start and stop itself automatically (See the following figure). The electric priming pump stops while the lamp is blinking. This phenomenon is not abnormal, however. If the switch is turned to the “OFF” position while the lamp is blinking, the lamp goes off and the electric priming pump stops. While the electric priming pump is operating, pressure is applied to the fuel circuit. Do not loosen the air bleeding plug at this time, since the fuel may spout out.
Reference: The operating procedure sticker is stuck near the air bleeding piping lever.
42
5.
After the specified time (approx. 7 minutes), lamp (4) goes off and the electric priming pump stops automatically. a If only the fuel filter was replaced, the air bleeding work is completed now.
6.
If the fuel was used up or the fuel piping or supply pump was replaced and there is not fuel in the fuel circuit, turn switch (3) “ON” after the electric priming pump stops automatically.
140E-5 Series
30 Testing and adjusting
7.
When lamp (4) goes off, the air bleeding work is completed.
8.
Turn lever (1) of the air bleeding piping to the cross position with the piping to close the circuit valve.
SEN00149-05
9.
Start the engine with the starting motor. a Do not operate the starting motor continuously for more than 20 seconds. q After starting the engine, run it at low idle for about 5 minutes to bleed all air from the fuel circuit. q Stop the engine and check that the air bleeding valve is closed. 10. If the engine does not start, try to start it again according to the following procedure. k When starting the engine, check that there is no person around it. a Carry out the work with the air bleeding valve closed. (Do not open the air bleeding valve after step 7.) a After the engine fails to start, wait for about 2 minutes before trying to start again. 1) Turn the electric priming pump switch ON. 2) While the electric priming pump is operating, crank the engine. q If the engine does not start, repeat the above operation. a Do not operate the starting motor continuously for more than 20 seconds. a If the engine fails to start, wait for about 2 minutes and try to start again. 3) After starting the engine, run it at low idle for about 5 minutes to bleed all air from the fuel circuit. 4) Stop the engine and check that the air bleeding valve is closed. 5) After the above operation, start the engine normally.
140E-5 Series
43
SEN00149-05
30 Testing and adjusting
Testing fuel system for leakage 1 k
a
9. Very high pressure is generated in the highpressure circuit of the fuel system. If fuel leaks while the engine is running, it is dangerous since it can catch fire. After testing the fuel system or removing its parts, test it for fuel leakage according to the following procedure. Clean and degrease the engine and the parts around it in advance so that you can test it easily for fuel leakage.
1.
Spray color checker (developer) over the fuel supply pump, common rail, fuel injector, and joints of the high-pressure piping.
2.
Run the engine at speed below 1,000 rpm and stop it after its speed is stabilized.
3.
Inspect the fuel piping and devices for fuel leakage. a Inspect mainly around the high-pressure circuit parts coated with the color checker for fuel leakage. a If any fuel leakage is detected, repair it and inspect again from step 1.
4.
Run the engine at low idle.
5.
Inspect the fuel piping and devices for fuel leakage. a Inspect mainly around the high-pressure circuit parts coated with the color checker for fuel leakage. a If any fuel leakage is detected, repair it and inspect again from step 1.
6.
Run the engine at high idle.
7.
Inspect the fuel piping and devices for fuel leakage. a Inspect mainly around the high-pressure circuit parts coated with the color checker for fuel leakage. a If any fuel leakage is detected, repair it and inspect again from step 1.
8.
Run the engine at high idle and load it. a When testing the engine mounted on the machine, stall the torque converter or relieve the oil from the hydraulic pump.
44
Inspect the fuel piping and devices for fuel leakage. a Inspect mainly around the high-pressure circuit parts coated with the color checker for fuel leakage. a If any fuel leakage is detected, repair it and inspect again from step 1. a If no fuel leakage is detected, inspection is completed.
140E-5 Series
30 Testing and adjusting
SEN00149-05
Testing and adjusting alternator belt tension 1 Testing Press the intermediate point of the belt between alternator pulley and drive pulley with a finger and measure deflection (a) of the belt. a Pressing force: Approx. 98 N {Approx. 10 kg} a Deflection (a): 13 – 16 mm (1 piece)
Adjusting a If the deflection is out of the standard range, adjust it according to the following procedure. 1.
Loosen mounting bolts (2), (3) and (4) of alternator (1), and then loosen locknut (5).
2.
Move alternator (1) with adjustment nut (6) to adjust the tension of belt (7).
3.
Tighten locknut (5), and then tighten mounting bolts (3), (2) and (1). a After adjusting, test the belt tension again.
140E-5 Series
45
SEN00149-05
Testing and adjusting fan belt tension
30 Testing and adjusting
1
Testing Press the intermediate point (at the arrow) of the belt (1) between fan pulley and crankshaft pulley with a finger and measure the deflection of the belt. a Check the belts one by one. a Pressing force: Approx. 98 N {Approx. 10 kg} a Deflection: 15 – 17 mm (When new) 19 – 21 mm (When retightened) Adjusting a If the deflection is out of the standard range, adjust it according to the following procedure. 1.
Loosen lock bolt of tension pulley (3).
2.
Move tension pulley (3) with adjustment bolt (2) to adjust the belt tension. a After adjusting, test the belt tension again.
3.
Tighten lock bolt of tension pulley (3).
46
140E-5 Series
30 Testing and adjusting
SEN00149-05
Handling controller high-voltage circuit 1 1.
Before disconnecting or connecting the connector between the engine controller and engine, be sure to turn the starting switch OFF.
2.
If the T-adapter is inserted in or connected to the connector between the engine controller and engine for troubleshooting, do not start the engine. a You may turn the starting switch to the OFF or ON position but must not turn it to the START position.
140E-5 Series
47
SEN00149-05
KOMATSU 140E-5 Series engine Form No. SEN00149-05
© 2010 KOMATSU All Rights Reserved Printed in Japan 04-10
48
SEN00151-04
ENGINE 1SHOP MANUAL
140E-5 Series
40 Troubleshooting
1
General information on troubleshooting Points to remember when troubleshooting ..................................................................................................... 2 Method of displaying trouble diagnosis lamps (Method of displaying error code) .......................................... 3 Error codes and failure codes list.................................................................................................................... 5 Information in troubleshooting table.............................................................................................................. 10 Connection table for connector pin numbers ................................................................................................ 12 T- branch box and T- branch adapter table ................................................................................................... 48
140E-5 Series
1
SEN00151-04
40 Troubleshooting
Points to remember when troubleshooting k k k k k k
1
When troubleshooting a machine, stop it in a level ground, and check that the lock pin, chocks, and parking brake are securely fitted. When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not allow any unauthorized person to come near. If the radiator cap is removed when the engine is hot, hot coolant may spurt out and cause burns, so be sure to wait for the engine to cool down before starting troubleshooting. Be extremely careful not to touch any hot parts or to get caught in any rotating parts. When disconnecting wiring, always disconnect the negative (-) terminal of the battery first. When removing the plug or cap from a location which is under pressure from oil, water, or air, always release the internal pressure first. When installing measuring equipment, be sure to connect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent reoccurrence of the failure. When carrying out troubleshooting, an important point is of course to understand the structure and function. However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea of possible causes of the failure that would produce the reported symptoms. 1.
2.
3.
2
When carrying out troubleshooting, do not hurry to disassemble the components. If components are disassembled immediately after any failure occurs: q Parts that have no connection with the failure or other unnecessary parts will be disassembled. q It will become impossible to find the cause of the failure. It will also cause a waste of manhours, parts, or oil or grease, and at the same time, will also lose the confidence of the user or operator. For this reason, when carrying out troubleshooting, it is necessary to carry out thorough prior investigation and to carry out troubleshooting in accordance with the fixed procedure. Points to ask user or operator 1) Have any other problems occurred apart from the problem that has been reported? 2) Was there anything strange about the machine before the failure occurred? 3) Did the failure occur suddenly, or were there problems with the machine condition before this? 4) Under what conditions did the failure occur? 5) Had any repairs been carried out before the failure? When were these repairs carried out? 6) Has the same kind of failure occurred before? Check before troubleshooting 1) Check for symptoms of any abnormality in the machine and engine. 2) Be sure to check the CHECKS BEFORE STARTING items.
3) 4)
5)
Check other inspection items, if necessary. Some other maintenance items can be checked externally, so check any item that is considered to be necessary. Check the controller for display of an error.
4.
Confirming failure Confirm the extent of the failure yourself, and judge whether to handle it as a real failure or as a problem with the method of operation, etc. a When operating the machine or engine to reenact the troubleshooting symptoms, do not carry out any investigation or measurement that may make the problem worse.
5.
Troubleshooting Use the results of the investigation and inspection in Items 2 – 4 to narrow down the causes of failure, then use the troubleshooting matrix to locate the position of the failure exactly. a The basic procedure for troubleshooting is as follows. 1) Start from the simple points. 2) Start from the most likely points. 3) Investigate other related parts or information.
6.
Measures to remove root cause of failure Even if the failure is repaired, if the root cause of the failure is not repaired, the same failure will occur again. To prevent this, always investigate why the problem occurred. Then, remove the root cause.
140E-5 Series
40 Troubleshooting
SEN00151-04
Method of displaying trouble diagnosis lamps (Method of displaying error code)
1
For generator If the trouble diagnosis lamps and diagnosis lamp indication selector switch are installed on the applicable machine side, the trouble diagnosis lamps indicate as follows. When the starting switch is turned ON, the trouble diagnosis lamps indicate as follows in the normal display mode and error code display mode. Combination of trouble diagnosis lamps and diagnosis lamp indication selector switch Item
Normal display mode Error code display mode (While starting switch is ON or engine is running) (While starting switch is ON and engine is stopped) When normal
Diagnosis lamp indication selector switch R Y
When error occurs OFF
Lamp off
Either lamp lights up
When error occurs ON Error code is indicated by number of flashes. Lamp off
Indication when starting switch is turned ON (Initial indication) q The following is displayed once whenever the starting switch is turned ON, regardless of the position of the diagnosis lamp indication selector switch. q If the starting switch is turned ON, the red lamp and yellow lamp indicate as follows.
140E-5 Series
3
SEN00151-04
40 Troubleshooting
Indication in normal display mode (when diagnosis lamp indication selector switch is OFF) q The normal display mode means the state in which the diagnosis lamp indication selector switch is kept OFF while the starting switch is ON or the engine is running. q While the engine controller system is operating normally in the normal state, the red lamp and yellow lamp are turned OFF. If the system has an error, either lamp is turned ON.
Indication in error code display mode (when diagnosis lamp indication selector switch is ON) The error code display mode means the state in which the diagnosis lamp indication selector switch is kept ON while the engine is stopped (with the starting switch is ON). q In this state, the red lamp indicates the error code by the number of flashes. The yellow lamp is kept turned OFF at this time. q When starting the engine, turn the diagnosis lamp indication selector switch OFF. Do not turn the diagnosis lamp indication selector switch ON while the engine is running. q
4
140E-5 Series
40 Troubleshooting
SEN00151-04
Error codes and failure codes list
1
For construction equipment INSITE error code
Machine failure code
Failure phenomenon
111
CA111
Engine Controller Internal Failure
115
CA115
Eng. Ne and Bkup Speed Sensor Error
122
CA122
Charge (boost) Air Press Sensor High Error
123
CA123
Charge (boost) Air Press Sensor Low Error
131
CA131
Throttle Sensor High Error
132
CA132
Throttle Sensor Low Error
135
CA135
Oil Press. Sensor High Error
141
CA141
Oil Press. Sensor Low Error
144
CA144
Coolant Temp. Sensor High Error
145
CA145
Coolant Temp. Sensor Low Error
153
CA153
Charge (boost) Air Temp. Sensor High Error
154
CA154
Charge (boost) Air Temp. Sensor Low Error
187
CA187
Sensor Sup. 2 Volt. Low Error
221
CA221
Ambient Air Press. Sensor High Error
222
CA222
Ambient Air Press. Sensor Low Error
227
CA227
Sensor Sup. 2 Volt. High Error
234
CA234
Eng. Overspeed
238
CA238
Ne Speed Sensor Sup. Volt. Error
263
CA263
Fuel Temp. Sensor High Error
265
CA265
Fuel Temp. Sensor Low Error
271
CA271
PCV1 Short Error
272
CA272
PCV1 Open Error
273
CA273
PCV2 Short Error
274
CA274
PCV2 Open Error
322
CA322
Injector #1 System Open/Short Error
323
CA323
Injector #5 System Open/Short Error
324
CA324
Injector #3 System Open/Short Error
325
CA325
Injector #6 System Open/Short Error
331
CA331
Injector #2 System Open/Short Error
332
CA332
Injector #4 System Open/Short Error
342
CA342
Engine Controller Data Matching Error
351
CA351
INJ. Drive Circuit Error
352
CA352
Sensor Sup. 1 Volt. Low Error
386
CA386
Sensor Sup. 1 Volt. High Error
431
CA431
Idle Validation Switch Error
432
CA432
Idle Validation Process Error
441
CA441
Supply Voltage Low Error
442
CA442
Supply Voltage High Error
140E-5 Series
Reference document No.
Troubleshooting of electrical system (E-mode), Part 1 SEN00153-02
5
SEN00151-04
40 Troubleshooting
INSITE error code
Machine failure code
449
CA449
Rail Press. High Error 2
451
CA451
Rail Press. Sensor High Error
452
CA452
Rail Press. Sensor Low Error
553
CA553
Rail Press. High Error 1
554
CA554
Rail Press Sensor In Range Error
559
CA559
No-pressure Feed By Supply pump 1
689
CA689
Eng. Ne Speed Sensor Error
731
CA731
Eng. Bkup Speed Sensor Phase Error
757
CA757
All Engine Controller Data Lost Error
778
CA778
Eng. Bkup Speed Sensor Error
1228
CA1228
EGR Valve Servo Error 1
1625
CA1625
EGR Valve Servo Error 2
1626
CA1626
Bypass Valve Solenoid Drive Short Circuit Error
1627
CA1627
Bypass Valve Solenoid Drive Open Error
1628
CA1628
Bypass Valve Servo Error 1
1629
CA1629
Bypass Valve Servo Error 2
1631
CA1631
Bypass Valve Lift Sensor High Error
1632
CA1632
Bypass Valve Lift Sensor Low Error
1633
CA1633
KOMNET Error
1642
CA1642
EGR Inlet Press Sensor Low Error
1653
CA1653
EGR Inlet Press Sensor High Error
2185
CA2185
Throttle Sens. Sup. Volt. High Error
2186
CA2186
Throttle Sens. Sup. Volt. Low Error
a
Failure phenomenon
2249
CA2249
No-pressure Feed By Supply pump 2
2271
CA2271
EGR Valve Lift Sensor High Error
2272
CA2272
EGR Valve Lift Sensor Low Error
2351
CA2351
EGR Valve Solenoid Drive Short Error
2352
CA2352
EGR Valve Solenoid Drive Open Error
2555
CA2555
Intake Air Heater Relay Open Error
2556
CA2556
Intake Air Heater Relay Short Error
(143)
B@BAZG
Eng. Oil Press Low Torque Derate
(146)
B@BCNS
Eng. Overheat
(415)
B@BAZG
Eng. Oil Press. Low Speed Derate
Reference document No.
Troubleshooting of electrical system (E-mode), Part 2 SEN00154-02
a
INSITE error code: An error code of 3 or 4 digits displayed on the INSITE (bench test tool) when the occurrence condition of the failure is confirmed with the INSITE. Machine failure code: An error code of 5 or 6 digits displayed on the machine monitor when the occurrence condition of the failure is confirmed with the machine monitor, etc. on the machine side.
6
140E-5 Series
40 Troubleshooting
SEN00151-04
For generator Machine failure code
Failure phenomenon
A8
Speed Adj. Vol. High (Isochronous) A8
A9
Speed Adj. Vol. Low (Isochronous) A9
AA
Speed Adj. Vol. High (Droop) AA
AB
Speed Adj. Vol. Low (Droop) AB
AF
KOMNET Error (CR710) AF
b6
Droop Rate Adj. Vol. High b6
b7
Droop Rate Adj. Vol. Low b7
b8
Low Idle Speed Adj. Vol. High b8
b9
Low Idle Speed Adj. Vol. Low b9
bc
Speed Adj. Vol. High (Default) bc
bd
Speed Adj. Vol. Low (Default) bd
bE
Ramptime Adj. Vol. High bE
bF
Ramptime Adj. Vol. Low bF
CA111
Engine Controller Internal Failure
CA115
Eng. Ne and Bkup Speed Sensor Error
CA122
Charge (boost) Air Press Sensor High Error
CA123
Charge (boost) Air Press Sensor Low Error
CA135
Oil Press. Sensor High Error
CA141
Oil Press. Sensor Low Error
CA144
Coolant Temp. Sensor High Error
CA145
Coolant Temp. Sensor Low Error
CA153
Charge (boost) Air Temp. Sensor High Error
CA154
Charge (boost) Air Temp. Sensor Low Error
CA187
Sensor Sup. 2 Volt. Low Error
CA221
Ambient Air Press. Sensor High Error
CA222
Ambient Air Press. Sensor Low Error
CA227
Sensor Sup. 2 Volt. High Error
CA234
Eng. Overspeed
CA238
Ne Speed Sensor Sup. Volt. Error
CA263
Fuel Temp. Sensor High Error
CA265
Fuel Temp. Sensor Low Error
CA271
PCV1 Short Error
CA272
PCV1 Open Error
CA273
PCV2 Short Error
CA274
PCV2 Open Error
CA322
Injector #1 System Open/Short Error
CA323
Injector #5 System Open/Short Error
CA324
Injector #3 System Open/Short Error
CA325
Injector #6 System Open/Short Error
140E-5 Series
Reference document No.
–
Troubleshooting of electrical system (E-mode), Part 1 SEN00153-02
7
SEN00151-04
40 Troubleshooting
Machine failure code
8
Failure phenomenon
CA331
Injector #2 System Open/Short Error
CA332
Injector #4 System Open/Short Error
CA342
Engine Controller Data Matching Error
CA351
INJ. Drive Circuit Error
CA352
Sensor Sup. 1 Volt. Low Error
CA386
Sensor Sup. 1 Volt. High Error
CA441
Supply Voltage Low Error
CA442
Supply Voltage High Error
CA449
Rail Press. High Error 2
CA451
Rail Press. Sensor High Error
CA452
Rail Press. Sensor Low Error
CA553
Rail Press. High Error 1
CA559
No-pressure Feed By Supply pump 1
CA689
Eng. Ne Speed Sensor Error
CA731
Eng. Bkup Speed Sensor Phase Error
CA757
All Engine Controller Data Lost Error
CA778
Eng. Bkup Speed Sensor Error
CA1228
EGR Valve Servo Error 1
CA1625
EGR Valve Servo Error 2
CA1633
KOMNET Error
CA2185
Throttle Sens. Sup. Volt. High Error
CA2186
Throttle Sens. Sup. Volt. Low Error
CA2249
No-pressure Feed By Supply pump 2
CA2271
EGR Valve Lift Sensor High Error
CA2272
EGR Valve Lift Sensor Low Error
CA2351
EGR Valve Solenoid Drive Short Error
CA2352
EGR Valve Solenoid Drive Open Error
CA2555
Intake Air Heater Relay Open Error
CA2556
Intake Air Heater Relay Short Error
CA143
Eng. Oil Press Low Torque Derate
CA146
Eng. Overheat
Reference document No.
Troubleshooting of electrical system (E-mode), Part 1 SEN00153-02
Troubleshooting of electrical system (E-mode), Part 2 SEN00154-02
140E-5 Series
40 Troubleshooting
140E-5 Series
SEN00151-04
9
SEN00151-04
40 Troubleshooting
Information in troubleshooting table a
1
The following information is summarized in the troubleshooting table and the related electrical circuit diagram. Before carrying out troubleshooting, understand that information fully. Error code
Failure code
Display on INSITE
Display on applicable machine
Contents of trouble
Contents of trouble detected by engine controller
Action of controller
Action taken by engine controller to protect system or devices when engine controller detects trouble
Trouble
Trouble in engine
Problem that appears Problem that appears on engine as a result of action taken by engine controller (shown above) on machine Related information Information related to detected trouble or troubleshooting Cause
Standard value in normal state/Remarks on troubleshooting
• Standard value in normal state to judge possible causes • Remarks on judgment
1
2
Possible causes and standard value in normal state
10
• Disconnection Connector is connected imperfectly or wiring harness is broken. • Ground fault Wiring harness which is not connected to chassis ground circuit is in contact with chassis ground circuit. • Hot short Wiring harness which is not connected to power source (24 V) circuit is in contact with power source (24 V) circuit. • Short circuit Independent wiring harnesses are in contact with each other abnormally.
Possible causes of trouble (Given numbers are reference numbers, which do not indicate priority) 1) Method of indicating connector No. and handling of Tadapter Insert or connect T-adapter as explained below for troubleshooting, unless otherwise specified. 3 • If connector No. has no marks of “male” and “female”, disconnect connector and insert T-adapters in both male side and female side. • If connector No. has marks of “male” and “female”, disconnect connector and connect T-adapter to only male side or female side. 2) Entry order of pin Nos. and handling of tester leads Connect positive (+) lead and negative (–) lead of tester as explained below for troubleshooting, unless otherwise specified. 4 • Connect positive (+) lead to pin No. or wiring harness entered on front side. • Connect negative (–) lead to pin No. or harness entered on rear side.
140E-5 Series
40 Troubleshooting
SEN00151-04
Related circuit diagram
This drawing is a part of the electric circuit diagram related to troubleshooting. • Connector No.: Indicates (Model – Number of pins) and (Color). • “Connector No. and pin No.” from each branching/merging point: Shows the ends of branch or source of merging within the parts of the same wiring harness. • Arrow : Roughly shows the location on the machine.
140E-5 Series
11
SEN00151-04
Connection table for connector pin numbers a
12
40 Troubleshooting
(Rev. 2009.04)
The terms of male and female refer to the pins, while the terms of male housing and female housing refer to the mating portion of the housing.
140E-5 Series
40 Troubleshooting
140E-5 Series
SEN00151-04
13
SEN00151-04
14
40 Troubleshooting
140E-5 Series
40 Troubleshooting
140E-5 Series
SEN00151-04
15
SEN00151-04
16
40 Troubleshooting
140E-5 Series
40 Troubleshooting
140E-5 Series
SEN00151-04
17
SEN00151-04
18
40 Troubleshooting
140E-5 Series
40 Troubleshooting
140E-5 Series
SEN00151-04
19
SEN00151-04
20
40 Troubleshooting
140E-5 Series
40 Troubleshooting
140E-5 Series
SEN00151-04
21
SEN00151-04
22
40 Troubleshooting
140E-5 Series
40 Troubleshooting
140E-5 Series
SEN00151-04
23
SEN00151-04
24
40 Troubleshooting
140E-5 Series
40 Troubleshooting
140E-5 Series
SEN00151-04
25
SEN00151-04
26
40 Troubleshooting
140E-5 Series
40 Troubleshooting
140E-5 Series
SEN00151-04
27
SEN00151-04
28
40 Troubleshooting
140E-5 Series
40 Troubleshooting
140E-5 Series
SEN00151-04
29
SEN00151-04
30
40 Troubleshooting
140E-5 Series
40 Troubleshooting
140E-5 Series
SEN00151-04
31
SEN00151-04
32
40 Troubleshooting
140E-5 Series
40 Troubleshooting
140E-5 Series
SEN00151-04
33
SEN00151-04
34
40 Troubleshooting
140E-5 Series
40 Troubleshooting
140E-5 Series
SEN00151-04
35
SEN00151-04
36
40 Troubleshooting
140E-5 Series
40 Troubleshooting
140E-5 Series
SEN00151-04
37
SEN00151-04
38
40 Troubleshooting
140E-5 Series
40 Troubleshooting
140E-5 Series
SEN00151-04
39
SEN00151-04
40
40 Troubleshooting
140E-5 Series
40 Troubleshooting
140E-5 Series
SEN00151-04
41
SEN00151-04
42
40 Troubleshooting
140E-5 Series
40 Troubleshooting
140E-5 Series
SEN00151-04
43
SEN00151-04
44
40 Troubleshooting
140E-5 Series
40 Troubleshooting
140E-5 Series
SEN00151-04
45
SEN00151-04
46
40 Troubleshooting
140E-5 Series
40 Troubleshooting
140E-5 Series
SEN00151-04
47
SEN00151-04
40 Troubleshooting
T- branch box and T- branch adapter table a
(Rev. 2009.03) 1
q
q
q q
Out of kit
799-601-4201
799-601-4101
799-601-9300
799-601-9200
799-601-9100
799-601-9000
799-601-8000
799-601-7500
799-601-7400
799-601-7100
799-601-7000
799-601-2800
Identification symbol
799-601-2700
Part name
T-adapter kit 799-601-2500
Part No.
Number of pins
The vertical column indicates a part number of T-branch box or T-branch adapter while the horizontal column indicates a part number of harness checker assembly.
q
799-601-2600 T-box (for ECONO)
21
799-601-3100 T-box (for MS)
37
q
799-601-3200 T-box (for MS)
37
q q
799-601-3380 Plate for MS (14-pin) 799-601-3410 Adapter for BENDIX (MS)
24
MS-24P
q
799-601-3420 Adapter for BENDIX (MS)
24
MS-24P
q
799-601-3430 Adapter for BENDIX (MS)
17
MS-17P
q
799-601-3440 Adapter for BENDIX (MS)
17
MS-17P
q
799-601-3450 Adapter for BENDIX (MS)
5
MS-5P
q
799-601-3460 Adapter for BENDIX (MS)
10
MS-10P
q
799-601-3510 Adapter for BENDIX (MS)
5
MS-5P
q
799-601-3520 Adapter for BENDIX (MS)
17
MS-17P
q
799-601-3530 Adapter for BENDIX (MS)
19
MS-19P
q
799-601-2910 Adapter for BENDIX (MS)
14
MS-14P
q q
799-601-3470 Case 799-601-2710 Adapter for MIC
5
MIC-5P
q q
799-601-2720 Adapter for MIC
13
MIC-13P
q q
799-601-2730 Adapter for MIC
17
MIC-17P
q q q
799-601-2740 Adapter for MIC
21
MIC-21P
q q q
799-601-2950 Adapter for MIC
9
MIC-9P
799-601-2750 Adapter for ECONO
2
ECONO2P
q q
799-601-2760 Adapter for ECONO
3
ECONO3P
q q
799-601-2770 Adapter for ECONO
4
ECONO4P
q q
799-601-2780 Adapter for ECONO
8
ECONO8P
q q
799-601-2790 Adapter for ECONO
12 ECONO12P q q
799-601-2810 Adapter for DLI
8
DLI-8P
q q
799-601-2820 Adapter for DLI
12
DLI-12P
q q
799-601-2830 Adapter for DLI
16
DLI-16P
q q
799-601-2840 Extension cable (ECONO type)
12 ECONO12P q q
q q q
q
q q
q
q q q
q
q
q
799-601-2850 Case 799-601-4350 T-box (for DRC 60, ECONO)
q
q
60
q
799-601-4360 Case 799-601-7010 Adapter for X (T-adapter)
1
q
q
799-601-7020 Adapter for X
2
X2P
q q q
q
799-601-7030 Adapter for X
3
X3P
q q q
q
799-601-7040 Adapter for X
4
X4P
q q q
q
799-601-7050 Adapter for SWP
6
SW6P
q q q
799-601-7060 Adapter for SWP
8
SW8P
q q q
799-601-7310 Adapter for SWP
12
SW12P
799-601-7070 Adapter for SWP
14
SW14P
799-601-7320 Adapter for SWP
16
SW16P
799-601-7080 Adapter for M (T-adapter)
1
799-601-7090 Adapter for M
2
799-601-7110 Adapter for M
3
48
q q
q
q
q
M2P
q q q
q
M3P
q q q
q
q
140E-5 Series
40 Troubleshooting
SEN00151-04
799-601-7150 Adapter for S (White)
10
S10P
q q q
q
799-601-7160 Adapter for S (Blue)
12
S12P
q q q
799-601-7170 Adapter for S (Blue)
16
S16P
q q q
Out of kit
q
799-601-4201
q q q
799-601-4101
S8P
799-601-9300
8
799-601-9200
799-601-7140 Adapter for S
799-601-9100
M8P
799-601-9000
8
799-601-8000 q
799-601-7340 Adapter for M
799-601-7500
q
q q q
799-601-7400
q q q
M6P
799-601-7100
M4P
6
799-601-7000
4
799-601-7130 Adapter for M
799-601-2800
799-601-7120 Adapter for M
Part name
799-601-2700
Identification symbol
Part No.
799-601-2500
Number of pins
T-adapter kit
q
q q
799-601-7330 Adapter for S (White)
16
S16PW
799-601-7350 Adapter for S (White)
12
S12PW
799-601-7180 Adapter for AMP040
8
A8P
q
799-601-7190 Adapter for AMP040
12
A12P
q
q
799-601-7210 Adapter for AMP040
16
A16P
q q q
q
799-601-7220 Adapter for AMP040
20
A20P
q q q
q
799-601-7230 Short connector for X
2
—
q q q
q
q
q q
799-601-7240 Case
q
799-601-7270 Case 799-601-7510 Adapter for 070
10
07-10
q
799-601-7520 Adapter for 070
12
07-12
q
799-601-7530 Adapter for 070
14
07-14
q
799-601-7540 Adapter for 070
18
07-18
q
799-601-7550 Adapter for 070
20
07-20
q
799-601-7360 Adapter for relay
5
REL-5P
q
799-601-7370 Adapter for relay
6
REL-6P
q
799-601-7380 Adapter for JFC
2
—
799-601-9010 Adapter for DTM
2
DTM2
q
q
799-601-9020 Adapter for DT
2
DT2
q
q
799-601-9030 Adapter for DT
3
DT3
q
q
799-601-9040 Adapter for DT
4
DT4
q
q
q
799-601-9050 Adapter for DT
6
DT6
q
q
799-601-9060 Adapter for DT (Gray)
8
DT8GR
q
q
799-601-9070 Adapter for DT (Black)
8
DT8B
q
q
799-601-9080 Adapter for DT (Green)
8
DT8G
q
q
799-601-9090 Adapter for DT (Brown)
8
DT8BR
q
q
799-601-9110 Adapter for DT (Gray)
12
DT12GR
q
q
799-601-9120 Adapter for DT (Black)
12
DT12B
q
q
799-601-9130 Adapter for DT (Green)
12
DT12G
q
q
799-601-9140 Adapter for DT (Brown)
12
DT12BR
q
q
799-601-9210 Adapter for HD30-18
8
D18-8
q q
799-601-9220 Adapter for HD30-18
14
D18-14
q q
799-601-9230 Adapter for HD30-18
20
D18-20
q q
799-601-9240 Adapter for HD30-18
21
D18-21
q q
799-601-9250 Adapter for HD30-24
9
D24-9
q q
799-601-9260 Adapter for HD30-24
16
D24-16
q q
799-601-9270 Adapter for HD30-24
21
D24-21
q q
799-601-9280 Adapter for HD30-24
23
D24-23
q q
799-601-9290 Adapter for HD30-24
31
D24-31
q q
799-601-9310 Plate for HD30 (24-pin) 799-601-9320 T-box (for ECONO)
140E-5 Series
24
q q q q
q q
q
q q
q
49
Out of kit
799-601-4201
799-601-4101
799-601-9300
799-601-9200
799-601-9100
799-601-9000
799-601-8000
799-601-7500
799-601-7400
799-601-7100
799-601-7000
799-601-2800
Identification symbol
799-601-2700
Part name
T-adapter kit 799-601-2500
Part No.
40 Troubleshooting
Number of pins
SEN00151-04
q
799-601-9330 Case
q
799-601-9340 Case 799-601-9350 Adapter for DRC
40
DRC-40
q
799-601-9360 Adapter for DRC
24
DRC-24
q
799-601-9410* Socket for engine (CRI-T2)
2
G
Adapter for engine (CRI-T2) 799-601-9420 Adapter for engine (CRI-T3) PFUEL Oil pressure sensor
3
A3
q q
2
P
q q
799-601-9440* Socket for engine (CRI-T2)
3
1,2,3
q
795-799-5520* Socket for engine (HPI-T2)
2
S
q
Socket for engine (HPI-T2) 795-799-5530* Socket for engine (CRI-T3) Temperature sensor
2
C
q q
2
A
q q
795-799-5460 Cable for engine (HPI-T2)
3
—
q
795-799-5470 Cable for engine (HPI-T2)
3
—
q
799-601-9430*
795-799-5540*
Socket for engine (CRI-T2) Socket for engine (CRI-T3) PCV
Socket for engine (HPI-T2) Socket for engine (CRI-T3) TIM
q
q
795-799-5480 Cable for engine (HPI-T2)
3
—
799-601-4110 Adapter for engine (140-T3) PIM
4
ITT3N
q q
799-601-4130 Adapter for engine (CRI-T3) NE, CAM
3
FCIN
q q
3
FCIG
q q
799-601-4150 Adapter for engine (CRI-T3) POIL
3
FCIB
q q
Adapter for engine (CRI-T3) 799-601-4160 Oil pressure switch
2
4160
q q
799-601-4180 Adapter for engine (CRI-T3) PEVA
3
4180
q q
Socket for engine (CRI-T3) 799-601-4190* Commonrail pressure
3
1,2,3L
q q
4
1,2,3,4C
q q
799-601-4240* Socket for engine (CRI-T3) PAMB
3
1,2,3A
q q
799-601-4250* Socket for engine (CRI-T3) PIM
3
1,2,3B
q q
799-601-4330* Socket for engine (CRI-T3) G
3
1,2,3,G
q q
Socket for engine (CRI-T3) 799-601-4340* Pump actuator
2
2,PA
q q
4
1,2,3,4T
799-601-4260 Adapter for controller (ENG)
4
DTP4
799-601-4140
799-601-4230*
799-601-4380*
Adapter for engine (CRI-T3) Atomosphere pressure
Socket for engine (CRI-T3) Air intake pressure/temperature
Socket for engine (CRI-T3)(95) Air intake pressure/temperature
q q q
799-601-4211 Adapter for controller (ENG)
50
DRC50
q
799-601-4220 Adapter for controller (ENG)
60
DRC60
q
799-601-4390* Socket for controller (95 ENG)
60
—
q
799-601-4280* Box for controller (PUMP)
121
—
q
799-601-9720 Adapter for controller (HST)
16
HST16A
q
799-601-9710 Adapter for controller (HST)
16
HST16B
q
799-601-9730 Adapter for controller (HST)
26
HST26A
q
2, 3, 4,
—
q
799-601-9890
Multi-adapter for DT2 – 4 and DTM2
“*” Shows not T-adapter but socket.
50
140E-5 Series
40 Troubleshooting
140E-5 Series
SEN00151-04
51
SEN00151-04
KOMATSU 140E-5 Series engine Form No. SEN00151-04
© 2009 KOMATSU All Rights Reserved Printed in Japan 09-09 (01)
52
SEN00152-03
ENGINE 1SHOP MANUAL
140E-5 Series
40 Troubleshooting
1
Troubleshooting of mechanical system (S-mode) Troubleshooting of mechanical system (S-mode)........................................................................................... 4 Method of using troubleshooting charts ............................................................................................... 4 S-1 Starting performance is poor ......................................................................................................... 8 S-2 Engine does not start................................................................................................................... 10 S-3 Engine does not pick up smoothly............................................................................................... 14 S-4 Engine stops during operations ................................................................................................... 15 S-5 Engine does not rotate smoothly ................................................................................................. 16 S-6 Engine lacks output (or lacks power)........................................................................................... 17 S-7 Exhaust smoke is black (incomplete combustion) ....................................................................... 18 S-8 Oil consumption is excessive (or exhaust smoke is blue) ........................................................... 20 S-9 Oil becomes contaminated quickly .............................................................................................. 21 S-10 Fuel consumption is excessive.................................................................................................. 22 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) ........................................ 23 S-12 Oil pressure drops ..................................................................................................................... 24
140E-5 Series
1
SEN00152-03
40 Troubleshooting
S-13 Oil level rises (Entry of coolant/fuel) .......................................................................................... 25 S-14 Coolant temperature becomes too high (overheating) .............................................................. 27 S-15 Abnormal noise is made ............................................................................................................ 28 S-16 Vibration is excessive ................................................................................................................ 29
2
140E-5 Series
40 Troubleshooting
140E-5 Series
SEN00152-03
3
SEN00152-03
40 Troubleshooting
Troubleshooting of mechanical system (S-mode)
1
Method of using troubleshooting charts
1
The troubleshooting chart consists of the “questions”, “check items”, “causes”, and “troubleshooting” blocks. The questions and check items are used to pinpoint high probability causes by simple inspection or from phenomena without using troubleshooting tools. Next, troubleshooting tools or direct inspection are applied to check the narrowed causes in order from the most probable one to make final confirmation according to the troubleshooting procedure. Questions: Items to be drawn from the user or operator. They correspond to A and B in the chart on the right. The items in A are basic ones. The items in B can be drawn from the user or operator, depending on their level. Check items: Simple check items used by the serviceman to narrow the causes. They correspond to C in the chart on the right. Causes: Items to be narrowed from the questions and check items. The serviceman narrows down the probable causes from A, B, and C. Troubleshooting: Items used to find out the true cause by verifying the narrowed causes finally in order from the most probable one by applying troubleshooting tools or direct inspection. Items listed in the [Questions] and [Check items] and related to the [Causes] are marked with E, Q, and w. E: Causes to be referred to for questions and check items Q: Causes related to questions and check items w: Causes highly probable among ones marked with Q a When narrowing the “causes”, apply the items marked with w before those marked with Q. When narrowing the “causes”, do not apply the items marked with E (If no items have other marks and the causes cannot be narrowed, however, you may apply them.)
4
140E-5 Series
40 Troubleshooting
140E-5 Series
SEN00152-03
5
SEN00152-03
40 Troubleshooting
Exhaust gas color is black (incomplete combustion) Let us assume that a trouble of “Exhaust gas color is black” occurred and we checked the [Questions] and [Check items] and found the following 3 items to be the causal symptoms; [Color of exhaust gas gradually became black], [Power was lost gradually], and [Dust indicator is red].
6
140E-5 Series
40 Troubleshooting
SEN00152-03
There is a causal relationship between 3 items in the [Questions] and [Check items] sections and 6 items in the [Causes] sections. The method of pinpointing the [cause] from the causal relationship and approaching the [troubleshooting] is explained according to Step 1 — Step 3 shown below.
140E-5 Series
7
SEN00152-03
40 Troubleshooting
S-1 Starting performance is poor
1
General causes why starting performance is poor
Causes
Clogged air cleaner element Cracked EGR cooler (Coolant in exhaust pipe) ["with EGR" only] Defective contact of valve, vale seat Worn piston ring, cylinder Clogged air breather hole of fuel tank cap Leaking or clogged fuel piping, entry of air Clogged fuel filter, element Clogged feed pump gauze filter Stuck, seized supply pump plunger Defective injector Defective intake air heater system Defective alternator (regulator section) Defective alternator (generator section) Defective, deteriorated battery
• Defective electrical system
• Coolant in exhaust pipe ("with EGR" only)
Troubleshooting
Check items
Questions
a The common rail fuel injection system (CRI) controls the fuel injection timing electrically. Accordingly, even if the starting operation is carried out, the engine may not start until the crankshaft revolves 2 turns at maximum. This phenomenon does not indicate a trouble, however. Confirm recent repair history Degree of use of Operated for long period machine Became worse gradually Starting performance Engine starts easily when warm Non-specified fuel is being used Replacement of filters has not been carried out according to Operation and Maintenance Manual Engine oil must be added more frequently When engine is preheated or when temperature is low, preheating monitor does not indicate normally (if monitor is installed) During operation, charge level monitor indicates abnormal charge (if monitor is installed) Dust indicator is red (if indicator is installed) Air breather hole of fuel tank cap is clogged Fuel is leaking from fuel piping When priming pump is operated, it makes no reaction or it is heavy Starting motor cranks engine slowly If air bleeding plug of fuel filter is removed, fuel does not While engine is flow out cranked with starting motor If spill hose from injector is disconnected, little fuel spills When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Engine does not pick up smoothly and combustion is irregular There is hunting from engine (rotation is irregular) Blow-by gas is excessive Inspect air cleaner directly When EGR cooler outlet gas piping is removed, coolant containing antifreeze flows out (*1) ["with EGR" only] When compression pressure is measured, it is found to be low When air is bled from fuel system, air comes out Inspect fuel filter, element directly Inspect feed pump gauze filter directly Carry out troubleshooting according to “No-pressure feed by supply pump (*2)” in E-mode When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change When starting switch is turned to HEAT, intake air heater mount does not become warm Is voltage 20 – 30 V between alternator terminal B and terminal E with Yes engine at low idle? No When specific gravity of electrolyte and voltage of battery are measured, they are low Remedy
8
E E Q Q ww
EE QQ
E
w
QQQQ wwQQ
w
w
w w ww w
w Q
w Q wQQ
w
ww w QQ w
w w
QwQQ
q q qq
q
q
q q q q q
q q
Correct Replace Clean Correct Clean Clean Replace Replace Replace Replace Replace Replace
• Improper selection of fuel
Replace
• Insufficient intake of air
Clean
• Insufficient supply of fuel
140E-5 Series
40 Troubleshooting
SEN00152-03
*1: EGR cooler outlet gas piping Loosen 4 mounting bolts (1) of the EGR cooler outlet gas piping and check that the coolant flows out. A little condensate produced from cooled exhaust gas may flow out. If it is colorless and transparent, however, it is not a problem.
*2: Code [559/CA559] and code [2249/CA2249] in E-mode
140E-5 Series
9
SEN00152-03
40 Troubleshooting
S-2 Engine does not start
1
a) Engine does not turn
Defective starting circuit wiring
Defective starting motor (motor section)
Defective starting motor (safety relay section)
• Problem in drive devices on applicable machine side → Carry out troubleshooting for devices on applicable machine
Defective starting switch
• Defective electrical system
Defective battery relay
• Water hammer caused by coolant which entered cylinder
Defective connection of battery terminal
• Internal parts of engine seized → See “S-4 Engine stops during operations.”
Defective or deteriorated battery
General causes why engine does not turn
Broken flywheel ring gear
Cracked EGR cooler (Coolant in exhaust pipe) ["with EGR" only]
Causes
E EE
Operated for long period
Q
Condition of horn when Horn does not sound starting switch is turned Horn volume is low ON
w
Battery electrolyte is low
w Q Q w
When starting switch is turned ON, there is no operating sound from battery relay Check items
When starting switch is turned to START, starting pinion does not move out
Q
Speed of rotation is low
w w w Q w
Soon disengages again
w
Makes rattling noise and does not turn
Q
q q
Inspect flywheel ring gear directly
Troubleshooting
Q
w
w
Makes grating noise
When EGR cooler outlet gas piping is removed, coolant containing antifreeze flows out (*1). ["with EGR" only]
q
When specific gravity of electrolyte and voltage of battery are measured, they are low There is not voltage (20 – 30 V) between battery relay terminal B and terminal E Turn starting switch OFF, connect cord, and carry out troubleshooting at ON
w
w
Battery terminal is loose
When starting switch is turned to START, starting pinion moves out, but
Q
q
When terminal B and terminal C of starting switch are connected, engine starts
q
When terminal B and terminal C at safety relay outlet are connected, engine starts
q
Even if terminal B and terminal C at safety relay outlet are connected, engine does not start
10
Replace
Replace
Replace
Correct
Replace
Replace
Replace
Remedy
q
Carry out troubleshooting on applicable machine side
Degree of use of machine
Replace
Questions
Confirm recent repair history
—
140E-5 Series
40 Troubleshooting
SEN00152-03
*1: EGR cooler outlet gas piping Loosen 4 mounting bolts (1) of the EGR cooler outlet gas piping and check that the coolant flows out. A little condensate produced from cooled exhaust gas may flow out. If it is colorless and transparent, however, it is not a problem.
140E-5 Series
11
SEN00152-03
40 Troubleshooting
b) Engine turns but no exhaust smoke comes out
• Supply of fuel is extremely small
Use of improper fuel Insufficient fuel in tank
• Improper selection of fuel (particularly in winter)
Defective fuel injector
• Fuel is not being supplied
Clogged air breather hole of fuel tank cap Leaking or clogged fuel piping, entry of air Clogged fuel filter element Clogged feed pump gauze filter Seized, abnormally worn feed pump
General causes why engine turns but no exhaust smoke comes out
Broken supply pump shaft, key Stuck, seized supply pump plunger Defective supply pump PCV Wrong connection of supply pump PCV Defective operation of overflow valve (Does not close) Defective operation of flow damper
Causes
EEE
Operated for long period
wQwww
Exhaust smoke suddenly stopped coming out (when starting again) Replacement of filters has not been carried out according to Operation and Maintenance Manual
Q
QQQ
QQ
w
Air breather hole of fuel tank cap is clogged Rust and water are found when fuel tank is drained
w
Fuel is leaking from fuel piping
w w
When priming pump is operated, it makes no reaction or it is heavy [“with EGR” only]
wQQ
When fuel filter is removed, there is not fuel in it Check items
E
w
When fuel tank is inspected, it is found to be empty
If air bleeding plug of fuel filter is removed, fuel does not flow While engine is cranked with start- out ing motor If spill hose from injector is disconnected, little fuel spills
Q
Q
wQ
Q
wwww
Q
qq
q
q
When air is bled from fuel system, air comes out
q
Inspect fuel filter directly Troubleshooting
ww
EE
q
Inspect feed pump gauze filter directly
q
Inspect feed pump directly Carry out troubleshooting according to “No-pressure feed by supply pump (*1)” in E-mode Carry out troubleshooting according to “Abnormality in PCV1 (*2) or Abnormality in PCV2 (*3)” in E-mode
q q q
Inspect overflow valve directly
qq Clean Correct Replace Clean Replace
Remedy
Replace Add
Engine can be started in reduced cylinder mode
Replace
Degree of use of machine
Replace Replace Replace Correct Replace Replace
Questions
Confirm recent repair history
*1: Code [559/CA559] and code [2249/CA2249] in E-mode *2: Code [271/CA271] and code [272/CA272] in E-mode *3: Code [273/CA273] and code [274/CA274] in E-mode
12
140E-5 Series
40 Troubleshooting
SEN00152-03
c) Exhaust smoke comes out but engine does not start (fuel is being injected)
Clogged air cleaner element Worn dynamic valve system (Valve, rocker lever, etc.) Worn piston ring, cylinder liner Use of improper fuel Clogged air breather hole of fuel tank cap Leaking or clogged fuel system, entry of air Clogged fuel filter, strainer Clogged feed pump gauze filter Stuck, seized supply pump plunger Clogged injector, defective spray Defective, deteriorated battery Defective coolant temperature sensor, wiring harness Defective intake air heater system
Causes
General causes why exhaust smoke comes out but engine does not start • Lack of rotating force due to defective electrical system • Insufficient supply of fuel • Insufficient intake of air • Improper selection of fuel
Confirm recent repair history
E
Questions
Degree of use of machine Operated for long period
EE E w QQ
w
Suddenly failed to start Non-specified fuel is being used Replacement of filters has not been carried out according to Operation and Maintenance Manual
w
Q
ww w
Engine oil must be added more frequently When engine is preheated or when temperature is low, preheating monitor does not indicate normally (if monitor is installed)
w w
Dust indicator is red (if indicator is installed)
Q
Air breather hole of fuel tank cap is clogged
ww
Rust and water are found when fuel tank is drained
w
When fuel filter is removed, there is not fuel in it
w wQQ
Fuel is leaking from fuel piping When priming pump is operated, it makes no reaction or it is heavy
w w
When engine is cranked, abnormal sound is generated around cylinder head While engine is cranked with starting motor,
ww w
If spill hose from injector is disconnected, little fuel spills
When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low
w q
Inspect air cleaner directly
q
Inspect dynamic valve system directly
q
When compression pressure is measured, it is found to be low Troubleshooting
Q
If air bleeding plug of fuel filter is removed, fuel does not flow out
q
When air is bled from fuel system, air comes out
q
Inspect fuel filter, strainer directly
q
Inspect feed pump gauze filter directly Carry out troubleshooting according to “No-pressure feed by supply pump (*1)” in E-mode
q q
When injector unit is tested, spray condition is bad When specific gravity of electrolyte and voltage of battery are measured, they are low Coolant temperature gauge does not indicate normally (if coolant temperature gauge is installed) When starting switch is turned to HEAT, intake air heater mount does not become warm Remedy
q q q Clean Replace Replace Replace Clean Correct Clean Clean Replace Clean Replace Replace Replace
Check items
Starting motor cranks engine slowly
*1: Code [559/CA559] and code [2249/CA2249] in E-mode
140E-5 Series
13
SEN00152-03
40 Troubleshooting
S-3 Engine does not pick up smoothly
1
Clogged injector, defective spray
E
Defective operation of flow damper (Large leakage from injector)
Defective EGR valve or bypass valve ["with EGR" only]
E
Defective contact of valve and valve seat Improper valve clearance Seized turbocharger, interference of turbocharger Worn piston ring, cylinder liner Clogged air breather hole of fuel tank cap Leaking or clogged fuel piping, entry of air Clogged fuel filter, strainer Clogged feed pump gauze filter Stuck, seized supply pump plunger
Clogged air cleaner element
Causes
General causes why engine does not pick up smoothly q Insufficient intake of air q Insufficient supply of fuel q Defective condition of fuel spray q Improper selection of fuel q Controller is controlling in derate mode (limiting injection rate (output) because of an error in electrical system) q EGR valve is stuck open ["with EGR" only] (There is much EGR gas and intake of air is insufficient)
Operated for long period
E
E
Q
Engine pick-up suddenly became worse
w
E E Q Q
Q w w w
Non-specified fuel is being used Replacement of filters has not been carried out according to Operation and Maintenance Manual
w
w w w
Oil must be added more frequently w
Dust indicator is red (if indicator is installed)
w
Air breather hole of fuel tank cap is clogged
w w
Rust and water are found when fuel tank is drained Fuel is leaking from fuel piping
w
When priming pump is operated, it makes no reaction or it is heavy
w Q Q
Check items
When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Color of exhaust gas
Q
w
w
Blue under light load w
Black
Q
w
w
w
When engine is cranked, abnormal sound is generated around cylinder head
w
When engine is cranked, interference sound is generated around turbocharger High idle speed under no load is normal, but speed suddenly drops when load is applied There is hunting from engine (rotation is irregular)
Q
w w
Q
Q w
Q
w w
Blow-by gas is excessive q
Inspect air cleaner directly Carry out troubleshooting according to “Abnormality in EGR valve servo (*1)” in E-mode or “Abnormality in bypass valve servo (*1)” in E-mode ["with EGR" only] Troubleshooting
w
q q
When compression pressure is measured, it is found to be low
q q
Inspect valve clearance directly
q
When turbocharger is rotated by hand, it is found to be heavy
q
When air is bled from fuel system, air comes out
q
Inspect fuel filter, strainer directly
q
Inspect feed pump gauze filter directly Carry out troubleshooting according to “No-pressure feed by supply pump (*2)” in E-mode
q
Replace Adjust Replace Replace Clean Correct Clean Clean Replace
Replace
Remedy
Clean
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change
q
q Replace
Degree of use of machine
Replace
Questions
Confirm recent repair history
*1: Code [1228/CA1228] and code [1625/CA1625] or code [1628/CA1628] and code [1629/CA1629] in Emode *2: Code [559/CA559] and code [2249/CA2249] in E-mode
14
140E-5 Series
40 Troubleshooting
SEN00152-03
S-4 Engine stops during operations
1 Broken dynamic valve system (valve, rocker arm, etc.) Broken, seized piston, connecting rod Broken, seized crankshaft bearing Broken, seized gear train Insufficient fuel in tank Clogged air breather hole of fuel tank cap Leaking, clogged fuel piping Clogged fuel filter, strainer Clogged feed pump gauze filter Broken, seized feed pump Broken supply pump shaft, key Stuck, seized supply pump plunger Broken auxiliary equipment (pump, compressor, etc.) Defective engine controller power supply wiring Defective starting switch wiring
Problem in drive devices on applicable machine side
Causes
General causes why engine stops during operations q Seized parts inside engine q Insufficient supply of fuel q There is overheating q Problem in drive devices on applicable machine side o Requires troubleshooting on applicable machine side.
Confirm recent repair history E E
Degree of use of machine Operated for long period
Questions
Abnormal noise was heard and engine stopped suddenly Condition when engine stopped
w w w w w Q
Engine overheated and stopped
Q w
Q Q
Q Q
There was hunting and engine stopped
w Q
Q Q Q
Q Q
Non-specified fuel is being used
Q Q Q
Replacement of filters has not been carried out according to Operation and Maintenance Manual
w w
Fuel level monitor indicates low level (if monitor is installed)
w
When fuel tank is inspected, it is found to be empty
w
Q
w
Fuel is leaking from fuel piping
w
When priming pump is operated, it makes no reaction or it is heavy
w Q Q w w
Rust and water are found when fuel tank is drained w w w
Metal particles are found when oil is drained
w w
Does not turn at all When engine is cranked by hand
w
Engine stopped slowly
Air breather hole of fuel tank cap is clogged
Check items
Q w Q w
w
Turns in opposite direction
w
Moves by amount of gear backlash
w w
Supply pump shaft does not turn
w
Engine turns, but stops when load is applied to machine q
Inspect dynamic valve system directly
q
Inspect piston, connecting rod directly
q
Inspect gear train directly
q
Inspect fuel filter, strainer directly
q
Inspect feed pump gauze filter directly
q
Inspect feed pump directly Carry out troubleshooting according to “No-pressure feed by supply pump (*1)” in E-mode Engine rotates when pump auxiliary equipment (pump, compressor, etc.) is removed
q q q q
Inspect controller power supply wiring
q
Inspect starting switch wiring Remedy
Replace Replace Replace Replace Add Clean Correct Clean Clean Replace Replace Replace Replace Correct Correct
Troubleshooting
Carry out troubleshooting on applicable machine side
q
Inspect crankshaft bearing directly
—
*1: Code [559/CA559] and code [2249/CA2249] in E-mode 140E-5 Series
15
SEN00152-03
40 Troubleshooting
S-5 Engine does not rotate smoothly
1
Defective Bkup speed sensor, wiring harness
Defective Ne speed sensor, wiring harness
Clogged injector, defective spray (dirt in injector)
Defective operation of flow damper (Large leakage from injector)
Clogged fuel filter, strainer
Clogged feed pump gauze filter
Leaking or clogged fuel piping, entry of air
Clogged air breather hole of fuel tank cap
Insufficient fuel in tank
Defective operation of bypass valve ["with EGR" only]
Low setting of low idle speed
Defective operation of EGR valve ["with EGR" only]
Causes
General causes why engine does not rotate smoothly q Air in fuel system q Defective speed sensor (Error at degree that it is not indicated) q Defective EGR valve ["with EGR" only] q Defective bypass valve ["with EGR" only]
Confirm recent repair history
Condition of hunting
E E
Operated for long period Occurs at a certain speed range
Q Q Q
Occurs at low idle
w
E E Q Q Q Q Q Q Q Q Q
Q Q
Occurs even when speed is raised
Q
Q Q
w
Occurs on slopes
Q Q
Replacement of filters has not been carried out according to Operation and Maintenance Manual
w w w
Check items
When fuel tank is inspected, it is found to be empty
w
Air breather hole of fuel tank cap is clogged
Q Q
Rust and water are found when fuel tank is drained Fuel is leaking from fuel piping
w
When priming pump is operated, it makes no reaction or it is heavy
w Q Q
Troubleshooting
Carry out troubleshooting according to “Abnormality in EGR valve servo (*1)” in E-mode ["with EGR" only]
q
Carry out troubleshooting according to “Abnormality in bypass valve servo (*2)” in Emode ["with EGR" only]
q q
When air is bled from fuel system, air comes out
q
Inspect feed pump gauze filter directly
q
Inspect fuel filter, strainer directly When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change
q q
Carry out troubleshooting according to “Abnormality in engine Ne speed sensor (*3)” in E-mode
q
Carry out troubleshooting according to “Abnormality in engine Bkup speed sensor (*4)” in E-mode
*1: *2: *3: *4:
16
Code Code Code Code
Correct
Replace
Replace
Replace
Replace
Correct
Clean
Add
Replace
Replace
Correct
Remedy
q Correct
Questions
Degree of use of machine
[1228/CA1228] and code [1625/CA1625] in E-mode [1628/CA1628] and code [1629/CA1629] in E-mode [689/CA689] in E-mode [778/CA778] in E-mode
140E-5 Series
40 Troubleshooting
SEN00152-03
S-6 Engine lacks output (or lacks power)
1
General causes why engine lacks output
Defective drive of injector (signal, solenoid)
Q
Q Q Q Q
Defective fuel temperature sensor, wiring harness
Clogged injector, defective spray (dirt in injector)
Stuck, seized supply pump plunger
Clogged feed pump gauze filter
Clogged fuel filter, strainer
Leaking, clogged fuel piping
Clogged air breather hole of fuel tank cap
Worn piston ring, cylinder liner
Improper valve clearance
• Controller is controlling in derate mode (limiting injection rate (output) because of an error in electrical system)
Clogged air cleaner element
• There is overheating → See “S-14 Coolant temperature becomes too high (Overheating)”
Air leakage from air intake piping
• Improper selection of fuel
Defective contact of valve and valve seat
• Defective spray condition of fuel
Seized turbocharger, interference of turbocharger
• Insufficient supply of fuel
Defective charge (boost) pressure sensor, wiring harness
• Insufficient intake of air
Defective installation of charge (boost) pressure sensor (air leakage)
Causes
Confirm recent repair history
Power was lost
E
Operated for long period
E
E
E E
Q
Q
Q Q Q Q
Q
Suddenly
Q
Gradually
Non-specified fuel is being used Replacement of filters has not been carried out according to Operation and Maintenance Manual
w Q Q Q
Engine oil must be added more frequently
w
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
Blue under light load
Check items
When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low
w w
When engine is cranked, interference sound is generated around turbocharger
w
When engine is cranked, abnormal sound is generated around cylinder head
Q
High idle speed is too low High idle speed under no load is normal, but speed suddenly drops when load is applied
w w Q w
Engine does not pick up smoothly and combustion is irregular
Q Q Q Q Q Q
There is hunting from engine (rotation is irregular)
w
Blow-by gas is excessive Inspect air cleaner directly
q
Inspect air intake piping directly
q q q q
When boost pressure is measured, it is found to be low
w
q
When compression pressure is measured, it is found to be low
q q
Inspect valve clearance directly Troubleshooting
w
q
Inspect fuel filter, strainer directly
q
Inspect feed pump gauze filter directly Carry out troubleshooting according to “No-pressure feed by supply pump (*1)” in Emode When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change
q q q q
Inspect charge (boost) pressure sensor mount directly Carry out troubleshooting according to “Abnormality in charge pressure sensor (*2)” in E-mode Carry out troubleshooting according to “Abnormality in fuel temperature sensor (*3)” in E-mode
140E-5 Series
Correct
Replace
Replace
Replace
Clean
Replace
Correct
Clean
Replace
Adjust
Replace
Replace
Correct
Remedy
q
Clean
*1: Code [559/CA559] and code [2249/CA2249] in E-mode *2: Code [122/CA122] and code [123/CA123] in E-mode *3: Code [263/CA263] and code [265/CA265] in E-mode
q
Replace
Color of exhaust gas
w w w
Black
Replace
Questions
Degree of use of machine
17
SEN00152-03
40 Troubleshooting
S-7 Exhaust smoke is black (incomplete combustion)
Defective coolant temperature sensor, wiring harness
Improper fuel injection pressure
Improper injection timing
Clogged fuel spill piping (on cylinder head side)
Abnormally worn injector
Clogged, seized injector
Stuck, seized supply pump plunger
Worn piston ring, cylinder liner
Crushed, clogged muffler
Leakage of air between turbocharger and cylinder head
Improper valve clearance
Defective contact of valve and valve seat
EGR gas piping is clogged ["with EGR" only]
Defective EGR valve or bypass valve ["with EGR" only]
Seized turbocharger, interference of turbocharger
Causes
Clogged air cleaner element
General causes why exhaust smoke is black q Insufficient intake of air q Excessive injection of fuel q Defective condition of fuel injection q Improper selection of fuel q There is overheating o See “S-14 Coolant temperature becomes too high (Overheating)” q Controller is controlling in derate mode (limiting injection rate (output) because of an error in electrical system) q EGR valve is stuck open ["with EGR" only] (There is much EGR gas and intake of air is insufficient) q EGR gas piping is clogged ["with EGR" only] (Entry of exhaust gas into air intake at acceleration or deceleration) (*2)
1
Confirm recent repair history Operated for long period
E
Suddenly became black Color of exhaust gas Gradually became black color Blue under light load
w
E
E
E
w Q Q
Q Q
w
Q
Q Q w Q Q
Non-specified fuel is being used w
Oil must be added more frequently Power was lost
E
w
Suddenly
Q
Q
Gradually
Q
Q
Q Q Q
w
Dust indicator is red (if indicator is installed)
w
Muffler is crushed w
Air leaks between turbocharger and cylinder head, clamp is loosened
Q Q Q
Engine is operated in low-temperature mode at normal temperature
Check items
When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low
Q w w
When engine is cranked, interference sound is generated around turbocharger
w
When engine is cranked, abnormal sound is generated around cylinder head Torque converter stall speed or pump relief speed is high (Fuel is injected excessively)
Q Q
Exhaust noise is abnormal
Q
Engine does not pick up smoothly and combustion is irregular
Q Q
Blow-by gas is excessive
w
w
Q
Q Q Q
Q w w w
If spill hose from injector is disconnected, abnormally much fuel spills q
Inspect air cleaner directly
q
When turbocharger is rotated by hand, it is fount to be heavy
Troubleshooting
Carry out troubleshooting according to “Abnormality in EGR valve servo (*1)” in Emode or “Abnormality in bypass valve servo (*1)” in E-mode ["with EGR" only]
q q
Inspect EGR gas piping directly (*2) ["with EGR" only]
q
When compression pressure is measured, it is found to be low
q q
Inspect valve clearance directly
q
When muffler is removed, exhaust color improves Carry out troubleshooting according to “No-pressure feed by supply pump (*3)” in Emode
q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change
q q q
Inspect fuel spill piping (on cylinder head side) directly Carry out troubleshooting according to “Abnormality in coolant temperature sensor (*4)” in E-mode
18
Adjust
Adjust
Correct
Replace
Replace
Replace
Replace
Replace
Adjust
Correct
Replace
Replace
Replace
Clean
Replace
Remedy
q Replace
Questions
Degree of use of machine
140E-5 Series
40 Troubleshooting
SEN00152-03
*1: Code [1228/CA1228] and code [1625/CA1625] or code [1628/CA1628] and code [1629/CA1629] in Emode *2: EGR inlet pressure pipings Remove 2 EGR inlet pressure pipings (2) and check their inside for clogging. Reference: EGR inlet pressure sensor is applied to only machines Serial No. up to 530896.
*3: Code [559/CA559] and code [2249/CA2249] in E-mode *4: Code [144/CA144] and code [145/CA145] in E-mode
140E-5 Series
19
SEN00152-03
40 Troubleshooting
S-8 Oil consumption is excessive (or exhaust smoke is blue) General causes why oil consumption is excessive
• Long-time operation of engine at low idle or high idle (Do not run engine at idle for more than 20 minutes continuously) • External leakage of oil • Wear of parts in lubrication system
Dust sucked in from intake system Worn, damaged valve (stem, guide, seal) Worn seal at turbocharger end Turbocharger Worn seal at blower end Oil leakage from EGR valve stem ["with EGR" only] Clogged breather, breather hose Broken piston ring Worn piston ring, cylinder liner Worn, damaged rear oil seal Broken oil cooler Oil leakage from oil cooler Oil leakage from oil filter Oil leakage from oil piping Oil leakage from oil drain plug Oil leakage from oil pan, cylinder head, etc.
Causes
• Abnormal consumption of oil
Questions
1
Confirm recent repair history Degree of use of Operated for long period machine Oil consumption suddenly increased
EEEE
E w
Q
Oil must be added more frequently Oil becomes contaminated quickly
Q Q
w Q Q w
w w w w w
Outside of engine is dirty with oil
w
There are loose piping clamps in intake system
w Q w
Inside of turbocharger exhaust outlet pipe is dirty with oil
w
There is oil in coolant
w
Oil level in clutch chamber or damper chamber is high
Q
Exhaust smoke is blue under light load Amount of blow-by gas
Q
Excessive
Troubleshooting
Q w
None
When intake manifold is removed, dust is found inside When intake manifold is removed, inside is found to be dirty abnormally Excessive play of turbocharger shaft When EGR valve is removed, exhaust port is found to be dirty with oil ["with EGR" only] Check breather and breather hose directly When compression pressure is measured, it is found to be low
q q q q q q q q q
Inspect rear oil seal directly
q q
Pressure-tightness test of oil cooler shows there is leakage
q q q
There is external leakage of oil from engine Remedy
20
w w w w
Correct Replace Replace Replace Replace Clean Replace Replace Replace Replace Replace Correct Correct Correct Correct
Check items
Inside of turbocharger intake outlet pipe is dirty with oil
140E-5 Series
40 Troubleshooting
SEN00152-03
S-9 Oil becomes contaminated quickly
1
General causes why oil becomes contaminated quickly
Defective turbocharger turbine side seal Worn EGR valve guide ["with EGR" only] Worn valve, valve guide Worn piston ring, cylinder liner Clogged breather, breather hose Clogged oil cooler Clogged oil filter Defective oil filter safety valve Clogged turbocharger lubrication drain tube Exhaust smoke is bad
Causes
• Entry of exhaust gas into oil due to internal wear • Clogging of lubrication passage • Use of improper fuel • Use of improper oil
Confirm recent repair history Degree of use of Operated for long period machine
EEEE Q
Non-specified fuel is being used
Q
Engine oil must be added more frequently Even when engine oil temperature rises, oil filter clogging monitor indicates clogging (if monitor is installed) Metal particles are found when oil is drained
w w Q Q Q w
Inside of exhaust pipe is dirty with oil
w
Color of exhaust gas color Amount of blow-by gas
w
Blue under light load
w
Black
Q
Excessive
w
None
Excessive play of turbocharger shaft When EGR valve is removed, exhaust port is found to be dirty with oil ["with EGR" only] When compression pressure is measured, it is found to be low
q q q q q
Inspect breather and breather hose directly
q
Inspect oil cooler directly
q
Inspect oil filter directly
q
Spring of oil filter safety valve is hitched or broken
q
Inspect turbocharger lubrication drain tube directly Remedy
140E-5 Series
Q w
Replace Replace Replace Replace Clean Replace Replace Replace Clean
Troubleshooting
Check items
Engine oil temperature rises quickly
See S-7
Questions
• Operation under excessive load
—
21
SEN00152-03
40 Troubleshooting
S-10 Fuel consumption is excessive
1
General causes why fuel consumption is excessive
Fuel leakage inside head cover Fuel leakage from fuel filter, piping, etc. Defective feed pump oil seal Defective supply pump plunger Defective common rail pressure Defective spray by injector Defective operation of injector Improper fuel injection timing Defective coolant temperature sensor, wiring harness
Causes
• Leakage of fuel • Defective condition of fuel injection (fuel pressure, injection timing)
Questions
• Excessive injection of fuel
Confirm recent repair history Degree of use of Operated for long period machine More than for other machines of same model Condition of fuel Gradually increased consumption Suddenly increased
EE
E Q
Q Q Q w
There is external leakage of fuel from engine
w
Engine oil level rises and oil smells of diesel fuel w When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Low idle speed is high
w w Q Q
Torque converter stall speed or pump relief speed is high Exhaust smoke color
Q Q
Black White
Q
Remove and inspect head cover directly
q
Inspect feed pump oil seal directly Carry out troubleshooting according to “No-pressure feed by supply pump (*2)” in E-mode When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change If spill hose from injector is disconnected, much fuel spills Carry out troubleshooting according to “Abnormality in coolant temperature sensor (*2)” in E-mode Confirm with INSITE or with monitoring function on applicable machine side Remedy
Q Q
q q q q q q
q
Correct Correct Replace Replace Correct Replace Replace Correct Correct
Check items
Combustion is irregular
Troubleshooting
Q Q Q Q
*1: Code [559/CA559] and code [2249/CA2249] in E-mode *2: Code [144/CA144] and code [145/CA145] in E-mode
22
140E-5 Series
40 Troubleshooting
SEN00152-03
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)1 Causes
• Internal leakage in lubrication system
Broken oil cooler core, O-ring
Insufficient protrusion of cylinder liner
Damaged cylinder liner O-ring, holes caused by pitting
Internal cracks in cylinder block
Broken cylinder head, head gasket
• Internal leakage in cooling system
Broken hydraulic oil cooler or power train oil cooler on applicable machine side
General causes why oil is in coolant
E
Degree of use of machine Operated for long period Oil level
Q Q Q Q Q
Gradually increased
Hard water is being used as coolant
w
There are excessive air bubbles in radiator, coolant spurts back
Q w w
Hydraulic oil or power train oil on applicable machine side is milky
w
When hydraulic oil or power train oil is drained, water is found
w q
Pressure-tightness test of cylinder head shows there is leakage
q q
Inspect cylinder block, liner directly
q
Inspect cylinder liner directly
q
140E-5 Series
Replace
Replace
Replace
Remedy
Replace
Pressure-tightness test of oil cooler shows there is leakage
Carry out troubleshooting on applicable machine side
Check items
Oil level has risen and oil is milky
Troubleshooting
E Q Q
Q
Suddenly increased
Replace
Questions
Confirm recent repair history
—
23
SEN00152-03
40 Troubleshooting
S-12 Oil pressure drops
1
General causes why oil pressure drops • Leakage, clogging, wear in lubrication system • Defective oil pressure control • Selection of oil by the temperature etc. specified in the Operation and Maintenance Manual is not observed.
Confirm recent repair history Degree of use of Operated for long period E E E machine Oil pressure monitor indicates low oil pressure (if monitor is installed) Q w Non-specified oil is being used Q Q Replacement of filters has not been carried out according to Operation and w Maintenance Manual Indicates pressure drop at low idle w Q Q Oil pressure Indicates pressure drop at low, high idle Q w w w Q Q Q monitor Indicates pressure drop on slopes w (if installed) Sometimes indicates pressure drop w Q Q Oil level monitor indicates oil level drop (if monitor is installed) w w Oil level in oil pan is low w External hydraulic piping is leaking, crushed w w Oil is milky or smells of diesel oil w Metal particles are found when oil pan is drained w w
Remedy
Q
q q q See S-13
Metal particles are found in oil filter q Inspect oil pan strainer, pipe directly Oil pump rotation is heavy, there is play in oil pump Valve and spring of oil pump relief valve are fatigued, damaged Inspect oil filter directly Relief valve of EGR oil pump is damaged, oil leaks from it ["with EGR" only] Inspect EGR hydraulic piping directly ["with EGR" only] Carry out troubleshooting according to “Abnormality in oil pressure sensor (*1)” in E-mode If oil level sensor is replaced, oil pressure monitor indicates normally
Q
q q q q q q
—
Clean Clean Replace Adjust Replace Correct Replace Replace Replace Replace
Metal particles are found when oil filter is drained
Replace Add
Troubleshooting
Check items
Questions
• Deterioration of oil due to overheating
Worn journal of bearing Lack of oil in oil pan Coolant, fuel in oil Clogged strainer in oil pan Clogged, broken pipe in oil pan Defective oil pump Defective oil pump relief valve Clogged oil filter Leaking, crushed, clogged hydraulic piping Defective EGR oil pump ["with EGR" only] Leaking EGR hydraulic piping ["with EGR" only] Defective oil pressure sensor, wiring harness Defective oil level sensor, wiring harness
Causes
*1: Code [135/CA135] and code [141/CA141] in E-mode
24
140E-5 Series
40 Troubleshooting
SEN00152-03
S-13 Oil level rises (Entry of coolant/fuel)
1
General causes why oil level rises
Cracked EGR cooler (Entry of coolant) ["with EGR" only] Broken cylinder head, head gasket Fuel leakage inside head cover Cracks inside cylinder block Damaged cylinder liner O-ring, holes caused by pitting Worn, damaged rear oil seal Broken oil cooler core, O-ring Clogged water pump drain hole (breather hole), defective seal Defects in supply pump Defective seal of auxiliary equipment (pump, compressor)
Causes
• Coolant in oil (milky) • Fuel in oil (smells diluted diesel fuel)
Confirm recent repair history Degree of use of Operated for long period EE E E machine Fuel must be added more frequently w w Coolant must be added more frequently Q Q There is oil in coolant Q Q Q w Oil smells of diesel fuel w w Oil is milky Q Q When engine is started, drops of water come from muffler Q Q When radiator cap is removed and engine is run at low idle, an abnormal number of w Q bubbles appear, or coolant spurts back Exhaust smoke is white Q Water pump drain hole (breather hole) is clogged w When water pump drain hole (breather hole) is cleaned, coolant comes out w Oil level in clutch or damper chamber of machine is low w Oil level in hydraulic tank of machine is low w When EGR cooler outlet gas piping is removed, coolant containing antifreeze flows q out (*1) ["with EGR" only] When compression pressure is measured, it is found to be low q Remove and inspect head cover directly q Inspect cylinder block, liner directly q q Inspect rear oil seal directly q Pressure-tightness test of oil cooler shows there is leakage q Remove and inspect water pump directly q Remove and inspect supply pump directly q Inspect seal of auxiliary equipment directly q Remedy
140E-5 Series
Replace Replace Correct Replace Replace Correct Replace Replace Replace Replace
Troubleshooting
Check items
Questions
a If oil is in coolant, carry out troubleshooting for “S-11 Oil is in coolant”
25
SEN00152-03
40 Troubleshooting
*1: EGR cooler outlet gas piping Loosen 4 mounting bolts (1) of the EGR cooler outlet gas piping and check that the coolant flows out. A little condensate produced from cooled exhaust gas may flow out. If it is colorless and transparent, however, it is not a problem.
26
140E-5 Series
40 Troubleshooting
SEN00152-03
S-14 Coolant temperature becomes too high (overheating) General causes why coolant temperature becomes too high
1 Rise in power train oil temperature on applicable machine side
Defective coolant temperature gauge
Slipping fan belt, worn fan pulley
Defective radiator cap (pressure valve)
Clogged radiator core
Clogged, crushed radiator fins
Defective operation of thermostat
Broken water pump
• Rise in oil temperature in power train → Carry out troubleshooting for machine
Lack of coolant
• Problem in coolant circulation system
Clogged, broken oil cooler
• Drop in heat dissipation efficiency
Damaged cylinder liner O-ring, hole caused by pitting
• Lack of cooling air (deformation, damage of fan)
Broken cylinder head, head gasket
External leakage of coolant from EGR cooler ["with EGR" only]
Causes
Degree of use of machine Condition of overheating
Operated for long period
E E E
Sudden overheated
Q
E E Q w
Coolant temperature Rises quickly gauge (if installed) Does not go down from red range
Q
Radiator coolant level monitor indicates drop of coolant level (if monitor is installed) Q
w
Q
w w
w Q
Engine oil level has risen, oil is milky
w
Fan belt tension is low When fan pulley is turned, it has play
w w
Milky oil is floating on coolant w
There are excessive air bubbles in radiator, coolant spurts back Check items
Q Q w w
Always tends to overheat
When light bulb is held behind radiator core, no light passes through
w
Radiator shroud, inside of underguard on applicable machine side are clogged with dirt or mud
w
w
w
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 Power train oil temperature enters red range faster than engine coolant temperature (if oil temperature gauge and coolant temperature gauge are installed)
w q
Inspect EGR cooler for coolant leakage ["with EGR" only]
q
When compression pressure is measured, it is found to be low
q
Inspect cylinder liner directly
q q
Temperature difference between upper and lower tanks of radiator is large When operation of thermostat is carried out, it does not open at cracking temperature
q q
Temperature difference between upper and lower tanks of radiator is slight
q
Inspect radiator core directly
q
When operation of radiator cap is carried out, its cracking pressure is low
q
Inspect fan belt, pulley directly
q
140E-5 Series
Replace
Replace
Correct
Correct
Replace
Replace
Add
Replace
Replace
Replace
Remedy
Replace
When coolant temperature is measured, it is fount to be normal
Replace
Troubleshooting
Inspect oil cooler directly
Carry out troubleshooting on applicable machine
Questions
Confirm recent repair history
—
27
SEN00152-03
40 Troubleshooting
S-15 Abnormal noise is made
1
General causes why abnormal noise is made
Improper fuel injection timing (abnormality in coolant temperature sensor)
Dirt caught in injector
Clogged, seized injector
Deformed cooling fan, loose fan belt, interference of fan belt
Removed, seized gear train bushing
Improper gear train backlash
Excessive wear of piston ring, cylinder liner
a When the engine is accelerated, it is operated in the acceleration mode and its sound becomes a little larger for up to about 5 seconds. This does not indicate abnormality, however.
Improper valve clearance
a The engine is operated in the low-temperature mode while it is not warmed up sufficiently. Accordingly, the engine sound becomes a little larger. This does not indicate abnormality, however.
Defective inside of muffler (dividing board out of position)
a Judge if the noise is an internal noise or an external noise before starting troubleshooting.
Broken dynamic valve system (valve, rocker lever)
• Air sucked in from intake system
Cracked, leaking EGR gas piping ["with EGR" only]
• Abnormal combustion
Interference of turbocharger, seized turbocharger
• Abnormality due to defective parts
Leakage of air between turbocharger and cylinder head
Causes
Degree of use of machine Condition of abnormal noise
E
Operated for long period
Q
Gradually occurred
Q
Q Q Q
Sudden occurred
Q Q
Non-specified fuel is being used
w w
Oil must be added more frequently Metal particles are found when oil filter is drained
w
When engine is cranked, interference sound is generated around turbocharger When engine is cranked, abnormal sound is generated around EGR gas piping ["with EGR" only]
w w
When engine is cranked, abnormal sound is generated around cylinder head Check items
w
w
Air leaks between turbocharger and cylinder head
w w
When engine is cranked, beat noise is generated around muffler When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Color of exhaust gas
w Q w
Blue under light load
Q w
Black
Q
Engine does not pick up smoothly and combustion is irregular
Q
Abnormal noise is loud when engine is accelerated
Q
w Q
w
Blow-by gas is excessive
q
When turbocharger is rotated by hand, it is fount to be heavy
q
Inspect EGR gas piping directly ["with EGR" only]
q
Inspect dynamic valve system directly Troubleshooting
Q
q
When muffler is removed, abnormal noise disappears
q
Inspect valve clearance directly
q
When compression pressure is measured, it is found to be low
q q
Inspect gear train directly
q
Inspect fan and fan belt directly When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change
q q q
Abnormal noise is heard only when engine is started
q
28
Replace
Replace
Correct
Replace
Replace
Replace
Adjust
Replace
Replace
Replace
Replace
Remedy
Replace
Confirm with INSITE or with monitoring function on applicable machine side
Correct
Questions
Confirm recent repair history
140E-5 Series
40 Troubleshooting
SEN00152-03
S-16 Vibration is excessive
1
General causes why vibration is excessive
Stuck dynamic valve system (valve, rocker lever) Worn main bearing, connecting rod bearing Improper gear train backlash Worn camshaft bushing Loose engine mounting bolts, broken cushions Misalignment between engine and devices on applicable machine side Worn front support spigot joint portion Broken output shaft, parts in damper on applicable machine side
Causes
• Defective parts (abnormal wear, breakage) • Misalignment between engine and chassis • Abnormal combustion
Confirm recent repair history Degree of use of Operated for long period machine Suddenly increased Condition of vibration Gradually increased Non-specified fuel is being used Metal particles are found when oil filter is drained Metal particles are found when oil pan is drained Oil pressure is low at low idle Vibration occurs at mid-range speed Vibration follows engine speed
EE Q
Q Q Q w w Q
Exhaust smoke is black
w
Inspect dynamic valve system directly Inspect main bearing and connecting rod bearing directly Inspect gear train directly Inspect camshaft bushing directly Inspect engine mounting bolts and cushions directly When alignment is checked, radial runout or facial runout is detected Inspect front support spigot joint portion directly Inspect output shaft or inside of damper directly
q
Remedy
140E-5 Series
E
Q Q Q Q w w Q Q Q Q Q Q Q Q
q q q q q q Q Replace Replace Replace Replace Replace Adjust Replace Replace
Troubleshooting
Check items
Questions
a If abnormal noise is made and vibration is excessive, carry out troubleshooting for “S-15 Abnormal noise is made”, too.
29
SEN00152-03
KOMATSU 140E-5 Series engine Form No. SEN00152-03
© 2009 KOMATSU All Rights Reserved Printed in Japan 01-09 (01)
30
SEN00153-03
ENGINE 1SHOP MANUAL
140E-5 Series
40 Troubleshooting
1
Troubleshooting of electrical system (E-mode), Part 1 Troubleshooting of electrical system (E-mode), Part 1 ................................................................................... 3 Troubleshooting method for disconnecting wiring harness of pressure sensor system ....................... 3 E-1 Code [111/CA111] Engine Controller Internal Failure .................................................................... 6 E-2 Code [115/CA115] Eng. Ne and Bkup Speed Sensor Error........................................................... 7 E-3 Code [122/CA122] Charge (boost) Air Press Sensor High Error................................................... 8 E-4 Code [123/CA123] Charge (boost) Air Press Sensor Low Error ................................................. 12 E-5 Code [131/CA131] Throttle Sensor High Error ............................................................................ 16 E-6 Code [132/CA132] Throttle Sensor Low Error............................................................................. 20 E-7 Code [135/CA135] Oil Press. Sensor High Error......................................................................... 22 E-8 Code [141/CA141] Oil Press. Sensor Low Error ......................................................................... 24 E-9 Code [144/CA144] Coolant Temp. Sensor High Error ................................................................. 26 E-10 Code [145/CA145] Coolant Temp. Sensor Low Error................................................................ 28 E-11 Code [153/CA153] Charge (boost) Air Temp. Sensor High Error .............................................. 30 E-12 Code [154/CA154] Charge (boost) Air Temp. Sensor Low Error ............................................... 32
140E-5 Series
1
SEN00153-03
40 Troubleshooting
E-13 Code [187/CA187] Sensor Sup. 2 Volt. Low Error..................................................................... 34 E-14 Code [221/CA221] Ambient Air Press. Sensor High Error......................................................... 38 E-15 Code [222/CA222] Ambient Air Press. Sensor Low Error ......................................................... 40 E-16 Code [227/CA227] Sensor Sup. 2 Volt. High Error .................................................................... 42 E-17 Code [234/CA234] Eng. Overspeed .......................................................................................... 42 E-18 Code [238/CA238] Ne Speed Sensor Sup. Volt. Error............................................................... 44 E-19 Code [263/CA263] Fuel Temp. Sensor High Error..................................................................... 46 E-20 Code [265/CA265] Fuel Temp. Sensor Low Error ..................................................................... 48 E-21 Code [271/CA271] PCV1 Short Error ........................................................................................ 50 E-22 Code [272/CA272] PCV1 Open Error ........................................................................................ 52 E-23 Code [273/CA273] PCV2 Short Error ........................................................................................ 54 E-24 Code [274/CA274] PCV2 Open Error ........................................................................................ 56 E-25 Code [322/CA322] Injector #1 System Open/Short Error .......................................................... 58 E-26 Code [323/CA323] Injector #5 System Open/Short Error .......................................................... 60 E-27 Code [324/CA324] Injector #3 System Open/Short Error .......................................................... 62 E-28 Code [325/CA325] Injector #6 System Open/Short Error .......................................................... 64 E-29 Code [331/CA331] Injector #2 System Open/Short Error .......................................................... 66 E-30 Code [332/CA332] Injector #4 System Open/Short Error .......................................................... 68 E-31 Code [342/CA342] Engine Controller Data Matching Error ....................................................... 70 E-32 Code [351/CA351] INJ. Drive Circuit Error ................................................................................ 72 E-33 Code [352/CA352] Sensor Sup. 1 Volt. Low Error..................................................................... 74 E-34 Code [386/CA386] Sensor Sup. 1 Volt. High Error .................................................................... 75 E-35 Code [431/CA431] Idle Validation Switch Error ......................................................................... 78 E-36 Code [432/CA432] Idle Validation Process Error ....................................................................... 80 E-37 Code [441/CA441] Supply Voltage Low Error............................................................................ 81 E-38 Code [442/CA442] Supply Voltage High Error........................................................................... 81
2
140E-5 Series
40 Troubleshooting
Troubleshooting of electrical system (E-mode), Part 1
SEN00153-03
1
Troubleshooting method for disconnecting wiring harness of pressure sensor system 1 a
Since pressure sensor consists not only of resistors but also electronic circuits such as amplifiers, it may have the deferences among the registances measured and its own polarities. So troubleshooting must be performed carefully.
Failure codes applicable to this diagnosis CA123: Charge air pressure sensor low error (for "EGR-less" only) q CA222: Ambient pressure sensor low error q
Procedure 1. Measure and record resistance of pressure sensor unit. 1) Disconnect pressure sensor connector (1) and connect socket (2) to the sensor. 2) Measure resistances R1 and R2 between pins. a If tester probes polarities to apply are reversed, measured values may change. Therefore, when measuring resistances, apply the same tester probe polarities to the pressure sensor in steps 1 and 2. a If measured value is infinite, take measurements with tester probes polarities exchanged each other and record the finite value obtained as a measured value. a Since measured values may be different from each other, take several measurements. Cause of the differences appears to be that the sensor may be charged by the tester. Take several measurement in both steps 1 and 2. Take the fact into consideration this differences when determining whether the wiring harness is disconnected in step 3.
2. Measure and record resistance with wiring harness between pressure sensor and engine controller connected 1) Since 5 V power supply to pressure sensor is supplied to other sensors, disconnect the other sensor connectors first.(*) 2) Connect the pressure sensor to be measured, disconnect connector (3) on engine controller side, and connect T-adapter (4) to wiring harness side. 3) Connect T-box (5) to T-adapter (4) and measure respective pins for resistances R1' and R2'. 3. Judging open circuit If there is an "apparent difference" between resistances R1 and R2 measured in step 1 and resistances R1' and R2' measured in step 2, "wiring harness is disconnected". 140E-5 Series
3
SEN00153-03
40 Troubleshooting
a "Apparent difference" means a difference of 10 or more times.
List of pressure sensor measuring locations and reference values Sensor Charge pressure sensor
Ambient pressure sensor
Measuring location at sensor pin
Internal resistance of measured sensor (Reference value)
R2: Between (1) and (3)
Approx. 2.9kz
R1: Between (2) and (3)
Approx. 4.3kz
R2: Between (1) and (3)
Approx. 3.2kz
R1: Between (2) (+) and (1) (-) R1: Between (1) (+) and (2) (-)
Approx. 4.6kz Approx. 2.9kz
Remarks Sensor is common to engine models 140 for EGR-less, 125, 170 and 12V140 Sensor is common to engine models 95, 125, 140, 170 and 12V140 If polarities are reversed, resistance value changes.
*: When measuring R2', disconnect the following connectors. (See circuit diagram related to code [187/ CA187]) q When measuring R2' of charge pressure sensor (CA123) Connectors of resistance RES, engine oil pressure sensor, ambient pressure sensor, and G sensor q When measuring R2' of ambient pressure sensor (CA222) Connectors of charge pressure sensor, resistance RES, engine oil pressure sensor, and G sensor
4
140E-5 Series
40 Troubleshooting
SEN00153-03
Measurement record (For measuring locations, see circuit diagram related to each code) Sensor
Charge pressure sensor
Sensor unit (Measuring location on sensor pin side) R2: Between (1) and (3) R1: Between (2) and (3) R2: Between (1) and (3)
Ambient pressure sensor
140E-5 Series
R1: Between (2) (+) and (1) (-) R1: Between (1) (+) and (2) (-)
Measured value
Sensor + Wiring harness (Measuring location on wiring harness side of engine controller) R1: Between (1) (+) and (2) (-) R1': Between (44) and (47) R2': Between (37) and (38) (*) R1': Between (3) (+) and (38) (-) R1': Between (38) (+) and (3) (-)
Measured value
5
SEN00153-03
40 Troubleshooting
E-1 Code [111/CA111] Engine Controller Internal Failure Error code
Failure code
111
CA111
Trouble
1
Abnormality in engine controller
Contents of trouble
• Abnormality occurred in controller.
Action of controller
• None in particular.
Problem that appears • Engine runs normally but it may stop during operation or may not be able to start. on machine Related information
• Different machine models may have different connector Nos. Cause
1 Defective fuse
Possible causes and standard value in normal state
Standard value in normal state/Remarks on troubleshooting Check fuse or circuit breaker on machine side directly for defect. (If fuse is broken or circuit breaker is turned OFF, circuit probably has ground fault.)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wir- Wiring harness between E03 (female) 2 Resistance Max. 1 z ing or defective contact in (3), (4) – battery (+) connector) Wiring harness between E03 (female) Resistance Max. 1 z (1), (2) – chassis ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring har- Wiring harness between E03 (female) Resistance Min. 1 Mz 3 ness (Short circuit with GND (3), (4) – battery (+) and chassis ground circuit) Wiring harness between E03 (female) (1), (2) – chassis ground and chassis Resistance Min. 1 Mz ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 4 Defective engine controller
E03
Voltage
Between (3), (4) – (1), (2)
20 – 30V
Circuit diagram related to controller power supply
6
140E-5 Series
40 Troubleshooting
SEN00153-03
E-2 Code [115/CA115] Eng. Ne and Bkup Speed Sensor Error Error code
Failure code
115
CA115
Trouble
1
Abnormality in engine Ne and Bkup sensors
Contents of trouble
• Abnormality occurred in Ne speed sensor circuit and Bkup speed sensor circuit simultaneously.
Action of controller
• None in particular.
Problem that appears • Engine cannot be started (if engine has been stopped). on machine • Engine stops (if engine has been running). Related information Cause
Possible causes and standard value in normal state
1
Defective Ne speed sensor Carry out troubleshooting for code [689/CA689]. system
2
Defective Bkup speed senCarry out troubleshooting for code [778/CA778]. sor system
3
Defective mount of Ne speed sensor
Check mount of Ne speed sensor directly for defect (defective installation of sensor, internal trouble of flywheel, etc.)
4
Defective mount of Bkup speed sensor
Check mount of Bkup speed sensor directly for defect (defective installation of sensor, internal trouble of supply pump, etc.)
5
Defective connection (Wrong connection)
Check Ne speed sensor and Bkup speed sensor directly for defective connection (wrong connection).
6 Defective engine controller
140E-5 Series
Standard value in normal state/Remarks on troubleshooting
If causes 1 – 5 are not detected, engine controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
7
SEN00153-03
40 Troubleshooting
E-3 Code [122/CA122] Charge (boost) Air Press Sensor High Error a
1
For “with EGR” Error code
Failure code
122
CA122
Trouble
Abnormally high level in charge (boost) pressure sensor
Contents of trouble
• Signal voltage in charge (boost) pressure sensor circuit is abnormally high.
Action of controller
• Fixes charge (boost) pressure (400 kPa {4.08 kg/cm2}) and continues operation.
Problem that appears • Acceleration performance of engine drops. on machine Related information
• If sensor connector is disconnected, code [123/CA123] for "Low Error" is displayed, even in normal condition. Cause 1
2
Possible causes and standard value in normal state
Defective sensor power supply system
Defective charge boost pressure sensor
Standard value in normal state/Remarks on troubleshooting If code [187/CA187] or [227/CA227] is indicated, carry out troubleshooting for it first. 1. Turn starting switch to OFF position. 2. Disconnect connector PIM. 3. Turn starting switch to ON position. If code changes from [122/CA122] to [123/CA123], charge (boost) pressure sensor is defective.
1. Turn starting switch to OFF position, then perform troubleshooting. Short circuit in wiring har- 2. Disconnect connectors ENG and PIM, and connect T-adapter 3 ness to female side of ENG. Between ENG (female) (37) and (44)
Resistance Min. 1 Mz
1. Turn starting switch to OFF position. 2. Disconnect connector PIM, and connect T-adapter to female side or insert T-adapter into connector ENG. Hot short circuit in wiring 3. Turn starting switch to ON position (with connector PIM 4 harness disconnected). (contact with 24 V circuit) Between PIM (female) (3) and (2), or Voltage Max. 1 V between ENG (44) and (47) 5
8
If no failure is found by above checks, engine controller is defecDefective engine controltive. (Since this is an internal failure, troubleshooting cannot be ler performed.)
140E-5 Series
40 Troubleshooting
SEN00153-03
Circuit diagram related to charge (boost) pressure sensor a For “with EGR”
140E-5 Series
9
SEN00153-03 a
40 Troubleshooting
For “EGR-less” Error code
Failure code
122
CA122
Trouble
Abnormally high level in charge (boost) pressure sensor
Contents of trouble
• Signal voltage in charge (boost) pressure sensor circuit is abnormally high.
Action of controller
• Fixes charge (boost) pressure (400 kPa {4.08 kg/cm2}) and continues operation.
Problem that appears • Acceleration performance of engine drops. on machine Related information
• If sensor connector is disconnected, code [123/CA123] for "Low Error" is displayed, even in normal condition. Cause 1
2
Possible causes and standard value in normal state
Defective sensor power supply system
Defective charge boost pressure sensor
Standard value in normal state/Remarks on troubleshooting If code [187/CA187] or [227/CA227] is indicated, carry out troubleshooting for it first. 1. Turn starting switch to OFF position. 2. Disconnect connector PIM. 3. Turn starting switch to ON position. If code changes from [122/CA122] to [123/CA123], charge (boost) pressure sensor is defective.
1. Turn starting switch to OFF position, then perform troubleshooting. Short circuit in wiring har- 2. Disconnect connectors ENG and PIM, and connect T-adapter 3 ness to female side of ENG. Between ENG (female) (37) and (44)
Resistance Min. 1 Mz
1. Turn starting switch to OFF position. 2. Disconnect connector PIM, and insert T-adapter into Hot short circuit in wiring connector ENG. 4 harness 3. Turn starting switch to ON position (with connector PIM (contact with 24 V circuit) disconnected). Between ENG (44) and (47) 5
10
Voltage
Max. 1 V
If no failure is found by above checks, engine controller is defecDefective engine controltive. (Since this is an internal failure, troubleshooting cannot be ler performed.)
140E-5 Series
40 Troubleshooting
SEN00153-03
Circuit diagram related to charge (boost) pressure sensor a For “EGR-less”
140E-5 Series
11
SEN00153-03
40 Troubleshooting
E-4 Code [123/CA123] Charge (boost) Air Press Sensor Low Error Error code
Failure code
123
CA123
Trouble
1
Abnormally low level in charge (boost) pressure sensor
Contents of trouble
• Signal voltage in charge (boost) pressure sensor circuit is abnormally low.
Action of controller
• Fixes charge (boost) pressure (400 kPa {4.08 kg/cm2}) and continues operation.
Problem that appears • Acceleration performance of engine drops. on machine Related information
a
• If sensor connector is disconnected, this code is displayed.
For “with EGR” Cause
Standard value in normal state/Remarks on troubleshooting If code [187/CA187] or [227/CA227] is displayed, perform troubleshooting for it first.
Defective power supply sys- 1. Turn starting switch to OFF position. tem of charge pressure sen- 2. Disconnect connectors PIM and connect T-adapter to 1 sor (boost pressure sensor) female side. 3. Turn starting switch to ON position. Between PIM (female) (1) and (2)
Power input
Voltage
4.75 – 5.25 V
1. Turn starting switch to OFF position. 2. Disconnect connectors ENG and PIM and connect Tadapters to each female side.
Possible causes and standard value in normal state
Open circuit in wiring harBetween ENG (female) (37) and PIM ness (female) (1) 2 (wire breakage or defective Between ENG (female) (44) and PIM contact of connector) (female) (3)
Resistance
Max. 1z
Resistance
Max. 1z
Between ENG (female) (47) and PIM (female) (2)
Resistance
Max. 1z
3
Short circuit in wiring harness
1. Turn starting switch to OFF position. 2. Disconnect connectors ENG and PIM. 3. Connect T-adapter to female side of ENG. Between ENG (female) (44) and (47)
Ground fault in wiring har4 ness (contact with ground circuit)
5
Defective boost pressure sensor
12
Min. 1 Mz
1. Turn starting switch to OFF position, then perform troubleshooting. 2. Disconnect connectors ENG and PIM, and connect Tadapters to either female side. Between ENG (female) (44) or PIM (female) (3) and ground
Resistance
Min. 1 Mz
a If no failure is found by checks on causes 1 to 4, and check result of checks on cause 5 is abnormal, sensor is defective. 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector ENG or PIM. 3. Turn starting switch to ON position. Between ENG (44) and (47), or between PIM (3) and (2)
6 Defective engine controller
Resistance
Sensor output
Voltage
0.3 – 4.7 V
If no failure is found by above checks, engine controller is defective. (Since this is an internal failure, troubleshooting cannot be performed.)
140E-5 Series
40 Troubleshooting
SEN00153-03
Circuit diagram related to charge (boost) pressure sensor a For "with EGR"
140E-5 Series
13
SEN00153-03
a
40 Troubleshooting
For "EGR-less" Cause
Standard value in normal state/Remarks on troubleshooting
Defective power supply sysIf code [187/CA187] or [227/CA227] is indicated, carry out 1 tem of charge pressure sentroubleshooting for it first. sor (boost pressure sensor)
2
Short circuit in wiring harness
1. Turn starting switch to OFF position. 2. Disconnect connectors ENG and PIM. 3. Connect T-adapter to female side of ENG. Between ENG (female) (44) and (47)
Possible causes and standard value in normal state
Ground fault in wiring har3 ness (contact with ground circuit)
Min. 1 Mz
1. Turn starting switch to OFF position, then carry out troubleshooting. 2. Disconnect connectors ENG and PIM, and connect Tadapter to female side of ENG. Between ENG (female) (44) and ground
4
Resistance
Resistance
Min. 1 Mz
Disconnection in wiring har- If cause is not found by the above checks, wiring harness may ness be disconnected. (*)
Defective charge pressure (boost pressure) sensor 5 (lmproper input voltage of engine controller)
a If causes 1 - 4 are not the cause for the trouble and check result of cause 5 is abnormal, sensor is defective. 1. Turn starting switch to OFF position. 2. Connect T-adapter to connector ENG. 3. Turn starting switch to ON position. Between ENG (44) and (47)
6 Defective engine controller
Sensor output
Voltage
0.3 – 4.7 V
If no abnormality is found by the above checks, the engine controller is defective. (Since the failure is in it, troubleshooting cannot be performed.)
*: Refer to "Troubleshooting method for disconnected wiring harness of pressure sensor system."
14
140E-5 Series
40 Troubleshooting
SEN00153-03
Circuit diagram related to charge (boost) pressure sensor a For "EGR-less"
140E-5 Series
15
SEN00153-03
40 Troubleshooting
E-5 Code [131/CA131] Throttle Sensor High Error
1
Throttle sensor of accelerator pedal type (Case of HD325/405-7) Error code 131 Contents of trouble Action of controller
Failure code Trouble Abnormally high level in throttle sensor CA131 • Signal voltage in throttle sensor circuit is abnormally high. • Sets throttle angle with signal other than throttle signal and continues operation (depending on each model).
Problem that appears • Different problems occur on different machine models. on machine Related information • Different machine models may have different connector Nos. Cause Defective sensor power 1 supply system
2
Possible causes and standard value in normal state
Defective accelerator pedal (Internal trouble)
Disconnection in wiring harness (Disconnection in wir3 ing or defective contact in connector)
Ground fault in wiring har4 ness (Short circuit with GND circuit)
5 Defective engine controller
16
Standard value in normal state/Remarks on troubleshooting If code [2185/CA2185] or [2186/CA2186] is indicated, carry out troubleshooting for it first. a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Accelerator WAS1 Voltage pedal All range Between (1) – (3) 4.75 – 5.25 V (Power supply) (9 ± 2% of source Released voltage) Between (2) – (3) (73 ± 2% of source Pressed voltage) Sensor voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness and controller, too, for another cause of trouble, and then judge. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between E02 (female) Resistance Max. 1 z (22) – WAS1 (female) (1) Wiring harness between E02 (female) Resistance Max. 1 z (9) – WAS1 (female) (2) Wiring harness between E02 (female) Resistance Max. 1 z (23) – WAS1 (female) (3) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between E02 (female) (22) – WAS1 (female) (1) and chassis Resistance Min. 1 Mz ground Wiring harness between E02 (female) (9) – WAS1 (female) (2) and chassis Resistance Min. 1 Mz ground Wiring harness between E02 (female) (23) – WAS1 (female) (3) and chassis Resistance Min. 1 Mz ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Accelerator Voltage E02 pedal All range 4.75 – 5.25 V Between (22) – (23) (Power supply) (9 ± 2% of source Released voltage) Between (9) – (23) (73 ± 2% of source Pressed voltage)
140E-5 Series
40 Troubleshooting
SEN00153-03
Circuit diagram related to throttle sensor of accelerator pedal type (Case of HD325/405-7)
140E-5 Series
17
SEN00153-03
40 Troubleshooting
1 Throttle sensor of fuel control dial type (Case of PC800/800SE/850/850SE/850LC-8) Error code
Failure code
131
CA131
Trouble
Abnormally high level in throttle sensor
Contents of trouble
• Signal voltage in throttle sensor circuit is abnormally high.
Action of controller
• Sets throttle angle with signal other than throttle signal and continues operation (depending on each model).
Problem that appears • Different problems occur on different machine models. on machine Related information
• Different machine models may have different connector Nos. Cause Defective sensor power 1 supply system
Standard value in normal state/Remarks on troubleshooting If code [2185/CA2185] or [2186/CA2186] is indicated, carry out troubleshooting for it first. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
2
Defective fuel control dial (Internal trouble)
P20 (male)
Resistance
Between (1) – (3)
4.0 – 6.0 kz
Between (2) – (1)
0.25 – 5.0 kz
Between (2) – (3)
0.25 – 5.0 kz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wir3 ing or defective contact in connector) Possible causes and standard value in normal state
Wiring harness between E02 (female) Resistance Max. 1 z (22) – P20 (female) (1) Wiring harness between E02 (female) Resistance Max. 1 z (9) – P20 (female) (2) Wiring harness between E02 (female) Resistance Max. 1 z (23) – P20 (female) (3) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between E02 (female) (22) – P20 (female) (1) and chassis Resistance Min. 1 Mz ground
Ground fault in wiring har4 ness (Short circuit with GND Wiring harness between E02 (female) circuit) (9) – P20 (female) (2) and chassis Resistance Min. 1 Mz ground Wiring harness between E02 (female) (23) – P20 (female) (3) and chassis Resistance Min. 1 Mz ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 5 Defective engine controller
18
E02
Voltage
Between (22) – (23)
Power supply
4.75 – 5.25 V
Between (9) – (23)
Signal
0.5 – 4.5 V
140E-5 Series
40 Troubleshooting
SEN00153-03
Circuit diagram related to throttle sensor of fuel control dial type (Case of PC800/800SE/850/850SE/850LC-8)
140E-5 Series
19
SEN00153-03
40 Troubleshooting
E-6 Code [132/CA132] Throttle Sensor Low Error Error code
Failure code
132
CA132
Trouble
1
Abnormally low level in throttle sensor
Contents of trouble
• Signal voltage in throttle sensor circuit is abnormally low.
Action of controller
• Sets throttle angle with signal other than throttle signal and continues operation (depending on each model).
Problem that appears • Different problems occur on different machine models. on machine Related information Possible causes and standard value in normal state
20
Cause
Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for E-5 Code [131/CA131].
140E-5 Series
40 Troubleshooting
140E-5 Series
SEN00153-03
21
SEN00153-03
40 Troubleshooting
E-7 Code [135/CA135] Oil Press. Sensor High Error Error code
Failure code
135
CA135
1
Trouble Abnormally high level in oil pressure sensor
Contents of trouble
• Signal voltage in oil pressure sensor circuit is abnormally high.
Action of controller
• Sets oil pressure to default value (250 kPa {2.55 kg/cm2}) and continues operation.
Problem that appears on machine Related information Cause 1
Defective sensor power supply system
Standard value in normal state/Remarks on troubleshooting If code [187/CA187] or [227/CA227] is indicated, carry out troubleshooting for it first.
1. Turn starting switch to OFF position. 2. Disconnect connector POIL. Defective engine oil pres- 3. Turn starting switch to ON position. 2 sure sensor If code changes from [135/CA135] to [141/CA141] , engine oil pressure sensor is defective.
Possible causes and standard value in normal state
1. Turn starting switch to OFF position. 2. Disconnect connectors ENG and POIL, and connect TShort circuit in wiring haradapters to either female side. 3 ness Between ENG (female) (13) and (37), or Resistance Min. 1 Mz between POIL (female) (1) and (3) 1. Turn starting switch to OFF position. 2. Disconnect connector POIL. 3. Connect T-adapter to female side of connector POIL or insert Hot short circuit in wiring T-adapter into connector ENG. 4 harness 4. Turn starting switch to ON position (with connector POIL (contact with 24 V circuit) disconnected). Between ENG (female) (13) and (47), or between POIL (female) (3) and (2) 5
22
Voltage
Max. 1 V
If no failure is found by above checks, engine controller is defecDefective engine controltive. (Since this is an internal failure, troubleshooting cannot be ler performed.)
140E-5 Series
40 Troubleshooting
SEN00153-03
Circuit diagram related to oil pressure sensor a For “with EGR” a There is connector PEVA only for serial No. up to 530896.
a
For “EGR-less”
140E-5 Series
23
SEN00153-03
40 Troubleshooting
E-8 Code [141/CA141] Oil Press. Sensor Low Error Error code
Failure code
141
CA141
Trouble
1
Abnormally low level in oil pressure sensor
Contents of trouble
• Signal voltage in oil pressure sensor circuit is abnormally low.
Action of controller
• Sets oil pressure to default value (250 kPa {2.55 kg/cm2}) and continues operation.
Problem that appears on machine Related information Cause
Standard value in normal state/Remarks on troubleshooting If code [187/CA187] or [227/CA227] is displayed, carry out troubleshooting for it first.
1. Turn starting switch to OFF position. Defective power supply sys2. Disconnect connector POIL and connect T-adapter to 1 tem of engine oil pressure female side. sensor 3. Turn starting switch to ON position. Between POIL (female) (1) and (2)
Power input
Voltage
4.75 – 5.25V
1. Turn starting switch to OFF position. 2. Disconnect connectors ENG and POIL and connect Tadapters to each female side. a If power supply input in checks on cause 1 is normal, this check is not required. Between ENG (female) (37) and POIL (female) (1)
Possible causes and standard value in normal state
Open circuit in wiring harness 2 (wire breakage or defective a If power supply input in checks on contact of connector) cause 1 is normal, this check is not required. Between ENG (female) (47) and POIL (female) (2) Between ENG (female) (13) and POIL (female) (3) (Sensor output)
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
1. Turn starting switch to OFF position. 2. Disconnect connectors ENG and POIL, and connect Tadapters to either female side.
Ground fault of wiring har3 ness (contact with ground circuit) Between ENG (female) (13) or POIL (female) (3) and ground
4
Short circuit in wiring harness
Resistance
Min. 1 Mz
1. Turn starting switch to OFF position. 2. Disconnect connectors ENG and POIL, and connect Tadapters to either female side. Between ENG (female) (13) and (47), or between POIL (female) (2) and (3)
Resistance
Min. 1 Mz
a If no failure is found by checks on causes 1 to 4 and check result of checks on cause 5, sensor is defective. 1. Turn starting switch to OFF position. Defective engine oil pres5 sure sensor (improper input 2. Insert T-adapter into connector ENG or POIL. voltage to engine controller) 3. Turn starting switch to ON position. 0.3 – 4.7 Between ENG (13) and (47), or Sensor Voltage V output between POIL (3) and (2) 6 Defective engine controller
24
If no failure is found by above checks, engine controller is defective. (Since this is an internal failure, troubleshooting cannot be performed.)
140E-5 Series
40 Troubleshooting
SEN00153-03
Circuit diagram related to oil pressure sensor a For "with EGR" a There is connector PEVA only ofr serial No. up to 530896.
a
For "EGR-less"
140E-5 Series
25
SEN00153-03
40 Troubleshooting
E-9 Code [144/CA144] Coolant Temp. Sensor High Error Error code
Failure code
144
CA144
Trouble
1
Abnormally high level in coolant temperature sensor
Contents of trouble
• Signal voltage in coolant temperature sensor circuit is abnormally high.
Action of controller
• Fixes coolant temperature (90°C) and continues operation.
Problem that appears • Engine starting performance decreases during low temperature. on machine
Related information
• This failure code is generated if temperature sensor connector is disconnected. • Because troubleshooting "socket" for this sensor features female connector alone, it is not connectable to female connector of sensor wiring harness, and thus not usable for checking open circuit (not designed as a T-adapter). Cause
Standard value in normal state/Remarks on troubleshooting 1. Turn starting switch to OFF position. 2. Disconnect connector TWTR and connect T-adapter to male side. a If coolant temperature sensor has resistance of 700 z – 37 kz with coolant temperature above 0 °C, regard coolant temperature sensor as normal. 0 °C
1
Defective coolant temperature sensor
Resistance
25 °C Resistance Between TWTR (male) (A) and (B) 50 °C Resistance a Coolant temperature -Resistaure characteristics 80 °C Resistance
Possible causes and standard value in normal state
95 °C Resistance
30 – 37 kz 9.3 – 10.7 kz 3.2 – 3.8 kz 1.0 – 1.3 kz 700 – 800 z
1. Turn starting switch to OFF position. 2. Disconnect connector ENG and connect T-adapter to female side. 2
Open or short circuit in wir- Between ENG (female) (15) and (38) (Coolant temperature: Min. 0 °C) ing harness a The resistance is the same as that Resistance shown in the resistance characteristics table of the coolant temperature sensor of cause 1.
3 Defective engine controller
26
700 z – 37 kz
If no failure is found by above checks, engine controller is defective. (Since this is an internal failure, troubleshooting cannot be performed.)
140E-5 Series
40 Troubleshooting
SEN00153-03
Circuit diagram related to coolant temperature sensor a For “with EGR”
a
There are not connector SBP and line to the SBP for “EGR-less” in above figure.
140E-5 Series
27
SEN00153-03
40 Troubleshooting
E-10 Code [145/CA145] Coolant Temp. Sensor Low Error Error code
Failure code
145
CA145
Trouble
1
Abnormally low level in coolant temperature sensor
Contents of trouble
• Signal voltage in coolant temperature sensor circuit is abnormally low.
Action of controller
• Fixes coolant temperature (90°C) and continues operation.
Problem that appears • Engine starting performance decreases during low temperature. on machine Related information
• If temperature sensor connector is disconnected, this failure code is not generated but code [144/CA144] for "High Error" is generated. Cause
Standard value in normal state/Remarks on troubleshooting 1. Turn starting switch to OFF position. 2. Disconnect connector TWTR and connect T-adapter to male side. a If coolant temperature sensor has resistance of 700 z – 37 kz with coolant temperature above 0 °C, regard coolant temperature sensor as normal.
1
Between TWTR (male) (A) and Defective coolant tempera(B) ture sensor a Coolant temperature-Resistaure characteristics
Possible causes and standard value in normal state
Between (B) and ground
0 °C
Resistance
30 – 37 kz
25 °C
Resistance
9.3 – 10.7 kz
50 °C
Resistance
3.2 – 3.8 kz
80 °C
Resistance
1.0 – 1.3 kz
95 °C
Resistance
700 – 800 z
Whole coolant temperature range
Resistance
Min. 1 Mz
1. Turn starting switch to OFF position. 2. Disconnect connector ENG and connect T-adapter to female side. 2
Short circuit in wiring harness
Ground fault of wiring har3 ness (contact with ground circuit)
4 Defective engine controller
28
Between ENG (female) (15) and (38) (Coolant temperature: Min. 0 °C) a The resistance is the same as that shown in the resistance characteristics table of the coolant temperature sensor of cause 1.
Resistance
700 z – 37 kz
1. Turn starting switch to OFF position. 2. Disconnect connectors ENG and TWTR, and connect Tadapter to female side of ENG. Between ENG (female) (15) and ground
Resistance
Min. 1 Mz
If no failure is found by above checks, engine controller is defective. (Since this is an internal failure, troubleshooting cannot be performed.)
140E-5 Series
40 Troubleshooting
SEN00153-03
Circuit diagram related to coolant temperature sensor a For "with EGR"
a
There are not connector SBP and line to the SBP for "EGR-less" in above figure.
140E-5 Series
29
SEN00153-03
40 Troubleshooting
E-11 Code [153/CA153] Charge (boost) Air Temp. Sensor High Error Error code
Failure code
153
CA153
Trouble
1
Abnormally high level in charge (boost) temperature sensor
Contents of trouble
• Signal voltage in charge (boost) temperature sensor circuit is abnormally high.
Action of controller
• Fixes charge (boost) temperature (intake air temperature) (70°C) and continues operation.
Problem that appears • Engine starting performance decreases during low temperature. on machine
Related information
• Because troubleshooting "socket" for this sensor features female connector alone, it is not connectable to female connector of sensor wiring harness, and thus not usable for checking open circuit (not designed as a T-adapter). • This failure code is generated if temperature sensor connector is disconnected. Cause
Standard value in normal state/Remarks on troubleshooting 1. Turn starting switch to OFF position. 2. Disconnect connector TIM and connect socket to male side. a If temperature sensor has resistance of 280 z - 382 kz, regard boost temperature sensor as normal.
1
Defective boost temperature sensor
Possible causes and standard value in normal state
-40 °C Resistance
291 – 382 kz
-20 °C Resistance
85 – 109 kz
Resistance
29 – 36 kz
30 °C Resistance
7.3 – 8.8 kz
60 °C Resistance
2.3 – 2.7 kz
90 °C Resistance
860 – 970 z
130 °C Resistance
280 – 320 z
0 °C Between TIM (male) (A) and (B) a Boost temperature-Resistance characteristic
1. Turn starting switch to OFF position. 2. Disconnect connector ENG and connect T-adapter to female side. 2
Open or short circuit in wir- Between ENG (female) (23) and (47) ing harness a The resistance is the same as that shown in the resistance character- Resistance istics table of the coolant temperature sensor of cause 1.
3 Defective engine controller
30
280 z – 382 kz
If no failure is found by above checks, engine controller is defective. (Since this is an internal failure, troubleshooting cannot be performed.)
140E-5 Series
40 Troubleshooting
SEN00153-03
Circuit diagram related to charge (boost) temperature sensor a For “with EGR”
a
Pin number of connector PIM is not "2" but "3" for “EGR-less” in above figure.
140E-5 Series
31
SEN00153-03
40 Troubleshooting
E-12 Code [154/CA154] Charge (boost) Air Temp. Sensor Low Error Error code
Failure code
154
CA154
Trouble
1
Abnormally low level in charge (boost) temperature sensor
Contents of trouble
• Signal voltage in charge (boost) temperature sensor circuit is abnormally low.
Action of controller
• Fixes charge (boost) temperature (intake air temperature) (70°C) and continues operation.
Problem that appears • Engine starting performance decreases during low temperature. on machine Related information
• If temperature sensor connector is disconnected, this failure code is not generated but code [153/CA153] for "High Error" is generated. Cause
Standard value in normal state/Remarks on troubleshooting 1. Turn starting switch to OFF position. 2. Disconnect connector TIM and connect socket to male side of. a If temperature sensor has resistance of 280 z - 382 kz, regard boost temperature sensor as normal.
1
Defective boost temperature sensor
Possible causes and standard value in normal state
Between TIM (male) (A) and (B) a Boost temperature-Resistance characteristic
-40 °C
Resistance
291 – 382 kz
-20 °C
Resistance
85 – 109 kz
0 °C
Resistance
29 – 36 kz
30 °C
Resistance
7.3 – 8.8 kz
60 °C
Resistance
2.3 – 2.7 kz
90 °C
Resistance
860 – 970 z
130 °C
Resistance
280 – 320 z
1. Turn starting switch to OFF position. 2. Disconnect connector ENG and connect T-adapter to female side. 2
Short circuit in wiring harness
Between ENG (female) (23) and (47) a The resistance is the same as that shown in the resistance characteristics table of the coolant temperature sensor of cause 1.
Resistance
280 z – 382 kz
1. Turn starting switch to OFF position. Ground fault of wiring har- 2. Disconnect connectors ENG and TIM and connect Tadapter to female side of ENG. 3 ness (contact with ground circuit) ResisMin. Between ENG (female) (23) and ground tance 1 Mz 4 Defective engine controller
32
If no failure is found by above checks, engine controller is defective. (Since this is an internal failure, troubleshooting cannot be performed.)
140E-5 Series
40 Troubleshooting
SEN00153-03
Circuit diagram related to charge (boost) temperature sensor a For "with EGR"
a
Pin number of connector PIM is not "2" but "3" for "EGR-less" in above figure.
140E-5 Series
33
SEN00153-03
40 Troubleshooting
E-13 Code [187/CA187] Sensor Sup. 2 Volt. Low Error Error code
Failure code
187
CA187
Trouble
1
Abnormally low level in sensor power supply 2 circuit
Contents of trouble
• Signal voltage in sensor power supply 2 (5 V) circuit is abnormally low.
Action of controller
• Operates Bkup speed sensor with signals of Ne speed sensor. • Sets oil pressure sensor to default value (250 kPa {2.55 kg/cm2}) and continues operation. • Sets ambient pressure sensor to default value (52.44 kPa {0.53 kg/cm2}) and continues operation. • Fixes charge (boost) pressure sensor value (400 kPa {4.08 kg/cm2}) and continues operation. • Sets EGR inlet pressure sensor to default value (102 kPa {1.04 kg/cm2}) and continues operation. ["serial No. up to 530896 with EGR" only] • Limits output of EGR valve lift sensor and closes EGR valve and bypass valve. ["with EGR" only] • Limits output of bypass valve lift sensor and closes EGR valve and bypass valve. ["with EGR" only]
Problem that appears • Output drops. on machine Related information Cause
Standard value in normal state/Remarks on troubleshooting 1. Turn starting switch to OFF position. 2. Disconnect following connectors one by one and turn starting switch to ON position each time. 3. After each troubleshooting, turn starting switch to OFF position. If this failure code is not displayed when a connector is disconnected, that sensor or engine wiring harness is defective. a Other failure codes are displayed, too. This is because the connector is disconnected. Ignore codes other than [187/ CA187].
1
Defective sensor or wiring harness
Possible causes and standard value in normal state
2 Defect in related system
3 Defective engine controller
Sensor or harness
Connector
Bkup speed sensor
G connector
Oil pressure sensor
POIL connector
Boost pressure sensor
PIM connector
Ambient pressure sensor
PAMB connector
EGR valve lift sensor *
SEGR connector *
Bypass valve lift sensor *
SBP connector *
EGR inlet pressure sensor **
PEVA connector **
Engine wiring harness
ENG
If another failure code is displayed, perform troubleshooting for it. 1. Turn starting switch to OFF position. 2. Disconnect connector ENG and connect T-adapter to male side. 3. Turn starting switch to ON position with connector ENG disconnected. Between ENG (male) (37) and (47)
Voltage
4.75 – 5.25 V
*: "with EGR" only **: "only early model of "with EGR", serial No. up to 530896.
34
140E-5 Series
40 Troubleshooting
SEN00153-03
Circuit diagram related to sensor power supply 2 (5 V) a For serial No. up to 530896 "with EGR"
140E-5 Series
35
SEN00153-03
40 Troubleshooting
Circuit diagram related to sensor power supply 2 (5 V) a For serial No. and up 530897 "with EGR"
36
140E-5 Series
40 Troubleshooting
SEN00153-03
Circuit diagram related to sensor power supply 2 (5 V) a For "EGR-less"
140E-5 Series
37
SEN00153-03
40 Troubleshooting
E-14 Code [221/CA221] Ambient Air Press. Sensor High Error a
1
For “with EGR” Error code
Failure code
221
CA221
Trouble
Abnormally high level in atmospheric pressure sensor
Contents of trouble
• Signal voltage in atmospheric pressure sensor circuit is abnormally high.
Action of controller
• Sets atmospheric pressure to default value (52.44 kPa {0.53 kg/cm2}) and continues operation.
Problem that appears • Output drops. on machine Related information Cause 1
2
Possible causes and standard value in normal state
Defective sensor power supply system
Defective ambient pressure sensor
Standard value in normal state/Remarks on troubleshooting If code [187/CA187] or [227/CA227] is indicated, carry out troubleshooting for it first. 1. Turn starting switch to OFF position. 2. Disconnect connector PAMB. 3. Turn starting switch to ON position. If code changes from [221/CA221] to [222/CA222], sensor is defective.
1. Turn starting switch to OFF position. Short circuit in wiring har- 2. Disconnect connector ENG and PAMB, and connect T3 adapter to female side of ENG. ness Between ENG (female) (37) and (3) 1. 2. Hot short circuit in wiring 3. 4 harness 4. (contact with 24 V circuit)
Turn starting switch to OFF position. Disconnect connector PAMB. Insert T-adapter into connector ENG. Turn starting switch to ON position (with connector PAMB disconnected).
Between ENG (3) and (38) 5
38
Resistance Min. 1 Mz
Voltage
Max. 1 V
If no failure is found by above checks, engine controller is defecDefective engine controltive. (Since this is an internal failure, troubleshooting cannot be ler performed.)
140E-5 Series
40 Troubleshooting
SEN00153-03
Circuit diagram related to atmospheric pressure sensor a For “with EGR”
a
There are not connector SBP and line to the SBP for "EGR-less" in above figure.
140E-5 Series
39
SEN00153-03
40 Troubleshooting
E-15 Code [222/CA222] Ambient Air Press. Sensor Low Error Error code
Failure code
222
CA222
Trouble
1
Abnormally low level in atmospheric pressure sensor
Contents of trouble
• Signal voltage in atmospheric pressure sensor circuit is abnormally low.
Action of controller
• Sets atmospheric pressure to default value (52.44 kPa {0.53 kg/cm2}) and continues operation.
Problem that appears • Output drops. on machine
Related information
• Since troubleshooting "socket" for this sensor features female connector alone, it is not usable for checking open circuit in wiring harness and voltage at sensor connector (not designed as a T-adapter). • If sensor connector is disconnected, this failure code is generated. Cause
Standard value in normal state/Remarks on troubleshooting
Defective power supply line If failure code [187/CA187] or [227/CA227] is displayed, per1 of ambient pressure sensor form troubleshooting for it first.
2
Short circuit in wiring harness
1. Turn starting switch to OFF position. 2. Disconnect connectors PAMB and ENG. 3. Connect T-adapter to female side of ENG. Between ENG (female) (3) and (38)
Possible causes and standard value in normal state
Resistance
Min. 1 Mz
1. Turn starting switch to OFF position. Ground fault in wiring har- 2. Disconnect connectors PAMB and ENG and connect Tadapter to female side of ENG. 3 ness (contact with ground circuit) ResisMin. Between ENG (female) (3) and ground tance 1 Mz 4
Open circuit in wiring harness
If no failure is found by above checks, wiring harness may have open circuit. (*)
a If no failure is found by checks on causes 1 to 4 and check result of checks on cause 5 is abnormal, sensor is defective. Defective ambient pressure 1. Turn starting switch to OFF position. 5 sensor (defective input volt- 2. Insert T-adapter into connector ENG. 3. Turn starting switch to ON position. age to engine controller) Sensor 0.3 – 4.7 Between ENG (3) and (38) Voltage output V 6 Defective engine controller
If no failure is found by above checks, engine controller is defective. (Since this is an internal failure, troubleshooting cannot be performed.)
*: Refer to "Troubleshooting method for open circuit in wiring harness of pressure sensor system".
40
140E-5 Series
40 Troubleshooting
SEN00153-03
Circuit diagram related to atmospheric pressure sensor a For "with EGR"
a
There are not connector SBP and line to the SBP for "EGR-less" in above figure.
140E-5 Series
41
SEN00153-03
40 Troubleshooting
E-16 Code [227/CA227] Sensor Sup. 2 Volt. High Error Error code 227 Contents of trouble
Action of controller
• • • • • • • •
1
Failure code Trouble Abnormally high level in sensor power supply 2 circuit CA227 Signal voltage in sensor power supply 2 (5 V) circuit is abnormally high. Operates Bkup speed sensor with signals of Ne speed sensor. Sets oil pressure sensor to default value (250 kPa {2.55 kg/cm2}) and continues operation. Sets ambient pressure sensor to default value (52.44 kPa {0.53 kg/cm2}) and continues operation. Fixes charge (boost) pressure sensor value (400 kPa {4.08 kg/cm2}) and continues operation. Sets EGR inlet pressure sensor to default value (102 kPa {1.04 kg/cm2}) and continues operation. ["serial No. up to 530896 with EGR" only] Limits output of EGR valve lift sensor and closes EGR valve and bypass valve. ["with EGR" only] Limits output of bypass valve lift sensor and closes EGR valve and bypass valve. ["with EGR" only]
Problem that appears • Output drops. on machine Related information • Different machine models may have different connector Nos. Possible causes and standard value in normal state
Cause
Standard value in normal state/Remarks on troubleshooting
1 Carry out troubleshooting for code [187/CA187].
E-17 Code [234/CA234] Eng. Overspeed Error code
Failure code
234
CA234
Trouble
1
Engine overspeed
Contents of trouble
• Engine speed is above operating range.
Action of controller
• Limits fuel injection rate until engine speed lowers to operating range.
Problem that appears • Engine speed fluctuates. on machine Related information Cause Possible causes and standard value in normal state
42
Standard value in normal state/Remarks on troubleshooting
1 Defective related system
If another failure code is indicated, carry out troubleshooting for it.
2 Improper way of use
Way of use may be improper. Teach proper way of use to operator.
3 Defective engine controller
If causes 1 – 2 are not detected, engine controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
140E-5 Series
40 Troubleshooting
140E-5 Series
SEN00153-03
43
SEN00153-03
40 Troubleshooting
E-18 Code [238/CA238] Ne Speed Sensor Sup. Volt. Error Error code
Failure code
238
CA238
Trouble
1
Abnormality in Ne speed sensor power supply
Contents of trouble
• Abnormality occurred in Ne speed sensor power supply (5 V) circuit.
Action of controller
• Controls Ne speed sensor with signals of Bkup speed sensor.
Problem that appears • Running engine stops (when Bkup speed sensor is also abnormal). on machine Stopped engine cannot be started (when Bkup speed sensor is also abnormal). Related information
• Different machine models may have different connector Nos. Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
1
Defective Ne speed sen- Disconnect devices at right in order. If error code disapsor (Internal trouble) Ne speed pears when a device is dissensor connected, that device has a defect in it.
NE connector
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes and standard value in normal state
Disconnection in wiring harness (Disconnection Wiring harness between ENG (female) 2 in wiring or defective con- (16) – NE (female) (1) tact in connector) Wiring harness between ENG (female) (48) – NE (female) (2)
Resistance Max. 1 z Resistance Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring 3 harness (Short circuit with GND circuit)
Wiring harness between ENG (female) Resistance Min. 1 Mz (16) – NE (female) (1) and chassis ground Wiring harness between ENG (female) Resistance Min. 1 Mz (48) – NE (female) (2) and chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit in wiring har4 ness (with another wiring Wiring harness between ENG (female) harness) (16) – NE (female) (1) and between ENG Resistance Min. 1 Mz (female) (48) – NE (female) (2) a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective engine control5 ler ENG Voltage Between (16) – (48)
44
4.75 – 5.25 V
140E-5 Series
40 Troubleshooting
SEN00153-03
Circuit diagram related to Ne speed sensor power supply
140E-5 Series
45
SEN00153-03
40 Troubleshooting
E-19 Code [263/CA263] Fuel Temp. Sensor High Error Error code
Failure code
263
CA263
Trouble
1
Abnormally high level in fuel temperature sensor
Contents of trouble
• Signal voltage in fuel temperature sensor circuit is abnormally high.
Action of controller
• Uses signals from coolant temperature sensor to perform fuel injection rate correction based on fuel temperature. • Fixes fuel temperature (90°C) and continues operation.
Problem that appears on machine
Related information
• This failure code is generated if temperature sensor connector is disconnected. • Because troubleshooting "socket" for this sensor features female connector alone, it is not connectable to female connector of sensor wiring harness, and thus not usable for checking open circuit (not designed as a T-adapter). Cause
Standard value in normal state/Remarks on troubleshooting 1. Turn starting switch to OFF position. 2. Disconnect connector TFUEL and connect socket to male side. a If coolant temperature sensor resistance is 700 z to 37 kz with coolant temperature above 0 °C, regard coolant temperature sensor as normal. 0 °C
1
Defective fuel temperature sensor Between TFUEL (male)(A) and (B) a Fuel temperature-Resistance characteristics
Possible causes and standard value in normal state
Resistance
30 – 37 kz
25 °C Resistance
9.3 – 10.7 kz
50 °C Resistance
3.2 – 3.8 kz
80 °C Resistance
1.0 – 1.3 kz
95 °C Resistance
700 – 800 z
1. Turn starting switch to OFF position. 2. Disconnect connector ENG and connect T-adapter to female side. 2
Open or short circuit in wir- Between ENG (female) (30) and (47) (Fuel temperature: Min. 0 °C) ing harness a The resistance is the same as that Resistance shown in the resistance characteristics table of the coolant temperature sensor of cause 1.
3 Defective engine controller
46
700 z – 37 kz
If no failure is found by above checks, engine controller is defective. (Since this is an internal failure, troubleshooting cannot be performed.)
140E-5 Series
40 Troubleshooting
SEN00153-03
Circuit diagram related to fuel temperature sensor a For “with EGR”
a
Pin number of connector PIM is not "2" but "3" for “EGR-less” in above figure.
140E-5 Series
47
SEN00153-03
40 Troubleshooting
E-20 Code [265/CA265] Fuel Temp. Sensor Low Error Error code
Failure code
265
CA265
Trouble
1
Abnormally low level in fuel temperature sensor
Contents of trouble
• Signal voltage in fuel temperature sensor circuit is abnormally low.
Action of controller
• Uses signals from coolant temperature sensor to perform fuel injection rate correction based on fuel temperature. • Fixes fuel temperature (90°C) and continues operation.
Problem that appears on machine Related information
• If temperature sensor connector is disconnected, this code is not generated but code [263/ CA263] for "High Error" is generated. Cause
Standard value in normal state/Remarks on troubleshooting 1. Turn starting switch to OFF position. 2. Disconnect connector TFUEL and connect socket to male side. a If coolant temperature sensor resistance is 700 z to 37 kz with coolant temperature above 0 °C, regard coolant temperature sensor as normal.
1
Defective fuel temperature sensor
Possible causes and standard value in normal state
Between TFUEL (male)(A) and (B) a Fuel temperature-Resistance characteristic
Between (B) and ground
0 °C
Resistance
30 – 37 kz
25 °C
Resistance
9.3 – 10.7 kz
50 °C
Resistance
3.2 – 3.8 kz
80 °C
Resistance
1.0 – 1.3 kz
95 °C
Resistance
700 – 800 z
All fuel temperature range
Resistance
Min. 1 Mz
1. Turn starting switch to OFF position. 2. Disconnect connector ENG and connect T-adapter to female side. 2
Short circuit in wiring harness
Between ENG (female) (30) and (47) (Fuel temperature: Min. 0 °C) a The resistance is the same as that shown in the resistance characteristics table of the coolant temperature sensor of cause 1.
Resistance
700 z – 37 kz
1. Turn starting switch to OFF position. Ground fault in wiring har- 2. Disconnect connector TFUEL, and connect T-adapter to female side of ENG. 3 ness (contact with ground circuit) ResisMin. Between ENG (female) (30) and ground tance 1 Mz 4 Defective engine controller
48
If no failure is found by above checks, engine controller is defective. (Since this is an internal failure, troubleshooting cannot be performed.)
140E-5 Series
40 Troubleshooting
SEN00153-03
Circuit diagram related to fuel temperature sensor a For "with EGR"
a
Pin number of connector PIM is not "2" but "3" for "EGR-less" in above figure.
140E-5 Series
49
SEN00153-03
40 Troubleshooting
E-21 Code [271/CA271] PCV1 Short Error Error code
Failure code
271
CA271
Trouble
1
Short circuit in PCV1
Contents of trouble
• There is short circuit in PCV1 circuit of supply pump.
Action of controller
• None in particular.
Problem that appears on machine Related information
• Different machine models may have different connector Nos. Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
1
Defective supply pump PCV1 (Internal trouble)
PCV1 (male)
Resistance
Between (1) – (2)
2.3 – 5.3 z
Between (1), (2) – chassis ground
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes and standard value in normal state
Wiring harness between ENG Ground fault in wiring har(female) (4) – PCV1 (female) (1) and Resistance Min. 1 Mz 2 ness (Short circuit with GND chassis ground circuit) Wiring harness between ENG (female) (5) – PCV1 (female) (2) and Resistance Min. 1 Mz chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between ENG Hot short (Short circuit with (female) (4) – PCV1 (female) (1) and 3 24V circuit) in wiring harchassis ground ness Wiring harness between ENG (female) (5) – PCV1 (female) (2) and chassis ground
Voltage
Max. 1 V
Voltage
Max. 1 V
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4 Defective engine controller
50
ENG (female)
Resistance
Between (4) – (5)
2.3 – 5.3 z
Between (4), (5) – chassis ground
Min. 1 Mz
140E-5 Series
40 Troubleshooting
SEN00153-03
Circuit diagram related to supply pump PCV1
140E-5 Series
51
SEN00153-03
40 Troubleshooting
E-22 Code [272/CA272] PCV1 Open Error Error code
Failure code
272
CA272
Trouble
1
Disconnection in PCV1
Contents of trouble
• There is disconnection in PCV1 circuit of supply pump.
Action of controller
• None in particular.
Problem that appears on machine Related information
• Different machine models may have different connector Nos. Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Defective supply pump 1 PCV1 (Internal disconnection)
Possible causes and standard value in normal state
PCV1 (male)
Resistance
Between (1) – (2)
2.3 – 5.3 z
Between (1), (2) – chassis ground
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wir- Wiring harness between ENG 2 Resistance Max. 1 z ing or defective contact in (female) (4) – PCV1 (female) (1) connector) Wiring harness between ENG Resistance Max. 1 z (female) (5) – PCV1 (female) (2) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG Ground fault in wiring har(female) (4) – PCV1 (female) (1) and Resistance Min. 1 Mz 3 ness (Short circuit with GND chassis ground circuit) Wiring harness between ENG (female) (5) – PCV1 (female) (2) and Resistance Min. 1 Mz chassis ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4 Defective engine controller
52
ENG (female)
Resistance
Between (4) – (5)
2.3 – 5.3 z
Between (4), (5) – chassis ground
Min. 1 Mz
140E-5 Series
40 Troubleshooting
SEN00153-03
Circuit diagram related to supply pump PCV1
140E-5 Series
53
SEN00153-03
40 Troubleshooting
E-23 Code [273/CA273] PCV2 Short Error Error code
Failure code
273
CA273
Trouble
1
Short circuit in PCV2
Contents of trouble
• There is short circuit in PCV2 circuit of supply pump.
Action of controller
• None in particular.
Problem that appears on machine Related information
• Different machine models may have different connector Nos. Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
1
Defective supply pump PCV2 (Internal trouble)
PCV2 (male)
Resistance
Between (1) – (2)
2.3 – 5.3 z
Between (1), (2) – chassis ground
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes and standard value in normal state
Wiring harness between ENG Ground fault in wiring har(female) (9) – PCV2 (female) (1) and Resistance Min. 1 Mz 2 ness (Short circuit with GND chassis ground circuit) Wiring harness between ENG (female) (10) – PCV2 (female) (2) and Resistance Min. 1 Mz chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between ENG Hot short (Short circuit with (female) (9) – PCV2 (female) (1) and 3 24V circuit) in wiring harchassis ground ness Wiring harness between ENG (female) (10) – PCV2 (female) (2) and chassis ground
Voltage
Max. 1 V
Voltage
Max. 1 V
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4 Defective engine controller
54
ENG (female)
Resistance
Between (9) – (10)
2.3 – 5.3 z
Between (9), (10) – chassis ground
Min. 1 Mz
140E-5 Series
40 Troubleshooting
SEN00153-03
Circuit diagram related to supply pump PCV2
140E-5 Series
55
SEN00153-03
40 Troubleshooting
E-24 Code [274/CA274] PCV2 Open Error Error code
Failure code
274
CA274
Trouble
1
Disconnection in PCV2
Contents of trouble
• There is disconnection in PCV2 circuit of supply pump.
Action of controller
• None in particular.
Problem that appears on machine Related information
• Different machine models may have different connector Nos. Cause Defective supply pump 1 PCV2 (Internal disconnection)
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. PCV2 (male)
Resistance
Between (1) – (2)
2.3 – 5.3 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wir- Wiring harness between ENG 2 Resistance Max. 1 z ing or defective contact in (female) (9) – PCV2 (female) (1) connector) Wiring harness between ENG Resistance Max. 1 z (female) (10) – PCV2 (female) (2) Possible causes and standard value in normal state
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG Ground fault in wiring har(female) (9) – PCV2 (female) (1) and Resistance Min. 1 Mz 3 ness (Short circuit with GND chassis ground circuit) Wiring harness between ENG (female) (10) – PCV2 (female) (2) and Resistance Min. 1 Mz chassis ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4 Defective engine controller
56
ENG (female)
Resistance
Between (9) – (10)
2.3 – 5.3 z
Between (9), (10) – chassis ground
Min. 1 Mz
140E-5 Series
40 Troubleshooting
SEN00153-03
Circuit diagram related to supply pump PCV2
140E-5 Series
57
SEN00153-03
40 Troubleshooting
E-25 Code [322/CA322] Injector #1 System Open/Short Error Error code
Failure code
322
CA322
Trouble
1
Disconnection or short circuit in injector #1 system
Contents of trouble
• There is disconnection or short circuit in injector #1 circuit.
Action of controller
• None in particular.
Problem that appears • Output drops. on machine • Rotation is unstable. Related information
• While engine is running normally, pulse voltage of about 70 V is applied to positive (+) side of injector. This pulse voltage cannot be measured with circuit tester. • Different machine models may have different connector Nos. Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
1
Defective injector #1 (Internal trouble)
CN1 (male)
Resistance
Between (1) – (2)
0.4 – 1.1 z
Between (1), (2) – chassis ground
Min. 1M z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wir- Wiring harness between ENG 2 Resistance Max. 1 z ing or defective contact in (female) (45) – CN1 (female) (1) connector) Wiring harness between ENG Resistance Max. 1 z (female) (53) – CN1 (female) (2) Possible causes and standard value in normal state
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG Ground fault in wiring har(female) (45) – CN1 (female) (1) and 3 ness (Short circuit with GND chassis ground circuit) Wiring harness between ENG (female) (53) – CN1 (female) (2) and chassis ground 4
Resistance Min. 1 Mz
Resistance Min. 1 Mz
Defective injector or wiring If failure code of another cylinder is displayed, carry out trouharness of another cylinder bleshooting for it, too. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
5 Defective engine controller
58
ENG (female)
Resistance
Between (45) – (53)
0.4 – 1.1 z
Between (45), (53) – chassis ground
Min. 1 Mz
140E-5 Series
40 Troubleshooting
SEN00153-03
Circuit diagram related to injector #1 a For “with EGR”
a
For “EGR-less”
q
Improper installation of injector wiring harness (H)
Q: Injector wiring harness (H) is in good condition being laid close to injector (N)
140E-5 Series
x: Injector wiring harness (H) is in bad condition without being laid close to injector (N) a: Injector wiring harness (H) may interfere with rocker arm.
59
SEN00153-03
40 Troubleshooting
E-26 Code [323/CA323] Injector #5 System Open/Short Error Error code
Failure code
323
CA323
Trouble
1
Disconnection or short circuit in injector #5 system
Contents of trouble
• There is disconnection or short circuit in injector #5 circuit.
Action of controller
• None in particular.
Problem that appears • Output drops. on machine • Rotation is unstable. Related information
• While engine is running normally, pulse voltage of about 70 V is applied to positive (+) side of injector. This pulse voltage cannot be measured with circuit tester. • Different machine models may have different connector Nos. Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
1
Defective injector #5 (Internal trouble)
CN5 (male)
Resistance
Between (1) – (2)
0.4 – 1.1 z
Between (1), (2) – chassis ground
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wir- Wiring harness between ENG 2 Resistance Max. 1 z ing or defective contact in (female) (46) – CN5 (female) (1) connector) Wiring harness between ENG Resistance Max. 1 z (female) (60) – CN5 (female) (2) Possible causes and standard value in normal state
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG Ground fault in wiring har(female) (46) – CN5 (female) (1) and 3 ness (Short circuit with GND chassis ground circuit) Wiring harness between ENG (female) (60) – CN5 (female) (2) and chassis ground 4
Resistance Min. 1 Mz
Resistance Min. 1 Mz
Defective injector or wiring If failure code of another cylinder is displayed, carry out trouharness of another cylinder bleshooting for it, too. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
5 Defective engine controller
60
ENG (female)
Resistance
Between (46) – (60)
0.4 – 1.1 z
Between (46), (60) – chassis ground
Min. 1 Mz
140E-5 Series
40 Troubleshooting
SEN00153-03
Circuit diagram related to injector #5 a For “with EGR”
a
For “EGR-less”
q
Improper installation of injector wiring harness (H)
Q: Injector wiring harness (H) is in good condition being laid close to injector (N)
140E-5 Series
x: Injector wiring harness (H) is in bad condition without being laid close to injector (N) a: Injector wiring harness (H) may interfere with rocker arm.
61
SEN00153-03
40 Troubleshooting
E-27 Code [324/CA324] Injector #3 System Open/Short Error Error code
Failure code
324
CA324
Trouble
1
Disconnection or short circuit in injector #3 system
Contents of trouble
• There is disconnection or short circuit in injector #3 circuit.
Action of controller
• None in particular.
Problem that appears • Output drops. on machine • Rotation is unstable. Related information
• While engine is running normally, pulse voltage of about 70 V is applied to positive (+) side of injector. This pulse voltage cannot be measured with circuit tester. • Different machine models may have different connector Nos. Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
1
Defective injector #3 (Internal trouble)
CN3 (male)
Resistance
Between (1) – (2)
0.4 – 1.1 z
Between (1), (2) – chassis ground
Min. 1M z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wir- Wiring harness between ENG 2 Resistance Max. 1 z ing or defective contact in (female) (55) – CN3 (female) (1) connector) Wiring harness between ENG Resistance Max. 1 z (female) (52) – CN3 (female) (2) Possible causes and standard value in normal state
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG Ground fault in wiring har(female) (55) – CN3 (female) (1) and 3 ness (Short circuit with GND chassis ground circuit) Wiring harness between ENG (female) (52) – CN3 (female) (2) and chassis ground 4
Resistance Min. 1 Mz
Resistance Min. 1 Mz
Defective injector or wiring If failure code of another cylinder is displayed, carry out trouharness of another cylinder bleshooting for it, too. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
5 Defective engine controller
62
ENG (female)
Resistance
Between (55) – (52)
0.4 – 1.1 z
Between (55), (52) – chassis ground
Min. 1M z
140E-5 Series
40 Troubleshooting
SEN00153-03
Circuit diagram related to injector #3 a For “with EGR”
a
For “EGR-less”
q
Improper installation of injector wiring harness (H)
Q: Injector wiring harness (H) is in good condition being laid close to injector (N)
140E-5 Series
x: Injector wiring harness (H) is in bad condition without being laid close to injector (N) a: Injector wiring harness (H) may interfere with rocker arm.
63
SEN00153-03
40 Troubleshooting
E-28 Code [325/CA325] Injector #6 System Open/Short Error Error code
Failure code
325
CA325
Trouble
1
Disconnection or short circuit in injector #6 system
Contents of trouble
• There is disconnection or short circuit in injector #6 circuit.
Action of controller
• None in particular.
Problem that appears • Output drops. on machine • Rotation is unstable. Related information
• While engine is running normally, pulse voltage of about 70 V is applied to positive (+) side of injector. This pulse voltage cannot be measured with circuit tester. • Different machine models may have different connector Nos. Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
1
Defective injector #6 (Internal trouble)
CN6 (male)
Resistance
Between (1) – (2)
0.4 – 1.1 z
Between (1), (2) – chassis ground
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wir- Wiring harness between ENG 2 Resistance Max. 1 z ing or defective contact in (female) (57) – CN6 (female) (1) connector) Wiring harness between ENG Resistance Max. 1 z (female) (59) – CN6 (female) (2) Possible causes and standard value in normal state
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG Ground fault in wiring har(female) (57) – CN6 (female) (1) and 3 ness (Short circuit with GND chassis ground circuit) Wiring harness between ENG (female) (59) – CN6 (female) (2) and chassis ground 4
Resistance Min. 1 Mz
Resistance Min. 1 Mz
Defective injector or wiring If failure code of another cylinder is displayed, carry out trouharness of another cylinder bleshooting for it, too. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
5 Defective engine controller
64
ENG (female)
Resistance
Between (57) – (59)
0.4 – 1.1 z
Between (57), (59) – chassis ground
Min. 1 Mz
140E-5 Series
40 Troubleshooting
SEN00153-03
Circuit diagram related to injector #6 a For “with EGR”
a
For “EGR-less”
q
Improper installation of injector wiring harness (H)
Q: Injector wiring harness (H) is in good condition being laid close to injector (N)
140E-5 Series
x: Injector wiring harness (H) is in bad condition without being laid close to injector (N) a: Injector wiring harness (H) may interfere with rocker arm.
65
SEN00153-03
40 Troubleshooting
E-29 Code [331/CA331] Injector #2 System Open/Short Error Error code
Failure code
331
CA331
Trouble
1
Disconnection or short circuit in injector #2 system
Contents of trouble
• There is disconnection or short circuit in injector #2 circuit.
Action of controller
• None in particular.
Problem that appears • Output drops. on machine • Rotation is unstable. Related information
• While engine is running normally, pulse voltage of about 70 V is applied to positive (+) side of injector. This pulse voltage cannot be measured with circuit tester. • Different machine models may have different connector Nos. Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
1
Defective injector #2 (Internal trouble)
CN2 (male)
Resistance
Between (1) – (2)
0.4 – 1.1 z
Between (1), (2) – chassis ground
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wir- Wiring harness between ENG 2 Resistance Max. 1 z ing or defective contact in (female) (54) – CN2 (female) (1) connector) Wiring harness between ENG Resistance Max. 1 z (female) (51) – CN2 (female) (2) Possible causes and standard value in normal state
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG Ground fault in wiring har(female) (54) – CN2 (female) (1) and 3 ness (Short circuit with GND chassis ground circuit) Wiring harness between ENG (female) (51) – CN2 (female) (2) and chassis ground 4
Resistance Min. 1 Mz
Resistance Min. 1 Mz
Defective injector or wiring If failure code of another cylinder is displayed, carry out trouharness of another cylinder bleshooting for it, too. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
5 Defective engine controller
66
ENG (female)
Resistance
Between (54) – (51)
0.4 – 1.1 z
Between (54), (51) – chassis ground
Min. 1 Mz
140E-5 Series
40 Troubleshooting
SEN00153-03
Circuit diagram related to injector #2 a For “with EGR”
a
For “EGR-less”
q
Improper installation of injector wiring harness (H)
Q: Injector wiring harness (H) is in good condition being laid close to injector (N)
140E-5 Series
x: Injector wiring harness (H) is in bad condition without being laid close to injector (N) a: Injector wiring harness (H) may interfere with rocker arm.
67
SEN00153-03
40 Troubleshooting
E-30 Code [332/CA332] Injector #4 System Open/Short Error Error code
Failure code
332
CA332
Trouble
1
Disconnection or short circuit in injector #4 system
Contents of trouble
• There is disconnection or short circuit in injector #4 circuit.
Action of controller
• None in particular.
Problem that appears • Output drops. on machine • Rotation is unstable. Related information
• While engine is running normally, pulse voltage of about 70 V is applied to positive (+) side of injector. This pulse voltage cannot be measured with circuit tester. • Different machine models may have different connector Nos. Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
1
Defective injector #4 (Internal trouble)
CN4 (male)
Resistance
Between (1) – (2)
0.4 – 1.1 z
Between (1), (2) – chassis ground
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wir- Wiring harness between ENG 2 Resistance Max. 1 z ing or defective contact in (female) (56) – CN4 (female) (1) connector) Wiring harness between ENG Resistance Max. 1 z (female) (58) – CN4 (female) (2) Possible causes and standard value in normal state
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG Ground fault in wiring har(female) (56) – CN4 (female) (1) and 3 ness (Short circuit with GND chassis ground circuit) Wiring harness between ENG (female) (58) – CN4 (female) (2) and chassis ground 4
Resistance Min. 1 Mz
Resistance Min. 1 Mz
Defective injector or wiring If failure code of another cylinder is displayed, carry out trouharness of another cylinder bleshooting for it, too. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
5 Defective engine controller
68
ENG (female)
Resistance
Between (56) – (58)
0.4 – 1.1 z
Between (56), (58) – chassis ground
Min. 1 Mz
140E-5 Series
40 Troubleshooting
SEN00153-03
Circuit diagram related to injector #4 a For “with EGR”
a
For “EGR-less”
q
Improper installation of injector wiring harness (H)
Q: Injector wiring harness (H) is in good condition being laid close to injector (N)
140E-5 Series
x: Injector wiring harness (H) is in bad condition without being laid close to injector (N) a: Injector wiring harness (H) may interfere with rocker arm.
69
SEN00153-03
40 Troubleshooting
E-31 Code [342/CA342] Engine Controller Data Matching Error Error code
Failure code
342
CA342
Trouble
1
Matching error in engine controller data
Contents of trouble
• Matching error occurred in engine controller data.
Action of controller
• None in particular.
Problem that appears • Engine continues operation normally, but it may stop during operation or may not be able to on machine start. Related information Possible causes and standard value in normal state
70
Cause
Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for E-1 Code [111/CA111].
140E-5 Series
40 Troubleshooting
140E-5 Series
SEN00153-03
71
SEN00153-03
40 Troubleshooting
E-32 Code [351/CA351] INJ. Drive Circuit Error Error code
Failure code
351
CA351
Trouble
1
Abnormality in injector drive circuit
Contents of trouble
• Abnormality occurred in injector drive circuit.
Action of controller
• Limits output and continues operation (Limits common rail pressure).
Problem that appears • Output drops. on machine Related information
• Different machine models may have different connector Nos. Cause
Possible causes and standard value in normal state
Standard value in normal state/Remarks on troubleshooting
1 Defective related system
If another failure code (code of abnormality in injector system) is indicated, carry out troubleshooting for it.
2 Defective fuse
Check fuse or circuit breaker on machine side directly for defect. (If fuse is broken or circuit breaker is turned OFF, circuit probably has ground fault.)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wir- Wiring harness between E03 (female) 3 Resistance Max. 1 z ing or defective contact in (3), (4) – battery (+) connector) Wiring harness between E03 (female) Resistance Max. 1 z (1), (2) – chassis ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harWiring harness between E03 (female) 4 ness (Short circuit with GND Resistance Min. 1 Mz (3), (4) – battery (+) and chassis ground circuit) Wiring harness between E03 (female) Resistance Min. 1 Mz (1), (2) – chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 5 Defective engine controller
72
E03
Voltage
Between (3), (4) – (1), (2)
20 – 30 V
140E-5 Series
40 Troubleshooting
SEN00153-03
Circuit diagram related to controller power supply
140E-5 Series
73
SEN00153-03
40 Troubleshooting
E-33 Code [352/CA352] Sensor Sup. 1 Volt. Low Error Error code
Failure code
352
CA352
Trouble
1
Abnormally low level in sensor power supply 1 circuit
Contents of trouble
• Signal voltage in sensor power supply (5 V) circuit is abnormally low.
Action of controller
• Limits output of common rail pressure sensor and continues operation (Limits common rail pressure).
Problem that appears • Output drops. on machine Related information Possible causes and standard value in normal state
74
Cause
Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for E-34 Code [386/CA386].
140E-5 Series
40 Troubleshooting
SEN00153-03
E-34 Code [386/CA386] Sensor Sup. 1 Volt. High Error Error code
Failure code
386
CA386
Trouble
1
Abnormally high level in sensor power supply 1 circuit
Contents of trouble
• Signal voltage in sensor power supply (5 V) circuit is abnormally high.
Action of controller
• Limits output of common rail pressure sensor and continues operation (Limits common rail pressure).
Problem that appears • Output drops. on machine Related information
• Different machine models may have different connector Nos. Cause
Standard value in normal state/Remarks on troubleshooting
1 Defective related system If another failure code is indicated, carry out troubleshooting for it. a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective sensor (Inter2 nal trouble)
Disconnection in wiring harness (Disconnection 3 in wiring or defective contact in connector) Possible causes and standard value in normal state
Disconnect devices at right in order. If error code disappears when a Common rail device is disconnected, pressure sensor that device has a defect in it.
PFUEL connector
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG (female) (33) – PFUEL (female) (1)
Resistance Max. 1 z
Wiring harness between ENG (female) (47) – PFUEL (female) (3)
Resistance Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring 4 harness (Short circuit with GND circuit)
Short circuit in wiring 5 harness (with another wiring harness)
Wiring harness between ENG (female) (33) – PFUEL (female) (1) and chassis ground
Resistance Min. 1 Mz
Wiring harness between CE01 (female) (47) – PFUEL (female) (3) and chassis ground
Resistance Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG (female) (33) – PFUEL (female) (1) and between ENG (female) (47) – PFUEL (female) (3)
Resistance Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective engine control6 ler ENG Voltage Between (33) – (47)
140E-5 Series
4.75 – 5.25 V
75
SEN00153-03
40 Troubleshooting
Circuit diagram related to sensor power supply 1 (5 V) a For “with EGR”
a
76
There are not connect for PEVA and line to the PEVA for serial No. 530897 and up.
140E-5 Series
40 Troubleshooting
SEN00153-03
Circuit diagram related to sensor power supply 1 (5 V) a For “EGR-less”
140E-5 Series
77
SEN00153-03
40 Troubleshooting
E-35 Code [431/CA431] Idle Validation Switch Error
1
Throttle sensor of accelerator pedal type (Case of HD325/405-7) Error code
Failure code
431
CA431
Trouble
Abnormality in idle validation switch
Contents of trouble
• Abnormality occurred in idle validation switch.
Action of controller
• Sets throttle angle to certain value and continues operation (depending on each model).
Problem that appears on machine Related information
• Different machine models may have different connector Nos. Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
Defective accelerator pedal 1 (Internal trouble)
WAS1
Signal name
Between (5) – (4)
Signal 1
Between (6) – (4)
Signal 2
Voltage See Fig. 1
If voltage is abnormal, check wiring harness and controller, too, for another cause of trouble, and then judge. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wir2 ing or defective contact in connector)
Wiring harness between E02 (female) Resistance Max. 1 z (32) – WAS1 (female) (4) Wiring harness between E02 (female) Resistance Max. 1 z (11) – WAS1 (female) (5) Wiring harness between E02 (female) Resistance Max. 1 z (1) – WAS1 (female) (6)
Possible causes and standard value in normal state
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between E02 (female) (32) – WAS1 (female) (4) and chassis Resistance Min. 1 Mz ground
Ground fault in wiring har3 ness (Short circuit with GND Wiring harness between E02 (female) circuit) (11) – WAS1 (female) (5) and chassis Resistance Min. 1 Mz ground Wiring harness between E02 (female) (1) – WAS1 (female) (6) and chassis Resistance Min. 1 Mz ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between E02 (female) (32) – WAS1 (female) (4) and chassis Hot short (Short circuit with ground 4 24V circuit) in wiring harWiring harness between E02 (female) ness (11) – WAS1 (female) (5) and chassis ground Wiring harness between E02 (female) (1) – WAS1 (female) (6) and chassis ground
78
Voltage
Max. 1 V
Voltage
Max. 1 V
Voltage
Max. 1 V
140E-5 Series
40 Troubleshooting
SEN00153-03
Cause Possible causes and standard value in normal state
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
5 Defective engine controller
E02
Signal name
Between (11) – (32)
Signal 1
Between (1) – (32)
Signal 2
Voltage See Fig. 1
Throttle sensor of accelerator pedal type (Case of HD325/405-7)
Fig. 1 Throttle: Idle validation: Operating range:
140E-5 Series
Signal voltage of throttle sensor Signal voltage of idle validation switch Operating range of accelerator pedal
79
SEN00153-03
40 Troubleshooting
E-36 Code [432/CA432] Idle Validation Process Error Error code
Failure code
432
CA432
Trouble
1
Abnormality in processing of idle validation
Contents of trouble
• Abnormality occurred in processing of idle validation switch circuit.
Action of controller
• Sets throttle angle to certain value and continues operation (depending on each model).
Problem that appears on machine Related information Possible causes and standard value in normal state
80
Cause
Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for E-35 Code [431/CA431].
140E-5 Series
40 Troubleshooting
SEN00153-03
E-37 Code [441/CA441] Supply Voltage Low Error Error code
Failure code
441
CA441
Trouble
1
Abnormally low power supply voltage
Contents of trouble
• Power supply voltage is abnormally low.
Action of controller
• None in particular.
Problem that appears • Engine continues operation normally, but it may stop during operation or may not be able to on machine start. Related information Possible causes and standard value in normal state
Cause
Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for E-1 Code [111/CA111].
E-38 Code [442/CA442] Supply Voltage High Error Error code
Failure code
442
CA442
Trouble
1
Abnormally high power supply voltage
Contents of trouble
• Power supply voltage is abnormally high.
Action of controller
• None in particular.
Problem that appears • Engine continues operation normally, but it may stop during operation or may not be able to on machine start. Related information Possible causes and standard value in normal state
140E-5 Series
Cause
Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for E-1 Code [111/CA111].
81
SEN00153-03
KOMATSU 140E-5 Series engine Form No. SEN00153-03
© 2010 KOMATSU All Rights Reserved Printed in Japan 06-10
82
SEN00154-02
ENGINE 1SHOP MANUAL
140E-5 Series
40 Troubleshooting
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
E-52 Code [1627/CA1627] Bypass Valve Solenoid Drive Open Error................................................ 25 E-53 Code [1628/CA1628] Bypass Valve Servo Error 1 .................................................................... 26 E-54 Code [1629/CA1629] Bypass Valve Servo Error 2 .................................................................... 27 E-55 Code [1631/CA1631] Bypass Valve Lift Sensor High Error ....................................................... 28 E-56 Code [1632/CA1632] Bypass Valve Lift Sensor Low Error ........................................................ 30 E-57 Code [1633/CA1633] KOMNET Error........................................................................................ 30 E-58 Code [1642/CA1642] EGR Inlet Press Sensor Low Error ......................................................... 31 E-59 Code [1653/CA1653] EGR Inlet Press Sensor High Error......................................................... 32 E-60 Code [2185/CA2185] Throttle Sens. Sup. Volt. High Error ........................................................ 34 E-61 Code [2186/CA2186] Throttle Sens. Sup. Volt. Low Error......................................................... 38 E-62 Code [2249/CA2249] No-pressure Feed By Supply pump 2 ..................................................... 38 E-63 Code [2271/CA2271] EGR Valve Lift Sensor High Error ........................................................... 39 E-64 Code [2272/CA2272] EGR Valve Lift Sensor Low Error ............................................................ 41 E-65 Code [2351/CA2351] EGR Valve Solenoid Drive Short Error.................................................... 42 E-66 Code [2352/CA2352] EGR Valve Solenoid Drive Open Error ................................................... 44 E-67 Code [2555/CA2555] Intake Air Heater Relay Open Error ........................................................ 45 E-68 Code [2556/CA2556] Intake Air Heater Relay Short Error ........................................................ 46 E-69 Code [(143)/B@BAZG] Eng. Oil Press Low Torque Derate....................................................... 48 E-70 Code [(146)/B@BCNS] Eng. Overheat...................................................................................... 48 E-71 Code [(415)/B@BAZG] Eng. Oil Press. Low Speed Derate ...................................................... 49
2
140E-5 Series
40 Troubleshooting
SEN00154-02
Troubleshooting of electrical system (E-mode), Part 2
1
E-39 Code [449/CA449] Rail Press. High Error 2
1
Error code
Failure code
449
CA449
Trouble
Abnormally high common rail pressure 2
Contents of trouble
• Common rail pressure sensor circuit detected abnormally high pressure (level 2).
Action of controller
• Limits output and continues operation (Limits common rail pressure).
Problem that appears • Output drops. on machine Related information Possible causes and standard value in normal state
140E-5 Series
Cause
Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for E-42 Code [553/CA553].
3
SEN00154-02
40 Troubleshooting
E-40 Code [451/CA451] Rail Press. Sensor High Error Error code
Failure code
451
CA451
Trouble
1
Abnormally high level in common rail pressure sensor
Contents of trouble
• Signal voltage in common rail pressure sensor circuit is abnormally high.
Action of controller
• Limits output and continues operation (Limits common rail pressure).
Problem that appears • Output drops. on machine Related information
• Different machine models may have different connector Nos. Cause
Standard value in normal state/Remarks on troubleshooting
Defective sensor power 1 supply
If code [352/CA352] or [386/CA386] is indicated, carry out troubleshooting for it first. a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. PFUEL
Defective common rail 2 pressure sensor (Internal trouble)
Voltage
Between (1) – (3)
Power supply
4.75 – 5.25 V
Between (2) – (3)
Signal
0.25 – 4.6 V
Sensor voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness and controller, too, for another cause of trouble, and then judge. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection 3 in wiring or defective contact in connector)
Possible causes and standard value in normal state
Wiring harness between ENG (female) (33) – PFUEL (female) (1)
Resistance Max. 1 z
Wiring harness between ENG (female) (25) – PFUEL (female) (2)
Resistance Max. 1 z
Wiring harness between ENG (female) (47) – PFUEL (female) (3)
Resistance Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring 4 harness (Short circuit with GND circuit)
Wiring harness between ENG (female) (33) – PFUEL (female) (1) and chassis ground
Resistance Min. 1 Mz
Wiring harness between ENG (female) (25) – PFUEL (female) (2) and chassis ground
Resistance Min. 1 Mz
Wiring harness between ENG (female) (47) – PFUEL (female) (3) and chassis ground
Resistance Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG (female) (33) – PFUEL (female) (1) and between Resistance Min. 1 Mz Short circuit in wiring har- ENG (female) (25) – PFUEL (female) (2) 5 ness (with another wiring Wiring harness between ENG (female) harness) (33) – PFUEL (female) (1) and between Resistance Min. 1 Mz ENG (female) (47) – PFUEL (female) (3) Wiring harness between ENG (female) (25) – PFUEL (female) (2) and between Resistance Min. 1 Mz ENG (female) (47) – PFUEL (female) (3)
4
140E-5 Series
40 Troubleshooting
SEN00154-02
Cause Possible causes and standard value in normal state
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting.
6
Defective engine controller
ENG
Voltage
Between (33) – (47)
4.75 – 5.25 V
Between (25) – (47)
0.25 – 4.6 V
Circuit diagram related to common rail pressure sensor a For “with EGR”
140E-5 Series
5
SEN00154-02
40 Troubleshooting
Circuit diagram related to common rail pressure sensor a For “EGR-less”
6
140E-5 Series
40 Troubleshooting
SEN00154-02
E-41 Code [452/CA452] Rail Press. Sensor Low Error Error code
Failure code
452
CA452
Trouble
1
Abnormally low level in common rail pressure sensor
Contents of trouble
• Signal voltage in common rail pressure sensor circuit is abnormally low.
Action of controller
• Limits output and continues operation (Limits common rail pressure).
Problem that appears • Output drops. on machine Related information Possible causes and standard value in normal state
140E-5 Series
Cause
Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for E-40 Code [451/CA451].
7
SEN00154-02
40 Troubleshooting
E-42 Code [553/CA553] Rail Press. High Error 1 Error code
Failure code
553
CA553
Trouble
1
Abnormally high common rail pressure 1
Contents of trouble
• Common rail pressure sensor circuit detected abnormally high pressure (level 1).
Action of controller
• None in particular.
Problem that appears • Output drops. on machine Related information Cause
Possible causes and standard value in normal state
Standard value in normal state/Remarks on troubleshooting
1 Defective related system
If another failure code is indicated, carry out troubleshooting for it.
2 Use of improper fuel
Check fuel used directly (for high viscosity).
Defective electrical system 3 of common rail pressure sensor
Common rail pressure sensor may have electric trouble. Carry out troubleshooting for code [451/CA451] (E-40).
Defective mechanical sys4 tem of common rail pressure sensor
Check mechanical system of common rail pressure sensor directly.
5 Defective overflow valve
Check overflow valve directly for broken spring, worn seat, and stuck ball.
6 Clogging of overflow piping Check overflow piping directly for clogging. 7 Defective pressure limiter
8
Check pressure limiter directly for mechanical defect.
140E-5 Series
40 Troubleshooting
SEN00154-02
E-43 Code [554/CA554] Rail Press Sensor In Range Error Error code
Failure code
554
CA554
Trouble
1
In-range error in common rail pressure sensor
Contents of trouble
• In-range error occurred in common rail pressure sensor circuit.
Action of controller
• Limits output and continues operation (Limits common rail pressure).
Problem that appears • Output drops. on machine Related information Possible causes and standard value in normal state
140E-5 Series
Cause
Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for E-40 Code [451/CA451].
9
SEN00154-02
40 Troubleshooting
E-44 Code [559/CA559] No-pressure Feed By Supply pump 1 Error code
Failure code
559
CA559
Trouble
1
No-pressure feed by supply pump 1
Contents of trouble
• Supply pump does not feed fuel (level 1).
Action of controller
• Limits common rail pressure.
Problem that appears • Output drops. on machine Related information Cause 1 Defective related system 2 Use of improper fuel
Check fuel used directly (for high viscosity).
3
Possible causes and standard value in normal state
Standard value in normal state/Remarks on troubleshooting If another failure code is indicated, carry out troubleshooting for it.
Defective low-pressure circuit device
a For contents of troubleshooting, see Note 1. For check of pressure in fuel low-pressure circuit, see TESTING AND ADJUSTING, Testing fuel pressure. Pressure in fuel low-pressure circuit (At high idle or equivalent to rated load [by models])
0.15 – 0.3 MPa {1.5 – 3.0 kg/cm2}
4 Clogging of filter/strainer
a For contents of troubleshooting, see Note 2.
Defective electrical system 5 of supply pump PCV
Supply pump PCV may have electric trouble. Carry out troubleshooting for following codes; [271/CA271] (E-21), [272/CA272] (E-22), [273/CA273] (E-23), [274/CA274] (E-24)
6
Defective common rail pres- Common rail pressure sensor may be defective. Check wiring sure sensor harness for damage. a For testing of leakage from pressure limiter, see Testing and adjusting, “Testing fuel return rate and leakage.”
7 Defective pressure limiter
Leakage from pressure limiter (At equivalent to rated operation [by models])
Max. 10 cc/min
a For testing of return (spill) limit from injector, see Testing and adjusting, “Testing fuel return rate and leakage.”
8 Defective injector
9 Defective supply pump
Speed equivalent to rated output (stall load)
Return (Spill) limit from injector
1,600 rpm
960 cc/min
1,700 rpm
1,020 cc/min
1,800 rpm
1,080 cc/min
1,900 rpm
1,140 cc/min
2,000 rpm
1,200 cc/min
If causes 1 – 8 are not detected, supply pump may be defective.
Carry out the above troubleshooting and take a record of the contents of the attached “Check sheet for nopressure feed”.
10
140E-5 Series
40 Troubleshooting
SEN00154-02
Note 1: Check the low-pressure circuit parts for the following items. 1) Fuel level 2) Clogging of fuel tank breather 3) Sticking and wear of feed pump and clogging of filter 4) Leakage through and clogging of low-pressure fuel piping 5) Defective operation of bypass valve and installation of wrong part (See Fig. 1) 6) Clogging of fuel filter 7) Fuel in oil pan (Fuel leakage inside head cover) Fig. 1: Locations of overflow valve (1), bypass valve (2), and fuel inlet joint (3) q Overflow valve (1): Spring is seen through both holes. q Bypass valve (2): Spring is seen through hole on nut side. q Fuel inlet joint (3): Gauze filter is seen through both holes.
Note 2: Check, clean, and replace the filters and strainers according to the following procedure. 1) Gauze filter: Disassemble and check. If clogged, clean. 2) Upstream strainer of gauze filter: If the gauze filter is clogged, clean the upstream filter, too. 3) Fuel filter: If the trouble is not solved by performing 1) and 2) above, replace the fuel filter.
140E-5 Series
11
SEN00154-02
40 Troubleshooting
Check sheet for no-pressure feed Model Machine serial No. Engine Engine serial No.
Work No. Date of check Service meter Worker's name
# #
/
/ h
A. Visual check 1 Fuel leakage to outside 2 Clogging of fuel tank breather
Good NG
B. Check with machine monitor (Fault history function, monitoring function, and reduced cylinder mode function) 3 Check of error/failure code / / / / Check of monitoring information Standard value Code Displayed item Checking condition Unit Measured value (Reference value) Low idle rpm
*1 Engine speed High idle rpm
Equivalent to rating rpm
Low idle % 0 *2 Throttle opening High idle % 100 Fuel injection com*3 Equivalent to rating — mm3 mand 4 Common rail pres*4 Equivalent to rating MPa sure command Common rail fuel *5 Equivalent to rating MPa pressure Low idle CA — Fuel injection tim*6 High idle CA — ing command Equivalent to rating CA — *7 Boost pressure Equivalent to rating kPa — Engine coolant tem*8 Low idle °C — perature *9 Fuel temperature Low idle °C — Check of reduced cylinder mode operation (Engine speed) Standard value Function Reduced cylinder Checking condition Unit Measured value (Reference value) No. 1 cylinder Low idle rpm — No. 2 cylinder Low idle rpm — 5 No. 3 cylinder Low idle rpm — *10 No. 4 cylinder Low idle rpm — No. 5 cylinder Low idle rpm — No. 6 cylinder Low idle rpm —
Good NG
C. Check of fuel circuit pressure 6
Checking condition
Fuel low-pressure circuit pres- High idle or equivalent to rated load sure [by models])
Unit MPa {kg/cm2}
Standard value (Reference value) 0.15 – 0.3 {1.5 – 3.0}
Measured value
D. Check of strainers and filters 7 Visual check of strainers 8 Visual check of gauze filter 9 Visual check of fuel filter 10 Visual check of bypass valve E. Check of leakage and Checking condition return rate Leakage through pressure lim11 Equivalent to rated output [by models]) iter Equivalent to rating1,600 rpm Equivalent to rating1,700 rpm 12 Return rate from injector Equivalent to rating1,800 rpm Equivalent to rating1,900 rpm Equivalent to rating2,000 rpm
12
Good NG
—
—
— — — —
— — — —
—
—
—
—
Good NG — — — — — —
— — — — — —
Good NG
Good NG
Unit
Standard value (Reference value)
cc/min
Max. 10
cc/min cc/min cc/min cc/min cc/min
960 1,020 1,080 1,140 1,200
Measured value
Good NG
Speed:
Return rate:
140E-5 Series
40 Troubleshooting
SEN00154-02
*1 – *10: When inspecting with INSITE (bench test tool), see Operation and Maintenance Manual (Testing method). When inspecting with the monitoring function of the machine, use the codes specified for each machine model. Equivalent to rating : When inspecting the engine unit on the bench, operate it under a load equivalent to the rating. When the engine is installed to the machine, however, the operation load equivalent to the rating depends on the machine model.
140E-5 Series
13
SEN00154-02
40 Troubleshooting
E-45 Code [689/CA689] Eng. Ne Speed Sensor Error Error code
Failure code
689
CA689
Trouble
1
Abnormality in engine Ne speed sensor
Contents of trouble
• Abnormality occurred in engine Ne speed sensor circuit.
Action of controller
• Operates with signals of Bkup speed sensor.
Problem that appears • Running engine stops (when Bkup speed sensor is also abnormal). on machine • Stopped engine cannot be started (when Bkup speed sensor is also abnormal). Related information
• Different machine models may have different connector Nos. Cause Defective sensor power 1 supply system
Standard value in normal state/Remarks on troubleshooting If code [238/CA238] is indicated, carry out troubleshooting for it first. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection 2 in wiring or defective contact in connector)
Wiring harness between ENG (female) (16) – NE (female) (1)
Resistance Max. 1 z
Wiring harness between ENG (female) (48) – NE (female) (2)
Resistance Max. 1 z
Wiring harness between ENG (female) (27) – NE (female) (3)
Resistance Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring 3 harness (Short circuit with GND circuit)
Wiring harness between ENG (female) Resistance Min. 1 Mz (16) – NE (female) (1) and chassis ground Wiring harness between ENG (female) Resistance Min. 1 Mz (48) – NE (female) (2) and chassis ground Wiring harness between ENG (female) Resistance Min. 1 Mz (27) – NE (female) (3) and chassis ground
Possible causes and standard value in normal state
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG (female) (16) – NE (female) (1) and between Short circuit in wiring har- ENG (female) (48) – NE (female) (2) 4 ness (with another wiring Wiring harness between ENG (female) harness) (16) – NE (female) (1) and between ENG (female) (27) – NE (female) (3) Wiring harness between ENG (female) (48) – NE (female) (2) and between ENG (female) (27) – NE (female) (3) Defective mount of sen5 sor or defective rotation sensing part
14
Resistance Min. 1 Mz
Resistance Min. 1 Mz
Resistance Min. 1 Mz
Check Ne speed sensor directly for defective mount (defective clearance) or check rotation sensing part (flywheel) directly for defect. If causes 1 – 5 are not detected, engine Ne speed sensor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
6
Defective engine Ne speed sensor
7
If causes 1 – 6 are not detected, engine controller may be defecDefective engine controltive. (Since trouble is in system, troubleshooting cannot be carler ried out.)
140E-5 Series
40 Troubleshooting
SEN00154-02
Circuit diagram related to engine Ne speed sensor
140E-5 Series
15
SEN00154-02
40 Troubleshooting
E-46 Code [731/CA731] Eng. Bkup Speed Sensor Phase Error Error code
Failure code
731
CA731
Trouble
1
Abnormality in engine Bkup speed sensor phase
Contents of trouble
• Engine Bkup sensor circuit detected abnormality in phase.
Action of controller
• Controls with signals of engine Ne speed sensor.
Problem that appears • Running engine stops (when Ne speed sensor is also abnormal). on machine • Stopped engine cannot be started (when Ne speed sensor is also abnormal). Related information Cause Possible causes and standard value in normal state
Standard value in normal state/Remarks on troubleshooting
Defective engine Ne speed Engine Ne speed sensor may be defective. Carry out trouble1 sensor system shooting for [689/CA698] (E-45). 2
Defective engine Bkup speed sensor system
Engine Bkup speed sensor may be defective. Carry out troubleshooting for [778/CA778] (E-48).
E-47 Code [757/CA757] All Engine Controller Data Lost Error Error code
Failure code
757
CA757
Trouble
1
Loss of all data in engine controller
Contents of trouble
• All data in engine controller are lost.
Action of controller
• None in particular.
Problem that appears • Engine continues operation normally, but it may stop during operation or may not be able to on machine start. Related information Possible causes and standard value in normal state
16
Cause
Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for E-1 Code [111/CA111].
140E-5 Series
40 Troubleshooting
140E-5 Series
SEN00154-02
17
SEN00154-02
40 Troubleshooting
E-48 Code [778/CA778] Eng. Bkup Speed Sensor Error Error code
Failure code
778
CA778
Trouble
1
Abnormality in engine Bkup speed sensor
Contents of trouble
• Abnormality occurred in engine Bkup speed sensor circuit.
Action of controller
• Operates with signals of Ne speed sensor.
Problem that appears • Running engine stops (when Ne speed sensor is also abnormal). on machine • Stopped engine cannot be started (when Ne speed sensor is also abnormal). Related information
• Different machine models may have different connector Nos. Cause
Standard value in normal state/Remarks on troubleshooting
Defective sensor power 1 supply system
If code [187/CA187] or [227/CA227] is indicated, carry out troubleshooting for it first. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection 2 in wiring or defective contact in connector)
Wiring harness between ENG (female) (37) – G (female) (1)
Resistance Max. 1 z
Wiring harness between ENG (female) (47) – G (female) (2)
Resistance Max. 1 z
Wiring harness between ENG (female) (26) – G (female) (3)
Resistance Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring 3 harness (Short circuit with GND circuit) Possible causes and standard value in normal state
Wiring harness between ENG (female) (37) – G (female) (1) and chassis ground
Resistance Min. 1 Mz
Wiring harness between ENG (female) (47) – G (female) (2) and chassis ground
Resistance Min. 1 Mz
Wiring harness between ENG (female) (26) – G (female) (3) and chassis ground
Resistance Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG (female) (37) – G (female) (1) and between ENG Resistance Min. 1 Mz Short circuit in wiring har- (female) (47) – G (female) (2) 4 ness (with another wiring Wiring harness between ENG (female) harness) (37) – G (female) (1) and between ENG Resistance Min. 1 Mz (female) (26) – G (female) (3) Wiring harness between ENG (female) (47) – G (female) (2) and between ENG Resistance Min. 1 Mz (female) (26) – G (female) (3) Defective mount of sen5 sor or defective rotation sensing part
18
Check Bkup speed sensor directly for defective mount (defective clearance) or check rotation sensing part (in supply pump) directly for defect. If causes 1 – 5 are not detected, engine Bkup speed sensor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
6
Defective engine Bkup speed sensor
7
If causes 1 – 6 are not detected, engine controller may be defecDefective engine controltive. (Since trouble is in system, troubleshooting cannot be carler ried out.)
140E-5 Series
40 Troubleshooting
SEN00154-02
Circuit diagram related to engine Bkup speed sensor a For “with EGR”
140E-5 Series
19
SEN00154-02
40 Troubleshooting
Circuit diagram related to engine Bkup speed sensor a For “EGR-less”
20
140E-5 Series
40 Troubleshooting
SEN00154-02
E-49 Code [1228/CA1228] EGR Valve Servo Error 1 a
1
This code applies to only “with EGR”. Error code
Failure code
1228
CA1228
Trouble
Abnormality in EGR valve servo 1
Contents of trouble
• Abnormality (level 1) occurred in EGR valve servo.
Action of controller
• Performs open control.
Problem that appears on machine Related information Cause 1 Defective related system
Standard value in normal state/Remarks on troubleshooting If another failure code is indicated, carry out troubleshooting for it. a For measurement of EGR valve drive pressure, see Testing and adjusting, “Measuring EGR valve and bypass valve drive oil pressure”.
2
Improper EGR valve drive pressure
Engine speed
EGR valve drive pressure
Low idle
1.18 MPa {12 kg/cm2}
High idle
1.43 MPa {14.6 kg/cm2}
If EGR valve drive pressure is abnormal, check causes 3 and 4. a For check of engine oil pressure, see TESTING AND ADJUSTING, Testing engine oil pressure. Possible causes and standard value in normal state
Defective engine oil pres3 sure system (main circuit)
Engine speed
Engine oil pressure
Low idle
0.08 MPa {0.8 kg/cm2}
High idle
0.21 MPa {2.1 kg/cm2}
If engine oil pressure is abnormal, carry out troubleshooting for mechanical system (S-12 Oil pressure lowers).
140E-5 Series
4
Defective oil pump for EGR Check oil pump and relief valve for EGR valve circuit directly. valve
5
Defective oil feed piping for Check oil feed piping for EGR valve circuit directly. EGR valve
6
Defective oil return piping for EGR valve
Check oil return piping for EGR valve circuit directly.
7 Defective EGR valve
Check mechanical section of EGR valve directly.
8 Defective engine controller
If causes 1 – 7 are not detected, engine controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
21
SEN00154-02
40 Troubleshooting
E-50 Code [1625/CA1625] EGR Valve Servo Error 2 a
1
This code applies to only “with EGR”. Error code
Failure code
1625
CA1625
Trouble
Abnormality in EGR valve servo 2
Contents of trouble
• Abnormality (level 2) occurred in EGR valve servo.
Action of controller
• Limits output and continues operation. • Closes EGR valve and bypass valve.
Problem that appears • Output drops. on machine Related information Possible causes and standard value in normal state
22
Cause
Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for E-49 Code [1228/CA1228].
140E-5 Series
40 Troubleshooting
SEN00154-02
E-51 Code [1626/CA1626] Bypass Valve Solenoid Drive Short Circuit Error 1 a
This code applies to only “with EGR”. Error code
Failure code
1626
CA1626
Trouble
Short circuit in bypass valve solenoid drive circuit
Contents of trouble
• There is short circuit in drive circuit of bypass valve solenoid.
Action of controller
• Limits output and continues operation. • Closes EGR valve and bypass valve.
Problem that appears • Output drops. on machine Related information
• Different machine models may have different connector Nos. Cause
1
Defective bypass valve solenoid (Internal trouble)
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. BP (male)
Resistance
Between (1) – (2)
10 – 21 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection Wiring harness between ENG (female) 2 in wiring or defective con- (31) – BP (female) (1) tact in connector) Wiring harness between ENG (female) (11) – BP (female) (2) Possible causes and standard value in normal state
Resistance Max. 1 z Resistance Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring 3 harness (Short circuit with GND circuit)
Wiring harness between ENG (female) (31) Resistance Min. 1 Mz – BP (female) (1) and chassis ground Wiring harness between ENG (female) (11) Resistance Min. 1 Mz – BP (female) (2) and chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
Hot short (Short circuit Wiring harness between ENG (female) (31) 4 with 24V circuit) in wiring – BP (female) (1) and chassis ground harness Wiring harness between ENG (female) (11) – BP (female) (2) and chassis ground
Voltage
Max. 1 V
Voltage
Max. 1 V
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective engine control5 ler ENG (female) Resistance Between (31) – (11)
140E-5 Series
10 – 21 z
23
SEN00154-02
40 Troubleshooting
Circuit diagram related to bypass valve solenoid & lift sensor
24
140E-5 Series
40 Troubleshooting
SEN00154-02
E-52 Code [1627/CA1627] Bypass Valve Solenoid Drive Open Error a
1
This code applies to only “with EGR”. Error code
Failure code
1627
CA1627
Trouble
Disconnection in bypass valve solenoid drive circuit
Contents of trouble
• There is disconnection in drive circuit of bypass valve solenoid.
Action of controller
• Limits output and continues operation. • Closes EGR valve and bypass valve.
Problem that appears • Output drops. on machine Related information Possible causes and standard value in normal state
140E-5 Series
Cause
Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for E-51 Code [1626/CA1626].
25
SEN00154-02
40 Troubleshooting
E-53 Code [1628/CA1628] Bypass Valve Servo Error 1 a
1
This code applies to only “with EGR”. Error code
Failure code
1628
CA1628
Trouble
Abnormality in bypass valve servo 1
Contents of trouble
• Abnormality (level 1) occurred in bypass valve servo.
Action of controller
• Performs open control.
Problem that appears on machine Related information Cause 1 Defective related system
Standard value in normal state/Remarks on troubleshooting If another failure code is indicated, carry out troubleshooting for it. a For measurement of EGR valve drive pressure, see Testing and adjusting, “Measuring EGR valve and bypass valve drive oil pressure”.
2
Improper EGR valve drive pressure
Engine speed
Bypass valve drive pressure
Low idle
1.18 MPa {12 kg/cm2}
High idle
1.43 MPa {14.6 kg/cm2}
If EGR valve drive pressure is abnormal, check causes 3 and 4. a For check of engine oil pressure, see TESTING AND ADJUSTING, Testing engine oil pressure. Possible causes and standard value in normal state
Defective engine oil pres3 sure system (main circuit)
Engine speed
Engine oil pressure
Low idle
0.08 MPa {0.8 kg/cm2}
High idle
0.21 MPa {2.1 kg/cm2}
If engine oil pressure is abnormal, carry out troubleshooting for mechanical system (S-12 Oil pressure lowers).
26
4
Defective oil pump for bypass valve
Check oil pump and relief valve for bypass valve circuit directly.
5
Defective oil feed piping for Check oil feed piping for bypass valve circuit directly. bypass valve
6
Defective oil return piping for bypass valve
Check oil return piping for bypass valve circuit directly.
7 Defective bypass valve
Check mechanical section of bypass valve directly.
8 Defective engine controller
If causes 1 – 7 are not detected, engine controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
140E-5 Series
40 Troubleshooting
SEN00154-02
E-54 Code [1629/CA1629] Bypass Valve Servo Error 2 a
1
This code applies to only “with EGR”. Error code
Failure code
1629
CA1629
Trouble
Abnormality in bypass valve servo 2
Contents of trouble
• Abnormality (level 2) occurred in bypass valve servo.
Action of controller
• Limits output and continues operation. • Closes EGR valve and bypass valve.
Problem that appears • Output drops. on machine Related information Possible causes and standard value in normal state
140E-5 Series
Cause
Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for E-53 Code [1628/CA1628].
27
SEN00154-02
40 Troubleshooting
E-55 Code [1631/CA1631] Bypass Valve Lift Sensor High Error a
1
This code applies to only “with EGR”. Error code
Failure code
1631
CA1631
Trouble
Abnormally high level in bypass valve lift sensor
Contents of trouble
• Signal voltage in bypass valve lift sensor circuit is abnormally high.
Action of controller
• Limits output and continues operation. • Closes EGR valve and bypass valve.
Problem that appears • Output drops. on machine Related information
• Different machine models may have different connector Nos. Cause 1
Standard value in normal state/Remarks on troubleshooting
Defective sensor power If code [187/CA187] or [227/CA227] is indicated, carry out troublesupply shooting for it first. a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. SBP
Defective bypass valve 2 lift sensor (Internal trouble)
Voltage
Between (1) – (2)
Power supply
4.75 – 5.25 V
Between (3) – (2)
Signal
0.8 – 1.2 V
Between (4) – (2)
Signal
0.8 – 1.2 V
Sensor voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness and controller, too, for another cause of trouble, and then judge. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection 3 in wiring or defective contact in connector) Possible causes and standard value in normal state
Wiring harness between ENG (female) (37) – SBP (female) (1)
Resistance Max. 1 z
Wiring harness between ENG (female) (38) – SBP (female) (2)
Resistance Max. 1 z
Wiring harness between ENG (female) (29) – SBP (female) (3), (4)
Resistance Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring 4 harness (Short circuit with GND circuit)
Wiring harness between ENG (female) (37) Resistance Min. 1 Mz – SBP (female) (1) and chassis ground Wiring harness between ENG (female) (38) Resistance Min. 1 Mz – SBP (female) (2) and chassis ground Wiring harness between ENG (female) (29) – SBP (female) (3), (4) and chassis ground
Resistance Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Short circuit in wiring 5 harness (with another wiring harness)
Wiring harness between ENG (female) (37) – SBP (female) (1) and between ENG Resistance Min. 1 Mz (female) (38) – SBP (female) (2) Wiring harness between ENG (female) (37) – SBP (female) (1) and between ENG Resistance Min. 1 Mz (female) (29) – SBP (female) (3), (4) Wiring harness between ENG (female) (38) – SBP (female) (2) and between ENG Resistance Min. 1 Mz (female) (29) – SBP (female) (3), (4)
28
140E-5 Series
40 Troubleshooting
SEN00154-02
Cause Possible causes and standard value in normal state
Defective engine con6 troller
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. ENG
Voltage
Between (37) – (38)
4.75 – 5.25 V
Circuit diagram related to bypass valve solenoid & lift sensor
140E-5 Series
29
SEN00154-02
40 Troubleshooting
E-56 Code [1632/CA1632] Bypass Valve Lift Sensor Low Error a
1
This code applies to only “with EGR”. Error code
Failure code
1632
CA1632
Trouble
Abnormally low level in bypass valve lift sensor
Contents of trouble
• Signal voltage in bypass valve lift sensor circuit is abnormally low.
Action of controller
• Limits output and continues operation. • Closes EGR valve and bypass valve.
Problem that appears • Output drops. on machine Related information Possible causes and standard value in normal state
Cause
Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for E-55 Code [1631/CA1631].
E-57 Code [1633/CA1633] KOMNET Error Error code
Failure code
1633
CA1633
Trouble
1
Abnormality in KOMNET
Contents of trouble
• Abnormality occurred in circuit of KOMNET communication with machine.
Action of controller
• Operates in default mode or maintains condition when abnormality occurs.
Problem that appears on machine Related information Cause Possible causes and standard value in normal state
30
Carry out troubleshooting 1 on machine side
Standard value in normal state/Remarks on troubleshooting This fault is detected and indicated when KOMNET communication with machine monitor or controller on the machine side is abnormal. Accordingly, contents of troubleshooting depends on machine model. See Shop manual for machine.
140E-5 Series
40 Troubleshooting
SEN00154-02
E-58 Code [1642/CA1642] EGR Inlet Press Sensor Low Error a
1
This code applies to only “with EGR”. Error code
Failure code
1642
CA1642
Trouble
Abnormally low level in EGR inlet pressure sensor
Contents of trouble
• Signal voltage in EGR inlet pressure sensor circuit is abnormally low.
Action of controller
• Sets EGR inlet pressure to default value (102 kPa {1.04 kg/cm2}) and continues operation. • Limits output and continues operation.
Problem that appears • Output drops. on machine Related information Possible causes and standard value in normal state
Cause
Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for E-59 Code [1653/CA1653].
Reference: EGR inlet pressure sensor is applied to only machines Serial No. up to 530896.
140E-5 Series
31
SEN00154-02
40 Troubleshooting
E-59 Code [1653/CA1653] EGR Inlet Press Sensor High Error a
1
This code applies to only “with EGR”. Error code
Failure code
1653
CA1653
Trouble
Abnormally high level in EGR inlet pressure sensor
Contents of trouble
• Signal voltage in EGR inlet pressure sensor circuit is abnormally high.
Action of controller
• Sets EGR inlet pressure to default value (102 kPa {1.04 kg/cm2}) and continues operation. • Limits output and continues operation.
Problem that appears • Output drops. on machine Related information
• Different machine models may have different connector Nos. Cause 1
Defective sensor power supply
Standard value in normal state/Remarks on troubleshooting If code [187/CA187] or [227/CA227] is indicated, carry out troubleshooting for it first. a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting.
Defective EGR inlet pres2 sure sensor (Internal trouble)
PEVA Between (1) – (2)
Voltage Power supply
4.75 – 5.25 V
Sensor voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness and controller, too, for another cause of trouble, and then judge. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection 3 in wiring or defective contact in connector)
Possible causes and standard value in normal state
Wiring harness between ENG (female) (37) – PEVA (female) (1)
Resistance Max. 1 z
Wiring harness between ENG (female) (47) – PEVA (female) (2)
Resistance
Wiring harness between ENG (female) (20) – PEVA (female) (3)
Resistance Max. 1 z
Max. 1z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring 4 harness (Short circuit with GND circuit)
Wiring harness between ENG (female) (37) Resistance Min. 1 Mz – PEVA (female) (1) and chassis ground Wiring harness between ENG (female) (47) Resistance Min. 1 Mz – PEVA (female) (2) and chassis ground Wiring harness between ENG (female) (20) Resistance Min. 1 Mz – PEVA (female) (3) and chassis ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between ENG (female) (37) – PEVA (female) (1) and between Short circuit in wiring har- ENG (female) (47) – PEVA (female) (2) 5 ness (with another wiring Wiring harness between ENG (female) harness) (37) – PEVA (female) (1) and between ENG (female) (20) – PEVA (female) (3) Wiring harness between ENG (female) (47) – PEVA (female) (2) and between ENG (female) (20) – PEVA (female) (3) Defective engine control6 ler
32
Resistance Min. 1 Mz
Resistance Min. 1 Mz
Resistance Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. ENG
Voltage
Between (37) – (47)
4.75 – 5.25 V
140E-5 Series
40 Troubleshooting
SEN00154-02
Reference: EGR inlet pressure sensor is applied to only machines Serial No. up to 530896. Circuit diagram related to EGR inlet pressure sensor
140E-5 Series
33
SEN00154-02
40 Troubleshooting
E-60 Code [2185/CA2185] Throttle Sens. Sup. Volt. High Error
1
Throttle sensor of accelerator pedal type (Case of HD325/405-7) Error code
Failure code
2185
CA2185
Trouble
Abnormally high level in throttle sensor power supply
Contents of trouble
• Signal voltage in throttle sensor power supply (5 V) circuit is abnormally high.
Action of controller
• Sets throttle angle with signal other than throttle sensor signal and continues operation (depending on each model).
Problem that appears • Depends on machine model. on machine Related information
• Different machine models may have different connector Nos. Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
1
Defective accelerator pedal (Internal trouble)
Disconnect devices at right in order. If error code disappears when a device is disconnected, that device has a defect in it.
Accelerator pedal
WAS1 connector
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes and standard value in normal state
Disconnection in wiring harness (Disconnection Wiring harness between E02 (female) (22) 2 Resistance Max. 1 z in wiring or defective – WAS1 (female) (1) contact in connector) Wiring harness between E02 (female) (23) Resistance Max. 1 z – WAS1 (female) (3)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring 3 harness (Short circuit with GND circuit)
Wiring harness between E02 (female) (22) Resistance Min. 1 Mz – WAS1 (female) (1) and chassis ground Wiring harness between E02 (female) (23) Resistance Min. 1 Mz – WAS1 (female) (3) and chassis ground
Short circuit in wiring 4 harness (with another wiring harness)
5
34
Defective engine controller
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between E02 (female) (22) – WAS1 (female) (1) and between E02 Resistance Min. 1 Mz (female) (23) – WAS1 (female) (3) a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. E02
Voltage
Between (22) – (23)
4.75 – 5.25 V
140E-5 Series
40 Troubleshooting
SEN00154-02
Circuit diagram related to throttle sensor of accelerator pedal type (Case of HD325/405-7)
140E-5 Series
35
SEN00154-02
40 Troubleshooting
Throttle sensor of fuel control dial type (Case of PC800/800SE/850/850SE/850LC-8) Error code
Failure code
2185
CA2185
Trouble
Abnormally high level in throttle sensor power supply
Contents of trouble
• Signal voltage in throttle sensor power supply (5 V) circuit is abnormally high.
Action of controller
• Sets throttle angle with signal other than throttle sensor signal and continues operation (depending on each model).
Problem that appears • Depends on machine model. on machine Related information
• Different machine models may have different connector Nos. Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
1
Defective fuel control dial (Internal trouble)
Disconnect devices at right in order. If error code disappears when a device is disconnected, that device has a defect in it.
Fuel control dial
P20 connector
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes and standard value in normal state
Disconnection in wiring harness (Disconnection Wiring harness between E02 (female) (22) 2 Resistance Max. 1 z in wiring or defective – P20 (female) (1) contact in connector) Wiring harness between E02 (female) (23) Resistance Max. 1 z – P20 (female) (3)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring 3 harness (Short circuit with GND circuit)
Wiring harness between E02 (female) (22) Resistance Min. 1 Mz – P20 (female) (1) and chassis ground Wiring harness between E02 (female) (23) Resistance Min. 1 Mz – P20 (female) (3) and chassis ground
Short circuit in wiring 4 harness (with another wiring harness)
Defective engine con5 troller
36
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between E02 (female) (22) – P20 (female) (1) and between E02 Resistance Min. 1 Mz (female) (23) – P20 (female) (3) a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. E02
Voltage
Between (22) – (23)
4.75 – 5.25 V
140E-5 Series
40 Troubleshooting
SEN00154-02
Circuit diagram related to throttle sensor of fuel control dial type (Case of PC800/800SE/850/850SE/ 850LC-8)
140E-5 Series
37
SEN00154-02
40 Troubleshooting
E-61 Code [2186/CA2186] Throttle Sens. Sup. Volt. Low Error Error code
Failure code
2186
CA2186
Trouble
1
Abnormally low level in throttle sensor power supply
Contents of trouble
• Signal voltage in throttle sensor power supply (5 V) circuit is abnormally low.
Action of controller
• Sets throttle angle with signal other than throttle sensor signal and continues operation (depending on each model).
Problem that appears • Depends on machine model. on machine Related information Possible causes and standard value in normal state
Cause
Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for E-60 Code [2185/CA2185].
E-62 Code [2249/CA2249] No-pressure Feed By Supply pump 2 Error code
Failure code
2249
CA2249
Trouble
1
No-pressure feed by supply pump 2
Contents of trouble
• Supply pump does not feed fuel (level 2).
Action of controller
• Limits common rail pressure.
Problem that appears • Output drops. on machine Related information Possible causes and standard value in normal state
38
Cause
Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for E-44 Code [559/CA559].
140E-5 Series
40 Troubleshooting
SEN00154-02
E-63 Code [2271/CA2271] EGR Valve Lift Sensor High Error a
1
This code applies to only “with EGR”. Error code
Failure code
2271
CA2271
Trouble
Abnormally high level in EGR valve lift sensor
Contents of trouble
• Signal voltage in EGR valve lift sensor circuit is abnormally high.
Action of controller
• Limits output and continues operation. • Closes EGR valve and bypass valve.
Problem that appears • Output drops. on machine Related information
• Different machine models may have different connector Nos. Cause 1
Defective sensor power supply
Standard value in normal state/Remarks on troubleshooting If code [187/CA187] or [227/CA227] is indicated, carry out troubleshooting for it first. a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. SEGR
Defective EGR valve 2 lift sensor (Internal trouble)
Voltage
Between (1) – (2)
Power supply
4.75 – 5.25V
Between (3) – (2)
Signal
0.8 – 1.2 V
Between (4) – (2)
Signal
0.8 – 1.2 V
Sensor voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness and controller, too, for another cause of trouble, and then judge. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes and standard value in normal state
Disconnection in wiring harness (Disconnec3 tion in wiring or defective contact in connector)
Wiring harness between ENG (female) (37) Resistance Max. 1 z – SEGR (female) (1) Wiring harness between ENG (female) (47) Resistance Max. 1 z – SEGR (female) (2) Wiring harness between ENG (female) (19) Resistance Max. 1 z – SEGR (female) (3), (4) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring 4 harness (Short circuit with GND circuit)
Wiring harness between ENG (female) (37) Resistance Min. 1 Mz – SEGR (female) (1) and chassis ground Wiring harness between ENG (female) (47) Resistance Min. 1 Mz – SEGR (female) (2) and chassis ground Wiring harness between ENG (female) (19) – Resistance Min. 1 Mz SEGR (female) (3), (4) and chassis ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Short circuit in wiring 5 harness (with another wiring harness)
Wiring harness between ENG (female) (37) – SEGR (female) (1) and between ENG Resistance Min. 1 Mz (female) (47) – SEGR (female) (2) Wiring harness between ENG (female) (37) – SEGR (female) (1) and between ENG Resistance Min. 1 Mz (female) (19) – SEGR (female) (3), (4) Wiring harness between ENG (female) (47) – SEGR (female) (2) and between ENG Resistance Min. 1 Mz (female) (19) – SEGR (female) (3), (4)
140E-5 Series
39
SEN00154-02
40 Troubleshooting
Cause Possible causes and standard value in normal state
Defective engine con6 troller
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. ENG
Voltage
Between (37) – (47)
4.75 – 5.25 V
Circuit diagram related to EGR valve solenoid & lift sensor
40
140E-5 Series
40 Troubleshooting
SEN00154-02
E-64 Code [2272/CA2272] EGR Valve Lift Sensor Low Error a
1
This code applies to only “with EGR”. Error code
Failure code
2272
CA2272
Trouble
Abnormally low level in EGR valve lift sensor
Contents of trouble
• Signal voltage in EGR valve lift sensor circuit is abnormally low.
Action of controller
• Limits output and continues operation. • Closes EGR valve and bypass valve.
Problem that appears • Output drops. on machine Related information Possible causes and standard value in normal state
140E-5 Series
Cause
Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for E-63 Code [2271/CA2271].
41
SEN00154-02
40 Troubleshooting
E-65 Code [2351/CA2351] EGR Valve Solenoid Drive Short Error a
1
This code applies to only “with EGR”. Error code
Failure code
2351
CA2351
Trouble
Short circuit in drive circuit of EGR valve solenoid
Contents of trouble
• There is short circuit in drive circuit of EGR valve solenoid.
Action of controller
• Limits output and continues operation. • Closes EGR valve and bypass valve.
Problem that appears • Output drops. on machine Related information
• Different machine models may have different connector Nos. Cause
1
Defective EGR valve solenoid (Internal trouble)
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. EGR (male)
Resistance
Between (1) – (2)
10 – 21 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection Wiring harness between ENG (female) 2 in wiring or defective con- (22) – EGR (female) (1) tact in connector) Wiring harness between ENG (female) (11) – EGR (female) (2)
Resistance Max. 1 z Resistance Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Possible causes and standard value in normal state
Ground fault in wiring 3 harness (Short circuit with GND circuit)
Wiring harness between ENG (female) (22) Resistance Min. 1 Mz – EGR (female) (1) and chassis ground Wiring harness between ENG (female) (11) Resistance Min. 1 Mz – EGR (female) (2) and chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
Wiring harness between ENG (female) Hot short (Short circuit (22) – EGR (female) (1) and chassis 4 with 24V circuit) in wiring ground harness Wiring harness between ENG (female) (11) – EGR (female) (2) and chassis ground
Voltage
Max. 1 V
Voltage
Max. 1 V
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective engine control5 ler ENG (female) Resistance Between (22) – (11)
42
10 – 21 z
140E-5 Series
40 Troubleshooting
SEN00154-02
Circuit diagram related to EGR valve solenoid & lift sensor
140E-5 Series
43
SEN00154-02
40 Troubleshooting
E-66 Code [2352/CA2352] EGR Valve Solenoid Drive Open Error a
1
This code applies to only “with EGR”. Error code
Failure code
2352
CA2352
Trouble
Disconnection in drive circuit of EGR valve solenoid
Contents of trouble
• There is disconnection in drive current of EGR valve solenoid.
Action of controller
• Limits output and continues operation. • Closes EGR valve and bypass valve.
Problem that appears • Output drops. on machine Related information Possible causes and standard value in normal state
44
Cause
Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting E-65 Code [2351/CA2351].
140E-5 Series
40 Troubleshooting
SEN00154-02
E-67 Code [2555/CA2555] Intake Air Heater Relay Open Error Error code
Failure code
2555
CA2555
Trouble
1
Disconnection in intake air heater relay
Contents of trouble
• There is disconnection in intake air heater relay.
Action of controller
• None in particular.
Problem that appears • Engine does not start easily at low temperature. on machine Related information Possible causes and standard value in normal state
140E-5 Series
Cause
Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting E-68 Code [2556/CA2556].
45
SEN00154-02
40 Troubleshooting
E-68 Code [2556/CA2556] Intake Air Heater Relay Short Error Error code
Failure code
2556
CA2556
Trouble
1
Short circuit in intake air heater relay
Contents of trouble
• There is short circuit in intake air heater relay.
Action of controller
• None in particular.
Problem that appears • Engine does not start easily at low temperature. on machine Related information
• Condition for driving heater relay depends on machine. • Different machine models may have different connector Nos. Cause Defective intake air 1 heater relay (Internal trouble)
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. R18 (male)
Resistance
Between (1) – (2)
200 – 400 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes and standard value in normal state
Disconnection in wiring harness (Disconnection Wiring harness between E02 (female) 2 in wiring or defective con- (40) – R18 (female) (1) tact in connector) Wiring harness between E02 (female) (42) – R18 (female) (2)
Resistance Max. 1 z Resistance Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring 3 harness (Short circuit with GND circuit)
Wiring harness between E02 (female) (40) Resistance Min. 1 Mz – R18 (female) (1) and chassis ground Wiring harness between E02 (female) (42) Resistance Min. 1 Mz – R18 (female) (2) and chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
4
Defective engine controller
E02
Between (40) – (42)
46
Heater relay
Voltage
Under operating condition
Max. 1 V
Under stopping condition
20 – 30 V
140E-5 Series
40 Troubleshooting
SEN00154-02
Circuit diagram related to intake air heater (Case of PC800/800SE/850/850SE/850LC-8)
140E-5 Series
47
SEN00154-02
40 Troubleshooting
E-69 Code [(143)/B@BAZG] Eng. Oil Press Low Torque Derate Error code
Failure code
(143)
B@BAZG
Trouble
1
Derating of torque by engine oil pressure reduction
Contents of trouble
• Engine oil pressure is below operating range.
Action of controller
• Limits output and continues operation (Limits fuel injection rate and engine speed).
Problem that appears • Output drops. on machine Related information Possible causes and standard value in normal state
Cause 1
Standard value in normal state/Remarks on troubleshooting
Carry out troubleshooting on machine side
This fault is indicated on only machine side when detected. Accordingly, contents of troubleshooting depends on machine model. See Shop manual for machine.
E-70 Code [(146)/B@BCNS] Eng. Overheat Error code
Failure code
(146)
B@BCNS
Trouble
1
Engine overheat
Contents of trouble
• Engine coolant temperature is above operating range.
Action of controller
• Limits output and continues operation.
Problem that appears • Output drops. on machine Related information Possible causes and standard value in normal state
48
Cause 1
Carry out troubleshooting on machine side
Standard value in normal state/Remarks on troubleshooting This fault is indicated on only machine side when detected. Accordingly, contents of troubleshooting depends on machine model. See Shop manual for machine.
140E-5 Series
40 Troubleshooting
SEN00154-02
E-71 Code [(415)/B@BAZG] Eng. Oil Press. Low Speed Derate Error code
Failure code
(415)
B@BAZG
Trouble
1
Derating of speed by engine oil pressure reduction
Contents of trouble
• Engine oil pressure is below operating range.
Action of controller
• Limits output and continues operation (Limits fuel injection rate and engine speed).
Problem that appears • Output drops. on machine Related information Possible causes and standard value in normal state
140E-5 Series
Cause 1
Carry out troubleshooting on machine side
Standard value in normal state/Remarks on troubleshooting This fault is indicated on only machine side when detected. Accordingly, contents of troubleshooting depends on machine model. See Shop manual for machine.
49
SEN00154-02
KOMATSU 140E-5 Series engine Form No. SEN00154-02
© 2007 KOMATSU All Rights Reserved Printed in Japan 03-07 (01)
50
SEN00156-05
ENGINE 1SHOP MANUAL
140E-5 Series
50 Disassembly and assembly General information on disassembly and assembly General information on disassembly and assembly ....................................................................................... 2 How to read this manual ...................................................................................................................... 2 Coating materials list............................................................................................................................ 4 Special tools list.................................................................................................................................... 7 Sketches of special tools...................................................................................................................... 8
140E-5 Series
1
SEN00156-05
50 Disassembly and assembly
General information on disassembly and assembly
1
(Rev. 2009.01)
How to read this manual 1.
1
Removal and installation of assemblies Special tools q Special tools which are necessary for r e m o v a l o r i n s ta l l a t i o n o f pa r ts a r e described as A1, ••• X1 etc. and their part numbers, part names and quantities are described in the special tool list. q Also the following information is described in the special tool list. 1) Necessity t : Special tools that cannot be substituted and should always be used q : Special tools that will be useful if available and are substitutable with tools available on the market 2) Distinction of new and existing special tools N: Tools newly developed for this model. They have a new part number respectively. R: Tools made available by redesigning the existing tools which were developed for other models. Each of them has a new part number assigned by setting forward the part number of the existing tool. Blank : Tools already available for other models. They can be used without any modification. 3) Circle mark Q in sketch column: q The sketch of the special tool is presented in the section of “Sketches of special tools”. q Part No. of special tools starting with 79 T: means that they are not available from Komatsu Ltd. (i.e. tools to be made locally).
* *** ****
Removal q In “Removal” section, the work procedures, precautions and know-how to do the work, and the amount of oil and coolant to be drained are described. q Common tools that are necessary for removal are described as [1], [2]••• etc. and their part numbers, part names and quantities are not described. q Various symbols used in “Removal” section are explained and listed below. k : Precautions related to work safety a : Guidance or precautions for the work [*1] : This mark shows that instructions or precautions for parts installation work are given in “Installation” section. 6 : Amount of oil or coolant to be drained 4:
Weight of part or component
Installation q Unless otherwise instructed, installation of parts is to be done in the reverse order to removal. q Instructions and precautions for parts installation is shown with the mark ([*1], [*2]...) which corresponds to the mark in “Removal” section. q Common tools that are necessary for installation are described as [1], [2]••• etc. and their part numbers, part names and quantities are not described. q Marks shown in the “Installation” section stand for the following. k
: Precautions related to work safety : Guidance or precautions for the work 2 : Type of coating material 3 : Tightening torque
a
5
: Amount of oil or coolant to be replenished
Sketches of special tools q Various special tools are illustrated for the local manufacture.
2
140E-5 Series
50 Disassembly and assembly
2.
SEN00156-05
Disassembly and assembly of assemblies Special tools q Special tools which are necessary for disassembly and assembly of parts are described as A1, ••• X1 etc. and their part numbers, part names and quantities are described in the special tool list. q Also the following information is described in the special tool list. 1) Necessity t : Special tools that cannot be substituted and should always be used. q : Special tools that will be useful if available and are substitutable with tools available on the market. 2) Distinction of new and existing special tools N: Tools newly developed for this model. They have a new part number respectively. R: Tools made available by redesigning the existing tools which were developed for other models. Each of them has a new part number assigned by setting forward the part number of the existing tool. Blank : Tools already available for other models. They can be used without any modification. 3) Circle mark Q in sketch column: q The sketch of the special tool is presented in the section of “Sketches of special tools”. q Part No. of special tools starting with 79 T: means that they are not available from Komatsu Ltd. (i.e. tools to be made locally).
* *** ****
Disassembly q In “Disassembly” section, the work procedures, precautions and know-how to do the work, and the amount of oil and coolant to be drained are described. q Common tools that are necessary for disassembly are described as [1], [2]••• etc. and their part numbers, part names and quantities are not described. q The meanings of the symbols used in “Disassembly” section are as follows. k
: Precautions related to work safety : Guidance or precautions for the work 6 : Amount of oil or coolant drained
a
Assembly q In “Assembly” section, the work procedures, precautions and know-how to do the work, and the amount of oil and coolant to be replenished are described. q Common tools that are necessary for assembly are described as [1], [2]••• etc. and their part numbers, part names and quantities are not described. q The meanings of the symbols used in “Assembly” section are as follows. k
: Precautions related to work safety : Guidance or precautions for the work 2 : Type of coating material 3 : Tightening torque
a
5
: Amount of oil or coolant to be replenished
Sketches of special tools Various special tools are illustrated for the local manufacture.
q
140E-5 Series
3
SEN00156-05
50 Disassembly and assembly
Coating materials list a a
The recommended coating materials such as adhesives, gasket sealants, and greases used for disassembly and assembly are listed below. For coating materials not listed below, use the equivalent of products shown in this manual.
Category
Komatsu code
Part number
Q'ty
Container
Main features and applications
LT-1A
790-129-9030
150 g
Tube
• Used to prevent rubber gaskets, rubber cushions, and cork plugs from coming out.
LT-1B
790-129-9050
20 g (2 pcs.)
• Used for plastic (except polyethylene, polypropylene, tetrafluoroethylene and vinyl Polyethylene chloride), rubber, metal, and non-metal parts container which require immediate and strong adhesion.
LT-2
09940-00030
50 g
Polyethylene • Features: Resistance to heat and chemicals. container • Used to fix and seal bolts and plugs.
Adhesive
LT-3
790-129-9040
250 g
Holtz MH 705
790-129-9120
75 g
790-129-9140
Can
• Used to stick and seal metal, glass, and plastics.
Polyethylene • Used to seal plugs. container Tube
• Heat-resistant seal used to repair engines.
50 g
• Quick-setting adhesive. Polyethylene • Setting time: Within 5 sec. to 3 min. container • Used mainly to stick metals, rubbers, plastics, and woods. • Quick-setting adhesive. • Quick-setting type. Polyethylene (max. strength is obtained after 30 minutes) container • Used mainly to stick rubbers, plastics, and metals.
Aron-alpha 201
790-129-9130
2g
Loctite 648-50
79A-129-9110
50 cc
• Features: Resistance to heat and chemicals. Polyethylene • Used for fitted portions used at high temperacontainer tures.
1 kg
• Used to seal various threaded portions, pipe Polyethylene joints, and flanges. container • Used to seal tapered plugs, elbows, and nipples of hydraulic piping.
LG-5
Gasket sealant
790-129-9060 Adhesive: 1 kg (Set of adhesive Hardener: 500 g and hardener)
LT-4
ThreeBond 1735
790-129-9080
LG-6
790-129-9160
200 g
Tube
• Features: Silicon-based heat and cold-resistant sealant. • Used to seal flange surfaces and threaded portions. • Used to seal oil pan, final drive case, etc.
LG-7
790-129-9170
1 kg
Tube
• Features: Silicon-based quick-setting sealant. • Used to seal flywheel housing, intake manifold, oil pan, thermostat housing, etc.
Tube
• Features: Silicon-based, heat and cold-resistant, vibration-resistant, impact-resistant sealant. • Used to seal transfer case, etc.
LG-8 ThreeBond 1207B
4
(Rev. 2009.02) 1
419-15-18131
100 g
140E-5 Series
50 Disassembly and assembly
Gasket sealant
CateKomatsu code gory
Molybdenum disulfide lubricant
Container
Main features and applications
790-129-9310
200 g
Tube
• Used for rough surfaces such as the circle gear top seal which does not need to be clamped, water resistance of the clearance at the welded area, etc. • Can be coated with paint.
LG-10 ThreeBond 1206E
790-129-9320
200 g
Tube
• Used as lubricant/sealant when the radiator hoses are inserted. • Can be coated with paint.
LG-11 ThreeBond 1121
790-129-9330
200 g
Tube
• Feature: Can be used together with gaskets. • Used for covers of the transmission case and steering case etc.
ThreeBond 1211
790-129-9090
100 g
Tube
• Gasket sealant used to repair engine.
Tube
• Used to prevent scuffing and seizure of press-fitted portions, shrink-fitted portions, and threaded portions. • Used to lubricate linkages, bearings, etc.
Can
• Spray type • Thin molybdenum disulphide films are made on metal surfaces to prevent the metals from scuffing each other. • Applicable for the drive shaft splines, needle bearings, pins and bolts of various links, etc.
—
Can
• Feature: Seizure and scuffing prevention compound with metallic super-fine-grain, etc. • Used for the mounting bolt in the high temperature area of the exhaust manifold and the turbocharger, etc.
Various
Various
• Feature: Lithium grease with extreme pressure lubrication performance. • General purpose type.
—
LC-G NEVER-SEEZ
09940-00040
09995-00250
—
SYG2-400LI SYG2-350LI SYG2-400LI-A G2-LI SYG2-160LI G0-LI SYGA-160CNLI *: For cold district SYG0-400LI-A (*) SYG0-160CNLI (*)
Grease
Q'ty
LG-9 ThreeBond 1206D
LM-P
Seizure prevention compound
Part number
SEN00156-05
Molybdenum SYG2-400M disulfide grease SYG2-400M-A LM-G (G2-M) SYGA-16CNM
SYG2-400T-A SYG2-16CNT SYG0-400T-A (*) *: For cold district SYG0-16CNT (*)
Hyper White Grease G2-T, G0-T (*)
SYG2-400B Biogrease G2-B, G2-BT (*) SYGA-16CNB *: For use at high SYG2-400BT (*) temperature and SYGA-16CNBT under high load (*)
140E-5 Series
200 g
190 g
• Used for parts under heavy load. Caution: 400 g x 10 Bellows-type • Do not apply grease to rolling bearings like swing circle bearings, etc. and spline. 400 g x 20 container • The grease should be applied to work equipment 16 kg Can pins at their assembly only, not applied for greasing afterwards. 400 g 16 kg
400 g 16 kg
• Bellows-type container Can •
Seizure resistance, heat resistance and water resistance higher than molybdenum disulfide grease. Not conspicuous on machine since color is white.
Bellows-type • Since this grease is decomposed by natural baccontainer teria in short period, it has less effects on microCan organisms, animals, and plants.
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G2-U-S ENS grease
—
427-12-11871
SUNSTAR PAINT PRIMER 580 SUPER
Caulking material
Adhesive
Primer
SUNSTAR GLASS PRIMER 580 SUPER
6
SUNSTAR PAINT PRIMER 435-95
Q'ty
Container
Main features and applications
Tube
• Feature: Silicone grease with wide using temperature range, high resistance to thermal-oxidative degradation and performance to prevent deterioration of rubber and plastic parts. • Used for oil seals of the transmission, etc.
2 kg
Can
• Feature: Urea (organic system) grease with heat resistance and long life. Enclosed type. • Used for rubber, bearing and oil seal in damper. Caution: Do not mix with lithium grease.
20 ml
Glass container
• Used as primer for cab side. (Using limit: 4 months after date of manufacture)
20 ml
Glass container
• Used as primer for glass side. (Using limit: 4 months after date of manufacture)
20 ml
Glass container
200 g
417-926-3910
22M-54-27230
Adhesive for cab glass
G2-S ThreeBond 1855
Part number
• Used as primer for painted surface on cab side. (Using limit: 4 months after date of manufacture) • Used as primer for black ceramic-coated surface on glass side and for hard polycarbonate-coated surface. (Using limit: 4 months after date of manufacture)
SUNSTAR GLASS PRIMER 435-41
22M-54-27240
150 ml
Can
SUNSTAR SASH PRIMER GP-402
22M-54-27250
20 ml
Glass container
• Used as primer for sash (Almite). (Using limit: 4 months after date of manufacture)
SUNSTAR PENGUINE SEAL 580 SUPER “S” or “W”
417-926-3910
320 ml
Polyethylene container
• “S” is used for high-temperature season and “W” for low-temperature season as adhesive for glass. (Using limit: 4 months after date of manufacture)
Sika Japan, Sikaflex 256HV
20Y-54-39850
310 ml
Polyethylene container
• Used as adhesive for glass. (Using limit: 6 months after date of manufacture)
SUNSTAR PENGUINE SUPER 560
22M-54-27210
320 ml
Ecocart (Special container)
SUNSTAR PENGUINE SEAL No. 2505
417-926-3920
320 ml
Polyethylene container
SEKISUI SILICONE SEALANT
20Y-54-55130
333 ml
Polyethylene container
• Used to seal front window. (Using limit: 6 months after date of manufacture)
Cartridge
• Used to seal joint of glasses. Translucent white seal. (Using limit: 12 months after date of manufacture)
GE TOSHIBA SILICONES TOSSEAL 381
22M-54-27220
333 ml
Adhesive for cab glass
Grease
CateKomatsu code gory
50 Disassembly and assembly
• Used as adhesive for glass. (Using limit: 6 months after date of manufacture) • Used to seal joints of glass parts. (Using limit: 4 months after date of manufacture)
140E-5 Series
50 Disassembly and assembly
SEN00156-05
Special tools list
Disassembly and assembly of engine assembly
A
Part No.
Part name
1
790-501-2001
Engine repair stand t 1
2
790-901-1261
Bracket
t 1
Removal and installation of cylinder head valve spring
C
795-102-2103
Spring pusher
t 1
Removal and installation of piston ring
D
795-100-1191
Piston ring tool
t 1
Removal of cylinder liner
E
795-236-1000
Liner puller
t 1
Press fitting of cylinder liner
F
795-230-5472
Liner driver
t 1
Insertion of piston assembly
G
795-921-1100
Piston holder
t 1
Measuring projection of cylinder liner
H
795-502-1121
Gauge holder
t 1
Adjusting valve clearance
I
795-125-1210
Thickness gauge
q 1
Angle tightening of bolt
J
790-331-1110
Wrench
q 1
L
795-931-1100
Seal puller
t 1
1 M 2 Removal and installation of engine front seal and engine rear seal
1
N
2
3
795T-521-1111 Push tool
t 1
01050-31655
Bolt
t 3
01050-31635
Bolt
Remarks
Removal of oil seal N Q
t 3
Press fitting of engine front seal
795T-521-1150 Push tool
t 1
01050-31635
t 3
N Q Press fitting of engine front seal (sleeve type)
795T-421-1260 Push tool
t 1
N Q
01050-31640
Bolt
t 4
01643-31645
Washer
t 8
Bolt
795T-421-1240 Push tool
t 1
01050-31645
Bolt
t 4
01643-31645
Washer
t 4
795T-421-1231 Push tool
t 1
01050-31645
Bolt
t 4
01643-31645
Washer
t 8
795-630-5500
Standard puller
t 1
Bolt
t 2
Removal of fuel supply pump
P
01010-81090 01643-31032
Washer
t 2
Press fitting of valve stem seal
Q
795-130-1720
Push tool
t 1
140E-5 Series
Sketch
Work item
New / Remodel
a
Q'ty
a
Necessity
a
Tools with part number 79*T-***-**** means that they are not available from Komatsu Ltd. (i.e. tools to be made locally). Necessity: t ............ Special tools that cannot be substituted and should always be used q ............ Special tools that will be useful if available and are substitutable with tools available on the market New/Redesign: N ............ Tools newly developed for this model. They have a new part number respectively. R ............ Tools made available by redesigning the existing tools which were developed for other models. Each of them has a new part number assigned by setting forward the part number of the existing tool. Blank ..... Tools already available for other models. They can be used without any modification. Tools marked with Q in the sketch column are presented in the sketches of the special tools (See “Sketches of special tools”). Symbol
a
1
Press fitting of engine rear seal (standard type)
N Q Press fitting of engine rear seal N Q (sleeve type)
Used to remove pump unit
7
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Sketches of special tools
50 Disassembly and assembly
1
Note) We will not be liable for any result of use of special tools manufactured according to the following drawings. M1. Push tool
M2. Push tool
8
140E-5 Series
50 Disassembly and assembly
SEN00156-05
Note) We will not be liable for any result of use of special tools manufactured according to the following drawings. N1. Push tool
N2. Push tool
140E-5 Series
9
SEN00156-05
50 Disassembly and assembly
Note) We will not be liable for any result of use of special tools manufactured according to the following drawings. N3. Push tool
10
140E-5 Series
50 Disassembly and assembly
140E-5 Series
SEN00156-05
11
SEN00156-05
KOMATSU 140E-5 Series engine Form No. SEN00156-05
© 2011 KOMATSU All Rights Reserved Printed in Japan 10-11
12
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ENGINE 1SHOP MANUAL
140E-5 Series
50 Disassembly and assembly Disassembly and assembly, Part 1 (with EGR) Disassembly and assembly, Part 1 (with EGR)............................................................................................... 2 General disassembly of engine............................................................................................................ 2 General assembly of engine .............................................................................................................. 20
140E-5 Series
1
SEN00157-05
50 Disassembly and assembly
Disassembly and assembly, Part 1 (with EGR)
1
General disassembly of engine 1 a
The shapes, quantity, locations, etc. of the parts depend on each applicable machine. Take care.
1.
Preparation work Before disassembling the engine, check its parts for cracking, damage, etc. and clean it generally and carefully for accurate inspection of its parts and quick disassembly and assembly. a Before cleaning the engine, carefully seal or remove the openings, electric parts, and wiring connectors so that water will not enter them.
2.
Drain the engine coolant and engine oil. a The quantity of the oil depends on the applicable machines. 6
2
Air cleaner bracket 1) Disconnect wiring harness clamp (1). 2) Remove air cleaner bracket (2). a The type of the bracket depends on the applicable machines. 4 Air cleaner bracket: 30 kg
5.
EGR cover 1) Remove covers (1), (2), and (3).
Setting engine assembly 1) Prepare stable engine stands (Blocks [1]) and place the engine assembly on them so that it will not tip over. a The weight depends on the applicable machines. 4 Engine assembly: 2,000 kg
2)
3.
4.
Engine oil: Approx. 53 l
Starting motor assembly 1) Disconnect wiring harness (1) and connector (2). 2) Remove 3 mounting bolts (3) and remove starting motor assembly (4).
140E-5 Series
50 Disassembly and assembly
2)
6.
Remove covers (4), (5), (6), and (7). a Cover (6) is not installed to all the models.
Tube clamp and bracket 1) Remove clamps (1), (2), (3), and (4). a The clamps hold the tubes from the front and rear. 2) Remove brackets (5), (6), and (7).
SEN00157-05
8.
Clamp and bracket 1) Remove clamp (1) and brackets (2) and (3). 2) Remove bracket (4).
9.
Bypass valve assembly 1) Remove the wiring harness clamp and disconnect connectors SBP (1) and BP (2).
2) 7.
Bracket Remove brackets (1), (2), and (3).
140E-5 Series
3)
Remove clamps (3), (5), and (11) and remove tubes (6) and (7). Remove bolts (8) and (9) and remove bypass valve assembly (10).
3
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10. EGR valve assembly 1) Remove the wiring harness clamp and disconnect connectors SEGR (1) and EGR (2).
2) 3)
50 Disassembly and assembly
12. EGR tube 1) Remove EGR inlet pressure sensor tube (1). Reference: EGR inlet pressure sensor is applied to only machines Serial No. up to 530896. 2) Remove EGR tube (2).
Remove tubes (3) and (4). Remove bolts (5) and (6) and remove EGR valve assembly (7). 13. EGR cooler assembly 1) Remove brackets (1) and (2) and remove stay (3). 2) Remove EGR cooler coolant outlet tube (4) and bracket (5).
11. Bypass tube Remove brackets (1), (2), and (3) and remove bypass tube (4).
3) 4) 5)
4
Remove turbocharger drain tube clamps (6). Remove air vent tube (7), bracket (8), and EGR cooler inlet tube (9). Remove EGR cooler coolant inlet tube (10).
140E-5 Series
50 Disassembly and assembly
SEN00157-05
16. Turbocharger assembly 1) Remove heat insulation cover (1) and oil drain tube (2). 2) Remove exhaust connector (3).
6)
Remove the 4 bolts and remove EGR cooler assembly (11).
14. Bracket Remove bracket (12).
15. EGR valve bracket Remove EGR valve bracket (1). 4
Bracket: 20 kg
140E-5 Series
3)
Remove wiring harness (4) and 4 turbocharger lubrication tube clamps (5) and remove turbocharger lubrication tube (6).
4)
Remove the 4 nuts and remove air inlet pipe and turbocharger assembly (7). 4 Air inlet pipe and turbocharger assembly: 30 kg
5
SEN00157-05
50 Disassembly and assembly
17. Exhaust manifold Remove the 24 mounting bolts and exhaust manifold (1). 4
Exhaust manifold: 25 kg
20. Water pump assembly 1) Remove alternator drive pulley (1). 2) Remove tubes (2) and (3). 3) Remove water pump assembly (4). 18. Alternately assembly 1) Disconnect terminal B (1) and terminal R (2). 2) Remove cover (3). 3) Loosen alternator mounting bolt (4) and clamping bolt (5). 4) Loosen locknut (6) and tension adjustment nut (7) and remove V-belt (8). 5) Remove mounting bolt (4) and clamping bolt (5) and remove alternator assembly (9).
21. Oil cooler assembly 1) Using eyebolts [1], sling the oil cooler assembly temporarily. 2) Remove the 16 mounting bolts and oil cooler assembly (1). 4 Oil cooler assembly: 35 kg
19. Thermostat assembly 1) Remove tube (1) 2) Remove snap ring (2) and push bypass tube (3) into the thermostat case. 3) Remove the 5 mounting bolts and thermostat assembly (4). a One of the 5 mounting bolts is used to clamp the thermostat assembly and cover together and has been removed already.
6
140E-5 Series
50 Disassembly and assembly
22. Oil filter, fuel filter, and corrosion resistor Remove oil filter (1), pre-fuel filter (2), main fuel filter (3), and corrosion resistor (4). a Pre-fuel filter (2) may be installed on the applicable machine side. a Corrosion resistor is not set for some models.
SEN00157-05
25. Oil filter head 1) Remove oil tubes (1) and (2) and the block on the cylinder block side as a unit. 2) Remove oil filter head (3). a The type of the oil filter head depends on the applicable machines.
23. EGR valve and bypass valve oil drain tube Remove drain tube (5).
24. Controller cover and oil filler 1) Remove controller cover (1). 2) Remove the clamp and oil filler (2). a The position of the oil filler depends on the applicable machines.
26. Fuel filter head 1) Remove fuel tube (1). 2) Remove fuel filter head (2) and bracket (3) as a unit. a The wiring harness clamp and the bracket are fixed together. a The type of the fuel filter head depends on the applicable machines.
27. Corrosion resistor head, fuel filter head, and priming pump 1) Remove the 2 clamps and fuel tube (1). 2) Remove the 2 clamps and fuel tubes (2) and (3). 3) Remove the clamp and breather tube (4). 4) Remove the clamp of wiring harness (5). 5) Loosen the 2 clamps and disconnect tubes (8) and (9).
140E-5 Series
7
SEN00157-05
6)
50 Disassembly and assembly
Remove corrosion resistor head (10), fuel filter head (11), priming pump (12), and bracket as a unit. a Corrosion resistor is not set for some models.
28. Air intake connector assembly 1) Disconnect EGR inlet pressure sensor connector PEVA (1) and clamp of wiring harness (2). Reference: EGR inlet pressure sensor is applied to only machines Serial No. up to 530896. 2) Remove the mounting bolts and remove air intake connector assembly (3) and the joint housing on the front side of the engine as a unit. 4 Air intake connector assembly: 40 kg
29. Air intake manifold 1) Sling the air intake manifold temporarily. 2) Disconnect the clamps of connectors TFUEL (1), TIM(2), PIM (3), and wiring harness (4). 3) Disconnect fuel tube (5). 4) Remove wiring harness clamp (6) and tube clamp (7). 5) Remove clamp (8) of the high-pressure pipe. a Remove the 5 high-pressure pipe clamps above the air intake manifold, too.
6) 7) a
8
When replacing the remove connector (4).
air
heater,
Disconnect clamps (9), (10), (11), (12), and (13) of the high-pressure pipe. Remove the mounting bolts and air intake manifold (14). 4 Air intake manifold: 45 kg
140E-5 Series
50 Disassembly and assembly
30. Engine controller Disconnect connector (1) and remove engine controller (2).
31. Engine controller cooler 1) Disconnect fuel hose (1). a Fuel hose (1) may not be installed. 2) Remove engine controller cooler (2). 32. Plate Remove plate (3).
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33. Common rail and high-pressure pipe a Before removing the high-pressure pipe, loosen all of the clamps, brackets, and sleeve nuts to give the high-pressure pipe freedom. 1) Remove bracket (1).
2) 3) 4)
5)
140E-5 Series
Remove 6 cylinder head covers (3). a At this time, the clamp of wiring harness (4) comes off. Remove clamps (5), (6), (7), (8), (9), (10), and (11). Remove all the splash prevention covers of the high-pressure pipe. a When removing the cylinder head cover, remove the high-pressure pipe covers on the injector side, too. Remove 6 high-pressure pipes (12) and 2 high-pressure pipes (13). a Remove 6 high-pressure pipes (12) in the order of No. 1, No. 6, No. 5, No. 4, No. 3, and No. 2.
9
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6) 7) 8)
Disconnect fuel pressure sensor connector PFUEL (15) and POIL (16). Remove clamp (17) and the eye joint of tube (18) on the common rail side. Remove special bolts (19) and remove common rail (20).
34. Wiring and piping of fuel supply pump assembly 1) Disconnect sensor connectors PCV1 (1), PCV2 (2), and G (3). 2) Remove level gauge tube (4). 3) Remove clamps (5), (6), (8), (9), and (10). 4) Remove oil tubes (11), (12), and (13). 5) Remove fuel tubes (14) and (15). a Before removing the pump unit, remove the front cover.
50 Disassembly and assembly
35. EGR oil pump assembly Remove the bolts and EGR oil pump assembly (1).
36. Corrosion resistor tube and blow-by tube 1) Remove corrosion resistor tubes (1) and (2). a Corrosion resistor is not set for some models. 2) Remove breather remote tube (3).
37. Wiring harness assembly and sensor connector 1) Disconnect the clamps of coolant temperature sensor connector TWTR (1) and wiring harnesses (2) and (3) and remove bracket (4).
10
140E-5 Series
50 Disassembly and assembly
2) 3) 4)
Disconnect the connectors of Ne sensor NE (6), and atmospheric pressure sensor PAMB (7). Remove the 6 injector connectors and remove the wiring harness assembly. Remove bracket (8).
a
5)
Move lock [1] of the housing of connector (7) in the direction of the arrow, push down lock [2], and pull out connector (7).
Disconnect the injector connector according to the following procedure. 1] Apply flat-head screwdriver [1] to the stepped part (part (a)). 2] While pressing stopper (1a), move flat-head screwdriver [1] in direction (X) to disconnect the connector.
SEN00157-05
38. Oil pan 1) Move the blocks which are supporting the engine to positions where you can remove the oil pan mounting bolts. 2) While supporting oil pan (1) on a pallet lift, etc., remove the mounting bolts and oil pan (1).
39. Suction tube Remove bracket (1) and suction tube (2).
a
a
After removing the suction tube, sling the engine. Set stable blocks at the front, rear, right, and left under the cylinder block and place the engine on them. Arrange the above blocks so that you can rotate the crankshaft.
40. Flywheel 1) Using sling [1], lift up flywheel (1) temporarily. 2) Remove the 8 mounting bolts and lift off the flywheel. a Take care that the flywheel will not contact the Ne sensor on the back side. 4 Flywheel: 65 kg
140E-5 Series
11
SEN00157-05
50 Disassembly and assembly
43. Head cover Remove the mounting bolts and each head cover (1). a If the head cover was removed when the high-pressure pipe was removed and has not been installed, skip this step.
41. Flywheel housing Lift up housing (1) temporarily and remove the mounting bolts and the housing. 4
Housing: 75 kg
44. Rocker arm and shaft assembly Remove the 3 mounting bolts and rocker arm and shaft assembly (1). a Loosen locknut (3) and loosen adjustment screw (4) fully so that the valve spring tension will not be applied to the mounting bolts when the rocker arm is removed and installed.
42. Rear oil seal Remove rear oil seal (1) from the flywheel housing.
45. Fuel injector 1) Remove 2 nuts (2) of the solenoid valve of fuel injector (1). a Loosen nuts (2) alternately. 2) Pull out spring clamp (3). 3) Remove the bolt of clamp (4). 4) Remove bolt (7) and holder (6). 5) Push in connector (5) and remove the injector wiring harness. a Connector (5) has an O-ring.
12
140E-5 Series
50 Disassembly and assembly
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46. Push rod Remove push rod (1).
6)
Loosen the bolt of holder (8) of fuel injector (1). 47. Cylinder head assembly and crosshead 1) Remove crosshead (1). 2) Remove mounting bolts (2), auxiliary bolts, and cylinder head assembly (3). 3) Remove each cylinder head gasket.
7)
Insert a small L-bar [2] under connector (9) of fuel injector (1) and pry out fuel injector (1) slowly. a Do not grip the solenoid valve at the top of the injector to pull off the injector. 4)
140E-5 Series
Disassemble the cylinder head assembly according to the following procedure. 1] Using tool C, compress the valve spring and remove cotter (1). 2] Remove upper seat (2), outer spring (3), and inner spring (4).
13
SEN00157-05
3] 4]
Remove valve stem seal (5) and lower seat (6). Raise the cylinder head and remove valve (7).
50 Disassembly and assembly
49. Front support Lift up front support (1) temporarily, remove the mounting bolts, and lift off the front support. a The shape and weight of the front support depends on the applicable machines. 4
48. Damper assembly Lift up damper assembly (1) temporarily, remove the 6 mounting bolts (2), and lift off the damper assembly. a The fan drive pulley may be installed. 4
Damper assembly: 40 kg
50. Cam follower assembly 1) Remove the 3 cover mounting bolts and remove cover (1). 2) Remove mounting bolts (3) and cam follower (2).
3)
14
Front support: 65 kg
Remove snap rings (4) and remove lever assembly (5) from shaft (6).
140E-5 Series
50 Disassembly and assembly
51. Front cover 1) Install eyebolts [1] and lift up the front cover temporarily. 2) Remove the mounting bolts and sling front cover (1). Remove the front cover by moving it forward. 4 Front cover: 70 kg
52. Front oil seal Remove front oil seal (1) from the front cover.
SEN00157-05
4)
54. Camshaft 1) Match the holes of cam gear (1) to mounting bolts (2) and remove bolts (2).
2) 53. Fuel supply pump assembly and drive gear 1) Remove nut (1). 2) Set tool P to gear (3). 3) Tighten center bolt [1] of tool P and remove gear (3).
140E-5 Series
Remove pump mounting bolts (4), bracket (5), and fuel supply pump assembly (6). a While supporting the fuel supply pump assembly, remove the mounting bolts.
Sling camshaft (3) temporarily. Pull out the camshaft while turning it so that the cam bushing will not be damaged. 4 Camshaft: 20 kg
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55. Oil pump assembly and sub idler gear 1) Remove oil pump assembly (1). 2) Remove sub idler gear (2).
56. Main idler gear Remove mounting bolt (1) and main idler gear (2).
57. Setting of engine repair stand and underframe 1) Install tool A2 to the cylinder block. Sling the engine and set it to tool A1. 2) Remove the 4 mounting bolts from each of 2 underframes (1) and remove the underframes. a The number of underframes (1) depends on the applicable machines.
50 Disassembly and assembly
58. Piston cooling nozzle Remove the mounting bolts and piston cooling nozzles (1) and (2). a Be sure to remove the piston cooling nozzles before pulling out the piston.
59. Piston and connecting rod assembly a Before removing the piston and connecting rod assembly, measure its end play with dial gauge [1], if necessary.
1)
2) 3) 4) 5)
16
Check the stamped No. of the connecting rod cap. q The cap No. and cylinder No. must be the same. q The cap No. must be stamped on the cam side. a If the No. is not stamped, stamp it before removing the connecting rod. Rotate the crankshaft and bring the piston to be removed to the bottom dead center. Scrub the carbon off the top wall of the cylinder liner with fine sandpaper. Remove connecting rod cap mounting bolts (1). Hit connecting rod cap (2) with a plastic hammer so lightly that the threads of the connecting rod bolts will not be damaged and remove connecting rod cap (2) and connecting rod bearing as a unit.
140E-5 Series
50 Disassembly and assembly
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8)
6)
7)
Push in and remove the piston and connecting rod assembly with a wood bar, etc. from the oil pan side, while supporting piston (6) on the cylinder head side. a Take care not to damage the inside of the cylinder with a corner of the connecting rod. Remove the other piston and connecting rod assemblies according to the above procedure. a Take care not to damage the sliding portions of the pistons and bearings. a Assemble each connecting rod and cap temporarily so that they will not be assembled with other ones and keep them and the bearing together.
Disassemble the piston and connecting rod assembly according to the following procedure. 1] Remove 2 snap rings (3). 2] While supporting connecting rod (4), remove piston pin (5) to disconnect piston (6) and connecting rod.
3] a
Using tool D, remove piston ring (7). Keep the piston, connecting rod, connecting rod bearing, piston rings, and piston pin by cylinder.
60. Crankshaft a Before removing the crankshaft, measure its end play with dial gauge [1], if necessary.
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1) 2)
4)
Remove upper thrust bearing (5).
5)
The No. 7 main cap has lower thrust bearing (3).
Remove upper bearing (6). a Enter the positions of the main cap, main bearing, and thrust bearing on them with paint or attach position tags to them and arrange them by journal No.
Lift off crankshaft (4). a When removing the crankshaft, take care not to hit its sliding surfaces against the cylinder block. 4 Crankshaft: 140 kg
61. Cylinder liner a Before removing the cylinder liner, measure its projection with tool H, if necessary.
Remove mounting bolts (2) of main cap (1). Insert the bolts in the bolt holes of the main cap and remove the cap, while shaking it.
a
3)
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62. Using tool E, remove cylinder liner (1).
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General assembly of engine a a
50 Disassembly and assembly
1
The shapes, quantity, locations, etc. of the parts depend on each applicable machine. Take care. Clean each part carefully, and check it for bruise, flaw, cavity, etc. Make sure each oil or coolant path is through.
Tightening bolts by plastic-region turning angle method a Bolts tightened by plastic-region turning angle method q Cylinder head mounting bolt q Main cap mounting bolt q Connecting rod cap mounting bolt q Flywheel mounting bolt a If the plastic-region turning angle method is applied, the tightened bolts have permanent strain. Accordingly, the allowable number of using times of each bolt is limited. Observe the following precautions. q Before tightening each bolt, measure its stem length and make sure that the result is less than the using limit. If the stem is longer than the using limit, do not reuse it but replace it. q Check each mounting bolt head for punch marks. If there are punch marks more than the specified number, do not reuse it but replace it. 1.
20
2)
Before inserting the cylinder liners, prepare the cylinder block according to the following procedure. 1] Remove the rust and scales from faces A and B with sandpaper, etc. until the machined surfaces are exposed. 2] Polish part R with sandpaper of about No. 60 until it becomes a smooth rounded surface. 3] Polish parts R and h with sandpaper of about No. 60 until they become smooth. If part R is sharp or has burrs, finish it with a scraper or sandpaper. Finish this surface particularly smoothly so that it will not damage the O-ring. 4] If face B is so pitted that it cannot be repaired, replace the cylinder block. 5] If faces A and R are pitted, finish them smoothly. 6] Check the counterbored part and remove burrs. If chips or dust is on face C, the liner does not fit and coolant may leak and the projection of the liner may become improper consequently. a If the counterbored part is drooping, corroded, or pitted, repair it.
Cylinder block 1) Install tool A2 to the cylinder block, and then sling the cylinder block and set it to tool A1. 4 Cylinder block: 390 kg
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50 Disassembly and assembly
2.
Cylinder liner a Replace the O-ring and clevis seal with new ones. 1) Check that the cylinder liner O-ring groove and periphery of the liner are not roughened because of rusting or pitting. If those parts are roughened, replace the cylinder liner. 2) Install clevis seal (1), O-rings (2) and (3) to the cylinder liner. a Check that there are not a burr, dust, etc. in the groove of the liner. a Fit the clevis seal with the chamfered side down. When fitting it, press it against the seal groove all round so that it will not be twisted. a When installing O-rings (2) and (3), check the following. q O-ring (2): There is a yellow point for distinction. q O-ring (3): The whole ring is red. 2 Clevis seal and O-ring: Rubber lubricant (RF-1) a RF-1: DAIDO CHEMICAL INDUSTRY CO., LTD. If RF-1 is not available, apply clean engine oil SAE No. 30. a Since the clevis seal and O-ring are swollen and deteriorated by oil, apply a small amount of oil to them thinly with a brush just before fitting them.
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3)
After fitting the liner O-ring, check it for twist. If it is twisted, correct it with a smooth rod (about 10 mm in diameter).
4)
Apply gasket sealant to the parts of the cylinder block and cylinder liner which will fit to the counterbored parts. a Wipe off dirt and oil with cloth from the contact faces of the counterbored parts of the cylinder block and liner flange. 2 Cylinder block: Gasket sealant (LG-6) q Gasket sealant: 2 – 3 mm in diameter q Overlap (a) of gasket sealant: 6 ± 6 mm a If the applied gasket sealant is left for a long time, its surface becomes hard. Accordingly, install the cylinder block in 50 minutes.
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5) 6)
7)
22
50 Disassembly and assembly
Insert cylinder liner (1) in the cylinder block slowly, taking care not to damage the O-ring. Push in cylinder liner (1) further with both hands. a If the liner does not enter the cylinder smoothly, the O-ring may be broken. In this case, check the cylinder block for burrs. Using tool F, press fit cylinder liner (1) to the cylinder block.
8)
To prevent the gasket sealant from projecting through the clearance between the block and liner after the cylinder head is tightened, tighten the cylinder head temporarily with the used head gasket inserted. a At this time, observe the following tightening torque and tightening order. 3 Temporary tightening torque: 137 – 157 Nm {14 – 16 kgm}
9)
Remove the cylinder head and wipe off the gasket sealant projected from the counterbored part. a Be sure to perform steps 8) and 9) above since the projected gasket sealant can deform the grommet of the head gasket.
10) Using tool H, measure the projection of the cylinder liner. a When measuring the projection of the liner, tighten the liner with a plate so that it will not be lifted by the O-ring. q Projection of liner: 0.07 – 0.15 mm a If the gasket sealant is projected from the fitting parts of the cylinder block and cylinder liner up to the top of the cylinder block, wipe it off.
3.
Crankshaft 1) Fit upper main bearing (6) to the cylinder block, matching the projection of the former to the cut of the latter. a An oil hole is made on the upper main bearing. a Before fitting the bearing, make sure that its back side is free from foreign matter. 2 Inside of bearing: Engine oil (EO30)
2)
Drive the dowel pin so that it will be projected by 2.7 – 3.4 mm from the block end and then install upper thrust bearing (5) to the No. 7 journal. a Install the thrust bearing with the grooved surface on the crankshaft side.
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50 Disassembly and assembly
3)
4)
5)
Sling crankshaft (4) and install it to the cylinder block. a When replacing the crank gear, heat it with a bearing heater (30 A) (Set temperature: 150°C) and fit it just after it is heated. a When installing the crankshaft, take care not to hit its sliding surfaces against the cylinder block. 4 Crankshaft: 140 kg 2 Cylinder block journal: Engine oil (EO30)
Fit the lower main bearing to the main cap, matching the projection of the former to the cut of the latter. a Before fitting the bearing, check that its back side is free from foreign matter. Drive the dowel pin of cap No. 7 so that it will be projected by 2.7 – 3.4 mm from the cap end and then install thrust bearings (3) to both sides. a Install each thrust bearing with the grooved surface on the crankshaft side.
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6)
Make sure that the journal No. stamped at the center of main cap (2) and the journal No. of the cylinder block are the same and then install the main cap. a Install the main cap with the cast letter (F) toward the front of the engine.
7)
Before tightening the main cap mounting bolts, check the following items. If any of the following condition applies, do not reuse that bolt but replace it. q Number of tightening time of bolt: 6 (Number of punch marks on bolt head is 5.) q Length (a) of bolt stem: Min. 176.3 mm
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8)
50 Disassembly and assembly
Tighten main cap mounting bolts (1) according to the following procedure. a Tighten the bolts from the center one to the outer ones in order. 2 Threaded portion of mounting bolt and washer: Engine oil (EO30) 3 Mounting bolt 1st time: 108 – 128 Nm {11 – 13 kgm} 2nd time: 230 – 240 Nm {23.5 – 24.5 kgm} 3rd time: Using tool J, tighten the bolt by 90° (+30°/0).
10) Check that the crankshaft turns smoothly. 11) Measure the end play of the crankshaft with dial gauge [1]. a End play: 0.140 – 0.315 mm a If the end play is out of the standard, correct it. For details, see “Structure, function and maintenance standard”.
4.
a
9)
24
When not using tool J, make marks (b) on the main cap and bolt with paint, then tighten the bolt by 90° (+30°/0). Make punch mark (c) on the mounting bolt head. a When a new bolt is used, do not make a punch mark on its head.
Piston and connecting rod assembly a Select the grade of the piston according to the grade of the cylinder liner. q Set grade (Stamp): S, L q Stamping position Cylinder liner: Top end Piston: Top surface 1) Using tool D, fit piston rings (7) to the piston. a Fit the top ring and second ring to the piston with the stamped mark side up. q Stamp on top ring: 1RS q Stamp on second ring: 2RX a Take the expander out of the oil ring and fit it to the piston first and then fit the oil ring. At this time, check that the expander is fitted to the ring groove perfectly.
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50 Disassembly and assembly
2)
Set the abutment joint of each piston ring as shown in the following figure. a Adjust oil ring so that the joint of the expander will be at 180° to the abutment joint of the oil ring.
3)
Set the piston and connecting rod. a Set the cylinder No. on the head of piston (6) and the cast part No. of connecting rod (4) in the same direction, then insert piston pin (5) to assemble connecting rod (4) and piston (6). Fit snap rings (3) on both sides of the piston pin to secure the piston pin.
4)
5)
6)
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7)
Insert piston and connecting rod assembly (8) in the cylinder block so that the cast part number on the connecting rod will be directed to the front of the engine (the stamped cylinder number will be on the camshaft side). a Referring to step 2), check the abutment joint of each piston ring again. 2 Inside of connecting rod bearing and inside of cylinder: Engine oil (EO30)
8)
Using tool G, reduce the piston ring and push in the piston head with a wood bar, etc. into the cylinder block.
Fit the upper bearing to the connecting rod, matching the projection of the former to the cut of the latter. a Before fitting the bearing, check that its back side is free from foreign matter. Set the crankshaft so that the cylinder to be installed will be at the bottom dead center.
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9)
50 Disassembly and assembly
Before tightening the connecting rod cap mounting bolts, check the following items. If any of the following condition applies, do not reuse that bolt but replace it. q Number of tightening time of bolt: 6 (Number of punch marks on bolt head is 5.) q Length (a) of bolt stem: Min. 95.0 mm
10) Fit lower bearing (9) to the connecting rod cap, matching the projection of the former to the cut of the latter. 12) Tighten connecting rod cap mounting bolts (1) according to the following procedure. 3 Mounting bolt 1st time : 127 ± 4.9 Nm {13 ± 0.5 kgm} 2nd time : Using tool J, tighten the bolt by 90° (+30°/0).
11) Install connecting rod cap (2) to connecting rod (4), matching yellow marks (a) on them to each other. a Before fitting the bearing, check that its back side is free from foreign matter. 2 Inside of connecting rod cap bearing: Engine oil (EO30)
26
a
When not using tool J, make marks (b) on the connecting rod cap, and bolt with paint, then tighten the bolt by 90° (+30°/0).
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13) After tightening the bolt, make a punch mark (c) on its head. a When a new bolt is used, do not make a punch mark on its head.
2)
Install piston cooling nozzles (1) and (2) to each cylinder in order. a Install the piston cooling nozzles having the stamps of (F1) to the front side of the cylinder and install those having 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 hexagonal part of the nozzle for the mounting bolt. 3 Mounting bolt: 59 – 74 Nm {6.0 – 7.5 kgm}
14) Turn the crankshaft to check that it rotates normally. 15) Measure the side clearance of the connecting rod with dial gauge [1]. a Side clearance: 0.100 – 0.274 mm a If the side clearance is out of the standard, correct it. For details, see “Structure, function and maintenance standard”.
6.
5.
Underframe Install underframes (1). a The number of the underframes depends on the applicable machines.
Piston cooling nozzle 1) Rotate the crankshaft and set the No. 1 – No. 3 pistons to the following positions for installation of the piston cooling nozzles of each piston. q Set the No. 1 piston to top: Piston cooling nozzles of the No. 1 and No. 6 pistons can be installed. q Set the No. 2 piston to top: Piston cooling nozzles of the No. 2 and No. 5 pistons can be installed. q Set the No. 3 piston to top: Piston cooling nozzles of the No. 3 and No. 4 pistons can be installed.
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50 Disassembly and assembly
7.
Main idler gear 1) Install bearing (3) and shaft (2) to the outside of main idler gear (1) and install bearing (3) and plate (4) to the inside. a Direct the chamfered side of plate (4) toward the gear. 2) Matching the stamped (A) of the crankshaft gear to that of main idler gear (1), tighten mounting bolt (5). 3 Mounting bolt: 784 ± 44.1 Nm {80 ± 4.5 kgm}
9.
8.
28
Sub idler gear and oil pump assembly 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}
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: Engine oil (EO30)
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50 Disassembly and assembly
2)
Matching the stamped (C) of the camshaft gear to that of the main idler gear, tighten mounting bolt (2). 3 Mounting bolt: 98 – 123 Nm {10 – 12.5 kgm}
10. Cam follower assembly 1) Install 2 lever assemblies (5) to shaft (6). a Insert the cam followers so that the ball end of the shaft will be directed toward the rear of the engine. 2) Install snap rings (4).
3)
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4)
Fit the O-ring and install cover (3). 3 Mounting bolt: 9.8 – 12.7 Nm {1.0 – 1.3 kgm}
11. Fuel supply pump assembly and drive gear 1) Fit the key to the shaft of fuel supply pump assembly (6) and install them to the cylinder block. 2) Tighten mounting bolts (4) and install bracket (5). 2 Mounting bolt: Adhesive (LT-2)
Install cam follower assembly (1), matching it to the dowel pin, and then tighten mounting bolts (2). 3 Mounting bolt: 44.1 – 58.8 Nm {4.5 – 6.0 kgm}
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3)
Install fuel supply pump drive gear (3) to the fuel supply pump shaft and tighten mounting nut (1). a When installing to the fuel supply pump shaft, set stamp (B) of fuel supply pump drive gear (3) to stamp (B) of the main idler gear (circled in the figure). 3 Mounting nut: 176 – 196 Nm {18 – 20 kgm}
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q
q
a
Standard backlash of each gear Position
Range (mm)
A
0.141 – 0.425
B
0.129 – 0.391
C
0.129 – 0.391
D
0.141 – 0.425
E
0.080 – 0.417
F
0.095 – 0.346
G
0.118 – 0.369
Standard end play of each gear Position
Range (mm)
1
0.1 – 0.25
2
0.06 – 0.24
3
0.11 – 0.23
If the end play is out of the standard, correct it. For details, see “Structure, function and maintenance standard”.
12. Measuring backlash and end play a Measure the backlash and end play of each gear with dial gauge [1]. a Install the water pump drive gear and EGR oil pump drive gear temporarily to measure their backlash and end play. a Set the air compressor drive gear (on the right side of the camshaft gear) according to the applicable machines.
13. Removal from engine repair stand 1) Remove the engine from the engine repair stand and set it on stable blocks. 2) Remove the adapter from the engine.
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14. Front cover and front support a The front cover and front support are installed with the same mounting bolts. 1) Fit the gasket and install front cover (1) temporarily, using eyebolt [1]. 4 Front cover: 70 kg
2)
3)
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1)
Set large inside diameter side (a) of plastic inside cylinder (2) to the end of crankshaft (3). a Take care not to mistake the direction of the plastic inside cylinder.
2)
Push the metal ring of front seal (1) evenly as if you are passing over the large inside diameter side of plastic inside cylinder. a Hit the metal ring of front seal with plastic hammer evenly. Do not hit it strongly. After pushing in the seal, remove plastic inside cylinder (2). a When removing the inside cylinder, take care not to damage the seal lip.
Sling and install front support (2) and tighten the mounting bolts. a The shape and weight of the front support depends on the applicable machines. 4 Front support: 65 kg Tighten the front cover mounting bolts permanently.
3)
15. Front oil seal Install front oil seal (1) according to the following procedure. a Before installing the seal, check that the end corners and lip sliding surfaces of the crankshaft and front cover are free from flaw, burr, and rust. a When installing the seal, do not apply oil or grease to the shaft and seal lip. Wipe off the oil from the shaft. a Never remove inside plastic cylinder (2) of the replacement seal before installing the seal.
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4)
50 Disassembly and assembly
Using tool M1, tighten the 3 bolts evenly to press fit seal (3) until the end of tool M1 reaches the end of crankshaft (5). a Tighten tool M1 first until the 55-mm bolts stop and then replace the 55mm bolts with the 35-mm bolts and tighten them. a Seal driving distance (a) from crankshaft: 9.1 – 10.1 mm a When press fitting the seal, take care not to damage the lip of the seal with the tool set etc. a After press fitting the seal, remove the red sealant layer from its periphery. 4) 5)
Fit inner spring (4) and outer spring (3) and then install upper seat (2). Using tool C, compress the valve spring and install valve cotter (1). a Hit the valve stem lightly with a plastic hammer to check that the cotter is fitted to the groove of the valve stem.
16. Damper assembly Matching the dowel pin of damper assembly (1), tighten 6 mounting bolts (2). 3 Mounting bolt: 245 – 309 Nm {25 – 31.5 kgm} a The fan drive pulley may be installed. 6)
Check that the cylinder head mounting face and inside of the cylinder are free from foreign matter and then set cylinder head gasket (1). a When fitting the gasket, check that the grommets are fitted correctly.
17. Cylinder head assembly 1) Using tool Q, press fit valve stem seal (5) until it reaches the valve guide. 2) Install valve (7). 2 Stem of valve: Engine oil (EO30) 3) Install lower seat (6).
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50 Disassembly and assembly
7)
Before tightening the cylinder head mounting bolts, check the following items. If any of the following condition applies, do not reuse that bolt but replace it. q Number of tightening time of bolt: 6 (Number of punch marks on bolt head is 5.) q Length (a) of bolt stem: Short bolt: Min. 170.8 mm Long bolt: Min. 205.8 mm
8)
Install cylinder head assembly (2) and tighten mounting bolts (1) and auxiliary bolts. 2 Mounting bolt: Molybdenum disulfide lubricant (LM-P)
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a
When not using tool J, make marks (a) and (b) on the bolts and head with paint, then tighten the bolts by 90° (+30°/0). a After tightening bolts 1 – 6, tighten bolt 7. 3 Bolt 7: 66.6 ± 7.4 Nm {6.8 ± 0.8 kgm}
3
a
Mounting bolt: 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).
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18. Crosshead Install crosshead (1). a Adjust the crosshead according to the following procedure. 1] Loosen the locknut and return the adjustment screw. 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}
50 Disassembly and assembly
3)
Insert holder (2) in fuel injector (1), then insert them simultaneously, directing the injector connector (5) to the hole to insert the fuel high-pressure pipe. 4) Fit the ball washer to bolt (3) and tighten holder (2) temporarily. 2 Ball washer: Engine oil (EO30) 5) Insert high-pressure pipe sleeve (4) in the hole to insert the fuel high-pressure pipe and fix it temporarily, matching it to injector connector (5). a Tighten the sleeve nut on the common rail side temporarily, too, to prevent the high-pressure pipe from leaning. 6) Tighten holder (2) permanently. a While pulling the high-pressure pipe in the opposite direction to the injector, tighten bolt (3). 3 Holder mounting bolt: 58.8 – 73.5 Nm {6.0 – 7.5 kgm} a After tightening the holder, remove the high-pressure pipe and install the other injectors in order according to the above procedure.
19. Push rod Install push rod (1). a Check that the push rod is in the cam follower.
20. Fuel injector a Check that the inside of the injector sleeve is free from dirt. 1) Referring to step 21, install the common rail temporarily. 2 O-ring: Engine oil (EO30) 2) Fit the gasket and O-ring to the fuel injector.
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21. Common rail and high-pressure pipe k Before installing the high-pressure pipe, check it for the following defects. If there is any of these defects, it can cause fuel leakage. Accordingly, replace the high-pressure pipe. q Check the taper seal of the connecting part (Part (a): Part of 2 mm from the end) for visible lengthwise slit (b) and dent (c). q Check part (d) (end of the taper seal: Part at 2 mm from the end) for stepped-type wear (fatigue) which your nail can feel. 4)
a
1) 2)
3)
Secure common rail (1) temporarily with special bolts (2). Fit O-ring (4) to high-pressure pipe sleeve (3). Matching them to the injector connector, 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) Tighten special bolts (2) permanently. 3 Special bolt: 59 – 74 Nm {6.0 – 7.5 kgm}
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Tighten high-pressure pipe sleeve nuts (5) and (6) permanently with spanner-type torque wrench [1]. Sleeve nut: 39.2 – 49 Nm {4 – 5 kgm} a After finishing the work, check that Oring (4) is not projected from the end of the sleeve.
When installing the high-pressure pipe without removing the fuel injector (for example, when replacing only the high-pressure pipe with new one), follow the procedure below. q Tighten sleeve nut (5) by 2 turns with the hand into the threads of the fuel injector and then tighten it with the spanner. a If sleeve nut (5) does not catch the threads, press its end with a small rod, etc. toward the injector and turn the spanner.
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5)
6) 7)
8) 9) 10) 11) 12)
13)
36
Tighten clamps and brackets (7), (8), (9), (10), (11) and (12) with the hand first, then tighten clamp side permanently. 3 Clamp bolt: 9.8 ± 1.0 Nm {1.0 ± 0.1 kgm} Tighten clamps and brackets (7), (8), (9), (10), (11) and (12) of bracket side permanently. Install covers (13) and (14) to the sleeve nut. a Direct the cut of cover (13) down and direct the cut of cover (14) toward the cylinder block.
Tighten clamps and brackets (15), (16), (17), (18), (19) and (20) with the hand. Tighten clamp (21) and frame (22) with the hand. Tighten clamp (21) permanently. 3 Clamp bolt: 9.8 ± 1.0 Nm {1.0 ± 0.1 kgm} Tighten frame (22) permanently. Tighten clamps and brackets (15), (16), (17), (18), (19) and (20) of clamp side permanently. 3 Clamp bolt: 9.8 ± 1.0 Nm {1.0 ± 0.1 kgm} Tighten clamps and brackets (15), (16), (17), (18), (19) and (20) of bracket side permanently.
50 Disassembly and assembly
22. Rocker arm and shaft assembly Install rocker arm and shaft assembly (1) and tighten mounting bolts (2), (3) and (4). a Note that the lengths of the mounting bolts are different. Mounting bolt (2): Stem length; 120 mm Mounting bolt (3): Stem length; 90 mm Mounting bolt (4): Stem length; 75 mm a Before tightening the mounting bolts, check that the ball of the adjustment screw is fitted to the socket of the push rod. 3 Mounting bolt: 93 – 103 Nm {9.5 – 10.5 kgm}
23. Adjusting valve clearance a Adjust the clearance between the crosshead and rocker arm to the following value. a Valve clearance (when cold) Unit: mm
a 1)
Air intake valve
Exhaust valve
0.35 ± 0.02
0.57 ± 0.02
Rotate the crankshaft and adjust the valve clearance of each cylinder in the firing order of 1 – 5 – 3 – 6 – 2 – 4. Rotate the crankshaft forward and match stamped line of “1.6 TOP” (a) on vibration damper (1) to pointer (2), watching the movement of the valve.
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2)
3)
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Insert thickness gauge I between rocker arm (3) and crosshead (4) and tighten adjustment screw (5) to the degree that the thickness gauge can be moved lightly. Tighten locknut (6) to secure adjustment screw (5). 3 Locknut: 53 – 64.7 Nm {5.4 – 6.6 kgm} a After tightening the locknut, check the valve clearance again.
4
24. Cylinder head cover Fit the O-ring and install cylinder head cover (1). a Since the bolt at the front on the air intake manifold side is also used to secure the wiring harness clamp, tighten it temporarily. 3 Mounting bolt: 29.4 – 34.3 Nm {3.0 – 3.5 kgm}
25. Flywheel housing 1) Install flywheel housing (1). a Apply a string of gasket sealant 1 mm in diameter as shown below. a When installing the housing, take care not to damage the oil seal. 2 Mating face: Gasket sealant (LG-7)
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Threaded portion and seat of bolt: Engine oil (EO30) Flywheel housing: 75 kg
a
Tighten the flywheel housing mounting bolts in the following order in 2 steps. a When tightening the bolts for the 1st time, tighten bolts 1, 4 and 2, 9 twice. 3 Flywheel housing mounting bolt: 1st time: 147 – 235 Nm {15 – 24 kgm} 2nd time: 245 – 309 Nm {25 – 31.5 kgm}
2)
After installing the flywheel housing, 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
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26. Rear oil seal a Check the Teflon seal (Laydown lip seal) by checking the wear of the shaft and replace it with the "standard seal" or "sleeved seal". If the shaft is worn to the degree of luster (If wear which you feel with your finger is less than 10 mm) and does not have any flaw, install "standard seal A". In other cases, install "sleeved seal B". a (8): Plastic inside cylinder which is also used as installation guide. a (7): Sleeve. a Do not remove plastic inside cylinder (8) from rear seal (4) before installing the rear seal. a Handle rear seal (4) and sleeve (7) as an assembly and never separate them from each other. q
50 Disassembly and assembly
1.
Procedure for installing standard seal a When installing rear seal (4), do not apply oil or grease to the shaft and seal lip. 1) Set large inside diameter side (b) of guide (8) of rear seal (4) to the end of crankshaft (6). a Take care extremely not to mistake the direction of the plastic inside cylinder.
Left: Standard seal, Right: Sleeved seal
2)
3)
a a a
38
Push the metal ring of rear seal (4) evenly as if you are passing over the large inside diameter side of plastic inside cylinder. a Hit the metal ring of rear seal with plastic hammer evenly. Do not hit it strongly. After pushing in the seal, remove guide (8). a When removing the inside cylinder, take care not to damage the seal lip.
Clean, degrease, and dry the contact surface against the flywheel housing. Clean, degrease, and dry the seal lip surface (periphery of the crankshaft). Check that the end corners and lip sliding surfaces of the crankshaft are free from flaw, burr, and rust of the housing.
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50 Disassembly and assembly
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2.
4)
Tighten the 4 bolts evenly to press fit rear seal (4) until the end of tool N1 (for press fitting the seal) reaches the end of crankshaft (6). a Tighten tool N1 (for press fitting the seal) first until the bolt without washer stops and then tighten the bolt with 2 washers. a When press fitting the seal, take care not to damage the lip with the tool set etc. a After press fitting the seal, remove the red sealant layer from its periphery.
140E-5 Series
Procedure for installing sleeved seal a When installing the rear seal, do not apply oil or grease to the shaft, inside cylinder surface (C) of the sleeve (7) and seal lip. 1) Set sleeve and rear seal assembly (9) to tool N2 (for fitting the sleeved seal). 2 Sleeve inside cylinder surface (C): Gasket sealant (LG-7)
2)
Set sleeve (7) of the rear seal to the end of crankshaft (6) and tighten the 4 bolts evenly to press fit sleeve and rear seal assembly (9) until the end of tool N2 reaches the end of crankshaft (6). a Tighten tool N2 (for press fitting the sleeved seal) until the bolt with washer stops.
3)
Remove tool N2 (for press fitting the sleeved seal) and install tool N3 (for press fitting the seal).
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4)
Tighten the 4 bolts evenly to press fit sleeve and rear seal assembly (9) until the end of tool N3 reaches the end of crankshaft (6). a Tighten tool N3 (for press fitting the seal) first until the bolt without washer stops and then tighten the bolt with 2 washers. a After press fitting the seal, remove the red sealant layer from its periphery. a Rear seal driving depth: 13.2 ± 0.2 mm from end of crankshaft
50 Disassembly and assembly
2nd time: Using tool J, tighten the bolts by 90° (+30°/0) in the order of (1) – (8).
a
a a a
When not using tool J, make marks (f) on the flywheel with paint, then tighten the bolts by 90° (+30°/0) in the order of (1) – (8). After tightening each bolt, make punch mark (g) on its head to show the number of tightening times. When a new bolt is used, do not make a punch mark on its head. If there are 5 punch marks on the head of a bolt, do not reuse that bolt but replace it.
27. Flywheel Using eyebolt [1] (12 mm, P = 1.75), sling flywheel (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 contact 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. 0.13 mm q Facial runout: Max. 0.20 mm
a
Tighten the mounting bolts according to the following procedure. 3 Flywheel mounting bolt: 1st time: 118 ± 4.9 Nm {12 ± 0.5 kgm}
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50 Disassembly and assembly
28. Suction pipe Install the O-ring to oil pump and install suction tube (1), then install bracket (2) to the cylinder block.
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2] 3]
Install holder (3) to connector (1) and push in connector (1) to the position where the O-ring is fitted. Fix holder (3) with mounting bolt (4).
4] 29. Oil pan 1) Install the gasket and push up oil pan (1) with a pallet lift, etc. and tighten the mounting bolts. a Apply gasket sealant to the joint part. 2Joint part: Gasket sealant (LG-7) 2) Connect the level sensor connector.
Insert spring clamp (8) in the injector connector and secure wiring harness clamp (9) with bolt (10). 5] Install wiring harness terminal (6) to fuel injector (5) and tighten 2 nuts (7). a Stretch the wiring harness without slack and press it against the injector body. a Tighten the nuts alternately. 3 Terminal nut: 2 ± 0.2 Nm {0.2 ± 0.02 kgm}
30. Engine wiring harness assembly and sensor connector 1) Install the engine wiring harness assembly. 2) Install the injector wiring harness assembly. a Since the wiring harness assembly fitted with the O-ring is difficult to insert from inside, install it according to the following procedure. 1] Remove O-ring (2) from connector (1) and pass the wiring harness out from inside of the cylinder head and then fit the O-ring. 2 O-ring: Engine oil (EO30)
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3) 4)
Install bracket (11). Connect NE sensor connector NE (13), and atmospheric pressure sensor connector PAMB (14).
5)
Install bracket (15) and install the clamps of wiring harnesses (16) and (17). Connect coolant temperature sensor connector TWTR (18).
6)
31. EGR oil pump assembly Install EGR oil pump assembly (1).
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50 Disassembly and assembly
32. Piping and wiring of supply pump 1) Install bracket (1). 2) Install high-pressure pipes (2) and (3). 3 Sleeve nut of tube: (Pump side) 39.2 – 49 Nm {4 – 5 kgm} (Common rail side) 39.2 – 58.8 Nm {4 – 6 kgm} 3) Install the splash prevention cover and install clamps (4), (5), and (6). a Direct the cut of the splash prevention cover on the supply pump side toward the block and direct that on the common rail side down. a Tighten clamps (4), (5) and (6) with the hand first, and then tighten them permanen tly. (Tightening order: (4)o(5)o(6)) 3 Clamping bolt: 9.8 ± 1.0 Nm {1.0 ± 0.1 kgm} 4) Install fuel tubes (7) and (8). 3 Tube joint bolt: q Tube (7) (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} q Tube (8) (Pump side) 14.8 – 19.6 Nm {1.5 – 2.0 kgm} 5) Install oil tubes (9), (10) and (11). 3 Joint bolt of tube (10): (Pump side) 7.9 – 12.7 Nm {0.8 – 1.3 kgm} 3 Joint bolt of tubes (9) and (10): (Cylinder block side) 9.8 – 12.7 Nm {1.0 – 1.3 kgm} 3 Sleeve nut of tube (11): 43 – 47 Nm {4.4 – 4.8 kgm} 6) Tighten clamps (12), (13), (14), (15), (16) and (17) with the hand first, and then tighten them permanently. 3 Mounting bolt of clamps (14), (15) and (16): 9.8 ± 1 Nm {1.0 ± 0.1 kgm}
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50 Disassembly and assembly
7)
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Connect sensor connectors PCV2 (18), PCV1 (19) and G (20).
33. Breather remote tube and corrosion resistor tube 1) Install breather remote tube (1). 2) Install corrosion resistor tubes (2) and (3) temporarily. a Corrosion resistor is not set for some models.
34. Engine controller cooler 1) Install the O-ring and plate (1). 2) Install engine controller cooler (2) and fuel hose (3). a Install the hose on the engine controller cooler outlet side when installing the fuel filter head. a Fuel hose (3) may not be installed. 3) Connect fuel pressure sensor connector PFUEL (4) and engine oil pressure sensor connector POIL (5).
140E-5 Series
35. Engine controller Install engine controller (2) and connect connector (1).
36. Air intake manifold 1) Fit the gasket and sling and install air intake manifold (1) and then tighten the mounting bolts in the following order. a Fit the gasket with the UP mark up. 4 Air intake manifold: 45 kg 3 Mounting bolt: 58.8 – 73.5 Nm {6.0 – 7.5 kgm}
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2) 3)
Install brackets (7), (8), (9), (10) and (11). Install brackets (2), (3), (4), (5) and (6).
4)
Tighten clamp (12) of the high-pressure pipe. 3 Clamp bolt: 9.8 ± 1.0 Nm {1.0 ± 0.1 kgm} Tighten corrosion resistor tube clamp (13) and wiring harness clamp (14) temporarily. a The type of the corrosion resistor depends on the applicable machines. a Corrosion resistor is not set for some models. Install the clamps of sensor connectors TFUEL (15), TIM (16), PIM (17) and wiring harness (18). Install fuel tube (19). 3 Joint bolt: (Head side) 9.8 – 12.7 Nm {1.0 – 1.3 kgm} (Block side) 19.6 – 29.4 Nm {2.0 – 3.0 kgm}
5)
6) 7)
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50 Disassembly and assembly
37. Air intake connector assembly 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.)
3) 4)
5)
Fit the gasket and install air intake connector (3) to the air intake manifold and joint housing. Install EGR inlet pressure sensor PEVA (1). Reference: EGR inlet pressure sensor is applied to only machines Serial No. up to 530896. Install the clamp of wiring harness (2).
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50 Disassembly and assembly
38. Corrosion resistor head, fuel filter head, and priming pump a The type of the corrosion resistor head and fuel filter head depends on the applicable machines. a Corrosion resistor is not set for some models. 1) Install corrosion resistor head (10), fuel filter head (11), priming pump (12) and bracket as a unit. 2) Connect tubes (9) and (8) to the corrosion resistor head and then permanently tighten the tube where was tightened temporarily in step 33-2). a Tighten the clamp on the cylinder block side, too. 3 Tube joint bolt: 24.5 – 34.3 Nm {2.5 – 3.5 kgm} 3) Install fuel tube (3). 3 Tube joint bolt: (Pump side) 14.8 – 19.6 Nm {1.5 – 2.0 kgm} (Filter side) 24.5 – 34.3 Nm {2.5 – 3.5 kgm} 4) Install fuel tube (2) between the filter and cooling plate. 3 Tube joint bolt (Filter side): 24.5 – 34.3 Nm {2.5 – 3.5 kgm} 5) Install fuel tube (1). 3 Tube joint bolt (Pump side): 14.8 – 19.6 Nm {1.5 – 2.0 kgm} 6) Install breather tube (4). 7) Install the clamp of wiring harness (5).
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40. Oil filter head a The type of the oil filter head depends on the applicable machines. 1) Install oil filter head (3). 2) Fit the O-ring and install oil tubes (2) and (1).
41. Oil filler and controller cover 1) Fit the O-ring, install oil filler (2) and tighten the clamp. a The position of the oil filler depends on the applicable machines. 2) Install controller cover (1).
39. Pre-fuel filter head 1) Install pre-fuel filter head (2) and bracket (3) as a unit. 2) Install fuel tube (1). 3 Fuel tube joint bolt (Filter side): 43 – 47 Nm {4.4 – 4.8 kgm} a The type of the pre-fuel filter head depends on the applicable machines.
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50 Disassembly and assembly
42. Oil filter, fuel filter and corrosion resistor 1) Install oil drain tube (5) of the EGR valve and bypass valve. 2) Install corrosion resistor (4), main fuel filter (3), pre-fuel filter (2) and oil filter (1). a Corrosion resistor is not set for some models. a Pre-fuel filter (2) may not be installed.
2)
Install bypass tube (4) fitted with thermostat (3) and O-ring to thermostat housing (2).
3)
Fit the gasket and install thermostat assembly (5). Insert bypass tube (4) in the water pump assembly and install snap ring (6). Tighten the water pump assembly mounting bolts permanently. Fit the gasket and install tubes (7) and (8). Install alternator drive pulley (9).
43. Oil cooler assembly Using eyebolts [1] and guide bolt [2], fit the gasket, install oil cooler assembly (1) and tighten the 16 mounting bolts. 4
Oil cooler assembly: 35 kg
4) 5) 6) 7)
44. Water pump assembly and thermostat assembly 1) Fit the O-ring, install water pump assembly (1) and tighten the mounting bolts temporarily. a The mounting bolts are also used to secure the front cover.
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50 Disassembly and assembly
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45. Alternator assembly 1) Install the V-belts to the pulley of alternator assembly (9) and tighten mounting bolt (4) and clamping bolt (5) temporarily. 2) Adjust the belt tension with V-belt tension adjustment nut (7) and tighten mounting bolt (4) and clamping bolt (5) permanently. 3) Check the belt tension and tighten tension adjustment nut (7) and locknut (6). 4) Install wiring harness terminals B (1) and R (2). 5) Install cover (3).
47. Turbocharger assembly 1) Fit the gasket and install tube (8). 2) Fit the gasket and install air inlet pipe and turbocharger assembly (7). 4 Air inlet pipe and turbocharger assembly: 30 kg 3 Mounting nut: 44.1 – 49 Nm {4.5 – 5.0 kgm}
46. Exhaust manifold 1) Apply heat-resistant sealant to the mating portions of exhaust manifold (between ports No. 2 and No. 3 and between ports No. 4 and No. 5). 2 Mating portion: Heat-resistant sealant (Holtz MH 705) 2) Fit the gasket and sling and install exhaust manifold and then tighten the mounting bolts in the following order. 4 Exhaust manifold: 25 kg a Tighten the 3 bolts of (1) – (3) temporarily first in the numerical order, and tighten the bolts (4) – (24) temporarily in the numerical order. Then, tighten all the bolts again to the specified torque in the numerical order. 2 Mounting bolt: Seizure prevention compound (LC-G) 3 Mounting bolt: 58.8 – 73.5 Nm {6 – 7.5 kgm}
140E-5 Series
3)
4)
Fit the gasket and install lubrication tube (6) and 4 clamps (5). 3 Tube joint bolt: 24.5 – 34.3 Nm {2.5 – 3.5 kgm} Install wiring harness (4).
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5) 6)
Fit the gasket and install turbocharger oil drain tube (2). Install exhaust connector (3) and heat insulation cover (1).
50 Disassembly and assembly
2) 3)
4)
5) 6)
Install bracket (8). Fit the O-ring and the gasket and install EGR cooler coolant inlet tube (10). 3 Rubber hose: (Nut of tube clamp U-bolt) 10.8 – 26.5 Nm {1.1 – 2.7 kgm} 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} Install air vent tube (7). 3 Joint bolt: 19.6 – 29.4 Nm {2.0 – 3.0 kgm} Install turbocharger drain tube clamps (6).
48. EGR valve bracket Fit the gasket to the joint housing and sling and install bracket (1). 4
Bracket: 20 kg
7)
8)
Fit the gasket and O-ring and install EGR cooler coolant outlet tube (4) and bracket (5). 3 Nut of clamp U-bolt: 10.8 – 26.5 Nm {1.1 – 2.7 kgm} Install brackets (1), (2) and stay (3).
49. Bracket Install exhaust manifold cover bracket (12). 50. EGR cooler assembly 1) Install EGR cooler assembly (11) with the 4 bolts.
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51. EGR tube 1) Fit the gasket and install EGR tube (2). 3 Mounting bolt on EGR cooler side: 44.1 – 53.9 Nm {4.5 – 5.5 kgm} 2) Fit the gasket and install EGR inlet pressure sensor tube (1). Reference: EGR inlet pressure sensor is applied to only machines Serial No. up to 530896.
3)
Connect wiring harness connectors EGR (2) and SEGR (1) and install the clamp.
52. Bypass tube 1) Fit the gasket and install bypass tube (4). 2) Install brackets (3), (2) and (1).
54. Bypass valve assembly 1) Fit the gasket and install bypass valve assembly (10) with bolts (9) and (8). 3 Mounting bolt (9): 44.1 – 53.9 Nm {4.5 – 5.5 kgm} 2) Install tubes (7) and (6). 3 Tube sleeve nut: 24 – 27 Nm {2.4 – 2.8 kgm} 3) Install clamps (11), (5) and (3).
53. EGR valve assembly 1) Fit the gasket and install EGR valve assembly (7) with bolts (6) and (5). 3 Mounting bolt (6): 44.1 – 53.9 Nm {4.5 – 5.5 kgm} 2) Install tubes (4) and (3). 3 Tube sleeve nut: 24 – 27 Nm {2.4 – 2.8 kgm}
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4)
Connect wiring harness connectors BP (2) and SBP (1) and install the clamp.
55. Bracket and clamp 1) Install brackets (4), (3) and (2). 2) Install clamp (1).
56. Bracket Install brackets (3), (2) and (1).
50
50 Disassembly and assembly
57. Bracket and tube clamp 1) Install brackets (7), (6) and (5). 2) Install clamps (4), (3), (2) and (1).
58. EGR cover 1) Install covers (7), (6), (5) and (4). a Cover (6) may not be installed.
2)
Install covers (3), (2) and (1).
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50 Disassembly and assembly
59. Starting motor assembly 1) Fit the gasket and install starting motor assembly (4) with bolts (3). 2) Install wiring harness (1) and alternator connector terminal R (2).
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61. Tightening torque for sensor If a sensor is replaced, tighten the new sensor to the following torque. a The engine speed sensor may not be installed. Sensor name NE
60. Air cleaner bracket and wiring harness 1) Install air cleaner bracket (2). a The type of the bracket depends on the applicable machines. 4 Air cleaner bracket: 30 kg 2) Install wiring harness clamp (1).
3)
Tightening torque 4.9 – 7.9 Nm {0.5 – 0.8 kgm}
Engine speed
69 – 74 Nm {7 – 7.5 kgm} (Locknut)
Fuel temperature
23 ± 3 Nm {2.3 ± 0.3 kgm}
Boost pressure
23 ± 3 Nm {2.3 ± 0.3 kgm}
Boost temperature
23 ± 3 Nm {2.3 ± 0.3 kgm}
Coolant temperature
23 ± 3 Nm {2.3 ± 0.3 kgm}
EGR inlet pressure (*)
23 ± 3 Nm {2.3 ± 0.3 kgm}
Engine oil pressure
23 ± 3 Nm {2.3 ± 0.3 kgm}
Atmospheric pressure
7.3 – 12.7 Nm {0.7 – 1.3 kgm} (Big bolt) 4.1 – 9.5 Nm {0.4 – 1.0 kgm} (Small bolt)
Fuel pressure
Never disassemble.
(*): Reference: EGR inlet pressure sensor is applied to only machines Serial No. up to 530896. 62. Checking for fuel leakage a If fuel supply pump (2), common rail (1), or high-pressure pipe is removed and installed, after assembling the engine, check for fuel leakage according to the following procedure.
After assembling, check the installing condition of the wiring harness clamp.
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SEN00157-05 a 1)
2) 3)
4) 5)
6) 7)
8)
9)
52
50 Disassembly and assembly
Clean and degrease the engine and the parts around it in advance so that you can test it easily for fuel leakage. Spray color checker (developer) over the fuel supply pump, common rail, fuel injector, and joints of the high-pressure piping. Run the engine at speed below 1,000 rpm and stop it after its speed is stabilized. Check the fuel piping and devices for fuel leakage. a Check mainly around the high-pressure circuit parts coated with the color checker for fuel leakage. a If any fuel leakage is detected, repair it and check again from step 2). Run the engine at low idle. Check the fuel piping and devices for fuel leakage. a Check mainly around the high-pressure circuit parts coated with the color checker for fuel leakage. a If any fuel leakage is detected, repair it and check again from step 2). Run the engine at high idle. Check the fuel piping and devices for fuel leakage. a Check mainly around the high-pressure circuit parts coated with the color checker for fuel leakage. a If any fuel leakage is detected, repair it and check again from step 2). Run the engine at high idle and load it. a When checking while the components to be checked are mounted on the machine, stall the torque converter or relieve the hydraulic pump. Check the fuel piping and devices for fuel leakage. a Check mainly around the high-pressure circuit parts coated with the color checker for fuel leakage. a If any fuel leakage is detected, repair it and check again from step 2). a If no fuel leakage is detected, check is completed.
140E-5 Series
50 Disassembly and assembly
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KOMATSU 140E-5 Series engine Form No. SEN00157-05
© 2011 KOMATSU All Rights Reserved Printed in Japan 10-11
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ENGINE 1SHOP MANUAL
140E-5 Series
50 Disassembly and assembly Disassembly and assembly, Part 2 (EGR-less) Disassembly and assembly, Part 2 (EGR-less) .............................................................................................. 2 General disassembly of engine............................................................................................................ 2 General assembly of engine .............................................................................................................. 18
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50 Disassembly and assembly
Disassembly and assembly, Part 2 (EGR-less)
1
General disassembly of engine 1 a
The shapes, quantity, locations, etc. of the parts depend on each applicable machine. Take care.
1.
Preparation work Before disassembling the engine, check its parts for cracking, damage, etc. and clean it generally and carefully for accurate inspection of its parts and quick disassembly and assembly. a Before cleaning the engine, carefully seal or remove the openings, electric parts, and wiring connectors so that water will not enter them.
2.
Drain the engine coolant and engine oil. a The quantity of the oil depends on the applicable machines. 6
2
Air cleaner bracket 1) Disconnect wiring harness clamp (1). 2) Remove air cleaner bracket (2). a The type of the bracket depends on the applicable machines. 4 Air cleaner bracket: 30 kg
5.
Heat insulation cover 1) Remove covers (1), (2), (3), (4) and (5).
Setting engine assembly 1) Prepare stable engine stands (Blocks [1]) and place the engine assembly on them so that it will not tip over. a The weight depends on the applicable machines. 4 Engine assembly: 1,900 kg
2)
3.
4.
Engine oil: Approx. 53 l
Starting motor assembly 1) Disconnect wiring harness (1) and connector (2). 2) Remove 3 mounting bolts (3) and remove starting motor assembly (4).
140E-5 Series
50 Disassembly and assembly
6.
Bracket Remove brackets (1) and (2), stay (3), brackets (4) and (5).
7.
Front plate Remove front plate (1). 4
8.
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Remove wiring harness (3) and turbocharger lubrication tube clamp (4) and remove turbocharger lubrication tube (5).
3)
Sling turbocharger assembly (6) and exhaust connector (7). Remove the mounting nuts to remove the turbocharger and connector assembly. 4 Turbocharger and intake connector assembly: 40 kg
4)
Bracket: 20 kg
Turbocharger assembly 1) Remove heat insulation cover (1) and oil drain tube (2).
2)
9.
Exhaust manifold Remove the 24 mounting bolts and exhaust manifold (1). 4
140E-5 Series
Exhaust manifold: 25 kg
3
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10. Alternately assembly 1) Disconnect terminal B (1) and terminal R (2). 2) Remove cover (3). 3) Loosen alternator mounting bolt (4) and clamping bolt (5). 4) Loosen locknut (6) and tension adjustment nut (7) and remove V-belt (8). 5) Remove mounting bolt (4) and clamping bolt (5) and remove alternator assembly (9).
50 Disassembly and assembly
12. Water pump assembly 1) Remove alternator drive pulley (1). 2) Remove tubes (2) and (3). 3) Remove water pump assembly (4).
13. Oil cooler assembly 1) Using eyebolts [1], sling the oil cooler assembly temporarily. 2) Remove the 16 mounting bolts and oil cooler assembly (1). 4 Oil cooler assembly: 35 kg 11. Thermostat assembly 1) Remove tube (1) 2) Remove snap ring (2) and push bypass tube (3) into the thermostat case. 3) Remove mounting bolts and thermostat assembly (4).
4
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50 Disassembly and assembly
14. Corrosion resistor, oil filter and fuel filter 1) Remove corrosion resistor. 2) Remove oil filters (1) and main fuel filters (2). a The locations of the fuel filter and oil filter may be different from the photo, depending on the applicable machine. a Corrosion resistor is not set for some models.
15. Controller cover and oil filler head 1) Remove controller cover (1). 2) Remove oil filter head (2). a The type of the filter head depends on the applicable machines. 3) Remove oil tubes (3) and (4) and the block on the cylinder block side as a unit.
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16. Fuel filter head 1) Remove fuel tube clamp (1), then remove fuel tubes (2) and (3). 2) Remove fuel tube (4). 3) Remove fuel filter head (5).
17. Plates, electric priming pump cover and oil filler a Manual priming pump is set for some models. (See the procedure of "with EGR" ) 1) Remove plates (1), (2) and (3). 2) Remove electric priming pump cover (4). 3) Remove the clamp and oil filler (5).
18. Air bleeding valve and oil filler support bracket 1) Remove fuel tube (1). 2) Remove air bleeding valve plate (2) and oil filler support bracket (3).
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19. Electric priming pump a Electric priming pump is not set for some models. 1) Remove joint bolts (1) and fuel tube (2). 2) Remove joint bolt (3) and fuel tube (4). 3) Remove joint bolts (5) and (6) and fuel tube (7). 4) Remove fuel tube sleeve nut (8). 5) Remove the all mounting bolts and remove electric priming pump (9) and bracket (10) together.
50 Disassembly and assembly
2)
Remove high-pressure mounting bolts (7).
3)
Remove the mounting bolts and remove air intake connector (1) and joint housing (8) together. 4 Air intake connector assembly: 40 kg
a
pipe
bracket
When replacing air heater remove connector (10).
(9),
20. Air intake connector assembly 1) Remove clamp mounting bolts (2), (3), (4) and (5) from air intake connector (1) and remove wiring harness (6).
21. Air intake manifold 1) Sling the air intake manifold temporarily. 2) Disconnect the clamps of connectors TFUEL (1), TIM (2), PIM (3), and wiring harness (4).
6
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50 Disassembly and assembly
3)
4) 5)
Remove wiring harness clamp (5) and high-pressure pipe clamp (6).
Remove wiring harness clamps (7), (8), (9), (10) and (11) at the top of the air intake manifold. Remove fuel tube (12).
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22. Engine controller Disconnect connector (1) and remove engine controller (2).
23. Engine controller cooler 1) Disconnect fuel hose (1). a Fuel hose (1) may not be installed. 2) Remove engine controller cooler (2). 24. Plate Remove plate (3).
6) 7)
Disconnect clamps (13), (14), (15), (16), (17), and (18) of the high-pressure pipe. Remove the mounting bolts and air intake manifold (19). 4 Air intake manifold: 45 kg
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50 Disassembly and assembly
25. Common rail and high-pressure pipe a Before removing the high-pressure pipe, loosen all of the clamps, brackets, and sleeve nuts to give the high-pressure pipe freedom. 1) Remove bracket (1).
2) 3) 4)
5)
Remove 6 cylinder head covers (3). a At this time, the clamp of wiring harness (4) comes off. Remove clamps (5), (6), (7), (8), (9), (10), and (11). Remove all the splash prevention covers of the high-pressure pipe. a When removing the cylinder head cover, remove the high-pressure pipe covers on the injector side, too. Remove 6 high-pressure pipes (12) and 2 high-pressure pipes (13). a Remove 6 high-pressure pipes (12) in the order of No. 1, No. 6, No. 5, No. 4, No. 3, and No. 2.
26. Wiring and piping of fuel supply pump assembly 1) Disconnect sensor connectors PCV1 (1), PCV2 (2), and G (3). 2) Remove level gauge tube (4). 3) Remove clamps (5), (6), (7), (8), (9), and (10). 4) Remove oil tube (11). 5) Remove fuel tubes (12), (13), (14) and (15). a Before removing the supply pump unit, remove the front cover.
27. Blow-by tube Remove breather remote tube (1).
6) 7) 8)
8
Disconnect fuel pressure sensor connector PFUEL (15) and POIL (16). Remove clamp (17) and the eye joint of tube (18) on the common rail side. Remove special bolts (19) and remove common rail (20).
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28. Wiring harness assembly and sensor connector 1) Disconnect the clamps of coolant temperature sensor connector TWTR (1) and wiring harnesses (2) and (3) and remove bracket (4).
2) 3)
Disconnect the connectors of Ne sensor NE (6), and atmospheric pressure sensor PAMB (7). Remove bracket (8).
5) 4)
Remove 6 injector connectors (9) and remove the wiring harness assembly.
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a
Move lock [1] of the housing of connector (6) in the direction of the arrow, push down lock [2], and pull out connector (6).
a
Move lock [1] of the housing of connector (7) in the direction of the arrow, push down lock [2], and pull out connector (7).
Disconnect the injector connector according to the following procedure. 1] Apply flat-head screwdriver [1] to the stepped part (part (a)). 2] While pressing stopper (1a), move flat-head screwdriver [1] in direction (X) to disconnect the connector.
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29. Oil pan 1) Move the blocks which are supporting the engine to positions where you can remove the oil pan mounting bolts. 2) While supporting oil pan (1) on a pallet lift, etc., remove the mounting bolts and oil pan (1).
30. Suction tube Remove bracket (1) and suction tube (2).
50 Disassembly and assembly
31. Flywheel 1) Using sling [1], lift up flywheel (1) temporarily. 2) Remove the 8 mounting bolts and lift off the flywheel. a Take care that the flywheel will not contact the Ne sensor on the back side. 4 Flywheel: 65 kg
32. Flywheel housing Lift up housing (1) temporarily and remove the mounting bolts and the housing. 4
a
a
10
After removing the suction tube, sling the engine. Set stable blocks at the front, rear, right, and left under the cylinder block and place the engine on them. Arrange the above blocks so that you can rotate the crankshaft.
Housing: 75 kg
33. Rear oil seal Remove rear oil seal (1) from the flywheel housing.
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34. Head cover Remove the mounting bolts and each head cover (1). a If the head cover was removed when the high-pressure pipe was removed and has not been installed, skip this step.
35. Rocker arm and shaft assembly Remove the 3 mounting bolts and rocker arm and shaft assembly (1). a Loosen locknut (3) and loosen adjustment screw (4) fully so that the valve spring tension will not be applied the rocker arm and rocker shaft assembly mounting bolts when the rocker arm and rocker shaft assembly is removed.
6)
Remove holder (8) of fuel injector (1).
7)
Insert a small L-bar [2] under connector (9) of fuel injector (1) and pry out fuel injector (1) slowly. a Do not grip the solenoid valve at the top of the injector to pull off the injector.
36. Fuel injector 1) Remove 2 nuts (2) of the solenoid valve of fuel injector (1). a Loosen nuts (2) alternately. 2) Pull out spring clamp (3). 3) Remove the bolt of clamp (4). 4) Remove bolt (7) and holder (6). 5) Push in connector (5) and remove the injector wiring harness. a Connector (5) has an O-ring.
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37. Push rod Remove push rod (1).
38. Cylinder head assembly and crosshead 1) Remove crosshead (1). 2) Remove mounting bolts (2), auxiliary bolts, and cylinder head assembly (3). 3) Remove each cylinder head gasket.
4)
Disassemble the cylinder head assembly according to the following procedure. 1] Using tool C, compress the valve spring and remove cotter (1). 2] Remove upper seat (2), outer spring (3), and inner spring (4).
3]
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50 Disassembly and assembly
4]
Raise the cylinder head and remove valve (7).
39. Damper assembly Lift up damper assembly (1) temporarily, remove the 6 mounting bolts (2), and lift off the damper assembly. a The fan drive pulley may be installed. 4 Damper assembly: 40 kg
40. Front support Lift up front support (1) temporarily, remove the mounting bolts, and lift off the front support. a The shape and weight of the front support depends on the applicable machines. 4 Front support: 65 kg
Remove valve stem seal (5) and lower seat (6).
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50 Disassembly and assembly
41. Cam follower assembly 1) Remove the 3 cover mounting bolts and remove cover (1). 2) Remove mounting bolts (3) and cam follower (2).
3)
Remove snap rings (4) and remove lever assembly (5) from shaft (6).
42. Front cover 1) Install eyebolts [1] and lift up the front cover temporarily. 2) Remove the mounting bolts of front cover (1) and sling the front cover. Remove the front cover by moving it forward. 4 Front cover: 70 kg
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43. Front oil seal Remove front oil seal (1) from the front cover.
44. Fuel supply pump assembly and drive gear 1) Remove nut (1). 2) Set tool P to gear (3). 3) Tighten center bolt [1] of tool P and remove gear (3).
4)
Remove pump mounting bolts (4), bracket (5), and fuel supply pump assembly (6). a While supporting the fuel supply pump assembly, remove the mounting bolts.
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50 Disassembly and assembly
45. Camshaft 1) Match the holes of cam gear (1) to mounting bolts (2) and remove bolts (2).
2)
Sling camshaft (3) temporarily. Pull out the camshaft while turning it so that the cam bushing will not be damaged. 4 Camshaft: 20 kg
46. Oil pump assembly and sub idler gear 1) Remove oil pump assembly (1). 2) Remove sub idler gear (2).
48. Setting of engine repair stand and underframe 1) Install tool A2 to the cylinder block. Sling the engine and set it to tool A1. 2) Remove the 4 mounting bolts from each of 2 underframes (1) and remove the underframes. a The number of underframes (1) depends on the applicable machines.
49. Piston cooling nozzle Remove the mounting bolts and piston cooling nozzles (1) and (2). a Be sure to remove the piston cooling nozzles before pulling out the piston.
47. Main idler gear Remove mounting bolt (1) and main idler gear (2).
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50 Disassembly and assembly
50. Piston and connecting rod assembly a Before removing the piston and connecting rod assembly, measure its end play with dial gauge [1], if necessary.
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6)
7)
1)
2) 3) 4) 5)
Check the stamped No. of the connecting rod cap. q The cap No. and cylinder No. must be the same. q The cap No. must be stamped on the cam side. a If the No. is not stamped, stamp it before removing the connecting rod. Rotate the crankshaft and bring the piston to be removed to the bottom dead center. Scrub the carbon off the top wall of the cylinder liner with fine sandpaper. Remove connecting rod cap mounting bolts (1). Hit connecting rod cap (2) with a plastic hammer so lightly that the threads of the connecting rod bolts will not be damaged and remove connecting rod cap (2) and connecting rod bearing as a unit.
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8)
Push in and remove the piston and connecting rod assembly with a wood bar, etc. from the oil pan side, while supporting piston (6) on the cylinder head side. a Take care not to damage the inside of the cylinder with a corner of the connecting rod. Remove the other piston and connecting rod assemblies according to the above procedure. a Take care not to damage the sliding portions of the pistons and bearings. a Assemble each connecting rod and cap temporarily so that they will not be assembled with other ones and keep them and the bearing together.
Disassemble the piston and connecting rod assembly according to the following procedure. 1] Remove 2 snap rings (3). 2] While supporting connecting rod (4), remove piston pin (5) to disconnect piston (6) and connecting rod.
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3] a
50 Disassembly and assembly a
Using tool D, remove piston ring (7). Keep the piston, connecting rod, connecting rod bearing, piston rings, and piston pin by cylinder.
3)
Lift off crankshaft (4). a When removing the crankshaft, take care not to hit its sliding surfaces against the cylinder block. 4 Crankshaft: 140 kg
4)
Remove upper thrust bearing (5).
51. Crankshaft a Before removing the crankshaft, measure its end play with dial gauge [1], if necessary.
1) 2)
16
Remove mounting bolts (2) of main cap (1). Insert the bolts in the bolt holes of the main cap and remove the cap, while shaking it.
The No. 7 main cap has lower thrust bearing (3).
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5)
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Remove upper bearing (6). a Enter the positions of the main cap, main bearing, and thrust bearing on them with paint or attach position tags to them and arrange them by journal No.
52. Cylinder liner a Before removing the cylinder liner, measure its projection with tool H, if necessary.
53. Using tool E, remove cylinder liner (1).
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General assembly of engine a a
50 Disassembly and assembly
1
The shapes, quantity, locations, etc. of the parts depend on each applicable machine. Take care. Clean each part carefully, and check it for bruise, flaw, cavity, etc. Make sure each oil or coolant path is through.
Tightening bolts by plastic-region turning angle method a Bolts tightened by plastic-region turning angle method q Cylinder head mounting bolt q Main cap mounting bolt q Connecting rod cap mounting bolt q Flywheel mounting bolt a If the plastic-region turning angle method is applied, the tightened bolts have permanent strain. Accordingly, the allowable number of using times of each bolt is limited. Observe the following precautions. q Before tightening each bolt, measure its stem length and make sure that the result is less than the using limit. If the stem is longer than the using limit, do not reuse it but replace it. q Check each mounting bolt head for punch marks. If there are punch marks more than the specified number, do not reuse it but replace it. 1.
18
2)
Before inserting the cylinder liners, prepare the cylinder block according to the following procedure. 1] Remove the rust and scales from faces A and B with sandpaper, etc. until the machined surfaces are exposed. 2] Polish part R with sandpaper of about No. 60 until it becomes a smooth rounded surface. 3] Polish parts R and h with sandpaper of about No. 60 until they become smooth. If part R is sharp or has burrs, finish it with a scraper or sandpaper. Finish this surface particularly smoothly so that it will not damage the O-ring. 4] If face B is so pitted that it cannot be repaired, replace the cylinder block. 5] If faces A and R are pitted, finish them smoothly. 6] Check the counterbored part and remove burrs. If chips or dust is on face C, the liner does not fit and coolant may leak and the projection of the liner may become improper consequently. a If the counterbored part is drooping, corroded, or pitted, repair it.
Cylinder block 1) Install tool A2 to the cylinder block, and then sling the cylinder block and set it to tool A1. 4 Cylinder block: 390 kg
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50 Disassembly and assembly
2.
Cylinder liner a Replace the O-ring and clevis seal with new ones. 1) Check that the cylinder liner O-ring groove and periphery of the liner are not roughened because of rusting or pitting. If those parts are roughened, replace the cylinder liner. 2) Install clevis seal (1), O-rings (2) and (3) to the cylinder liner. a Check that there are not a burr, dust, etc. in the groove of the liner. a Fit the clevis seal with the chamfered side down. When fitting it, press it against the seal groove all round so that it will not be twisted. a When installing O-rings (2) and (3), check the following. q O-ring (2): There is a yellow point for distinction. q O-ring (3): The whole ring is red. 2 Clevis seal and O-ring: Rubber lubricant (RF-1) a RF-1: DAIDO CHEMICAL INDUSTRY CO., LTD. If RF-1 is not available, apply clean engine oil SAE No. 30. a Since the clevis seal and O-ring are swollen and deteriorated by oil, apply a small amount of oil to them thinly with a brush just before fitting them.
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3)
After fitting the liner O-ring, check it for twist. If it is twisted, correct it with a smooth rod (about 10 mm in diameter).
4)
Apply gasket sealant to the parts of the cylinder block and cylinder liner which will fit to the counterbored parts. a Wipe off dirt and oil with cloth from the contact faces of the counterbored parts of the cylinder block and liner flange. 2 Cylinder block: Gasket sealant (LG-6) q Gasket sealant: 2 – 3 mm in diameter q Overlap (a) of gasket sealant: 6 ± 6 mm a If the applied gasket sealant is left for a long time, its surface becomes hard. Accordingly, install the cylinder liner to the cylinder block in 50 minutes.
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5) 6)
7)
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50 Disassembly and assembly
Insert cylinder liner (1) in the cylinder block slowly, taking care not to damage the O-ring. Push in cylinder liner (1) further with both hands. a If the liner does not enter the cylinder smoothly, the O-ring may be broken. In this case, check the cylinder block for burrs. Using tool F, press fit cylinder liner (1) to the cylinder block.
8)
To prevent the gasket sealant from projecting through the clearance between the block and liner after the cylinder head is tightened, tighten the cylinder head temporarily with the used head gasket inserted. a At this time, observe the following tightening torque and tightening order. 3 Temporary tightening torque: 137 – 157 Nm {14 – 16 kgm}
9)
Remove the cylinder head and wipe off the gasket sealant projected from the counterbored part. a Be sure to perform steps 8) and 9) above since the projected gasket sealant can deform the grommet of the head gasket.
10) Using tool H, measure the projection of the cylinder liner. a When measuring the projection of the liner, tighten the liner with a plate so that it will not be lifted by the O-ring. q Projection of liner: 0.07 – 0.15 mm a If the gasket sealant is projected from the fitting parts of the cylinder block and cylinder liner up to the top of the cylinder block, wipe it off.
3.
Crankshaft 1) Fit upper main bearing (6) to the cylinder block, matching the projection of the former to the cut of the latter. a An oil hole is made on the upper main bearing. a Before fitting the bearing, make sure that its back side is free from foreign matter. 2 Inside of bearing: Engine oil (EO30)
2)
Drive the dowel pin so that it will be projected by 2.7 – 3.4 mm from the block end and then install upper thrust bearing (5) to the No. 7 journal. a Install the thrust bearing with the grooved surface on the crankshaft side.
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50 Disassembly and assembly
3)
4)
5)
Sling crankshaft (4) and install it to the cylinder block. a When replacing the crank gear, heat it with a bearing heater (30 A) (Set temperature: 150°C) and fit it just after it is heated. a When installing the crankshaft, take care not to hit its sliding surfaces against the cylinder block. 4 Crankshaft: 140 kg 2 Cylinder block journal: Engine oil (EO30)
Fit the lower main bearing to the main cap, matching the projection of the former to the cut of the latter. a Before fitting the bearing, check that its back side is free from foreign matter. Drive the dowel pin of cap No. 7 so that it will be projected by 2.7 – 3.4 mm from the cap end and then install thrust bearings (3) to both sides. a Install each thrust bearing with the grooved surface on the crankshaft side.
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6)
Make sure that the journal No. stamped at the center of main cap (2) and the journal No. of the cylinder block are the same and then install the main cap. a Install the main cap with the cast letter (F) toward the front of the engine.
7)
Before tightening the main cap mounting bolts, check the following items. If any of the following condition applies, do not reuse that bolt but replace it. q Number of tightening time of bolt: 6 (Number of punch marks on bolt head is 5.) q Length (a) of bolt stem: Min. 176.3 mm
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8)
50 Disassembly and assembly
Tighten main cap mounting bolts (1) according to the following procedure. a Tighten the bolts from the center one to the outer ones in order. 2 Threaded portion of mounting bolt and washer: Engine oil (EO30) 3 Mounting bolt 1st time: 108 – 128 Nm {11 – 13 kgm} 2nd time: 230 – 240 Nm {23.5 – 24.5 kgm} 3rd time: Using tool J, tighten the bolt by 90° (+30°/0).
10) Check that the crankshaft turns smoothly. 11) Measure the end play of the crankshaft with dial gauge [1]. a End play: 0.140 – 0.315 mm a If the end play is out of the standard, correct it. For details, see “Structure, function and maintenance standard”.
4.
a
9)
22
When not using tool J, make marks (b) on the main cap and bolt with paint, then tighten the bolt by 90° (+30°/0). Make punch mark (c) on the mounting bolt head. a When a new bolt is used, do not make a punch mark on its head.
Piston and connecting rod assembly a Select the grade of the piston according to the grade of the cylinder liner. q Set grade (Stamp): S, L q Stamping position Cylinder liner: Top end Piston: Top surface 1) Using tool D, fit piston rings (7) to the piston. a Fit the top ring and second ring to the piston with the stamped mark side up. q Stamp on top ring: 1RS q Stamp on second ring: 2RX a Take the expander out of the oil ring and fit it to the piston first and then fit the oil ring. At this time, check that the expander is fitted to the ring groove perfectly.
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50 Disassembly and assembly
2)
Set the abutment joint of each piston ring as shown in the following figure. a Adjust oil ring so that the joint of the expander will be at 180° to the abutment joint of the oil ring.
3)
Set the piston and connecting rod. a Set the cylinder No. on the head of piston (6) and the cast part No. of connecting rod (4) in the same direction, then insert piston pin (5) to assemble connecting rod (4) and piston (6). Fit snap rings (3) on both sides of the piston pin to secure the piston pin.
4)
5)
6)
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7)
Insert piston and connecting rod assembly (8) in the cylinder block so that the cast part number on the connecting rod will be directed to the front of the engine (the stamped cylinder number will be on the camshaft side). a Referring to step 2), check the abutment joint of each piston ring again. 2 Inside of connecting rod bearing and inside of cylinder: Engine oil (EO30)
8)
Using tool G, reduce the piston ring and push in the piston head with a wood bar, etc. into the cylinder block.
Fit the upper bearing to the connecting rod, matching the projection of the former to the cut of the latter. a Before fitting the bearing, check that its back side is free from foreign matter. Set the crankshaft so that the cylinder to be installed will be at the bottom dead center.
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9)
50 Disassembly and assembly
Before tightening the connecting rod cap mounting bolts, check the following items. If any of the following condition applies, do not reuse that bolt but replace it. q Number of tightening time of bolt: 6 (Number of punch marks on bolt head is 5.) q Length (a) of bolt stem: Min. 95.0 mm
10) Fit lower bearing (9) to the connecting rod cap, matching the projection of the former to the cut of the latter. 12) Tighten connecting rod cap mounting bolts (1) according to the following procedure. 3 Mounting bolt 1st time : 127 ± 4.9 Nm {13 ± 0.5 kgm} 2nd time : Using tool J, tighten the bolt by 90° (+30°/0).
11) Install connecting rod cap (2) to connecting rod (4), matching yellow marks (a) on them to each other. a Before fitting the bearing, check that its back side is free from foreign matter. 2 Inside of connecting rod cap bearing: Engine oil (EO30)
24
a
When not using tool J, make marks (b) on the connecting rod cap, and bolt with paint, then tighten the bolt by 90° (+30°/0).
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13) After tightening the bolt, make a punch mark (c) on its head. a When a new bolt is used, do not make a punch mark on its head.
2)
Install piston cooling nozzles (1) and (2) to each cylinder in order. a Install the piston cooling nozzles having the stamps of (F1) to the front side of the cylinder and install those having 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 hexagonal part of the nozzle for the mounting bolt. 3 Mounting bolt: 59 – 74 Nm {6.0 – 7.5 kgm}
14) Turn the crankshaft to check that it rotates normally. 15) Measure the side clearance of the connecting rod with dial gauge [1]. a Side clearance: 0.100 – 0.274 mm a If the side clearance is out of the standard, correct it. For details, see “Structure, function and maintenance standard”.
6.
5.
Underframe Install underframes (1). a The number of the underframes depends on the applicable machines.
Piston cooling nozzle 1) Rotate the crankshaft and set the No. 1 – No. 3 pistons to the following positions for installation of the piston cooling nozzles of each piston. q Set the No. 1 piston to top: Piston cooling nozzles of the No. 1 and No. 6 pistons can be installed. q Set the No. 2 piston to top: Piston cooling nozzles of the No. 2 and No. 5 pistons can be installed. q Set the No. 3 piston to top: Piston cooling nozzles of the No. 3 and No. 4 pistons can be installed.
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50 Disassembly and assembly
7.
Main idler gear 1) Install bearing (3) and shaft (2) to the outside of main idler gear (1) and install bearing (3) and plate (4) to the inside. a Direct the chamfered side of plate (4) toward the gear. 2) Matching the stamped (A) of the crankshaft gear to that of main idler gear (1), tighten mounting bolt (5). 3 Mounting bolt: 784 ± 44.1 Nm {80 ± 4.5 kgm}
9.
8.
26
Sub idler gear and oil pump assembly 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}
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: Engine oil (EO30)
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50 Disassembly and assembly
2)
Matching the stamped (C) of the camshaft gear to that of the main idler gear, tighten mounting bolt (2). 3 Mounting bolt: 98 – 123 Nm {10 – 12.5 kgm}
10. Cam follower assembly 1) Install 2 lever assemblies (5) to shaft (6). a Insert the cam followers so that the ball end of the shaft will be directed toward the rear of the engine. 2) Install snap rings (4).
3)
Install cam follower assembly (1), matching it to the dowel pin, and then tighten mounting bolts (2). 3 Mounting bolt: 44.1 – 58.8 Nm {4.5 – 6.0 kgm}
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4)
Fit the O-ring and install cover (3). 3 Mounting bolt: 9.8 – 12.7 Nm {1.0 – 1.3 kgm}
11. Fuel supply pump assembly and drive gear 1) Fit the key to the shaft of fuel supply pump assembly (6) and install them to the cylinder block. 2) Tighten mounting bolts (4) and install bracket (5). 2 Mounting bolt: Adhesive (LT-2)
3)
Install fuel supply pump drive gear (3) to the fuel supply pump shaft and tighten mounting nut (1). a When installing to the fuel supply pump shaft, set stamp (B) of fuel supply pump drive gear (3) to stamp (B) of the main idler gear (circled in the figure). 3 Mounting nut: 176 – 196 Nm {18 – 20 kgm}
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50 Disassembly and assembly a
12. Measuring backlash and end play a Measure the backlash and end play of each gear with dial gauge [1]. a Install the water pump drive gear temporarily to measure their backlash and end play. a Set the air compressor drive gear (on the right side of the camshaft gear) according to the applicable machines.
q
q
28
If the end play is out of the standard, correct it. For details, see “Structure, function and maintenance standard”.
13. Removal from engine repair stand 1) Remove the engine from the engine repair stand and set it on stable blocks. 2) Remove the adapter from the engine. 14. Front cover and front support a The front cover and front support are installed with the same mounting bolts. 1) Fit the gasket and install front cover (1) temporarily, using eyebolt [1]. 4 Front cover: 70 kg
Standard backlash of each gear Position
Range (mm)
A
0.141 – 0.425
B
0.129 – 0.391
C
0.129 – 0.391
D
0.141 – 0.425
E
0.080 – 0.417
F
0.095 – 0.346
Standard end play of each gear Position
Range (mm)
1
0.1 – 0.25
2
0.06 – 0.24
3
0.11 – 0.23
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2)
3)
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Sling and install front support (2) and tighten the mounting bolts. a The shape and weight of the front support depends on the applicable machines. 4 Front support: 65 kg Tighten the front cover mounting bolts permanently.
2)
3) 15. Front oil seal Install front oil seal (1) according to the following procedure. a Before installing the seal, check that the end corners and lip sliding surfaces of the crankshaft and front cover are free from flaw, burr, and rust. a When installing the seal, do not apply oil or grease to the shaft and seal lip. Wipe off the oil from the shaft. a Never remove inside plastic cylinder (2) of the replacement seal before installing the seal. 1)
Push the metal ring of front seal (1) evenly as if you are passing over the large inside diameter side of plastic inside cylinder. a Hit the metal ring of front seal with plastic hammer evenly. Do not hit it strongly. After pushing in the seal, remove plastic inside cylinder (2). a When removing the inside cylinder, take care not to damage the seal lip.
Set large inside diameter side (a) of plastic inside cylinder (2) to the end of crankshaft (3). a Take care not to mistake the direction of the plastic inside cylinder.
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4)
50 Disassembly and assembly
Using tool M1, tighten the 3 bolts evenly to press fit seal (3) until the end of tool M1 reaches the end of crankshaft (5). a Tighten tool M1 first until the 55-mm bolts stop and then replace the 55mm bolts with the 35-mm bolts and tighten them. a Seal driving distance (a) from crankshaft: 9.1 – 10.1 mm a When press fitting the seal, take care not to damage the lip of the seal with the tool set etc. a After press fitting the seal, remove the red sealant layer from its periphery. 4) 5)
Fit inner spring (4) and outer spring (3) and then install upper seat (2). Using tool C, compress the valve spring and install valve cotter (1). a Hit the valve stem lightly with a plastic hammer to check that the cotter is fitted to the groove of the valve stem.
16. Damper assembly Matching the dowel pin of damper assembly (1), tighten 6 mounting bolts (2). 3 Mounting bolt: 245 – 309 Nm {25 – 31.5 kgm} a The fan drive pulley may be installed. 6)
Check that the cylinder head mounting face and inside of the cylinder are free from foreign matter and then set cylinder head gasket (1). a When fitting the gasket, check that the grommets are fitted correctly.
17. Cylinder head assembly 1) Using tool Q, press fit valve stem seal (5) until it reaches the valve guide. 2) Install valve (7). 2 Stem of valve: Engine oil (EO30) 3) Install lower seat (6).
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50 Disassembly and assembly
7)
Before tightening the cylinder head mounting bolts, check the following items. If any of the following condition applies, do not reuse that bolt but replace it. q Number of tightening time of bolt: 6 (Number of punch marks on bolt head is 5.) q Length (a) of bolt stem: Short bolt: Min. 170.8 mm Long bolt: Min. 205.8 mm
8)
Install cylinder head assembly (2) and tighten mounting bolts (1) and auxiliary bolts. 2 Mounting bolt: Molybdenum disulfide lubricant (LM-P)
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a
When not using tool J, make marks (a) and (b) on the bolts and head with paint, then tighten the bolts by 90° (+30°/0). a After tightening bolts 1 – 6, tighten bolt 7. 3 Bolt 7: 66.6 ± 7.4 Nm {6.8 ± 0.8 kgm}
3
a
Mounting bolt: 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).
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18. Crosshead Install crosshead (1). a Adjust the crosshead according to the following procedure. 1] Loosen the locknut and return the adjustment screw. 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}
19. Push rod Install push rod (1). a Check that the push rod is in the cam follower.
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50 Disassembly and assembly
20. Fuel injector a Check that the inside of the injector sleeve is free from dirt. 1) Referring to step 21, install the common rail temporarily. 2 O-ring: Engine oil (EO30) 2) Fit the gasket and O-ring to the fuel injector. 3) Insert holder (2) in fuel injector (1), then insert them simultaneously, directing the injector connector (5) to the hole to insert the fuel high-pressure pipe. 4) Fit the ball washer to bolt (3) and tighten holder (2) temporarily. 2 Ball washer: Engine oil (EO30) 5) Insert high-pressure pipe sleeve (4) in the hole to insert the fuel high-pressure pipe and fix it temporarily, matching it to injector connector (5). a Tighten the sleeve nut on the common rail side temporarily, too, to prevent the high-pressure pipe from leaning. 6) Tighten holder (2) permanently. a While pulling the high-pressure pipe in the opposite direction to the injector, tighten bolt (3). 3 Holder mounting bolt: 58.8 – 73.5 Nm {6.0 – 7.5 kgm} a After tightening the holder, remove the high-pressure pipe and install the other injectors in order according to the above procedure.
140E-5 Series
50 Disassembly and assembly
SEN00158-05
1) 2)
3)
Secure common rail (1) temporarily with special bolts (2). Fit O-ring (4) to high-pressure pipe sleeve (3). Matching them to the injector connector, 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) Tighten special bolts (2) permanently. 3 Special bolt: 59 – 74 Nm {6.0 – 7.5 kgm}
21. Common rail and high-pressure pipe k Before installing the high-pressure pipe, check it for the following defects. If there is any of these defects, it can cause fuel leakage. Accordingly, replace the high-pressure pipe. q Check the taper seal of the connecting part (Part (a): Part of 2 mm from the end) for visible lengthwise slit (b) and dent (c). q Check part (d) (end of the taper seal: Part at 2 mm from the end) for stepped-type wear (fatigue) which your nail can feel.
4)
a
140E-5 Series
Tighten high-pressure pipe sleeve nuts (5) and (6) permanently with spanner-type torque wrench [1]. Sleeve nut: 39.2 – 49 Nm {4 – 5 kgm} a After finishing the work, check that Oring (4) is not projected from the end of the sleeve.
When installing the high-pressure pipe without removing the fuel injector (for example, when replacing only the high-pressure pipe with new one), follow the procedure below. q Tighten sleeve nut (5) by 2 turns with the hand into the threads of the fuel injector and then tighten it with the spanner.
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50 Disassembly and assembly
a
If sleeve nut (5) does not catch the threads, press its end with a small rod, etc. toward the injector and turn the spanner.
13) Tighten clamps and brackets (15), (16), (17), (18), (19) and (20) of bracket side permanently.
5)
Tighten clamps and brackets (7), (8), (9), (10), (11) and (12) with the hand first, then tighten clamp side permanently. 3 Clamp bolt: 9.8 ± 1.0 Nm {1.0 ± 0.1 kgm} Tighten clamps and brackets (7), (8), (9), (10), (11) and (12) of bracket side permanently. Install covers (13) and (14) to the sleeve nut. a Direct the cut of cover (13) down and direct the cut of cover (14) toward the cylinder block.
22. Rocker arm and shaft assembly Install rocker arm and shaft assembly (1) and tighten mounting bolts (2), (3) and (4). a Note that the lengths of the mounting bolts are different. Mounting bolt (2): Stem length; 120 mm Mounting bolt (3): Stem length; 90 mm Mounting bolt (4): Stem length; 75 mm a Before tightening the mounting bolts, check that the ball of the adjustment screw is fitted to the socket of the push rod. 3 Mounting bolt: 93 – 103 Nm {9.5 – 10.5 kgm}
6) 7)
8)
Tighten clamps and brackets (15), (16), (17), (18), (19) and (20) with the hand. 9) Tighten clamp (21) and frame (22) with the hand. 10) Tighten clamp (21) permanently. 3 Clamp bolt: 9.8 ± 1.0 Nm {1.0 ± 0.1 kgm} 11) Tighten frame (22) permanently. 12) Tighten clamps and brackets (15), (16), (17), (18), (19) and (20) of clamp side permanently. 3 Clamp bolt: 9.8 ± 1.0 Nm {1.0 ± 0.1 kgm}
34
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50 Disassembly and assembly
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23. Adjusting valve clearance a Adjust the clearance between the crosshead and rocker arm to the following value. a Valve clearance (when cold) Unit: mm
a 1)
2)
3)
Air intake valve
Exhaust valve
0.35 ± 0.02
0.57 ± 0.02
24. Cylinder head cover Fit the O-ring and install cylinder head cover (1). a Since the bolt at the front on the air intake manifold side is also used to secure the wiring harness clamp, tighten it temporarily. 3 Mounting bolt: 29.4 – 34.3 Nm {3.0 – 3.5 kgm}
Rotate the crankshaft and adjust the valve clearance of each cylinder in the firing order of 1 – 5 – 3 – 6 – 2 – 4. Rotate the crankshaft forward and match stamped line of “1.6 TOP” (a) on vibration damper (1) to pointer (2), watching the movement of the valve.
Insert thickness gauge I between rocker arm (3) and crosshead (4) and tighten adjustment screw (5) to the degree that the thickness gauge can be moved lightly. Tighten locknut (6) to secure adjustment screw (5). 3 Locknut: 53 – 64.7 Nm {5.4 – 6.6 kgm} a After tightening the locknut, check the valve clearance again.
140E-5 Series
25. Flywheel housing 1) Install flywheel housing (1). a Apply a string of gasket sealant 1 mm in diameter as shown below. a When installing the housing, take care not to damage the oil seal. 2 Mating face: Gasket sealant (LG-7) 2 Threaded portion and seat of bolt: Engine oil (EO30) 4 Flywheel housing: 75 kg
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a
Tighten the flywheel housing mounting bolts in the following order in 2 steps. a When tightening the bolts for the 1st time, tighten bolts 1, 4 and 2, 9 twice. 3 Flywheel housing mounting bolt: 1st time: 147 – 235 Nm {15 – 24 kgm} 2nd time: 245 – 309 Nm {25 – 31.5 kgm}
50 Disassembly and assembly
26. Rear oil seal a Check the Teflon seal (Laydown lip seal) by checking the wear of the shaft and replace it with the "standard seal" or "sleeved seal". If the shaft is worn to the degree of luster (If wear which you feel with your finger is less than 10 mm) and does not have any flaw, install "standard seal A". In other cases, install "sleeved seal B". a (8): Plastic inside cylinder which is also used as installation guide. a (7): Sleeve. a Do not remove plastic inside cylinder (8) from rear seal (4) before installing the rear seal. a Handle rear seal (4) and sleeve (7) as an assembly and never separate them from each other. q
Left: Standard seal, Right: Sleeved seal
a 2)
36
After installing the flywheel housing, 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
a a
Clean, degrease, and dry the contact surface against the flywheel housing. Clean, degrease, and dry the seal lip surface (periphery of the crankshaft). Check that the end corners and lip sliding surfaces of the crankshaft are free from flaw, burr, and rust of the housing.
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50 Disassembly and assembly
1.
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4)
Procedure for installing standard seal a When installing rear seal (4), do not apply oil or grease to the shaft and seal lip. 1) Set large inside diameter side (b) of guide (8) of rear seal (4) to the end of crankshaft (6). a Take care extremely not to mistake the direction of the plastic inside cylinder.
2)
3)
Push the metal ring of rear seal (4) evenly as if you are passing over the large inside diameter side of plastic inside cylinder. a Hit the metal ring of rear seal with plastic hammer evenly. Do not hit it strongly. After pushing in the seal, remove guide (8). a When removing the inside cylinder, take care not to damage the seal lip.
140E-5 Series
2.
Tighten the 4 bolts evenly to press fit rear seal (4) until the end of tool N1 (for press fitting the seal) reaches the end of crankshaft (6). a Tighten tool N1 (for press fitting the seal) first until the bolt without washer stops and then tighten the bolt with 2 washers. a When press fitting the seal, take care not to damage the lip with the tool set etc. a After press fitting the seal, remove the red sealant layer from its periphery.
Procedure for installing sleeved seal a When installing the rear seal, do not apply oil or grease to the shaft, inside cylinder surface (C) of the sleeve (7) and seal lip. 1) Set sleeve and rear seal assembly (9) to tool N2 (for fitting the sleeved seal). 2 Sleeve inside cylinder surface (C): Gasket sealant (LG-7)
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2)
Set sleeve (7) of the rear seal to the end of crankshaft (6) and tighten the 4 bolts evenly to press fit sleeve and rear seal assembly (9) until the end of tool N2 reaches the end of crankshaft (6). a Tighten tool N2 (for press fitting the sleeved seal) until the bolt with washer stops.
50 Disassembly and assembly
27. Flywheel Using eyebolt [1] (12 mm, P = 1.75), sling flywheel (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 contact with the speed sensor. 2 Threaded portion and seat of bolt: Engine oil (EO30) 4
3) 4)
Remove tool N2 (for press fitting the sleeved seal) and install tool N3 (for press fitting the seal). Tighten the 4 bolts evenly to press fit sleeve and rear seal assembly (9) until the end of tool N3 reaches the end of crankshaft (6). a Tighten tool N3 (for press fitting the seal) first until the bolt without washer stops and then tighten the bolt with 2 washers. a After press fitting the seal, remove the red sealant layer from its periphery. a Rear seal driving depth: 13.2 ± 0.2 mm from end of crankshaft
Flywheel: 60 kg
a
Tighten the mounting bolts according to the following procedure. 3 Flywheel mounting bolt: 1st time: 118 ± 4.9 Nm {12 ± 0.5 kgm} 2nd time: Using tool J, tighten the bolts by 90° (+30°/0) in the order of (1) – (8).
a
a a a
38
When not using tool J, make marks (f) on the flywheel with paint, then tighten the bolts by 90° (+30°/0) in the order of (1) – (8). After tightening each bolt, make punch mark (g) on its head to show the number of tightening times. When a new bolt is used, do not make a punch mark on its head. If there are 5 punch marks on the head of a bolt, do not reuse that bolt but replace it.
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29. Oil pan 1) Install the gasket and push up oil pan (1) with a pallet lift, etc. and tighten the mounting bolts. a Apply gasket sealant to the joint part. 2Joint part: Gasket sealant (LG-7) 2) Connect the level sensor connector.
a
After installing the flywheel, measure its facial runout and radial runout with dial gauge [1]. q Radial runout: Max. 0.13 mm q Facial runout: Max. 0.20 mm
28. Suction pipe Install the O-ring to the oil pump and install suction tube (1), then install bracket (2) to the cylinder block.
30. Engine wiring harness assembly and sensor connector 1) Install the engine wiring harness assembly. 2) Install the injector wiring harness assembly. a Since the wiring harness assembly fitted with the O-ring is difficult to insert from inside, install it according to the following procedure. 1] Remove O-ring (2) from connector (1) and pass the wiring harness out from inside of the cylinder head and then fit the O-ring. 2 O-ring: Engine oil (EO30) 2] Install holder (3) to connector (1) and push in connector (1) to the position where the O-ring is fitted. 3] Fix holder (3) with mounting bolt (4).
4]
140E-5 Series
Insert spring clamp (8) in the injector connector and secure wiring harness clamp (9) with bolt (10).
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5]
40
Install wiring harness terminal (6) to fuel injector (5) and tighten 2 nuts (7). a Stretch the wiring harness without slack and press it against the injector body. a Tighten the nuts alternately. 3 Terminal nut: 2 ± 0.2 Nm {0.2 ± 0.02 kgm}
3) 4)
Install bracket (11). Connect NE sensor connector NE (13), and atmospheric pressure sensor connector PAMB (14).
5)
Install bracket (15) and install the clamps of wiring harnesses (16) and (17).
50 Disassembly and assembly
6)
Connect coolant temperature sensor connector TWTR (18).
140E-5 Series
50 Disassembly and assembly
31. Piping and wiring of supply pump 1) Install bracket (1). 2) Install fuel high-pressure pipings (2) and (3). 3 Sleeve nut of tube: (Pump side) 39.2 – 49 Nm {4 – 5 kgm} (Common rail side) 39.2 – 58.8 Nm {4 – 6 kgm} 3) Install the splash prevention cover and install clamps (4), (5), and (6). a Direct the cut of the splash prevention cover on the supply pump side toward the block and direct that on the common rail side down. a Tighten clamps (4), (5) and (6) with the hand first, and then tighten them permanently. a Tighten the clamps permanently in the order of (4), (5) and (6). 3 Clamping bolt: 9.8 ± 1 Nm {1.0 ± 0.1 kgm} 4) Install fuel tubes (7), (8) and (9). 3
Joint bolt of tube (7) (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} q Joint bolt of tube (8) (Pump side) 14.8 – 19.6 Nm {1.5 – 2.0 kgm} q Sleeve nut of tube (8) (Fuel cooler side) 43 – 47 Nm {4.4 – 4.8 kgm} q Joint bolt of tube (9) (Pump side) 14.8 – 19.6 Nm {1.5 – 2.0 kgm} Install fuel tube (10) temporarily. a After installing the electric priming pump, tighten the joint bolt to the specified torque. Install oil tube (11). 3 Joint bolt of tube (11): (Pump side) 7.9 – 12.7 Nm {0.8 – 1.3 kgm} (Cylinder block side) 9.8 – 12.7 Nm {1.0 – 1.3 kgm} Tighten clamps (12), (13), (14), (15), (17) and (18) with the hand first, and then tighten them permanently. 3 Mounting bolt of clamps (12), (13), (14): 9.8 ± 1.0 Nm {1.0 ± 0.1 kgm} Install fuel tube (19) temporarily. a After installing the electric priming pump, tighten the joint bolt and sleeve nut to the specified torque. q
5)
6)
7)
8)
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SEN00158-05
9)
Connect sensor connectors PCV2 (20), PCV1 (21) and G (22).
32. Electric priming pump and air bleeding valve a Manual priming pump is set for some models. (See the procedure of "with EGR" ) 1) Install the assembly of electric priming pump (1) and bracket (2). 2) Install oil filler bracket (3). 3) Install the assembly of air bleeding valve (4) and bracket (5). 4) Install fuel tube (6). a Fuel tube (6) was installed temporarily in the previous step. 3 Joint bolt of tube (6) (Supply pump side) 14.8 – 19.6 Nm {1.5 – 2.0 kgm} (Electric priming pump side) 19.6 – 29.4 Nm {2.0 – 3.0 kgm} 5) Install fuel tube (7). 3 Joint bolt of tube (7) 19.6 – 29.4 Nm {2.0 – 3.0 kgm} 6) Install fuel tubes (8) and (9). a Fuel tubes (8) and (9) were installed temporarily in the previous step. 3
Joint bolt of tube (8), (9) (Supply pump side) 14.8 – 19.6 Nm {1.5 – 2.0 kgm} q Sleeve nut of tube (8) (Electric priming pump side) 43 – 47 Nm {4.4 – 4.8 kgm} Install fuel tubes (10) and (11). 3 Joint bolt of tubes (10) and (11). 19.6 – 29.4 Nm {2.0 – 3.0 kgm} q
7)
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33. Breather remote tube and corrosion resistor tube 1) Install breather remote tube (1). 2) Install corrosion resistor tubes (2) and (3) temporarily. a Corrosion resistor is not set for some models.
34. Engine controller cooler 1) Install the O-ring and plate (1). 2) Install engine controller cooler (2) and fuel hose (3). a Install the hose on the engine controller cooler outlet side when installing the fuel filter head. a Fuel hose (3) may not be installed. 3) Connect fuel pressure sensor connector PFUEL (4) and engine oil pressure sensor connector POIL (5).
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50 Disassembly and assembly
35. Engine controller Install engine controller (2) and connect connector (1).
36. Air intake manifold 1) Fit the gasket and sling and install air intake manifold (1) and then tighten the mounting bolts in the following order. a Fit the gasket with the UP mark up. 4 Air intake manifold: 45 kg 3 Mounting bolt: 58.8 – 73.5 Nm {6.0 – 7.5 kgm}
140E-5 Series
50 Disassembly and assembly
2) 3)
Install brackets (7), (8), (9), (10) and (11). Install brackets (2), (3), (4), (5) and (6).
4)
Tighten clamp (12) of the high-pressure pipe. 3 Clamp bolt: 9.8 ± 1.0 Nm {1.0 ± 0.1 kgm} Tighten wiring harness clamp (13) temporarily.
5)
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37. Air intake connector assembly 1) Install joint housing (2) to bracket (1). 2) Install venturi nozzle, air heater (3) and connector (4) to joint housing (2). a Direct the terminal of the air heater toward the original direction. (The direction of the terminal depends on the applicable machines.)
3) 4)
6) 7)
Install clamp (19) of sensor connectors TFUEL (15), PIM (16), TIM (17) and wiring harness (18). Install fuel tube (20). 3 Joint bolt: (Head side) 9.8 – 12.7 Nm {1.0 – 1.3 kgm} (Block side) 19.6 – 29.4 Nm {2.0 – 3.0 kgm}
140E-5 Series
5)
Fit the gasket and install air intake connector (5) to the air intake manifold and joint housing (2). Install clamps (7), (8), (9), (10) and (11) of wiring harness.
Install high-pressure pipe bracket (6) to the joint housing.
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50 Disassembly and assembly
38. Oil filler and electric priming pump cover a Electric priming pump is not set for some models. 1) Install oil filler (1). a Tighten fuel tube clamp (2), too. 2) Install clamp (3). 3) Install electric priming pump cover (4).
40. Oil filter head and controller cover 1) Install oil filter head (1). 2) Fit the O-ring and install oil tubes (2) and (3). 3) Install clamp (4). 4) Install controller cover (5). 39. Fuel filter head and fuel tube 1) Install fuel filter head mounting plate (8). 2) Install the oil filler head and piping mounting plates (7) and (6).
3) 4)
Install fuel filter head (5). Install fuel tubes (3) and (2). 3
41. Oil filter, fuel filter and corrosion resistor 1) Install main fuel filters (2) and oil filters (1). a Pre-fuel filter (2) may not be installed. 2) Install corrosion resistor. a Corrosion resistor is not set for some models.
Joint bolt of tube (3), (2) 24.5 – 34.3 Nm {2.5 – 3.5 kgm} q Sleeve nut of tube (2) (Electric fuel supply pump side) 43 – 47 Nm {4.4 – 4.8 kgm} Install air bleeding tube (4). 3 Joint bolt of tube (4) 7.8 – 9.8 Nm {0.8 – 1.0 kgm} Install clamp (1). q
5) 6)
44
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50 Disassembly and assembly
42. Oil cooler assembly Using eyebolts [1] and guide bolt [2], fit the gasket, install oil cooler assembly (1) and tighten the 16 mounting bolts. 4
Oil cooler assembly: 35 kg
SEN00158-05
3) 4) 5) 6) 7)
43. Water pump assembly and thermostat assembly 1) Fit the O-ring, install water pump assembly (1) and tighten the mounting bolts temporarily. a The mounting bolts are also used to secure the front cover.
2)
Fit the gasket and install thermostat assembly (5). Insert bypass tube (4) in the water pump assembly and install snap ring (6). Tighten the water pump assembly mounting bolts permanently. Fit the gasket and install tubes (7) and (8). Install alternator drive pulley (9).
44. Alternator assembly 1) Install the V-belts to the pulley of alternator assembly (9) and tighten mounting bolt (4) and clamping bolt (5) temporarily. 2) Adjust the belt tension with V-belt tension adjustment nut (7) and tighten mounting bolt (4) and clamping bolt (5) permanently. 3) Check the belt tension and tighten tension adjustment nut (7) and locknut (6). 4) Install wiring harness terminals B (1) and R (2). 5) Install cover (3).
Install bypass tube (4) fitted with thermostat (3) and O-ring to thermostat housing (2).
140E-5 Series
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45. Exhaust manifold 1) Apply heat-resistant sealant to the mating portions of exhaust manifold (between ports No. 2 and No. 3 and between ports No. 4 and No. 5). 2 Mating portion: Heat-resistant sealant (Holtz MH 705) 2) Fit the gasket and sling and install exhaust manifold and then tighten the mounting bolts in the following order. 4 Exhaust manifold: 25 kg a Tighten the 3 bolts of (1) – (3) temporarily first in the numerical order, and tighten the bolts (4) – (24) temporarily in the numerical order. Then, tighten all the bolts again to the specified torque in the numerical order. 2 Mounting bolt: Seizure prevention compound (LC-G) 3 Mounting bolt: 58.8 – 73.5 Nm {6 – 7.5 kgm}
50 Disassembly and assembly
3)
4)
5) 6)
Fit the gasket and install lubrication tube (5) and 4 clamps (4). 3 Tube joint bolt: 24.5 – 34.3 Nm {2.5 – 3.5 kgm} Install wiring harness (3).
Fit the gasket and install turbocharger lubrication drain tube (3) and tube clamps (4). Install connector (2) and heat insulation cover (1).
46. Turbocharger assembly 1) Fit the gasket and install tube (8). 2) Fit the gasket and install air inlet pipe and turbocharger assembly (7). 4 Air inlet pipe and turbocharger assembly: 30 kg 3 Mounting nut: 44.1 – 49 Nm {4.5 – 5.0 kgm}
46
140E-5 Series
50 Disassembly and assembly
47. Front plate Fit the gasket to the air intake connector and sling and install front plate (1). 4
Bracket: 20 kg
48. Bracket Install brackets (1) and (2), stay (3), brackets (4) and (5).
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50. Starting motor assembly 1) Fit the gasket and install starting motor assembly (4) with bolts (3). 2) Install wiring harness (1) and alternator connector terminal R (2).
51. Air cleaner bracket and wiring harness 1) Install air cleaner bracket (2). a The type of the bracket depends on the applicable machines. 4 Air cleaner bracket: 30 kg 2) Install wiring harness clamp (1).
49. Heat insulation cover Install covers (1), (2), (3), (4) and (5). 3)
After assembling, check the installing condition of the wiring harness clamp.
52. Tightening torque for sensor If a sensor is replaced, tighten the new sensor to the following torque. Sensor name
140E-5 Series
Tightening torque
NE
4.9 – 7.9 Nm {0.5 – 0.8 kgm}
Fuel temperature
23 ± 3 Nm {2.3 ± 0.3 kgm}
Boost pressure
5.5 ± 0.5 Nm {0.56 ± 0.05 kgm}
Intake air temperature
23 ± 3 Nm {2.3 ± 0.3 kgm}
Coolant temperature
23 ± 3 Nm {2.3 ± 0.3 kgm}
Engine oil pressure
23 ± 3 Nm {2.3 ± 0.3 kgm}
Atmospheric pressure
4.5 ± 0.5 Nm {0.45 ± 0.05 kgm}
Fuel pressure
Never disassemble.
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53. Checking for fuel leakage a If fuel supply pump (2), common rail (1), or high-pressure pipe is removed and installed, after assembling the engine, check for fuel leakage according to the following procedure.
a 1) 2) 3)
4) 5)
6) 7)
8)
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50 Disassembly and assembly
9)
Check the fuel piping and devices for fuel leakage. a Check mainly around the high-pressure circuit parts coated with the color checker for fuel leakage. a If any fuel leakage is detected, repair it and check again from step 2). a If no fuel leakage is detected, check is completed.
Clean and degrease the engine and the parts around it in advance so that you can test it easily for fuel leakage. Spray color checker (developer) over the fuel supply pump, common rail, fuel injector, and joints of the high-pressure piping. Run the engine at speed below 1,000 rpm and stop it after its speed is stabilized. Check the fuel piping and devices for fuel leakage. a Check mainly around the high-pressure circuit parts coated with the color checker for fuel leakage. a If any fuel leakage is detected, repair it and check again from step 2). Run the engine at low idle. Check the fuel piping and devices for fuel leakage. a Check mainly around the high-pressure circuit parts coated with the color checker for fuel leakage. a If any fuel leakage is detected, repair it and check again from step 2). Run the engine at high idle. Check the fuel piping and devices for fuel leakage. a Check mainly around the high-pressure circuit parts coated with the color checker for fuel leakage. a If any fuel leakage is detected, repair it and check again from step 2). Run the engine at high idle and load it. a When checking while the components to be checked are mounted on the machine, stall the torque converter or relieve the hydraulic pump.
140E-5 Series
50 Disassembly and assembly
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KOMATSU 140E-5 Series engine Form No. SEN00158-05
© 2011 KOMATSU All Rights Reserved Printed in Japan 10-11
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ENGINE 1SHOP MANUAL
140E-5 Series
50 Disassembly and assembly Disassembly and assembly, Part 3 Disassembly and assembly, Part 3 ................................................................................................................. 2 Removal and installation of fuel supply pump unit (with EGR) ............................................................ 2 Removal and installation of fuel supply pump unit (EGR-less) ............................................................ 4 Replacement of oil seal of engine mounted on machine ..................................................................... 7
140E-5 Series
1
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50 Disassembly and assembly
Disassembly and assembly, Part 3 Removal and installation of fuel supply pump unit (with EGR) 1
1
4.
Remove the clamp and EGR oil tubes (4) and (5). [*2]
Removal 1. Remove cover (1).
5.
Disconnect sensor connectors PCV1 (8) and G (9).
2.
6.
Remove the clamp and fuel tubes (10) and (11) and then disconnect fuel tubes (12) and (13) and fuel hose (14). [*3]
7.
Remove the clamp and oil tubes (15) and (16). [*4]
8.
Remove the splash prevention cover, clamps (17), (18), (19), and bracket (20), and then remove high-pressure tube (21). [*5]
3.
2
Rotate the crankshaft forward and set intermediate point (a) between stamped “2/5 TOP” and “3/4 TOP” on damper (2) to pointer (3). a At this time, check that the forcing tap of the drive gear is set to the bolt hole at the top of cover (1). (If not, rotate the crankshaft 1 more turn.) a At this point, the key of the shaft is turned clockwise by 15° from the top.
Remove mounting nut (6). [*1] a Take care not to drop the nut into the gear case.
140E-5 Series
50 Disassembly and assembly
9.
Remove mounting bolts (23) and remove bracket (24) from supply pump assembly (22). a Leave bolts (23) tightened by 2 – 3 threads to prevent the pump from falling down.
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Installation q Carry out installation in the reverse order to removal. [*1]
3
Nut: 176 – 196 Nm {18 – 20 kgm}
[*2]
3
Sleeve nut of EGR oil tube (4): 43 – 47 Nm {4.4 – 4.8 kgm}
[*3]
3
10. Set tool P to the drive gear, tighten center bolt of P, and remove gear (25) from the shaft. 11. Remove mounting bolts (23) which have been left and remove supply pump assembly (22). a If tool P is removed, the gear falls down. Accordingly, keep it installed until the pump is installed.
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} Joint bolt of fuel tubes (10) and (11): (Pump side) 14.8 – 19.6 Nm {1.5 – 2.0 kgm}
[*4]
3
Joint bolt of oil tubes (15) and (16): (Pump side) 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)
2)
3)
140E-5 Series
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} Tighten clamps (17), (18), and (19) with the hand first, and then tighten them permanently. a Tighten clamps permanently in the order of (17), (18) and (19). 3 Clamp mounting bolt: 9.8 ± 1 Nm {1 ± 0.1 kgm} 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.
3
SEN00159-04
50 Disassembly and assembly
Removal and installation of fuel supply pump unit (EGR-less) 1
4.
Remove fuel filters (1) and oil filters (2). [*2] a Single cartridge is set for some models.
Removal 1. Remove cover (1).
5.
Remove oil filler (3) and electric priming pump cover (4). [*3] a Electric priming pump is not set for some models.
6.
Remove clamps (8) and (9) and fuel tubes (5), (6) and (7). [*4]
2.
3.
4
Rotate the crankshaft forward and set intermediate point (a) between stamped “2/5 TOP” and “3/4 TOP” on damper (2) to pointer (3). a At this time, check that the forcing tap of the drive gear is set to the bolt hole at the top of cover (1). (If not, rotate the crankshaft 1 more turn.) a At this point, the key of the shaft is turned clockwise by 15° from the top.
Remove mounting nut (6). [*1] a Take care not to drop the nut into the gear case.
140E-5 Series
50 Disassembly and assembly
SEN00159-04
7.
Remove sensor connectors (10), (11) and (12).
8.
Remove the scatter prevention cover bracket (13).
9.
Remove clamps (14), (15) and (16) and highpressure pipes (17) and (18). [*5]
14. Remove mounting bolts (32) and remove bracket (33) from supply pump assembly (31). a Leave bolts (32) tightened by 2 – 3 threads to prevent the pump from falling down.
10. Remove air bleeding valve (19) and oil filler bracket (20). 11. Remove clamps (21), (22) and (23).
[*6]
15. Set tools P (P1, P2, and P3), tighten center bolt of tool P1, and remove gear (33) from the shaft.
12. Remove fuel tubes (24), (25), (26), (27) and (28). [*7] 13. Remove clamp (29) and oil tube (30).
140E-5 Series
16. Remove mounting bolts (32) which have been left and remove supply pump assembly (31). a If tool P is removed, the gear falls down. Accordingly, keep it installed until the pump is installed.
[*8]
5
SEN00159-04
Installation q Carry out installation in the reverse order to removal.
50 Disassembly and assembly
[*7]
3 q
[*1]
3
q
Nut: 176 – 196 Nm {18 – 20 kgm}
q
[*2] a Apply engine oil thinly to the oil filter cartridge packing and tighten the oil filter cartridge 3/4 – 1 more turn after the packing touches the sealing face.
q
[*3]
3
q
Oil filler mounting U-clamp nut: 10.8 – 26.5 Nm {1.1 – 2.7 kgm}
[*4]
3 q q q
Joint bolt of tubes (5), (6): 24.5 – 34.3 Nm {2.5 – 3.5 kgm} Sleeve nut of tube (6): 43 – 47 Nm {4.4 – 4.8 kgm} Joint bolt of tube (7): (Filter head side) 7.8 – 9.8 Nm {0.8 – 1.0 kgm} (Fuel block side) 19.6 – 29.4 Nm {2.0 – 3.0 kgm}
Joint bolt of tube (24): (Both side) 14.8 – 19.6 Nm {1.5 – 2.0 kgm} Sleeve nut of tube (25): 43 – 47 Nm {4.4 – 4.8 kgm} Sleeve nut of tube (26): 43 – 47 Nm {4.4 – 4.8 kgm} Joint bolt of tube (27): (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} Joint bolt of tube (28): (Pump side) 14.8 – 19.6 Nm {1.5 – 2.0 kgm} (Fuel block side) 19.6 – 29.4 Nm {2.0 – 3.0 kgm}
[*8]
3 q
Joint bolt of tube (30): (Cylinder block side) 9.8 – 12.7 Nm {1.0 – 1.3 kgm} (Pump side) 7.9 – 12.7 Nm {0.8 – 1.3 kgm}
[*5] 1)
2)
3)
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} Tighten clamps (14), (15), and (16) with the hand first, and then tighten them permanently. a Tighten clamps permanently in the order of (14), (15) and (16). 3 Clamp mounting bolt: 9.8 ± 1 Nm {1 ± 0.1 kgm} 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
6
Clamps (21), (22) and (23) mounting bolt: 9.8 ± 1 Nm {1 ± 0.1 kgm}
140E-5 Series
50 Disassembly and assembly
Replacement of oil seal of engine mounted on machine 1 a
SEN00159-04
q
Left: Standard seal, Right: Sleeved seal
There are standard seal and sleeved seal. (Refer to the "Installation")
1. Rear oil seal a
For the work up to removal of the flywheel, see the Shop manual for the applicable machine. Removal of seal (For standard seal) 1) Drill through a hole of approx. 3 mm dia. on rear seal (4). 2) Replace the tip of tool L with the drill type one (DT). 3) Insert the top end of tool L into the drilled hole, and remove the front seal by the impact of slide hammer (SH). (Apply the slide hammer evenly not to tilt the rear seal.) (For sleeved seal) 1) Cut and remove the sleeve (7) with a chisel and a hammer. 2) Replace the tip of tool L with the puller type one (PT). 3) Hitch the end of tool L to the metal ring of rear seal (4) and pull out the seal with impacts slide hammer (SH). a Remove the metal powders completely. a Take care not to damage crankshaft (6). q
Tool L
Installation a Check the Teflon seal (Laydown lip seal) by checking the wear of the shaft and replace it with the "standard seal" or "sleeved seal". If the shaft is worn to the degree of luster (If wear which you feel with your finger is less than 10 mm) and does not have any flaw, install "standard seal A". In other cases, install "sleeved seal B". a (8): Plastic inside cylinder which is also used as installation guide. a (6): Sleeve. a Do not remove plastic inside cylinder (8) from rear seal (4) before installing the rear seal. a Handle rear seal (4) and sleeve (7) as an assembly and never separate them from each other. q
140E-5 Series
Left: Standard seal, Right: Sleeved seal
7
SEN00159-04 a a a
Clean, degrease, and dry the contact surface against the flywheel housing. Clean, degrease, and dry the seal lip surface (periphery of the crankshaft). Check that the end corners and lip sliding surfaces of the crankshaft are free from flaw, burr, and rust of the housing.
50 Disassembly and assembly
1.
Procedure for installing standard seal a When installing rear seal (4), do not apply oil or grease to the shaft and seal lip. 1) Set large inside diameter side (b) of guide (8) of rear seal (4) to the end of crankshaft (6). a Take care extremely not to mistake the direction of the plastic inside cylinder.
2)
3)
8
Push the metal ring of rear seal (4) evenly. a Hit the metal ring of rear seal with plastic hammer evenly. a Do not hit it strongly. After pushing in the seal, remove guide (8). a When removing the inside cylinder, take care not to damage the seal lip.
140E-5 Series
50 Disassembly and assembly
4)
Tighten the 4 bolts evenly to press fit rear seal (4) until the end of tool N1 (for press fitting the seal) reaches the end of crankshaft (6). a Tighten tool N1 (for press fitting the seal) first until the bolt without washer stops and then tighten the bolt with 2 washers. a When press fitting the seal, take care not to damage the lip with the tool set etc. a After press fitting the seal, remove the red sealant layer from its periphery.
SEN00159-04
2)
Set sleeve (7) of the rear seal to the end of crankshaft (6) and tighten the 4 bolts evenly to press fit sleeve and rear seal assembly (9) until the end of tool N2 reaches the end of crankshaft (6). a Tighten tool N2 (for press fitting the sleeved seal) until the bolt with washer stops.
3)
Remove tool N2 (for press fitting the sleeved seal) and install tool N3 (for press fitting the seal). Tighten the 4 bolts evenly to press fit sleeve and rear seal assembly (9) until the end of tool N3 reaches the end of crankshaft (6). a Tighten tool N3 (for press fitting the seal) first until the bolt without washer stops and then tighten the bolt with 2 washers. a After press fitting the seal, remove the red sealant layer from its periphery. a Rear seal driving depth: 13.2 ± 0.2 mm from end of crankshaft
4) 2.
Procedure for installing sleeved seal a When installing the rear seal, do not apply oil or grease to the shaft, inside cylinder surface (C) of the sleeve (7) and seal lip. 1) Set sleeve and rear seal assembly (9) to tool N2 (for fitting the sleeved seal). 2 Sleeve inside cylinder surface (C): Gasket sealant (LG-7)
140E-5 Series
9
SEN00159-04
50 Disassembly and assembly
2. Front oil seal Removal a For the work up to removal of the damper, see the Shop manual for the applicable machine. 1) Remove front oil seal (1).
Removal with tool L 1) Drill several holes about 3 mm in diameter into front oil seal (1). 2) Replace the tip of tool L with the drill type one. 3) Insert the top end of tool L into the drilled hole, and remove the front seal by the impact of slide hammer (SH). (Apply the slide hammer evenly not to tilt the front seal.) a Remove the metal powders completely. a When the sleeve is attached, cut sleeve (6) using a gad and hammer to remove it. a Take care not to damage crankshaft (5).
Installation a Check the seal by checking the wear of the shaft and replace it with the "standard seal" or "sleeved seal". If the shaft is worn to the degree of luster (If wear which you feel with your finger is less than 10 mm) and does not have any flaw, install "standard seal A". In other cases, install "sleeved seal B". a (7): Plastic inside cylinder which is also used as installation guide. a (6): Sleeve. a Do not remove installation guide (7) from front seal (3) before installing the front seal. a Handle front seal (3) and sleeve (6) as an assembly and never separate them from each other. Standard spare seal
10
Sleeved seal
140E-5 Series
50 Disassembly and assembly
1.
Procedure for installing standard seal a Before installing the seal, check that the end corners and lip sliding surfaces of the crankshaft are free from flaw, burr, and rust of the housing. a When installing the seal, do not apply oil or grease to the shaft and seal lip. Wipe off the oil from the shaft. a Never remove inside plastic cylinder (7) of the replacement seal before installing the seal. 1) Set large inside diameter side (b) of plastic inside cylinder (7) to the end of crankshaft (5). a Take care not to mistake the direction of the plastic inside cylinder.
SEN00159-04
2)
3)
4)
140E-5 Series
Push the metal ring of front seal (3) evenly as if you are passing over the large inside diameter side of plastic inside cylinder (7). a Hit the metal ring of front seal with plastic hammer evenly. a Do not hit it strongly. After pushing in the seal, remove plastic inside cylinder (7). a When removing the inside cylinder, take care not to damage the seal lip.
Using tool M1, tighten the 3 bolts evenly to press fit seal (9) until the end of tool M1 reaches the end of crankshaft (5). a Tighten tool M1 first until the 55-mm bolts stop and then replace the 55mm bolts with the 35-mm bolts and tighten them. a Seal driving distance (a) from crankshaft: 9.1 – 10.1 mm a When press fitting the seal, take care not to damage the lip of the seal with the tool set etc. a After press fitting the seal, remove the red sealant layer from its periphery.
11
SEN00159-04
KOMATSU 140E-5 Series engine Form No. SEN00159-04
© 2010KOMATSU All Rights Reserved Printed in Japan 04-10
12
SEN05198-00
ENGINE 1SHOP MANUAL
140E-5 Series
90 Repair and replacement of parts Information related to repair and replacement Flowchart ........................................................................................................................................................ 2 Special tool table............................................................................................................................................. 4 Special tool sketch .......................................................................................................................................... 6
140E-5 Series
1
SEN05198-00
90 Repair and replacement of parts
Flowchart Repair of cylinder block top and counterbore by grinding
a a
For removal, installation, disassembly and assembly of the engine, see the Shop Manual, "Disassembly and assembly". If the judgment of No. 9 is NO, examine A.
2
140E-5 Series
90 Repair and replacement of parts
140E-5 Series
SEN05198-00
3
SEN05198-00
90 Repair and replacement of parts
Special tool table Replacement/Rebuilding item
Symbol
Part No.
A
795-611-1300
Pressure test of cylinder head Replacement of valve guide
B C
Pump assembly
1
Push tool
1
2
795-411-1310
Push tool
1
795-100-4801
Seat puller
1
For valve seat insert
1
790-101-5001
Push tool KIT
1
KIT
2
790-101-5081
Plate
1
For intake valve
3
790-101-5071
Plate
1
For exhaust valve
795-100-3005
Seat cutter
1
KIT
795-100-3100
Body assembly
1
795-100-3200
Micrometer
1
795-100-3300
Gauge
1
795-100-3401
Tool head
1
795-100-3601
Head support
1
2
795-100-3710
Cutter
1
For oversize machining
3
795-100-3720
Cutter
1
For 30°
4
795-100-3730
Cutter
1
For 45°
5
G
795-100-4211
Pilot
1
f10.000 mm
795-100-4221
Pilot
1
f10.010 mm
795-100-4231
Pilot
1
f10.020 mm f10.030 mm
795-100-4241
Pilot
1
1
795-140-6410
Guide puller
1
2
795-130-1310
Guide driver
1
Valve refacer
1
Repair of valve by grinding
H
Commercially available
Check of main bearing mounting hole inside diameter
J
Commercially available
Alignment bar
1
1
790-101-2800
Bearing puller
1
2
790-101-2300
Push puller
1
795-240-6401
Push tool
1
1
795-240-6411
Push tool
1
2
795-240-6420
Push tool
1
3
795-240-6431
Block
1
4
795-240-6440
Nut
1
Replacement of crankshaft gear
K L
Replacement of connecting rod small end bushing
L
M
Replacement of cam bushing
4
M
KIT
795-100-1522
Replacement of valve seat insert
Replacement of crosshead guide
1
Remarks
79A-471-1050
1
F
Coolant tester
Q'ty
1 D
E
Part name
795-213-1200
Push tool
1
1
795-213-1250
Bar
1
2
795-213-1210
Push tool
1
3
795-213-1240
Collar
1
4
795-213-1230
Guide
1
5
795-103-0400
Grip
1
KIT
KIT
140E-5 Series
90 Repair and replacement of parts
Replacement/Rebuilding item
Symbol
Part No.
N
795-931-1100 1
795T-421-1260 Sleeve jig
For pulling out
1
For press fitting standard seal (For wet type)
3
3
01643-31645
Washer
3
795T-421-1240 Sleeve jig
1
5
01050-31645
Bolt
3
6
01643-31645
Washer
3
795T-421-1231 Sleeve jig
1
8
01050-31645
Bolt
3
9
01643-31645
Washer
9
1 3 4 5 6 7
795T-421-1270 Sleeve jig 01050-31645
Bolt
01643-31645
Washer
795T-421-1240 Sleeve jig 01050-31645
Bolt
01643-31645
Washer
795T-421-1250 Sleeve jig
Remarks
1
Bolt
2
Q
Seal puller assembly
Q'ty
01050-31640
7 Replacement of engine rear seal
Part name
2 4 P
140E-5 Series
SEN05198-00
1 3 3
For press fitting sleeved seal (For wet type)
For press fitting standard seal (For dry type)
1 3 3 1
8
01050-31645
Bolt
3
9
01643-31645
Washer
9
For press fitting sleeved seal (For dry type)
5
SEN05198-00
90 Repair and replacement of parts
Special tool sketch Note) We will not be liable for any result of use of special tools manufactured according to the following drawings. P1. Sleeve jig
P4, Q4. Sleeve jig
6
140E-5 Series
90 Repair and replacement of parts
SEN05198-00
Note) We will not be liable for any result of use of special tools manufactured according to the following drawings. P7. Sleeve jig
Q1. Sleeve jig
140E-5 Series
7
SEN05198-00
90 Repair and replacement of parts
Note) We will not be liable for any result of use of special tools manufactured according to the following drawings. Q7. Sleeve jig
8
140E-5 Series
90 Repair and replacement of parts
140E-5 Series
SEN05198-00
9
SEN05198-00
KOMATSU 140E-5 Series engine Form No. SEN05198-00
© 2009 KOMATSU All Rights Reserved Printed in Japan 05-09 (01)
10
SEN05199-02
ENGINE 1SHOP MANUAL
140E-5 Series
90 Repair and replacement of parts Cylinder head Part names related to cylinder head ............................................................................................................... 2 Testing and inspection of cylinder head .......................................................................................................... 3 Pressure test of cylinder head ........................................................................................................................ 5 Replacement of valve guide............................................................................................................................ 5 Replacement of valve seat insert.................................................................................................................... 6 Replacement of crosshead guide ................................................................................................................. 13 Repair of cylinder head mounting face by grinding ....................................................................................... 14 Repair of valve by grinding ........................................................................................................................... 15
140E-5 Series
1
SEN05199-02
90 Repair and replacement of parts
Part names related to cylinder head
1. 2. 3. 4. 5. 6. 7.
2
Cylinder head Crosshead guide Valve guide Valve seat insert (intake side) Valve (intake valve) Valve (exhaust valve) Valve seat insert (exhaust side)
140E-5 Series
90 Repair and replacement of parts
SEN05199-02
Testing and inspection of cylinder head Unit: mm
Inspection item
Criteria
Remedy
• Presence of crack (External dye check) Water leakage from and crack • Presence of water leakage during air pressure test of cylinder head (0.29 – 0.34 MPa {3.0 – 3.5 kg/cm2}, 30 sec) • Water pressure test (0.34 – 0.39 MPa {3.5 – 4.0 kg/cm2}, 10 min) Tolerance Distortion of cylinder head top and bottom 0 – 0.06 Damage of valve contact surface of valve seat insert or looseness of valve seat insert Valve sinking quantity (both intake and exhaust valves)
• Presence of dent on valve seat insert contact surface • Check of valve seat insert contact surface • Airtightness test • Hit cylinder head lightly to check for looseness a See Fig. A Sink (a) Standard value Repair limit 0 ± 0.1
Repair by welding or replace cylinder head Repair by grinding or replace cylinder head Repair valve seat insert contact surface or replace valve seat insert Replace valve seat insert
—
a See Fig. B Valve head thickness (c) Valve
Standard value
Repair limit
Intake
2.4
1.9
Exhaust
2.15
1.6
Valve head thickness
Abnormality in valve
Replace valve
Valve seat contact surface angle (b) Intake valve: 30° Exhaust valve: 45° • Deformation of head into dish shape • Presence of crack or dent on seat contact surface of valve • Airtightness test • Play when new cotter pin is inserted in cotter groove • Uneven wear or bend of valve stem • Presence of dent at valve stem end
Outside diameter of valve stem
Repair stem
Valve
Standard size
Standard value
Repair limit
Intake
10
9.940 – 9.955
—
Exhaust
10
9.911 – 9.926
—
Intake
10
9.991 – 10.011
—
Exhaust
10
9.991 – 10.011
—
Inside diameter of valve guide
Projection of valve guide Outside diameter of crosshead guide Projection of crosshead guide
140E-5 Series
a See Fig. C Allowable range of projection (d): 22 ± 0.2 Standard size Standard value 11
11.000 – 11.011
a See Fig. D Allowable range of projection (e): 49 ± 0.25
Repair limit —
Replace valve
Replace valve guide
Replace crosshead guide Repair crosshead guide
3
SEN05199-02
90 Repair and replacement of parts
Illustrations related to testing and inspection table Fig. A
Fig. D
a: Sink
e: Projection 1. Crosshead guide 2. Cylinder head
Fig. B
b: Valve seat contact surface angle c: Valve head thickness Fig. C
d: Projection
4
140E-5 Series
90 Repair and replacement of parts
SEN05199-02
Pressure test of cylinder head
Replacement of valve guide
a
a
Pressure test tools
Symbol
Part No.
Part name
A
790-553-1601
Coolant tester
B
79A-471-1050
Pump assembly
q
If the cylinder head parts were repaired, perform the test according to the following procedure.
Valve guide replacement tools
Symbol C
Part No.
Part name
1
795-100-1522
Push tool
2
795-411-1310
Push tool
Pulling out of valve guide q
Using tool C1, pull out the valve guide.
Water pressure test 1.
Combine tools A and B and connect the hose to the cylinder head.
2.
Apply water pressure (0.34 – 0.39 MPa {3.5 – 4.0 kg/cm2}) for about 10 minutes and check around the cylinder head for leakage.
a
Warm the whole cylinder head and then perform the test with hot water at 80 – 95°C. Pay fully attention to handling the cylinder head and water whose temperature are high, and take care not to get burnt.
k
Press fitting of valve guide 1.
2.
3. a
Machine the valve guide hole of the cylinder head to the dimension below. q Inside diameter: 17(+0.011/0)mm Press fit the valve guide until the tool C2 end touches the cylinder head. Check that the projection of the valve guide is within the standard value. Projection tolerance of valve guide: 22 ± 0.2 mm
Air pressure test 1.
Connect the air compressor hose to the cylinder head.
2.
Put the cylinder head in a water tub, apply air pressure (0.29 – 0.34 MPa {3.0 – 3.5 kg/cm2} for about 30 seconds, and check for air leakage.
a
If any crack is detected in the cylinder head by the above tests, replace the cylinder head.
140E-5 Series
5
SEN05199-02
90 Repair and replacement of parts
Replacement of valve seat insert a
Valve seat insert replacement tools
Symbol
Part No.
D E
F
Part name
795-100-4801
Seat puller
1
790-101-5001
Push tool KIT
2
790-101-5081
Plate
3
790-101-5071
Plate
1
795-100-3005
Seat cutter
2
795-100-3710
Cutter
3
795-100-3720
Cutter
4
795-100-3730
Cutter
5
795-100-4211
Pilot
Pulling out of valve seat insert k k k
k
k
Keep the air pressure at 0.5 – 0.6 MPa {5 – 6 kg/cm2} during the work. When replacing the grinding stone, stop the air. Before starting the grinding work, perform a trial operation of the grinder for 1 minute and ensure that the grinder is normal. a After replacing the grinding stone, perform a trial operation for 3 minutes. Ensure that the grinding stone is free from damage and install it to the grinder shaft with no play. When using the grinder, put on safety glasses.
When pulling out with seat puller of tool D 1. Install grinding stone (4) to grinder (1). 2.
While matching the groove of sleeve (2), insert the grinder in holder (3). (Adjust the grinder position with set screw (5).)
3.
Adjust the position of grinder (1) so that the center of grinding stone (4) will be at the center of valve seat insert (a) and then tighten set screw (5) to fix grinder (1).
4.
Rotate grinding stone (4) and move it slowly until it touches valve seat insert (a).
5.
While lightly pressing grinding stone (4) against the inside surface of valve seat insert (a), make a groove about 1 mm deep all around the inside surface of valve seat insert (a).
6
140E-5 Series
90 Repair and replacement of parts
6.
Push in 3 claws (10) of puller head (9) of tool D with the hand and put them in valve seat insert (a).
7.
Tighten screw (12) to press 3 claws (10) against the inside groove of valve seat insert (a). a If screw (12) is tightened too strongly, the insert will be broken and become difficult to pull out. Accordingly, stop tightening when 3 claws (10) reach the groove fully.
8.
Put bridge (8) in the outside of puller head (9), place plates (11) and (7) on the bridge, and tighten nut (6) to pull out valve seat insert (a).
140E-5 Series
SEN05199-02
When pulling out valve seat insert (a) by welding a bar to it 1. Weld bar (b) (Length: 0.1 – 0.5 mm shorter than valve seat inside diameter, Diameter: Approx. 10 mm) to the inside of valve seat insert (a). a Take care that welding spatters will not stick to the head. 2.
After the temperature of the welded parts has decreased to around the ambient temperature, insert an unnecessary valve (c) in the reverse direction and hit its head with a small hammer to pull out valve seat insert (a). a If a large impact is given, the welded parts may come off. Take care.
7
SEN05199-02
90 Repair and replacement of parts
Press fitting of valve seat insert When press fitting hole for valve seat insert (a) is not repaired by cutting 1. Using tools E1 and E2 or tools E1 and E3, press fit standard valve seat insert (a) with press (d). a Do not press fit with a hammer. a Press fitting force of valve seat insert (a) Intake side: Approx. 14.7 kN {Approx. 1.5 ton} Exhaust side: Approx. 14.7 kN {Approx. 1.5 ton}
2.
8
Measure sinking quantity (f) of valve seat insert (a) from cylinder head bottom (e). a Sinking quantity (f) of valve seat insert (a) Intake side: 2.2 mm Exhaust side: 2.4 mm
140E-5 Series
90 Repair and replacement of parts
140E-5 Series
SEN05199-02
9
SEN05199-02
90 Repair and replacement of parts
Oversize machining of valve seat insert mounting hole q
Using tool F1 and attached cutter F2, increase the valve seat insert mounting hole to the next oversize.
a
Limit the increase of the mounting hole diameter to 1.0 mm. If the hole diameter needs to be increased more than 1.0 mm, replace the cylinder head.
Machining dimensions of valve seat insert and mounting hole Intake valve side Valve seat insert size
a
Unit: mm Valve seat insert d1
Valve seat insert mounting hole c1
d2
d3
c2
Standard
55.0 +0.111 +0.086
0 8.8 –0.1
55.0 +0.019 0
58.00 ± 0.2
0 11 –0.1
0.25 OS
55.25 +0.111 +0.086
0 8.8 –0.1
55.25 +0.019 0
58.25 ± 0.2
0 11 –0.1
0.50 OS
55.5 +0.111 +0.086
0 8.92 –0.1
55.5 +0.019 0
58.50 ± 0.2
0 11.12 –0.1
0.75 OS
55.75 +0.111 +0.086
0 9.05 –0.1
55.75 +0.019 0
58.75 ± 0.2
0 11.25 –0.1
1.00 OS
56.0 +0.111 +0.086
0 9.18 –0.1
56.0 +0.019 0
59.00 ± 0.2
0 11.38 –0.1
OS: Oversize
Exhaust valve side Valve seat insert size
a
10
Unit: mm Valve seat insert d1
Valve seat insert mounting hole c1
d2
d3
c2
Standard
52.0 +0.080 +0.070
0 8.6 –0.1
52.0 +0.019 0
55.00 ± 0.2
0 11 –0.1
0.25 OS
52.25 +0.080 +0.070
0 8.6 –0.1
52.25 +0.019 0
55.25 ± 0.2
0 11 –0.1
0.50 OS
52.5 +0.080 +0.070
0 8.72 –0.1
52.5 +0.019 0
55.50 ± 0.2
0 11.12 –0.1
0.75 OS
52.75 +0.080 +0.070
0 8.85 –0.1
52.75 +0.019 0
55.75 ± 0.2
0 11.25 –0.1
1.00 OS
53.0 +0.080 +0.070
0 8.98 –0.1
53.0 +0.019 0
56.00 ± 0.2
0 11.38 –0.1
OS: Oversize
140E-5 Series
90 Repair and replacement of parts
Valve seat insert
SEN05199-02
Finish machining of valve contact surface of valve seat insert 1. a
Using tool F1 and attached cutters F3 and F4, machine the valve contact surface of the valve seat insert to the following dimensions. Select tool F5 which will be inserted in the valve guide with no clearance.
Valve seat insert mounting hole
g: Cylinder head bottom a a a a a
Inside finished surface roughness: Max. 12.5S Mounting hole bottom surface roughness: Max. 12.5S Concentricity of valve guide hole and valve seat insert hole: Max. 0.07 mm (TIR) Squareness of valve guide hole to valve seat insert hole bottom: Max. 0.03 mm (TIR) TIR is an abbreviation for Total Indicator Reading, which is the difference between the maximum and minimum readings in runout measurement.
140E-5 Series
EV: Exhaust valve IV: Intake valve h: Finish machining width
11
SEN05199-02
2.
Fit the contact surface of the valve seat insert to the valve by using compound. 1) Thinly apply rough compound mixed with oil to the seat surface of a valve and insert that valve in the valve guide. 2) Install the fitting rod to the valve head and lightly hit valve against the valve seat while rotating it with both hands to fit the valve to the valve seat. 3) After the valve and valve seat are fitted and their surfaces become smooth, wipe off the compound. 4) Apply fine compound and fit the valve and valve seat again similarly to the above until they are fitted to each other without breakage.
90 Repair and replacement of parts
Final inspection q
q q
q
q q
Thinly apply red lead to the valve seat insert contact surface of a new valve and insert that valve in the valve guide. Lightly press the valve against the valve seat insert and rotate it 10°. Check the valve seat insert contact surface of the valve and ensure that the contact is even and is not broken. Or, make marks (m) (about 20 places) on the valve seat insert contact surface of a new valve with a pencil and insert that valve in the valve guide. Lightly press the valve against the valve seat insert and rotate it 10°. Ensure that all the pencil marks (m) have been erased evenly.
When master valve is used
EV: IV: j: k:
Exhaust valve Intake valve Cylinder head bottom Contact width against valve
a
Concentricity of contact surfaces of valve guide and valve seat insert: Max. 0.07 mm (TIR) TIR is an abbreviation for Total Indicator Reading, which is the difference between the maximum and minimum readings in runout measurement.
a
12
140E-5 Series
90 Repair and replacement of parts
Replacement of crosshead guide a
Crosshead guide replacement tools
Symbol G
Part No.
1.
1
795-140-6410
Guide puller
2
795-130-1310
Guide driver
Using tool G1, pull out crosshead guide (a) from cylinder head (b). Hold crosshead guide (a) with collet (4) of the puller.
2.
Tighten collet (4) with bolt (1) to lock sleeve (2).
3.
Rotate nut (3) and pull out the crosshead guide.
4.
Remove burrs and fins from and clean the crosshead guide mounting portion.
140E-5 Series
Press fitting of crosshead guide q
Part name
Pulling out of crosshead guide q
SEN05199-02
a a
Using tool G2, insert crosshead guide (a) in cylinder head (b) and press fit it with a copper or plastic hammer until the projection is within the tolerance. Projection tolerance of crosshead guide: 49 ± 0.25 mm Diameter of cylinder head crosshead guide f11 –0.027 hole: –0.054 mm
13
SEN05199-02
90 Repair and replacement of parts
Repair of cylinder head mounting face by grinding 1 Grinding 1.
Remove the valve seat insert. q For the removal procedure, see "Replacement of valve seat insert".
2.
Remove the distortion and corrosion of the cylinder head by grinding within the tolerance of cylinder head height (a). q Stamp "R" on the left side of the cylinder head.
a
Standard cylinder head height (a): 140 ± 0.05 mm Limit after grinding: 139.65 mm Grinding depth by 1 grinding: 0.10 – 0.15 mm Ground surface roughness: Max. 8S Flatness (Distortion): Max. 0.05 mm Grinding depth limit: 0.3 mm Difference in head height (a) for 1 unit: Max. 0.15 mm
a a a a a a
3.
Press fit the valve seat insert of the next oversize. q For the press fitting procedure, see "Replacement of valve seat insert".
Check after repair by grinding q
a a
14
Measure the valve recess and projection of the injector and ensure that they are within the standard values and then adjust if necessary. Valve recess Standard: 0 ± 0.1 mm Projection of the injector nozzle: 2.3 – 2.9
140E-5 Series
90 Repair and replacement of parts
Repair of valve by grinding a
SEN05199-02 a
Valve grinding tool
Symbol
Part No.
H
Commercially available
Part name Valve refacer
a
Grinding of seat contact surface of valve q
Using tool H, grind the seat contact surface of the valve.
a
Seat contact surface angle of valve (a) Intake valve: 30° ± 0°15' Exhaust valve: 45° ± 0°15'
Check after grinding q
a
a a
Measure the valve head thickness, sinking quantity of the valve, and contact of the seat contact surface of the valve, and ensure that they are within the standard values. Allowable limit of valve head thickness (b) Intake valve: Min. 1.9 mm (Standard size: 2.4 mm) Exhaust valve: Min. 1.6 mm (Standard size: 2.15 mm) Standard of contact surface (c) of valve Intake valve: 4.32 mm Exhaust valve: 3.41 mm Standard of valve sinking quantity: 0 ± 0.10 mm (Both intake and exhaust valves)
140E-5 Series
Apply dial gauge (1) to the facial runout measuring point of seat contact surface (c) of the valve and rotate the valve to measure its facial runout while pressing it toward left (d). Intake valve: Max. 0.045 mm (TIR) Exhaust valve: Max. 0.030 mm (TIR) TIR is an abbreviation for Total Indicator Reading, which is the difference between the maximum and minimum readings in runout measurement.
e: Block a q
q q
q
q q
Check the contact of the seat contact surface of the valve by either of the following methods. Thinly apply red lead to the seat contact surface of the ground valve and insert that valve in the valve guide. Lightly press the valve against the valve seat insert and rotate it 10°. Check the valve seat insert contact surface of the valve and ensure that the contact is even and is not broken. Make marks (f) (about 20 places) on the seat contact surface of the ground valve with a pencil and insert that valve in the valve guide. Lightly press the valve against the valve seat insert and rotate it 10°. Ensure that all the pencil marks (f) have been erased evenly.
15
SEN05199-02
KOMATSU 140E-5 Series engine Form No. SEN05199-02
© 2010 KOMATSU All Rights Reserved Printed in Japan 10-10
16
SEN05200-01
ENGINE 1SHOP MANUAL
140E-5 Series
90 Repair and replacement of parts Cylinder block Part names related to cylinder block............................................................................................................... 3 Testing and inspection of cylinder block.......................................................................................................... 4 Method of checking main bearing metal inside diameter with alignment bar.................................................. 6 Part names related to crankshaft .................................................................................................................... 7 Testing and inspection of crankshaft ............................................................................................................... 8 Part names related to connecting rod ............................................................................................................. 9 Testing and inspection of connecting rod...................................................................................................... 10 Replacement of flywheel ring gear.................................................................................................................11 Replacement of crankshaft gear ................................................................................................................... 12 Replacement of camshaft gear ..................................................................................................................... 13 Replacement of main bearing metal cap ...................................................................................................... 14 Replacement of connecting rod small end bushing ...................................................................................... 16 Replacement of cam bushing ....................................................................................................................... 17 Repair of cylinder block top by grinding ........................................................................................................ 19 Repair of counterbore by grinding................................................................................................................. 20 Check and identification after repair by grinding ........................................................................................... 22
140E-5 Series
1
SEN05200-01
90 Repair and replacement of parts
Gasket sealant application procedure........................................................................................................... 23 Repair standard for cylinder liner O-ring ....................................................................................................... 25 Replacement of engine rear seal .................................................................................................................. 26 Replacement of wear sleeve (when sleeve is installed)................................................................................ 30 Repair of crankshaft by grinding ................................................................................................................... 31 Improvement of surface roughness of crankshaft journal ............................................................................. 36
2
140E-5 Series
90 Repair and replacement of parts
SEN05200-01
Part names related to cylinder block
1. 2. 3. 4. 5. 6. 7.
Cylinder liner Clevis seal Cylinder liner O-ring Cylinder block Main bearing metal cap bolt Main bearing metal cap (No. 1, 2, 3, 4, 5 and 6 are same) Camshaft bushing
140E-5 Series
3
SEN05200-01
90 Repair and replacement of parts
Testing and inspection of cylinder block Unit: mm
Inspection item Crack Repair of contact of packing
Clearance to cylinder liner
Inside diameter of camshaft bushing
Projection of cylinder liner
Criteria
65
65.000 – 60.060
Standard value
11
Main bearing mounting hole diameter • Tighten main bearing metal cap bolt to specified torque • Measure in range of 10° on upper and lower sides of main bearing metal cap
Fit of main bearing metal cap and cylinder block (Interference)
Tolerance 0 – 0.09
a See Fig. E Standard size
Replace camshaft bushing
Repair by cutting Add shim
Repair by cutting or replace cylinder block
Standard value
127
Concentricity of adjacent holes a See Fig. F
Replace cylinder liner or cylinder block
11.000 – 11.050
Flatness of cylinder block top
General concentricity
Replace cylinder block
Replace cylinder liner or repair cylinder block
a See Fig. C Allowable range: 0.07 – 0.15
a See Fig. D Presence of corrosion Depth and bottom corrosion of Standard size counterbore
Distortion and wear of cylinder head mounting face
Remedy
Presence of crack (External dye check) Cylinder head bolt hole etc. a See Fig. A Water leakage caused by corrosion a See Fig. B Standard value Standard Standard size Bore of Outside diameter clearance cylinder block of cylinder liner 158.000 – 157.897 – f158 0.073 – 0.143 158.040 157.927 Inside diameter Standard size Standard value
127.000 – 127.018 Roundness of f127 must be 0.005 from front to rear of cylinder block Alignment bar for roundness of 0.010 must go Replace cylinder through smoothly block
Journal
Standard fit (Interference)
No. 1 – 6
0.002 – 0.060
No. 7
0.002 – 0.060
a See Fig. G
Inside diameter of counterbore and outside diameter of cylinder liner flange
Cylinder liner Standard size
Standard value
Upper section
170.2
170.10 – 170.20
Lower section
161.2
161.25 – 161.29
Replace cylinder liner
Cylinder block
4
Upper section
170.2
170.200 – 170.263
Lower section
161.2
161.17 – 161.23
Replace cylinder block
140E-5 Series
90 Repair and replacement of parts
SEN05200-01
Illustrations related to testing and inspection table Fig. A
Fig. D
a: Packing portion
f: Depth of counterbore
Fig. B
Fig. E
b: Clearance
g: Inside diameter
Fig. C
Fig. F
c: Cylinder liner d: Cylinder block e: Projection
h: Fit
140E-5 Series
5
SEN05200-01
Fig. G
90 Repair and replacement of parts
Method of checking main bearing metal inside diameter with alignment bar q
When checking the main bearing metal inside diameter with tool J (alignment bar), follow the procedure below. Unit: mm Specified dimension Diameter
i: Upper section j: Lower section
6
157
–0.014 –0.039
Roundness
0.005
Straightness
0.010
Length
Min. 1,300
1.
Set the cylinder block on the stand with the main bearing metal cap side up.
2.
Apply engine oil to the inside of the main bearing metal hole of the cylinder block. a Leave the main bearing metal cap removed.
3.
Set tool J (alignment bar) to the main bearing metal hole of the cylinder block.
4.
Install the main bearing metal cap and tighten it to the following torque.
5.
Check that tool J (alignment bar) moves smoothly.
140E-5 Series
90 Repair and replacement of parts
SEN05200-01
Part names related to crankshaft
1. 2. 3. 4.
Crankshaft Main bearing metal (upper) Main bearing metal (lower) Thrust metal (All of upper x 1 and lower x 2 are the same)
140E-5 Series
7
SEN05200-01
90 Repair and replacement of parts
Testing and inspection of crankshaft Unit: mm
Inspection item
Criteria
Crack
Check for crack by magnaflux inspection
Damage
Presence of damage in journal • Flaw • Seizure • Discoloration
Remedy Replace crankshaft If damaged slightly, repair with oilstone or by lapping. If seized, replace crankshaft Repair or replace crankshaft
Damage of tap holes at front and rear ends Clogging of oil hole
Presence of clogged oil hole
Repair
Standard value End play of crankshaft
Thrust metal thickness
Outside diameter of crankpin journal
Size Standard 0.25 US 0.50 US 0.75 US 1.00 US Standard 0.25 US 0.50 US 0.75 US 1.00 US
Roundness of crankpin journal
Roundness of crank main journal Clearance in crank main journal
Standard size 4.000 4.125 4.250 4.375 4.500 90.00 89.75 89.50 89.25 89.00 Standard
Tolerance
–0.07 –0.12
–0.050 –0.068
Replace thrust metal or repair with oversize crankshaft
Repair with undersize parts or replace crankshaft
0 – 0.009
Clearance in crankpin journal
Outside diameter of crank main journal
Replace thrust metal or repair with oversize parts
0.140 – 0.315
Repair with undersize parts or replace connecting rod bearing metal
0.042 – 0.110 Size Standard 0.25 US 0.50 US 0.75 US 1.00 US
Standard size 120.00 119.75 119.50 119.25 119.00 Standard
Tolerance
–0.050 –0.068
Repair with undersize parts or replace crankshaft
0 – 0.009 Repair with undersize parts or replace main bearing metal
0.044 – 0.106 Standard
Bend of crankshaft (Total indicator reading)
8
Concentricity of all main journals
0 – 0.15
Concentricity of adjacent journals
0 – 0.05
Replace crankshaft
140E-5 Series
90 Repair and replacement of parts
SEN05200-01
Part names related to connecting rod
1. 2. 3. 4. 5. 6. 7.
Connecting rod bolt Cap Dowel pin Bearing metal (lower) Bearing metal (upper) Rod Small end bushing
140E-5 Series
9
SEN05200-01
90 Repair and replacement of parts
Testing and inspection of connecting rod Unit: mm
Inspection item Crack Parallelism and twist of small and large end holes of connecting rod
Clearance between connecting rod small end bushing and piston pin
Criteria
Remedy
Check for crack by dye check or magnaflux inspection a See Fig. H Presence of bend (after small end bushing is installed) Parallelism: 0.20 Twist: 0.30 Tolerance Standard size Standard clearance Shaft Hole 0 –0.006
f52
–0.049 – –0.030
0.030 – 0.055
Replace connecting rod
Replace small end bushing Surface roughness of inside of small end bushing Max. 3.2S
Standard • Large end hole diameter Tolerance size • Without bearing metal. +0.026 • Inside surface roughness of large end hole: 95 –0.004 Max. 3.2S Replace bearing Connecting rod large end hole Standard clearance metal or connecting • Clearance to crankshaft bearing diameter rod (with bearing metal) 0.042 – 0.111 • Wave of large end hole: Max. 0.004 (All width)
Bearing metal thickness
Even if dimensions of each part are within allowable limits, if any clearance exceeds allowable clearance, replace parts (bearing metal etc.) Size Standard size Tolerance Standard 3.500 1.00 US 4.000 0 0.75 US 3.875 –0.010 0.50 US 3.750 0.25 US 3.625
Replace bearing metal and connecting rod
Flaw on inside of or seizure of Presence of flaw and seizure bearing metal Standard size
Distance between large and small end hole centers
264
Replace bearing metal
Tolerance 0 –0.040
Replace connecting rod
Streak and bruise on I-portion of connecting rod
a See Fig. J • Presence of lateral streak • Presence of lateral grinding mark
Replace connecting rod If there is bruise, replace connecting rod regardless of size of bruise
Fretting on cap mating face
Presence of fretting on mating face • Mating face roughness: Max. 6.3S • Back fitted area of mating face: Min. 70% a There must not be non-fitted area on outside of bolt hole center.
If fretting is felt with nail, replace connecting rod
Scuffing on cap bolt seat surface
Repair with oilstone
Scuffing on bolt seat surface
Replace bolt
Scuffing on washer surface
Replace washer
• • • •
Replace connecting rod
Scuffing on bolt seat surface
Deformation of dowel pin Damage of bolt
a a a
10
Presence of deformation of dowel pin Presence of deformation of dowel pin hole Presence of crack and/or damage on threaded portion of bolt Presence of bend of bolt
Replace bolt
If all the items of this criteria (particularly the wave of the large end hole) cannot be measured after the connecting rod is rebuilt, do not rebuild since the accuracy of the connecting rod large end hole after rebuilding cannot be confirmed. When reusability is judged, if there are honing marks left on the inside of the connecting rod large end hole, it is not required to measure the surface roughness of the inside and wave of the large end hole. Do not reuse the connecting rod cap mounting bolt more than 5 times. Each time the bolt is tightened, make a punch mark on it.
140E-5 Series
90 Repair and replacement of parts
Fig. H
SEN05200-01
Replacement of flywheel ring gear k
Take care not to throw down the flywheel and get hurt by mistake.
Removal of gear Make a notch at the tooth bottom of the gear with a grinder and break the gear to remove with a chisel. k Take care in handling the grinder and chisel.
q
a: Measured value Fig. J
Press fitting of gear 1. Check the gear mounting face. If there is a flaw, repair with an oilstone. 2.
Heat the gear at the specified shrink fit temperature for a certain time. a Gear shrink fit temperature: Max. 200°C Heating time: Min. 50 min
3.
Press fit the gear with the chamfered side directed toward the flywheel until its side contacts the flywheel.
b: Inspection range c: Streaks d: Lengthwise direction
140E-5 Series
11
SEN05200-01
90 Repair and replacement of parts
Replacement of crankshaft gear a
Crankshaft gear replacement tools
Symbol K
Part No.
Part name
1
790-101-2800
Bearing puller
2
790-101-2300
Push puller
4.
Using the drive tool, press fit the gear with the timing mark out until its side contacts the crankshaft flange. a Press fit the gear quickly before it cools down.
Removal of gear q Make a notch at the tooth bottom of the gear with a grinder, assemble tools K1 and K2, and rotate the nut to pull out the gear. a If the gear cannot be pulled out by the above method, make a notch at the tooth bottom of the gear with a grinder, heat the gear with a gas burner, and drive out the gear with a copper rod etc. a Take care not to damage the crankshaft.
Press fitting of gear 1. Check the gear mounting face, key way and flange surface. If there is a flaw, repair with an oilstone.
2.
Drive a new key into the key way of the crankshaft.
3.
Heat the gear at the specified shrink fit temperature for a certain time. a Gear shrink fit temperature: Max. 200°C Heating time: Min. 30 min
12
140E-5 Series
90 Repair and replacement of parts
SEN05200-01
Replacement of camshaft gear k
When setting the camshaft assembly on the press stand, take care not to catch your fingers between the press stand and the gear.
Removal of gear Set the camshaft assembly on the press stand and press the camshaft to pull out the gear.
Press fitting of gear 1. Check the gear mounting face, key way and flange surface. If there is a flaw, repair with an oilstone. 2.
Drive a new key into the key way of the camshaft.
3.
Install the thrust plate.
4.
Heat the gear at the specified shrink fit temperature for a certain time. a Gear shrink fit temperature: 220 – 240°C Heating time: 30 min
5.
Using the drive tool, press fit the gear with the timing mark out until its side contacts the camshaft flange. a Press fit the gear quickly before it cools down.
140E-5 Series
13
SEN05200-01
90 Repair and replacement of parts
Replacement of main bearing metal cap a
5.
When replacing the main bearing metal cap, work on the semi-finished cap according to the following procedure and install it.
Repair parts Part No.
Part name
6217-21-1240 No. 1, 2, 3, 4, 5, 6 main bearing metal cap 6217-21-1250 No. 7 main bearing metal cap
Inside machining of main bearing metal cap 1. Remove the cylinder liner. 2.
3.
4.
14
Install the replacement main bearing metal cap to the cylinder block and tighten it to the specified torque. a Match the notches of the cylinder block and main bearing metal cap to each other. 2 Main bearing metal cap mounting bolt: Apply engine oil to threaded portion and seat. a Tighten with the angle tightening wrench at the 3rd time. 3 Main bearing metal cap mounting bolt:
While checking the inside diameter of main bearing metal cap (1), cut little by little. a Cut to the degree that the boring bar tool almost touches the inside of cylinder block (2). a Inside diameter of main bearing metal cap q Machining dimension mm Tolerance: f127 +0.018 0 q After machining, remove the main bearing metal cap, assemble it again, and check its inside diameter. mm Tolerance: f127 +0.018 0 (Range to upper and lower 10° from mating face of main bearing metal cap) a Finished surface roughness: Max. 10S a Do not cut the inside surface of the cylinder block.
Unit: Nm {kgm} Range
Step
Target
1st time
98 {10}
88 – 108 {9 – 11}
2nd time
196 {20}
191 – 201 {19.5 – 20.5}
3rd time
Tightening by 90°
90° +30° 0
Set the cylinder block mounting jig on the table of the horizontal boring machine and install the cylinder block by fitting its cylinder liner mounting hole to the datum line of the jig.
Side machining of main bearing metal cap (Machine only No. 7 main bearing metal cap) 1. Insert cast iron bushing (3) and pass arbor (4) through it. 2.
Install facing tool (5) to the arbor.
3.
Cut main bearing metal cap (1) to the degree that facing tool almost touches the cylinder block surface.
Apply dial gauges to the inside of the 2 main bearing metal caps at the longest pitch among the caps to be used to center the arbor of the boring machine.
140E-5 Series
90 Repair and replacement of parts
4.
SEN05200-01
Cut the opposite side similarly. a Thrust metal mounting surface roughness: See the figure below a Do not cut the cylinder block. a Tolerance of main bearing metal cap 0 width: 44 –0.025 mm
140E-5 Series
15
SEN05200-01
90 Repair and replacement of parts
Replacement of connecting rod small end bushing
Press fitting of bushing 1. Set the connecting rod to block (3) of tool L.
a
2.
Install the bushing to push tool (1), set push tool (2), and fix them with nut (4). a Match the oil holes of the bushing and connecting rod to each other.
3.
Drive push tool (1) with the press to press fit the bushing. a Since the bushing is semi-finished, its inside diameter is small and the piston pin does not go through it. After press fitting the bushing, machine its inside with a reamer or a honing machine according to the maintenance standard. a After machining, remove all the chips from the oil hole and oil groove.
Connecting rod small end bushing replacement tool
Symbol
Part No.
L
795-240-6401
Part name Push tool (KIT)
Pulling out of bushing 1. Set the connecting rod to block (3) of tool L. 2.
16
Using push tool (1) and block (3), drive out the busing with the press. a After removing the bushing, remove sharp edges and burrs from and clean the bushing mounting hole.
140E-5 Series
90 Repair and replacement of parts
Replacement of cam bushing a
3.
Pulling out of No. 3, No. 4 and No. 5 bushings 1) Assemble bar (1), push tool (2), collar (3) and guide (4). 2) While hitting bar (1), drive out the bushing from the cylinder block.
4.
After removing the bushing, remove burrs and foreign matter from and clean the bushing mounting hole.
Cam bushing replacement tools
Symbol
Part No.
M
795-213-1200
a
SEN05200-01
Part name Push tool (KIT)
Before replacing the cam bushing, remove the plug at the rear of the cylinder block.
Removal 1.
Pulling out of No. 1 and No. 7 bushings 1) Assemble push tool (2), collar (3) and bar (1) of tool M. 2) While hitting bar (1), drive out the bushing from the cylinder block.
Installation a
2.
Cam bushing installation drawing
Pulling out of No. 2 and No. 6 bushings 1) Assemble bar (1), push tool (2), collar (3) and guide (4). 2) While hitting bar (1), drive out the bushing from the cylinder block.
140E-5 Series
17
SEN05200-01
90 Repair and replacement of parts
1.
Press fitting of No. 3, No. 4 and No. 5 bushings 1) Install bar (1), push tool (2), collar (3) and guide (4) to the bushing. 2) Press fit the bushing until the oil holes of the cylinder block and bushing are matched to each other. a Ensure that the pin 2 mm in diameter goes smoothly through the drilled hole of the cylinder block and oil holes (upper and lower) of the bushing.
3.
Press fitting of No. 1 and No. 7 bushings 1) Install bar (1), push tool (2) and collar (3) to the bushing. 2) Press fit the bushing until the oil holes of the cylinder block and bushing are matched to each other. a Ensure that the pin 2 mm in diameter goes smoothly through the drilled hole of the cylinder block and oil holes (upper and lower) of the bushing.
2.
Press fitting of No. 2 and No. 6 bushings 1) Install bar (1), push tool (2), collar (3) and guide (4) to the bushing. 2) Press fit the bushing until the oil holes of the cylinder block and bushing are matched to each other. a Ensure that the pin 2 mm in diameter goes smoothly through the drilled hole of the cylinder block and oil holes (upper and lower) of the bushing.
4.
Measurement after bushing is press fitted 1) Using dial inside gauge (a), measure the inside diameter of the bushing.
2)
18
Measure the clearance between the bushing and shaft. If it is out of the allowable range or the shaft does not go through smoothly, repair the inside of the bushing with a reamer. a After repairing the inside of the bushing with a reamer, remove all the chips from the oil hole and oil groove. a Inside diameter of cam bushing: f65 +0.06 mm 0 a Clearance to camshaft journal: 0.016 – 0.096 mm
140E-5 Series
90 Repair and replacement of parts
Repair of cylinder block top by grinding
SEN05200-01
1
Repair by grinding If there is distortion or corrosion on the cylinder block top, remove it by grinding. a If the cylinder liner contact surface of counterbore portion is blackened and grained (particularly in the forward and backward directions of the cylinder block) more than a half of the contact surface or the cylinder block top needs to be ground, repair the counterbore portion. a Rough criteria for repairing cylinder block top by grinding q The cylinder block top is worn and corroded in the shape of the trace of the head gasket. q Quantity (a) of the above wear is 0.15 mm or more.
Grinding of top q Measure the wear quantity and distortion of the cylinder block top. If the measured value is larger than the allowable limit, repair the cylinder block top by grinding within the allowable limit of cylinder block height (d).
Flatness of cylinder block top (per cylinder) Cylinder block height (d) Cylinder block top surface roughness
Standard dimension
Unit: mm Repair dimension
Max. 0.05
Max. 0.05
430.5 ± 0.04 430.1 ± 0.04 Max. 12.5S
Fig. 2
Fig. 1
a
140E-5 Series
When repairing with grinding stone (Reference) Grinding speed: 1,650 – 1,950 m/min Table speed: 15 – 30 m/min Grinding depth by 1 grinding: 0.025 mm Cross feed for 1 grinding: 1 – 2 mm Grinding stone: A461 V Grinding fluid: Water soluble grinding fluid
19
SEN05200-01
90 Repair and replacement of parts
Repair of counterbore by grinding 1 a
Counterbore grinding tool
Symbol
N
q
a q q
q
q q
Part No.
Part name
1
79A-513-1710 Basic machine
2
79A-513-1780 Guide plate
3
79A-513-1820 Cutter plate
4
79A-513-1860 Cutter
5
79A-513-1940 Cutter set gauge
6
79A-513-1950 Micrometer
7
79A-513-1960 Driver plate
8
79A-513-2090 Driver shaft
9
79A-513-2110
10
79A-513-2120 Service package
11
79A-513-2130 Case
12
79A-513-2140 Basic machine
13
79A-513-2160 Cutter plate
14
79A-513-2230 Cutter
15
79A-513-2240 Remover pin
16
79A-513-2250 Case
17
79A-513-2260 Service package
18
79A-513-2270 Compound
19
79A-513-2280 Primer
20
79A-513-2320 Bushing
q
q
Machine only the hatched part of counterbore portion depth (f). Set the machining margin of counterbore portion depth (f) so that cylinder liner projection (e) will be within the standard value. If counterbore portion depth (f) exceeds the standard dimension and the counterbore portion needs to be ground within the allowable limit, set the machining margin so that 1 shim shown next page will be used for 1 cylinder. Remove burrs and sharp edges from the tapered portion etc.
Driver handle
After repairing the top of cylinder block by grinding, measure the counterbore portion depth and repair the counterbore by grinding within the allowable limit of counterbore depth (f) if necessary. Rough criteria for repairing counterbore portion by grinding A dimension is out of the standard dimension. The cylinder liner contact surface of the counterbore portion is blackened and grained (particularly in the forward and backward directions) more than a half of the whole area. If counterbore portion depth (f) after the repair is 11.05 – 12.525 mm, adjust cylinder liner projection (f) to 0.07 – 0.15 mm with shims. Unit: mm
Counterbore portion depth (f) Cylinder liner projection (e) Counterbore surface roughness Grinding shape
20
Standard size
Repair limit
11 +0.05 +0
12.525
—
0.07 – 0.15
Max. 12.5S See right figure
*: See "b" and "c" in Fig. 2 of previous page for "Detail B and c".
140E-5 Series
90 Repair and replacement of parts
SEN05200-01
q
When grinding the counterbore portion, use tool N.
Shims for adjusting counterbore depth (reference) Unit: mm Part No.
T
t
Weight (kg)
6210-29-2260
1.50
0.025
0.023
6210-29-2250
0.80
0.025
0.012
6210-29-2240
0.50
0.025
0.008
6210-29-2230
0.26
0.025
0.004
6210-29-2220
0.20
0.020
0.003
6210-29-2210
0.16
0.016
0.002
q
Remarks
Outside diameter and inside diameter of shim
140E-5 Series
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SEN05200-01
90 Repair and replacement of parts
Check and identification after repair by grinding
1
After repairing by grinding, check the flat portions around the water and oil holes on the cylinder block top for flaw. Remove all burrs and sharp edges. After grinding the top surface, check cylinder block height (d) is 430.1 ± 0.04 mm, and use the oversize head gasket.
q
q q
Unit: mm
a
Spare parts used
q
Head gasket
Part No.
Plate thickness
Standard
6210-17-1814
2.0
Oversize
6210-19-1814
2.4
The 2 letters of "OS" are stamped on the plate for identification. After repairing, stamp the contents of repair on the cylinder block top (rear of the left bank). Stamp method is shown in the following table. Oversize head gasket
Shim
Stamp
—
—
Unnecessary
Q
—
OS
—
Q
SH
Q
Q
WS
(Stamp letter size shall be 5 – 10 mm)
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140E-5 Series
90 Repair and replacement of parts
Gasket sealant application procedure q
a
SEN05200-01
1
When press fitting the cylinder liner again after pulling it out, apply gasket sealant (LG-6) to the cylinder block top deck (cylinder liner flange contact surface of the cylinder block) according to the following procedure. When using shim for the deck, apply the gasket sealant similarly.
1.
Wipe off dirt, oil etc. from cylinder block top (c) and the cylinder liner flange contact surface with cloths.
2.
Apply LG-6 to gasket sealant application area (a). q String diameter: 2 – 3 mm q Overlap length of starting and ending points (b): 6 ± 6 mm a When using shim for the deck q Thinly apply LG-6 to the underside (e) of shim (1) and fit the shim to the cylinder block deck. q Then, apply LG-6 as when no shim is used.
3.
Press fit cylinder liner to the cylinder block. At this time, apply a little amount of rubber lubricant (RF-1) to cylinder block contact surface (d) of the O-ring and seal of the cylinder liner. a Apply the engine oil just before press fitting the cylinder liner. a RF-1: Product of DAIDO CHEMICAL INDUSTRY CO., LTD. If RF-1 cannot be obtained, apply clean engine oil SAE No. 30. a Since the clevis seal and O-ring are swelled and deteriorated with oil, apply a little amount of oil with a brush just before installing.
140E-5 Series
4.
Set the cylinder liner to the cylinder block, install the used head gasket, and tighten the cylinder head temporarily. At this time, tighten the bolts in the following order. 3 Tightening torque: 147 ± 10 Nm {15 ± 1 kgm}
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SEN05200-01
5.
24
90 Repair and replacement of parts
Loosen the cylinder head mounting bolts, remove the cylinder head, and wipe off the excessive gasket sealant projected from the counterbore portion. a If the gasket sealant sticks to grommet (1) of the head gasket, it deforms the grommet into a heart shape and can cause coolant leakage into water hole (2). Accordingly, wipe off the gasket sealant thoroughly. a When installing the cylinder head after performing step "4.5", use a new head gasket.
140E-5 Series
90 Repair and replacement of parts
SEN05200-01
Repair standard for cylinder liner O-ring 1 After repairing the bushing at the cylinder liner Oring portion of the cylinder block, finish to the following dimensions. a Concentricity of (6) to standard (A): Max. ø0.05 mm Unit: mm No.
Finish dimension
1
ø167
2
ø161.45 ± 0.25
3
ø160.67 ± 0.064
4
176 ± 0.25 up to block top surface
5
184.94 ± 0.18 up to block top surface
6
ø158 +0.040 +0
7
ø159.03 (Gauge diameter)
140E-5 Series
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SEN05200-01
90 Repair and replacement of parts
Replacement of engine rear seal a
Engine rear seal replacement tools
Symbol
Part No.
O
795-931-1100
a
Part name Seal puller assembly
For disassembly and assembly of flywheel and flywheel housing, see "Disassembly and assembly".
2.
Pull slide hammer (1) of the seal puller to pull out the seal with impacts. a Rear seal (c) can be pulled out easily, if it is driven in a little to separate it from the flywheel housing in advance. a Do not damage the crankshaft. a Do not use a drill since chips will enter the engine.
Types of engine rear seal (Teflon seal) Illustration No.
a
Application
a1
Single lip for dry type (without sleeve)
a2
Single lip for dry type (sleeved)
b1
Double lip for wet type (without sleeve)
b2
Double lip for wet type (sleeved)
The sleeved rear seals are used to repair when the shaft is worn largely.
Removal of rear seal (sleeved) 1. Install drill type attachment (6) to the seal puller.
Removal of rear seal (without sleeve) 1. Hitch seal puller end (5) of tool O to the metal ring of rear seal (c).
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140E-5 Series
90 Repair and replacement of parts
2.
Screw drill end (6) into the metal ring of rear seal (c) and pull slide hammer (1) of the seal puller to pull out the seal with impacts. a Rear seal (c) can be pulled out easily, if it is driven in a little to separate it from the flywheel housing in advance. a Do not damage the crankshaft. a Do not use a drill since chips will enter the engine.
Check of crankshaft for wear 1. If the crankshaft is worn to a degree of luster (you cannot feel the wear with the cushion of your finger and the wear depth is maximum of about 10 µm) and there is no scratch on it, it can be used. 2.
SEN05200-01 a
a
1.
Set larger inside diameter side (f) of internal plastic cylinder (d) to crankshaft end (g). a Take care not to mistake the direction of rear seal (c).
2.
Hold the metal ring of seal (c) with both hands and push it in evenly. a Push in the rear seal as if you pass over large inside diameter side (f) of internal plastic cylinder (d).
3.
Remove internal plastic cylinder (d), taking care not to damage lip (h).
In other cases than 1 above, install the sleeved rear seal.
Installation of rear seal (without sleeve) a Do not remove internal plastic cylinder (d) of the spare rear seal (which is used as an installation guide) before installing the rear seal since it is also used to protect the seal lip.
140E-5 Series
Before installing the rear seal, remove all flaws, sharp edges, burrs, rust, etc. from the end corners and sliding surfaces of the crankshaft and from the flywheel housing. Do not apply oil or grease to the sliding surfaces of the crankshaft and lip (e) of the rear seal. Wipe off the oil from the sliding surfaces of the crankshaft thoroughly.
27
SEN05200-01
4.
Install sleeve jig (1) and clamp bolts (2) (Stem length: 40 mm (wet), 45 mm (dry)). a Do not install washers to the bolts.
5.
Evenly tighten clamp bolts (2) to press fit the rear seal until they stop. a Take care not to damage the end of lip (j) on the transmission side.
90 Repair and replacement of parts
Installation of rear seal (with sleeve) a Handle the spare rear seal and sleeve (n) as an assembly and do not separate them.
a
a 6.
28
Remove clamp bolts (2) (Stem length: 40 mm (wet), 45 mm (dry)), install 2 washers (3) each, and tighten bolts (2) evenly again to press fit the rear seal until end (k) of sleeve jig (1) touches end (m) of the crankshaft. a Take care not to damage the end of lip (j) on the transmission side. a After press fitting, remove the gasket sealant projected around the periphery.
1.
Before installing the rear seal, remove all flaws, sharp edges, burrs, rust, etc. from the end corners and sliding surfaces of the crankshaft and from the flywheel housing. Do not apply oil or grease to the sliding surfaces of the crankshaft and lip (e) of the rear seal. Wipe off the oil from the sliding surfaces of the crankshaft thoroughly. Apply gasket sealant to inside wall (p) of rear seal (c) and set it to sleeve jig (4). 2 Inside wall (p) of rear seal (c): Gasket seal (LG-7)
140E-5 Series
90 Repair and replacement of parts
2.
Install sleeve jig (4), clamp bolts (5) (Stem length: 45 mm), and 1 washer (6).
3.
Evenly tighten clamp bolts (5) to press fit the rear seal until they stop. a Be sure to press fit rear seal (c) and sleeve (n) as an assembly.
4.
Replace sleeve jig (4) and clamp bolts (5) with sleeve jig (7) and clamp bolts (8) (Stem length: 45 mm) respectively and tighten bolts (8) evenly to press fit the rear seal until they stop. a Do not install washers to the bolts.
140E-5 Series
SEN05200-01
5.
Remove clamp bolts (8) (Stem length: 45 mm), install 2 washers (9) each, and tighten bolts (8) evenly again to press fit the rear seal until end (q) of sleeve jig (7) touches end (r) of the crankshaft. a After press fitting, remove the gasket sealant projected around the periphery.
29
SEN05200-01
90 Repair and replacement of parts
Replacement of wear sleeve (when sleeve is installed) a
If the wear sleeve is worn or damaged, replace it according to the following procedure.
Pulling out of sleeve 1. Make a groove on wear sleeve (1) with a grinder.
2.
30
Put a chisel to the groove on the sleeve and hit it with a hammer to remove the sleeve. a If the sleeve is difficult to remove, remove it by the following method. q Make a V-notch on the sleeve with a grinder. q Break the V-notched portion with a chisel to remove the sleeve. k Take extreme care not to let the chisel fly out. a When pulling out the wear sleeve, take care not to damage the crankshaft.
140E-5 Series
90 Repair and replacement of parts
Repair of crankshaft by grinding q
q
q
When the crankshaft is worn, seized or damaged slightly and needs to be repaired, grind it to one of the following undersizes. Undersizes: 0.25, 0.50, 0.75, 1.00 mm If the crankshaft is bent or worn unevenly, it should not be repaired but should be replaced. (Repairing the crankshaft requires high technologies) Finish fillet portion (R), shoulder portion (r) and area (R) around the hole of the crankshaft with extreme care.
SEN05200-01
Pin journal oil hole (See figure below) q Finish part (d) with sandpaper. q Check part (e) extremely carefully since quenching crack tends to occur in that part.
Finish dimensions of fillet portion (R): 5.3 +0.3 0 mm Surface roughness: 3.2S
q
Finish the main journal and pin journal according to the following procedure.
Main journal oil hole (See figure below) Dimension of tapered part (a) of oil hole: 12 mm q Angle (b) of tapered part of oil hole: 120° q Surface roughness of oil hole top (c): 1.6S (Finished with sandpaper) q Dimension of parts (R) at 2 places: 1 – 2 mm
q
q
140E-5 Series
The outside surface roughness of the pin journal and main journal must be maximum of 0.6S.
Equipment necessary for grinding Magnaflux inspection machine q Shore hardness tester q Etching kit q Crankshaft grinding machine q Crankshaft polishing machine q Surface roughness gauge q Fillet (R) gauge q
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SEN05200-01
90 Repair and replacement of parts
Inspection before repair by grinding
Check during and after repair by grinding
Visual check q Check for crack, damage, discoloration by seizure, wear, etc. and judge if the crankshaft can be repaired by grinding.
Check of fillet (R) portion q Check that each fillet (R) portion is connected to the journal shoulder smoothly. q Using fillet (R) gauges [1] and [2], check that "dimension (R)" is between the minimum value gauge and maximum value gauge. q (c) is the contact point of minimum value gauge. q (d) are the contact points of maximum value gauge. Fillet (R) Min. radius: 5.3 mm Max. radius: 5.6 mm
Hardness check of journal surface Allowable range: HRC55 – 60 a If the hardness is below the allowable limit, discard the crankshaft. Check for twist Tolerance of throw (a): 82.5 ± 0.05 mm Dispersion of throw (a) among cylinders: Max. 0.1 If any of the above items is out of the allowable limit, discard the crankshaft. q Dimension (b) is the stroke.
Check for grinding burn mark by etching After repairing by grinding, check that there is no grinding burn mark by etching inspection. q If any burn mark is detected, grind about 0.02 mm again to the next undersize dimension. Undersizes: 0.25, 0.50, 0.75, 1.00 mm q After checking, neutralize and clean the checked surface and apply rust preventive oil. q
Magnaflux inspection Before using the repaired crankshaft, check it by magnaflux inspection to ensure that it has no crack. q Extremely closely check journal fillet portion (a) which is in the dangerous area of each web of the crankshaft. q After the magnaflux inspection, be sure to demagnetize the crankshaft. q
32
140E-5 Series
90 Repair and replacement of parts
SEN05200-01
Measurement of bend (Measurement of alignment) q Measure the bend of the ground crankshaft and ensure that it is within the standard value. q Measure the bend (alignment) at the following 4 places. Tolerance of overall length alignment: Max. 0.15 mm Tolerance of adjacent alignment: Max. 0.05 mm Tolerance of front end alignment: Max. 0.03 mm Tolerance of rear end alignment: Max. 0.03 mm
Grinding of thrust surface a It is not always required to grind the thrust surfaces of the front and rear to the same undersize dimension. a If the thrust surface was repaired by grinding, ensure that the end play of the crankshaft is within the allowable range. (See the section of general assembly) Undersize dimensions of thrust surface
Unit: mm
Rear thrust surface Standard
Front thrust surface
Standard
q
0.125 OS
0.25 OS
Standard size Repair limit
0.125 OS
0.25 OS
52.125 +0.050 52.25 +0.050 52 +0.050 0 0 0 52.060
52.185
52.310
Standard 52.125 +0.050 52.25 +0.050 52.375 +0.050 0 0 0 size Repair limit
52.185
52.310
52.435
Standard 52.375 +0.050 52.50 +0.050 52.25 +0.050 0 0 0 size Repair limit
52.310
52.435
52.560
Squareness of thrust surface (TIR) Permissible deviation: 0.04 mm
Grinding of main journal a Grind all the main journals to the same undersize. a When grinding, leave the polish finishing margin of 0.007 – 0.008 mm.
Grinding of pin journal a Grind all the pin journals to the same undersize. a When grinding, leave the polish finishing margin of 0.007 – 0.008 mm.
Undersize dimensions of main journal
Undersize dimensions of pin journal
Size
Standard size
Standard 0.25 US 0.50 US 0.75 US 1.00 US
120.000 119.750 119.500 119.250 119.000
Unit: mm Tolerance
–0.050 –0.068
Roundness, cylindricality (TIR) and surface roughness of main journal Permissible deviation: Max. 0.009 mm Surface roughness: 0.6S
140E-5 Series
Size
Standard size
Standard 0.25 US 0.50 US 0.75 US 1.00 US
90.000 89.750 89.500 89.250 89.000
Unit: mm Tolerance
–0.050 –0.068
Roundness, cylindricality (TIR) and surface roughness of pin journal Permissible deviation: Max. 0.009 mm Surface roughness: 0.6S
33
SEN05200-01
Grinding of sides of main journal and pin journal q When repairing worn surfaces (c) of main journal (a) and pin journal (b), limit the grinding quantity to the minimum. q (d) is thickness of worn surface. q Width of crankpin journal When only 1 side is ground Standard: 58 +0.074 mm 0 q Width of main journal (#7 only) Standard: 52 +0.05 mm 0 q Squareness of thrust surface (TIR) Permissible deviation: 0.04 mm
90 Repair and replacement of parts
Prevention of grinding burn q Apply the flange grinding method. q Use all the width of the grinding stone. Avoid grinding the boss surface. q Apply cooling oil sufficiently. q Set the standard peripheral speed of the grinding stone to 2,000 m/min when the crankshaft rotation speed is 50 rpm. Finishing of surface Surface roughness standard Journal surface (c): 0.6S (finished with sandpaper) Thrust surface and fillet portion (d): Max. 3.2S Front seal insertion portion (e) (Range of 33 mm from end): 1 – 2.5S q Polish finishing margin: 0.007 – 0.008 mm q
Dressing of grinding stone Dress the grinding stone for each journal. q Grinding stone dresser Grooving angle (a): 75° ± 1° Tip diameter (b): 0.38 ± 0.25 mm Use a cylindrical copper rod of the above form having an industrial diamond embedded in its tip. q Adjust the grinding stone edge to the arc of the fillet with the grinding stone modifying device. Test and correct the grinding stone edge by grinding a piece of wood on trial, while checking with gauges. q
34
140E-5 Series
90 Repair and replacement of parts
Work after repair by grinding q Ensure again that each dimension is as specified. q Clean each part thoroughly and apply rust-preventive oil. q When storing the crankshaft for a long period, support it on 3 points or keep it erected with a sling.
SEN05200-01
2.
Measure the outside diameter of the main journal in directions (X) and (Y) at 2 places ((1) and (2)) and that of the pin journal in directions (X) and (Y) at 2 places ((1) and (2)) with a micrometer or an air micrometer.
Balancing (Reference) Avoid performing repair that may affect the crankshaft balancing. q Allowable limit of unbalance: 110 gcm Limits for reading balance accurately Bend of crankshaft: 0.09 mm (TIR) Rotation speed of crankshaft: Max. 325 rpm q When balancing, perform the following corrections. Front key way: 30.7 gcm q Correct the balance by drilling holes in or grind the counterweight, if necessary. Repair quantity limit of counterweight: 56 g Drilling direction: Radial direction or in parallel with each other Number of holes: Max. 6 Hole diameter: 13 mm or 15 mm Hole depth: Max. 40 mm Distance between hole and side: Min. 5 mm Distance between holes: Min. 5 mm Measuring procedure for bend and outside diameter of journal portion 1. Measure the bend on the basis of the #1 and #7 journals. Apply the dial gauge to the journal to be measured, set the dial to 0 at the top, and rotate the crankshaft 1 turn and read the minimum and maximum values.
140E-5 Series
35
SEN05200-01
Improvement of surface roughness of crankshaft journal 1 q
If the surface roughness of the journal portions of the crankshaft is out of the standard or the journal surface has a flaw, bruise or rust which can be removed, improve the surface roughness.
1.
Cleaning and blowing air Before starting grinding, brush the oil holes and blow air into them.
2.
90 Repair and replacement of parts
3.
Check the surface roughness with the standard piece. a Measure the surface roughness of the journal by comparing it with the standard piece. Surface roughness standard (Pin journal and main journal) Journal surface: Max. 0.8S Round part: Max. 3.2S
4.
If the surface roughness does not satisfy the standard, make round polishing with the sandpaper (#500) again between both ends. a After improving the surface roughness, be sure to brush the oil holes and blow air into them. a Ensure that the there is no flaw or bruise on the journal portion and the round part of each fillet. If there is any flaw or bruise, polish again from step 1.
Improvement of surface roughness of journal portions
When improving with special polishing machine q Use the special polishing machine shown below.
1.
Set the rotation speed of the crank shaft to 40 – 50 rpm. Improve the surface roughness by making round polishing with sandpaper (belt type) between both ends of each journal. a Use sandpaper (belt type) of #320. a Move the sandpaper smoothly without stopping at a place. a Do not use honing oil.
2.
Replace the sandpaper with one of #500. Apply honing oil to the journal surface. Make round polishing with the sandpaper between both ends of the journal, while operating handle (1) to move the sandpaper by the play. a Move the sandpaper smoothly without stopping at a place.
If the special polishing machine is not available, use the following clamp jig for polishing to improve the surface roughness.
1.
36
Using the crankshaft grinding machine, rotate the crankshaft to polish. q Sandpaper: #800 q Grinding oil: Honing oil (Diesel fuel oil may be used) q Rotation speed of crankshaft: 40 rpm
140E-5 Series
90 Repair and replacement of parts
2.
SEN05200-01
While moving the polishing jig in the axial direction by the play of the journal width (approx. 5 mm), polish the journal. a Finish polishing each journal in about 6 minutes. Each time honing of 1 journal is finished, replace the sandpaper with new one. a When honing the pin journal, set it to the center of rotation.
Assembly and using procedure of clamp jig for polishing 1. Assemble the clamp jigs for the pin journal and main journal as shown in the following figure.
2.
Cut off sandpaper (#800) (a, b) to the shapes shown below. q (a) is for the pin journal and its size is as follows; L: 171 mm, W: 82 mm q (b) is for the main journal and its size is as follows. L: 218 mm, W: 75 mm a Make slits (c) 20 mm long on both sides of the sandpaper at intervals of 10 mm and cut off one part at each end (d).
140E-5 Series
3.
Insert 2 pieces of upper and lower sandpapers (a) or (b) in slit (e) and fix the ends with tape (f).
4
Fold slit portion (d) of the sandpaper along the round part of the clamp.
5.
Hold the journal with the clamp and fix the lever ends with rubber tube (g) etc.
37
SEN05200-01
90 Repair and replacement of parts
Clamp jig for polishing a Make the polishing jig according to the following drawings. Clamp jig for polishing (for pin journal) Plate 1 (Use 2 pieces for 1 jig)
Lever 2 (Use 2 pieces for 1 jig)
38
140E-5 Series
90 Repair and replacement of parts
SEN05200-01
Clamp jig for polishing (for main journal) Plate 1 (Use 2 pieces for 1 jig)
Lever 2 (Use 2 pieces for 1 jig)
140E-5 Series
39
SEN05200-01
KOMATSU 140E-5 Series engine Form No. SEN05200-01
© 2010 KOMATSU All Rights Reserved Printed in Japan 06-10
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