Komatsu Engine Saa6d140e 5 Workshop Manuals

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SEN00074-15

ENGINE 140E -5 SERIES

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 SEN00076-15

ENGINE 1SHOP MANUAL

140E-5 Series

00 Index and foreword 1

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

140E-5 Series 1
SEN00076-15 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 accord-
ingly.

Section Title Form Number

Shop Manual, contents binder, binder label and tabs ............................................................ SEN00074-15

00 Index and foreword ......................................................................................................... SEN00075-15

Index ............................................................................................................................... SEN00076-15 q
Foreword and general information .................................................................................. SEN00077-07

01 Specification.................................................................................................................... SEN00078-06
Specification and technical data...................................................................................... SEN00079-06

10 Structure, function and maintenance standard ............................................................... SEN00080-07

Structure, function and maintenance standard, Part 1.................................................... SEN00081-07
Structure, function and maintenance standard, Part 2.................................................... SEN00082-05

20 Standard value table ....................................................................................................... SEN00083-06

Standard service value table........................................................................................... SEN00147-06

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 q
Disassembly and assembly, Part 1 (with EGR) .............................................................. SEN00157-05 q
Disassembly and assembly, Part 2 (EGR-less) .............................................................. SEN00158-05 q
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

2 140E-5 Series
00 Index and foreword SEN00076-15

Table of contents 1
00 Index and foreword
Index SEN00076-15
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 SEN00079-06
Outline ..................................................................................................................................... 2
Specifications........................................................................................................................... 6
General view............................................................................................................................ 24
Weight table............................................................................................................................. 55
Engine performance curves..................................................................................................... 58

10 Structure, function and maintenance standard

Structure, function and maintenance standard, Part 1 SEN00081-07
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 SEN00082-05
Lubrication system ...................................................................................................................... 4
Lubrication system diagram..................................................................................................... 4
Oil pump .................................................................................................................................. 8
EGR oil pump .......................................................................................................................... 9
Oil filter .................................................................................................................................... 10
Oil cooler ................................................................................................................................. 12

140E-5 Series 3
SEN00076-15 00 Index and foreword

Fuel system ................................................................................................................................. 14

CRI system diagram ................................................................................................................ 14
Outline of CRI system.............................................................................................................. 16
Fuel piping ............................................................................................................................... 38
Fuel cooler ............................................................................................................................... 42
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

20 Standard value table

Standard service value table SEN00147-06
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

4 140E-5 Series
00 Index and foreword SEN00076-15

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

40 Troubleshooting
General information on troubleshooting SEN00151-04
Points to remember when troubleshooting .............................................................................. 2
Method of displaying trouble diagnosis lamps (Method of displaying error code) ................... 3
Error codes and failure codes list ............................................................................................ 5
Information in troubleshooting table ........................................................................................ 10
Connection table for connector pin numbers ........................................................................... 12
T- branch box and T- branch adapter table ............................................................................. 48
Troubleshooting of mechanical system (S-mode) SEN00152-03
Troubleshooting of mechanical system (S-mode) ....................................................................... 4
Method of using troubleshooting charts................................................................................... 4
S-1 Starting performance is poor ............................................................................................. 8
S-2 Engine does not start ........................................................................................................ 10
S-3 Engine does not pick up smoothly .................................................................................... 14
S-4 Engine stops during operations ........................................................................................ 15
S-5 Engine does not rotate smoothly ...................................................................................... 16
S-6 Engine lacks output (or lacks power) ................................................................................ 17
S-7 Exhaust smoke is black (incomplete combustion) ............................................................ 18
S-8 Oil consumption is excessive (or exhaust smoke is blue)................................................. 20
S-9 Oil becomes contaminated quickly ................................................................................... 21
S-10 Fuel consumption is excessive ....................................................................................... 22
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down).............................. 23
S-12 Oil pressure drops........................................................................................................... 24
S-13 Oil level rises (Entry of coolant/fuel) ............................................................................... 25
S-14 Coolant temperature becomes too high (overheating).................................................... 27
S-15 Abnormal noise is made ................................................................................................. 28
S-16 Vibration is excessive ..................................................................................................... 29
Troubleshooting of electrical system (E-mode), Part 1 SEN00153-03
Troubleshooting of electrical system (E-mode), Part 1 ............................................................... 3
Troubleshooting method for disconnecting wiring harness of pressure sensor system .......... 3
E-1 Code [111/CA111] Engine Controller Internal Failure........................................................ 6
E-2 Code [115/CA115] Eng. Ne and Bkup Speed Sensor Error .............................................. 7
E-3 Code [122/CA122] Charge (boost) Air Press Sensor High Error ...................................... 8
E-4 Code [123/CA123] Charge (boost) Air Press Sensor Low Error....................................... 12
E-5 Code [131/CA131] Throttle Sensor High Error ................................................................. 16
E-6 Code [132/CA132] Throttle Sensor Low Error .................................................................. 20
E-7 Code [135/CA135] Oil Press. Sensor High Error .............................................................. 22
E-8 Code [141/CA141] Oil Press. Sensor Low Error............................................................... 24
E-9 Code [144/CA144] Coolant Temp. Sensor High Error ...................................................... 26
E-10 Code [145/CA145] Coolant Temp. Sensor Low Error ..................................................... 28
E-11 Code [153/CA153] Charge (boost) Air Temp. Sensor High Error.................................... 30
E-12 Code [154/CA154] Charge (boost) Air Temp. Sensor Low Error .................................... 32

140E-5 Series 5
SEN00076-15 00 Index and foreword

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

E-14 Code [221/CA221] Ambient Air Press. Sensor High Error .............................................. 38
E-15 Code [222/CA222] Ambient Air Press. Sensor Low Error............................................... 40
E-16 Code [227/CA227] Sensor Sup. 2 Volt. High Error ......................................................... 42
E-17 Code [234/CA234] Eng. Overspeed................................................................................ 42
E-18 Code [238/CA238] Ne Speed Sensor Sup. Volt. Error .................................................... 44
E-19 Code [263/CA263] Fuel Temp. Sensor High Error .......................................................... 46
E-20 Code [265/CA265] Fuel Temp. Sensor Low Error........................................................... 48
E-21 Code [271/CA271] PCV1 Short Error.............................................................................. 50
E-22 Code [272/CA272] PCV1 Open Error ............................................................................. 52
E-23 Code [273/CA273] PCV2 Short Error.............................................................................. 54
E-24 Code [274/CA274] PCV2 Open Error ............................................................................. 56
E-25 Code [322/CA322] Injector #1 System Open/Short Error ............................................... 58
E-26 Code [323/CA323] Injector #5 System Open/Short Error ............................................... 60
E-27 Code [324/CA324] Injector #3 System Open/Short Error ............................................... 62
E-28 Code [325/CA325] Injector #6 System Open/Short Error ............................................... 64
E-29 Code [331/CA331] Injector #2 System Open/Short Error ............................................... 66
E-30 Code [332/CA332] Injector #4 System Open/Short Error ............................................... 68
E-31 Code [342/CA342] Engine Controller Data Matching Error............................................. 70
E-32 Code [351/CA351] INJ. Drive Circuit Error...................................................................... 72
E-33 Code [352/CA352] Sensor Sup. 1 Volt. Low Error .......................................................... 74
E-34 Code [386/CA386] Sensor Sup. 1 Volt. High Error ......................................................... 75
E-35 Code [431/CA431] Idle Validation Switch Error............................................................... 78
E-36 Code [432/CA432] Idle Validation Process Error ............................................................ 80
E-37 Code [441/CA441] Supply Voltage Low Error ................................................................. 81
E-38 Code [442/CA442] Supply Voltage High Error ................................................................ 81
Troubleshooting of electrical system (E-mode), Part 2 SEN00154-02
Troubleshooting of electrical system (E-mode), Part 2................................................................ 3
E-39 Code [449/CA449] Rail Press. High Error 2.................................................................... 3
E-40 Code [451/CA451] Rail Press. Sensor High Error .......................................................... 4
E-41 Code [452/CA452] Rail Press. Sensor Low Error ........................................................... 7
E-42 Code [553/CA553] Rail Press. High Error 1.................................................................... 8
E-43 Code [554/CA554] Rail Press Sensor In Range Error .................................................... 9
E-44 Code [559/CA559] No-pressure Feed By Supply pump 1 .............................................. 10
E-45 Code [689/CA689] Eng. Ne Speed Sensor Error ............................................................ 14
E-46 Code [731/CA731] Eng. Bkup Speed Sensor Phase Error ............................................. 16
E-47 Code [757/CA757] All Engine Controller Data Lost Error ............................................... 16
E-48 Code [778/CA778] Eng. Bkup Speed Sensor Error ........................................................ 18
E-49 Code [1228/CA1228] EGR Valve Servo Error 1.............................................................. 21
E-50 Code [1625/CA1625] EGR Valve Servo Error 2.............................................................. 22
E-51 Code [1626/CA1626] Bypass Valve Solenoid Drive Short Circuit Error .......................... 23
E-52 Code [1627/CA1627] Bypass Valve Solenoid Drive Open Error ..................................... 25
E-53 Code [1628/CA1628] Bypass Valve Servo Error 1.......................................................... 26
E-54 Code [1629/CA1629] Bypass Valve Servo Error 2.......................................................... 27
E-55 Code [1631/CA1631] Bypass Valve Lift Sensor High Error............................................. 28
E-56 Code [1632/CA1632] Bypass Valve Lift Sensor Low Error ............................................. 30
E-57 Code [1633/CA1633] KOMNET Error ............................................................................. 30
E-58 Code [1642/CA1642] EGR Inlet Press Sensor Low Error............................................... 31
E-59 Code [1653/CA1653] EGR Inlet Press Sensor High Error .............................................. 32
E-60 Code [2185/CA2185] Throttle Sens. Sup. Volt. High Error ............................................. 34
E-61 Code [2186/CA2186] Throttle Sens. Sup. Volt. Low Error .............................................. 38
E-62 Code [2249/CA2249] No-pressure Feed By Supply pump 2 .......................................... 38
E-63 Code [2271/CA2271] EGR Valve Lift Sensor High Error................................................. 39
E-64 Code [2272/CA2272] EGR Valve Lift Sensor Low Error ................................................. 41
E-65 Code [2351/CA2351] EGR Valve Solenoid Drive Short Error ......................................... 42
E-66 Code [2352/CA2352] EGR Valve Solenoid Drive Open Error ......................................... 44
E-67 Code [2555/CA2555] Intake Air Heater Relay Open Error.............................................. 45
E-68 Code [2556/CA2556] Intake Air Heater Relay Short Error .............................................. 46

6 140E-5 Series
00 Index and foreword SEN00076-15

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 7
SEN00076-15 00 Index and foreword

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

8 140E-5 Series
00 Index and foreword SEN00076-15

140E-5 Series 9
SEN00076-15

KOMATSU 140E-5 Series engine

Form No. SEN00076-15

© 2011 KOMATSU
All Rights Reserved
Printed in Japan 10-11

10
 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 1
SEN00077-07 00 Index and foreword

Safety notice 1
(Rev. 2008/08)
Important safety notice
Proper service and repair are extremely important for safe machine operation. The service and repair
techniques recommended by Komatsu and described in this manual are both effective and safe.
Some of these techniques require the use of tools specially designed by Komatsu for the specific
purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The
cautions accompanying these symbols should always be followed carefully. If any dangerous situa-
tion arises or may possibly arise, first consider safety, and take the necessary actions to deal with
the situation.

1. General precautions 7) If welding repairs are needed, always

k Mistakes in operation are extremely have a trained and experienced welder
dangerous. Read the Operation and carry out the work. When carrying out
Maintenance Manual carefully before w elding work, alw ays wear welding
operating the machine. In addition, gloves, apron, shielding goggles, cap and
read this manual and understand its other clothes suited for welding work.
contents before starting the work. 8) Before starting work, warm up your body
1) Before carrying out any greasing or thoroughly to start work under good condi-
repairs, read all the safety labels stuck to tion.
the machine. For the locations of the 9) Avoid continuing work for long hours and
safety labels and detailed explanation of take rests at proper intervals to keep your
precautions, see the Operation and Main- body in good condition. Take rests in
tenance Manual. specified safe places.
2) Decide a place in the repair workshop to
keep tools and removed parts. Always Safety points
keep the tools and parts in their correct
places. Always keep the work area clean 1 Good arrangement
and make sure that there is no dirt, water, 2 Correct work clothes
or oil on the floor. Smoke only in the areas 3 Following work standard
provided for smoking. Never smoke while
working. 4 Making and checking signs
3) When carrying out any operation, always Prohibition of operation and handling by
5
wear safety shoes and helmet. Do not unlicensed workers
wear loose work clothes, or clothes with 6 Safety check before starting work
buttons missing.
q Always wear safety glasses when hit- Wearing protective goggles
7
(for cleaning or grinding work)
ting parts with a hammer.
q Always wear safety glasses when Wearing shielding goggles and protectors
8
grinding parts with a grinder, etc. (for welding work)
4) When carrying out any operation with 2 or 9 Good physical condition and preparation
more workers, always agree on the oper- Precautions against work which you are
ating procedure before starting. Always 10
not used to or you are used to too much
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, fork-
lift, service car, etc.

2 140E-5 Series
00 Index and foreword SEN00077-07

2. Preparations for work 6) When removing a cover which is under

1) Before adding oil or making any repairs, internal pressure or under pressure from a
park the machine on a hard and level spring, always leave 2 bolts in diagonal
ground, and apply the parking brake and positions. Loosen those bolts gradually
block the wheels or tracks to prevent the and alternately to release the pressure,
machine from moving. and then remove the cover.
2) Before starting work, lower the work 7) When removing components, be careful
equipment (blade, ripper, bucket, etc.) to not to break or damage the electrical wir-
the ground. If this is not possible, insert ing. Damaged wiring may cause electrical
the lock pin or use blocks to prevent the fires.
work equipment from falling. In addition, 8) When removing piping, stop the fuel or oil
be sure to lock all the control levers and from spilling out. If any fuel or oil drips
hang warning signs on them. onto the floor, wipe it up immediately. Fuel
3) When disassembling or assembling, sup- or oil on the floor can cause you to slip
port the machine with blocks, jacks, or and can even start fires.
stands before starting work. 9) As a general rule, do not use gasoline to
4) Remove all mud and oil from the steps or wash parts. Do not use it to clean electri-
other places used to get on and off the cal parts, in particular.
machine. Always use the handrails, lad- 10) Be sure to assemble all parts again in their
ders or steps when getting on or off the original places. Replace any damaged
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 parts and parts which must not be reused
machine. If it is impossible to use the with new parts. When installing hoses and
handrails, ladders or steps, use a stand to wires, be sure that they will not be dam-
provide safe footing. aged by contact with other parts when the
machine is operated.
3. Precautions during work 11) When installing high pressure hoses,
1) Before disconnecting or removing compo- make sure that they are not twisted. Dam-
nents of the oil, water, or air circuits, first aged tubes are dangerous, so be
release the pressure completely from the extremely careful when installing tubes for
circuit. When removing the oil filler cap, a high pressure circuits. In addition, check
drain plug, or an oil pressure pickup plug, 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
loosen it slowly to prevent the oil from installed.
spurting out. 12) When assembling or installing parts,
2) The coolant and oil in the circuits are hot always tighten them to the specified
when the engine is stopped, so be careful torques. When installing protective parts
not to get scalded. Wait for the oil and such as guards, or parts which vibrate vio-
coolant to cool before carrying out any lently or rotate at high speed, be particu-
work on the oil or water circuits. larly careful to check that they are
3) Before starting work, stop the engine. installed correctly.
When working on or around a rotating 13) When aligning 2 holes, never insert your
part, in particular, stop the engine. When fingers or hand. Be careful not to get your
checking the machine without stopping fingers caught in a hole.
the engine (measuring oil pressure, 14) When measuring hydraulic pressure,
revolving speed, temperature, etc.), take check that the measuring tools are cor-
extreme care not to get rolled or caught in rectly assembled.
rotating parts or moving parts. 15) Take care when removing or installing the
4) Before starting work, remove the leads tracks of track-type machines. When
from the battery. Always remove the lead removing the track, the track separates
from the negative (–) terminal first. suddenly, so never let anyone stand at
5) When raising a heavy component (heavier either end of the track.
than 25 kg), use a hoist or crane. Before 16) If the engine is operated for a long time in
starting work, check that the slings (wire a place which is not ventilated well, you
ropes, chains, and hooks) are free from may suffer from gas poisoning. Accord-
damage. Always use slings which have ingly, open the windows and doors to ven-
ample capacity and install them to proper tilate well.
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.

140E-5 Series 3
SEN00077-07 00 Index and foreword

4. Precautions for sling work and making

signs
1) Only one appointed worker must make
signs and co-workers must communicate
with each other frequently. The appointed
sign maker must make specified signs
clearly at a place where he is well seen
from the operator's seat and where he can
see the working condition easily. The sign
maker must always stand in front of the
load and guide the operator safely.
q Do not stand under the load.
q Do not step on the load.
2) Check the slings before starting sling
work.
8) When installing wire ropes to an angular
3) Keep putting on gloves during sling work.
load, apply pads to protect the wire ropes.
(Put on leather gloves, if available.)
If the load is slippery, apply proper mate-
4) Measure the weight of the load by the eye
rial to prevent the wire rope from slipping.
and check its center of gravity.
9) Use the specified eyebolts and fix wire
5) Use proper sling according to the weight
ropes, chains, etc. to them with shackles,
of the load and method of slinging. If too
etc.
thick wire ropes are used to sling a light
10) Apply wire ropes to the middle portion of
load, the load may slip and fall.
the hook.
6) Do not sling a load with 1 wire rope alone.
q Slinging near the tip of the hook may
If it is slung so, it may rotate and may slip
cause the rope to slip off the hook
out of the rope. Install 2 or more wire
during hoisting. The hook has the
ropes symmetrically.
k Slinging with 1 rope may cause
maximum strength at the middle por-
tion.
turning of the load during hoisting,
untwisting of the rope, or slipping
of the rope from its original wind-
ing 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 form-
ing 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 allow-
able 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 11) Do not use twisted or kinked wire ropes.
sling a load vertically, up to 19.6 kN {2,000 12) When lifting up a load, observe the follow-
kg} of total weight can be suspended. ing.
This weight is reduced to 9.8 kN {1,000 q Wind in the crane slowly until wire
kg} when the 2 ropes make a hanging ropes are stretched. When settling
angle of 120°. If the 2 ropes sling a 19.6 the wire ropes with the hand, do not
kN {2,000 kg} load at a lifting angle of grasp them but press them from
150°, each of them is subjected to a force above. If you grasp them, your fingers
as large as 39.2 kN {4,000 kg}. may be caught.
q After the wire ropes are stretched,
stop the crane and check the condi-
tion of the slung load, wire ropes, and
pads.

4 140E-5 Series
00 Index and foreword SEN00077-07

q If the load is unstable or the wire rope 13) If the hoist stops because of a power fail-
or chains are twisted, lower the load ure, turn the power switch OFF. When
and lift it up again. turning on a switch which was turned OFF
q Do not lift up the load slantingly. by the electric shock prevention earth
13) When lifting down a load, observe the fol- leakage breaker, check that the devices
lowing. related to that switch are not in operation
q When lifting down a load, stop it tem- state.
porarily at 30 cm above the floor, and 14) If you find an obstacle around the hoist,
then lower it slowly. stop the operation.
q Check that the load is stable, and 15) After finishing the work, stop the hoist at
then remove the sling. the specified position and raise the hook
q Remove kinks and dirt from the wire to at least 2 m above the floor. Do not
ropes and chains used for the sling leave the sling installed to the hook.
work, and put them in the specified
place. 7. Selecting wire ropes
1) Select adequate ropes depending on the
5. Precautions for using mobile crane weight of parts to be hoisted, referring to
a Read the Operation and Maintenance the table below.
Manual of the crane carefully in advance
and operate the crane safely. Wire ropes
(Standard “Z” twist ropes without galvanizing)
6. Precautions for using overhead hoist crane (JIS G3525, No. 6, Type 6X37-A)
k When raising a heavy part (heavier Nominal
Allowable load
than 25 kg), use a hoist, etc. In Disas- diameter of rope
sembly and assembly, the weight of a mm kN ton
part heavier than 25 kg is indicated 10 8.8 0.9
after the mark of 4. 12 12.7 1.3
1) Before starting work, inspect the wire 14 17.3 1.7
ropes, brake, clutch, controller, rails, over 16 22.6 2.3
wind stop device, electric shock preven- 18 28.6 2.9
tion earth leakage breaker, crane collision 20 35.3 3.6
prevention device, and power application
25 55.3 5.6
warning lamp, and check safety.
30 79.6 8.1
2) Observe the signs for sling work.
40 141.6 14.4
3) Operate the hoist at a safe place.
4) Check the direction indicator plates (east, 50 221.6 22.6
west, south, and north) and the directions 60 318.3 32.4
of the control buttons without fail.
5) Do not sling a load slantingly. Do not move a The allowable load is one-sixth of the
the crane while the slung load is swinging. breaking strength of the rope used
6) Do not raise or lower a load while the (Safety coefficient: 6).
crane is moving longitudinally or laterally.
7) Do not drag a sling.
8) When lifting up a load, stop it just after it
leaves the ground and check safety, and
then lift it up.
9) Consider the travel route in advance and
lift up a load to a safe height.
10) Place the control switch on a position
where it will not be an obstacle to work
and passage.
11) After operating the hoist, do not swing the
control switch.
12) Remember the position of the main switch
so that you can turn off the power immedi-
ately in an emergency.

140E-5 Series 5
SEN00077-07 00 Index and foreword

8. Precautions for disconnecting and con- a Example of O-ring (Fitted to every joint of
necting hoses and tubes in air conditioner hoses and tubes)
circuit
1) Disconnection
k For the environment, the air condi-
tioner of this machine uses the
refrigerant (air conditioner gas:
R134a) which has fewer factors of
the depletion of the ozone layer.
However, it does not mean that you
may discharge the refrigerant into
the atmosphere as it is. Be sure to
recover the refrigerant when dis-
connecting the refrigerant gas cir-
cuit and then reuse it.
a Ask professional traders for collecting a For tightening torque, see the precautions for
and filling operation of refrigerant installation in each section of "Disassembly
(R134a). and assembly".
a Never release the refrigerant (R134a)
to the atmosphere.
k If the refrigerant gas gets in your
eyes or contacts your skin, you
may lose your sight and your skin
may be frozen. Accordingly, put
on safety glasses, safety gloves
and safety clothes when recover-
ing or adding the refrigerant.
Refrigerant gas must be recovered
and added by a qualified person.

2) Connection
1] When installing the air conditioner cir-
cuit hoses and tubes, take care that
dirt, dust, water, etc. will not enter
them.
2] When connecting the air conditioner
hoses and tubes, check that O-rings
(1) are fitted to their joints.
3] Check that each O-ring is not dam-
aged or deteriorated.
4] When connecting the refrigerant pip-
ing, apply compressor oil for refriger-
ant (R134a) (DENSO: ND-OIL8,
VA L E O T H E R M A L S Y S T E M S :
ZXL100PG (equivalent to PAG46))
to its O-rings.

6 140E-5 Series
00 Index and foreword SEN00077-07

How to read the shop manual 1

q Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one
of them is required, consult KOMATSU distributors.
q Materials and specifications are subject to change without notice.
q Shop manuals are divided into the “Chassis volume” and “Engine volume”. For the engine unit, see the
engine volume of the engine model mounted on the machine.

1. 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 dis-
assembly and service.

20. Standard value table

This section explains the standard values for new machine and judgement criteria for testing,
adjusting, and troubleshooting. This standard value table is used to check the standard values in
testing and adjusting and to judge parts in troubleshooting.

30. Testing and adjusting

This section explains measuring instruments and measuring methods for testing and adjusting, and
method of adjusting each part. The standard values and judgement criteria for testing and adjusting
are explained in Testing and adjusting.

40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is
divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also
explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.

50. Disassembly and assembly

This section explains the special tools and procedures for removing, installing, disassembling, and
assembling each component, as well as precautions for them. In addition, tightening torque and
quantity and weight of coating material, oil, grease, and coolant necessary for the work are also
explained.

90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
This section explains the method of reproducing, repairing, and replacing parts.

2. Revision and distribution

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

140E-5 Series 7
Komatsu Engine Saa6d140e 5 Workshop Manuals
Full download: http://manualplace.com/download/komatsu-engine-saa6d140e-5-workshop-manuals/
SEN00077-07 00 Index and foreword

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

q 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.

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

Symbol Item Remarks

k Safety Special safety precautions are necessary when performing work.

Special technical precautions or other precautions for preserving stan-

a Caution
dards are necessary when performing work.

4
Weight of parts of component or parts. Caution necessary when
Weight
selecting hoisting wire, or when working posture is important, etc.

3
Tightening Places that require special attention for tightening torque during
torque assembly.

2 Coat Places to be coated with adhesives, etc. during assembly.

5
Oil, coolant Places where oil, etc. must be added, and capacity.

6
Drain Places where oil, etc. must be drained, and quantity to be drained.

5. Units
In this shop manual, the units are indicated with International System of units (SI). For reference, con-
ventionally used Gravitational System of units is indicated in parentheses { }.

8 140E-5 Series

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