Manual de Taller Komatsu Saa6d140e 5 PDF

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 1
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 accord-
ingly.
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
2 140E-5 Series
00 Index and foreword SEN00076-16
Table of contents 1
00 Index and foreword
Index SEN00076-16
Composition of shop manual ................................................................................................... 2
Table of contents ..................................................................................................................... 3
Foreword and general information SEN00077-07
Safety notice............................................................................................................................ 2
How to read the shop manual.................................................................................................. 7
Explanation of terms for maintenance standard ...................................................................... 9
Handling of electric equipment and hydraulic component ....................................................... 11
Handling of connectors newly used for engines ...................................................................... 20
How to read electric wire code ................................................................................................ 23
Precautions when carrying out operation ................................................................................ 26
Method of disassembling and connecting push-pull type coupler ........................................... 29
Standard tightening torque table.............................................................................................. 32
Conversion table...................................................................................................................... 36
01 Specification
Specification and technical data SEN00079-07
Outline ..................................................................................................................................... 2
Specifications........................................................................................................................... 6
General view............................................................................................................................ 24
Weight table............................................................................................................................. 61
Engine performance curves..................................................................................................... 65
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 3
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 SEN00147-07
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
Testing air boost pressure........................................................................................................ 29
Testing exhaust temperature ................................................................................................... 30
Adjusting valve clearance ........................................................................................................ 31
4 140E-5 Series
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
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-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
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
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
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
140E-5 Series 9
SEN00076-16
KOMATSU 140E-5 Series engine
Form No. SEN00076-16
© 2012 KOMATSU
All Rights Reserved
Printed in Japan 12-12 (01)
10
SEN00077-07
ENGINE 1SHOP MANUAL
140E-5 Series
00 Index and foreword 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
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
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
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
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
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
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
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
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 tem-
porary standard size is set and an allow-
able difference from that size is indicated.
q The above size set temporarily is called
the “standard size” and the range of differ-
ence 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 Tolerance
–0.022
120
–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 indi-
cated by the same standard size and dif-
ferent tolerances of the hole and shaft.
The tightness of fit is decided by the toler-
ance.
q Indication of size of rotating shaft and hole
and relationship drawing of them
Example:
Tolerance
Standard size
Shaft Hole
–0.030 +0.046
60
–0.076 +0
140E-5 Series 9
2. Standard clearance and standard value 5. Clearance limit

q The clearance made when new parts are q Parts can be used until the clearance
assembled is called the “standard clear- between them is increased to a certain
ance“, which is indicated by the range limit. The limit at which those parts cannot
from the minimum clearance to the maxi- be used is called the “clearance limit”.
mum clearance. q If the clearance between the parts
q When some parts are repaired, the clear- exceeds the clearance limit, they must be
ance is generally adjusted to the standard replaced or repaired.
clearance.
q A value of performance and function of 6. Interference limit
new products or equivalent is called the q The allowable maximum interference
“standard value“, which is indicated by a between the hole of a part and the shaft of
range or a target value. another part to be assembled is called the
q When some parts are repaired, the value “interference limit”.
of performance/function is set to the stan- q The interference limit shows the repair
dard value. limit of the part of smaller tolerance.
q If the interference between the parts
3. Standard interference exceeds the interference limit, they must
q When the diameter of a hole of a part be replaced or repaired.
shown in the given standard size and tol-
erance 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 allow-

able 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 prod-
uct 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 vari-
ous tests or experiences in most cases,
however, it must be judged after consider-
ing the operating condition and customer's
requirement.
10 140E-5 Series
Handling of electric equipment and hydraulic component 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, con-
nectors used for connecting and disconnecting
one wire from another wire, and protectors or
tubes used for protecting the wiring.
Compared with other electrical components fit-
ted 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 (defec-
tive contact between male and female)
Problems with defective contact are likely
to occur because the male connector is
not properly inserted into the female con-
nector, or because one or both of the con-
nectors is deformed or the position is not
correctly aligned, or because there is cor-
rosion or oxidization of the contact sur-
faces. The corroded or oxidized contact
surfaces may become shiny again (and
contact may become normal) by connect-
ing and disconnecting the connector about
10 times.
2) Defective crimping or soldering of connec-

tors
The pins of the male and female connec-
tors are in contact at the crimped terminal
or soldered portion, but if there is exces-
sive force brought to bear on the wiring,
the plating at the joint will peel and cause
improper connection or breakage.
140E-5 Series 11
3) Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with
a crane with the wiring still connected, or a
heavy object hits the wiring, the crimping
of the connector may separate, or the sol-
dering may be damaged, or the wiring
may be broken.
4) High-pressure water entering connector

The connector is designed to make it diffi-
cult for water to enter (drip-proof struc-
ture), 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-cir-
cuited 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 sur-
face 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 com-
pressed 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 com-
pressed air, the contacts will become
even dirtier, so remove the oil and
water from the compressed air com-
pletely before cleaning with com-
pressed air.
12 140E-5 Series
3. Removing, installing, and drying connec-

tors and wiring harnesses
1) Disconnecting connectors
1] Hold the connectors when discon-
necting.
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 connec-
tors apart.
a Never pull with one hand.
2] When removing from clips

q 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 stop-
pers.
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 connec-

tors
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 disassem-
bled for a long time, it is particu-
larly easy for improper contact to
occur, so always cover the con-
nector.
140E-5 Series 13
2) Connecting connectors
1] Check the connector visually.
Check that there is no oil, dirt, or
water stuck to the connector pins
(mating portion).
Check that there is no deformation,
defective contact, corrosion, or dam-
age to the connector pins.
Check that there is no damage or
breakage to the outside of the con-
nector.
a If there is any oil, water, or dirt
stuck to the connector, wipe it off
with a dry cloth. If any water has
got inside the connector, warm
the inside of the wiring with a
dryer, but be careful not to make
it too hot as this will cause short
circuits.
a If there is any damage or break-
age, replace the connector.
2] Fix the connector securely.
Align the position of the connector
correctly, and then insert it securely.
For connectors with the lock stopper,
push in the connector until the stop-
per clicks into position.
3] Correct any protrusion of the boot and
any misalignment of the wiring har-
ness.
For connectors fitted with boots, cor-
rect any protrusion of the boot. In
addition, if the wiring harness is mis-
aligned, or the clamp is out of posi-
tion, adjust it to its correct position.
a If the connector cannot be cor-
rected easily, remove the clamp
and adjust the position.
q If the connector clamp has been
removed, be sure to return it to
its original position. Check also
that there are no loose clamps.
14 140E-5 Series
3) Heavy duty wire connector (DT 8-pole, 12- q Disconnection q Connection (Example of
pole) incomplete setting of (a))
Disconnection (Left of figure)
While pressing both sides of locks (a)
and (b), pull out female connector (2).
Connection (Right of figure)
1] Push in female connector (2) horizon-
tally until the lock clicks.
Arrow: 1)
2] Since locks (a) and (b) may not be set
completely, push in female connector
(2) while moving it up and down until
the locks are set normally.
Arrow: 1), 2), 3)
a Right of figure: Lock (a) is pulled
down (not set completely) and
lock (b) is set completely.
(1): Male connector
(2): Female connector
(a), (b): Locks
140E-5 Series 15
4) Drying wiring harness

If there is any oil or dirt on the wiring har-
ness, 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 fol-
lows.
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 com-
pressed 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 con-
nector.
After drying, leave the wiring harness
disconnected and carry out a continu-
ity test to check for any short circuits
between pins caused by water.
a After completely drying the con-
n e c t o r, b l o w i t w i t h c o n ta c t
restorer and reassemble.
16 140E-5 Series
4. Handling controller
1) The controller contains a microcomputer
and electronic control circuits. These con-
trol all of the electronic circuits on the
machine, so be extremely careful when
handling the controller.
2) Do not place objects on top of the control-
ler.
3) Cover the control connectors with tape or
a vinyl bag. Never touch the connector
contacts with your hand.
4) During rainy weather, do not leave the
controller in a place where it is exposed to
rain.
5) Do not place the controller on oil, water, or
soil, or in any hot place, even for a short
time. (Place it on a suitable dry stand).
6) Precautions when carrying out arc welding
When carrying out arc welding on the
body, disconnect all wiring harness con-
nectors connected to the controller. Fit an
arc welding ground close to the welding
point.
5. Points to remember when troubleshooting

electric circuits
1) Always turn the power OFF before discon-
necting 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 con-
nectors before going on to the next step.
a If the power is turned ON with the
connectors still disconnected, unnec-
essary abnormality displays will be
generated.
4) When carrying out troubleshooting of cir-
cuits (measuring the voltage, resistance,
continuity, or current), move the related
wiring and connectors several times and
check that there is no change in the read-
ing of the tester.
a If there is any change, there is proba-
bly defective contact in that circuit.
140E-5 Series 17
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 perfor-
mance 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 clean-
ing device is used, it is possible to filter out the
dirt that has collected during storage, so this is
an even more effective method.
18 140E-5 Series
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 equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit. Normally, flushing is
carried out twice: primary flushing is carried
out with flushing oil, and secondary flushing is
carried out with the specified hydraulic oil.
7. Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the
machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil cir-
cuit. The oil cleaning equipment is used to
remove the ultra fine (about 3 m) particles that
the filter built in the hydraulic equipment can-
not remove, so it is an extremely effective
device.
140E-5 Series 19
Handling of connectors newly used for engines 1

a Mainly, following engines are object for follow- 2. Pull lock type (PACKARD-2)
ing connectors. q 95 – 170, 12V140 engines
q 95E-5 q Various temperature sensors
q 107E-1 Example)
q 114E-3 Intake air temperature sensor in
q 125E-5 intake manifold: TIM
q 140E-5 Fuel temperature sensor: TFUEL
q 170E-5 Oil temperature sensor: TOIL
q 12V140E-3 Coolant temperature sensor: TWTR,
etc.
1. Slide lock type Disconnect the connector by pulling lock
(FRAMATOME-3, FRAMATOME-2) (B) (on the wiring harness side) of connec-
q 95 – 170, 12V140 engines tor (2) outward.
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)
Disconnect connector (1) according to the fol-

lowing procedure.
1) Slide lock (L1) to the right.
2) While pressing lock (L2), pull out connec-
tor (1) toward you.
a Even if lock (L2) is pressed, connec-
tor (1) cannot be pulled out toward
you, if part A does not float. In this
case, float part A with a small screw-
driver while press lock (L2), and then
pull out connector (1) toward you.
20 140E-5 Series
3. Push lock type

q 95, 107, 114 engines
Example)
Fuel pressure sensor in common rail
(BOSCH-03)
Disconnect connector (3) according to the fol-

lowing procedure.
1) While pressing lock (C), pull out connector
(3) in the direction of the arrow.
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.
q 107 engine
a If the lock is on the underside, use

flat-head screwdriver [1] since you
cannot insert your fingers.
2) While pressing up lock (C) of the connec-
tor with flat-head screwdriver [1], pull out
connector (3) in the direction of the arrow.
140E-5 Series 21
q 95, 125 – 170, 12V140 engines 4. Turn-housing type (Round green connector)
4) While pressing lock (E) of the connector, q 140 engine
pull out connector (5) in the direction of Example)
the arrow. Intake air pressure sensor in intake mani-
fold (CANNON-04): PIM etc.
Example)
Fuel pressure sensor in common rail: 1) Disconnect connector (6) according to the
PFUEL etc. (AMP-3) following procedure.
1] Turn housing (H1) in the direction of
the arrow.
a When connector is unlocked,
housing (H1) becomes heavy to
turn.
2] Pull out housing (H1) in the direction
of the arrow.
a Housing (H1) is left on the wiring har-
ness side.
Example)
Injection pressure control valve of fuel
supply pump: PCV (SUMITOMO-2)
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)
Speed sensor of fuel supply pump:
G (SUMITOMO-3)
a Pull the connector straight up.
22 140E-5 Series
How to read electric wire code 1

a The information about the wires unique to each machine model is described in Troubleshooting section,
Relational information of troubleshooting.
In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by sym-
bols. The electric wire code is helpful in understanding the electric circuit diagram.
Example: AEX 0.85 L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nomi-
nal No. of 0.85
Indicates color of wire by color code.
Color codes are shown in Table 3.
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 indi-
cated.)
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)
Using
Sym-
Type Material temperature Example of use
bol
range (°C)
Low-voltage Conduc- Annealed copper for elec-
tor tric appliance General wiring
wire for AV
(Nominal No. 5 and above)
automobile Insulator Soft polyvinyl chloride
Thin-cover Conduc- Annealed copper for elec- –30 to +60
low-voltage tor tric appliance General wiring
AVS
wire for (Nominal No. 3 and below)
automobile Insulator Soft polyvinyl chloride
Heat-resis- Conduc- Annealed copper for elec-

General wiring in extremely
tant low-volt- tor tric appliance
AEX –50 to +110 cold district, wiring at high-tem-
age wire for Heat-resistant crosslinked
Insulator perature place
automobile polyethylene
140E-5 Series 23
2. Dimensions
(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5
Number of
strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32
eter of strand
Conductor
Sectional
0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
area (mm2)
d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0
AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 –
Cov-
AV Standard – – – – – – – 4.6
er D
AEX Standard 2.0 2.2 2.7 3.0 3.1 – 3.8 4.6
Nominal No. 8 15 20 30 40 50 60 85 100

Number of
strands/Diam- 50/0.45 84/0.45 41/0.80 70/0.80 85/0.80 108/0.80 127/0.80 169/0.80 217/0.80
eter of strand
Conductor
Sectional
7.95 13.36 20.61 35.19 42.73 54.29 63.84 84.96 109.1
area (mm2)
d (approx.) 3.7 4.8 6.0 8.0 8.6 9.8 10.4 12.0 13.6
AVS Standard – – – – – – – – –
Cov-
AV Standard 5.5 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
er D
AEX Standard 5.3 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
“f” of nominal No. denotes flexible”.
24 140E-5 Series
3. Color codes table
(Table 3)
Color Code Color of wire Color Code Color of wire
B Black LgW Light green & White
Br Brown LgY Light green & Yellow
BrB Brown & Black LR Blue & Red
BrR Brown & Red LW Blue & White
BrW Brown & White LY Blue & Yellow
BrY Brown & Yellow O Orange
Ch Charcoal P Pink
Dg Dark green R Red
G Green RB Red & Black
GB Green & Black RG Red & Green
GL Green & Blue RL Red & Blue
Gr Gray RW Red & White
GR Green & Red RY Red & Yellow
GW Green & White Sb Sky Blue
GY Green & Yellow Y Yellow
L Blue YB Yellow & Black
LB Blue & Black YG Yellow &Green
Lg Light green YL Yellow & Blue
LgB Light green & Black YR Yellow & Red
LgR Light green & Red YW Yellow & White
Remarks: In a color code consisting of 2 colors, the first color is the color of the background and
the second color is the color of the marking.
Example: “GW” means that the background is Green and marking is White.
4. Types of circuits and color codes
(Table 4)
Type of wire AVS or AV AEX
Charge R WG – – – – R –
Ground B – – – – – B –
Start R – – – – – R –
Light RW RB RY RG RL – D –
Instrument Y YR YB YG YL YW Y Gr
Signal G GW GR GY GB GL G Br
L LW LR LY LB – L –
Type of
Br BrW BrR BrY BrB – – –
circuit
Lg LgR LgY LgB LgW – – –
O – – – – – – –
Others Gr – – – – – – –
P – – – – – – –
Sb – – – – – – –
Dg – – – – – – –
Ch – – – – – – –
140E-5 Series 25
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. Precautions when carrying out removal work

q If the coolant contains antifreeze, dispose of it correctly.
q After disconnecting hoses or tubes, cover them or fit plugs to prevent dirt or dust from entering.
q When draining oil, prepare a container of adequate size to catch the oil.
q Confirm the match marks showing the installation position, and make match marks in the necessary
places before removal to prevent any mistake when assembling.
q To prevent any excessive force from being applied to the wiring, always hold the connectors when dis-
connecting the connectors. Do not pull the wires.
q Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.
q Check the number and thickness of the shims, and keep in a safe place.
q When raising components, be sure to use lifting equipment of ample strength.
q When using forcing screws to remove any components, tighten the forcing screws uniformly in turn.
q Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from
entering after removal.
a 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
Plug (nut end) Sleeve nut (elbow end)
number
02 07376-70210 02789-20210
03 07376-70315 02789-20315
04 07376-70422 02789-20422
05 07376-70522 02789-20522
06 07376-70628 02789-20628
10 07376-71034 07221-21034
12 07376-71234 07221-21234
2) Split flange type hoses and tubes

Nominal
Flange (hose end) Sleeve head (tube end) Split flange
number
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500
3) If the part is not under hydraulic pressure, the following corks can be used.
Nominal Dimensions
Part Number
number D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34
26 140E-5 Series
2. Precautions when carrying out installation work

q Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
q Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any.
q Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
q Bend the cotter pins and lock plates securely.
q When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded por-
tion with 2 – 3 drops of adhesive.
q 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.
q Clean all parts, and correct any damage, dents, burrs, or rust.
q Coat rotating parts and sliding parts with engine oil.
q When press fitting parts, coat the surface with anti-friction compound (LM-P).
q After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
q When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
securely.
q When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align
the direction of the hook.
q When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
a When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other
hydraulic equipment removed for repair, always bleed the air as follows:
1) Start the engine and run at low idle.
2) Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times, stopping the
cylinder 100 mm from the end of its stroke.
3) Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke.
4) After doing this, run the engine at normal speed.
a When using the machine for the first time after repair or long storage, follow the same procedure.
3. 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 speci-
fied 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.
Fuel system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel
leakage.
140E-5 Series 27
4) 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.
5) 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”.
28 140E-5 Series
Method of disassembling and connecting push-pull type coupler 1

k Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to
release the residual pressure from the hydraulic tank.
k 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
Type 2
1. Disconnection
1) Hold the tightening portion and push body
(7) straight until sliding prevention ring (6)
contacts contact surface (a) of the hexag-
onal portion at the male end. (Fig. 6)
2) While holding the condition of Step 1), turn
lever (8) to the right (clockwise). (Fig. 7)
3) While holding the condition of Steps 1)
and 2), pull out whole body (7) to discon-
nect it. (Fig. 8)
2. Connection
q Hold the tightening portion and push body
contacts contact surface (a) of the hexag-
30 140E-5 Series
Type 3
1. Disconnection
1) Hold the tightening portion and push body
contacts contact surface (b) of the hexag-
2) While holding the condition of Step 1),
push cover (10) straight until it contacts
contact surface (b) of the hexagonal por-
tion at the male end. (Fig. 11)
3) While holding the condition of Steps 1)
and 2), pull out whole body (9) to discon-
nect it. (Fig. 12)
2. Connection
q Hold the tightening portion and push body
(9) straight until the sliding prevention ring
contacts contact surface (b) of the hexag-
140E-5 Series 31
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 Width across flats Tightening torque

mm mm Nm kgm
6 10 11.8 – 14.7 1.2 – 1.5
8 13 27 – 34 2.8 – 3.5
10 17 59 – 74 6.0 – 7.5
12 19 98 – 123 10.0 – 12.5
14 22 157 – 196 16 – 20
16 24 245 – 309 25 – 31.5
18 27 343 – 427 35 – 43.5
20 30 490 – 608 50 – 62
22 32 662 – 829 67.5 – 84.5
24 36 824 – 1,030 84 – 105
27 41 1,180 – 1,470 120 – 150
30 46 1,520 – 1,910 155 – 195
33 50 1,960 – 2,450 200 – 250
36 55 2,450 – 3,040 250 – 310
39 60 2,890 – 3,630 295 – 370
a The following table applies to the bolts in Fig. B.

mm mm Nm kgm
6 10 5.9 – 9.8 0.6 – 1.0
8 12 13.7 – 23.5 1.4 – 2.4
10 14 34.3 – 46.1 3.5 – 4.7
12 17 74.5 – 90.2 7.6 – 9.2
a Fig. A a Fig. B
Remarks: The widths across flats against the thread diameters of flanged bolts (marks with "*") in Fig. A are
the ones indicated in the table for bolts shown in Fig. B.
(Values of tightening torques shown in the table for Fig. A are applied.)
32 140E-5 Series
2. Table of tightening torques for split flange bolts

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

mm mm Nm kgm
10 14 59 – 74 6.0 – 7.5
12 17 98 – 123 10.0 – 12.5
16 22 235 – 285 23.5 – 29.5
3. 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 Width across flats Tightening torque Nm {kgm}

Nominal No.
mm mm Range Target
02 14 35 – 63 { 3.5 – 6.5} 44 { 4.5}
03,04 20 Varies depending 84 – 132 { 8.5 – 13.5} 103 {10.5}
05,06 24 on type of connec- 128 – 186 {13.0 – 19.0} 157 {16.0}
10,12 33 tor. 363 – 480 {37.0 – 49.0} 422 {43.0}
14 42 746 – 1,010 {76.0 – 103} 883 {90.0}
4. 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 Thread diameter Width across flats Tightening torque Nm {kgm}

No. mm mm Range Target
08 8 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}
10 10 17 9.81 – 12.74 {1.0 – 1.3} 11.27 {1.15}
12 12 19 14.7 – 19.6 {1.5 – 2.0} 17.64 {1.8}
14 14 22 19.6 – 24.5 {2.0 – 2.5} 22.54 {2.3}
16 16 24 24.5 – 34.3 {2.5 – 3.5} 29.4 {3.0}
18 18 27 34.3 – 44.1 {3.5 – 4.5} 39.2 {4.0}
20 20 30 44.1 – 53.9 {4.5 – 5.5} 49.0 {5.0}
24 24 32 58.8 – 78.4 {6.0 – 8.0} 68.6 {7.0}
30 30 32 93.1 – 122.5 { 9.5 – 12.5} 107.8 {11.0}
33 33 – 107.8 – 147.0 {11.0 – 15.0} 127.4 {13.0}
36 36 36 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5}
42 42 – 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5}
52 52 – 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0}
140E-5 Series 33
5. Table of tightening torques for hoses (taper seal type and face seal type)
a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the
torque below.
a Apply the following torque when the threads are coated (wet) with engine oil.
Tightening torque Nm {kgm} Taper seal Face seal

Nominal Width Nominal No. –
No. of across Thread
Thread size Number of
hose flats Range Target diameter (mm)
(mm) threads, type of
(Reference)
thread
34 – 54 { 3.5 – 5.5} – 9/16-18UN 14.3
02 19 44 { 4.5}
34 – 63 { 3.5 – 6.5} 14 – –
22 54 – 93 { 5.5 – 9.5} 74 { 7.5} – 11/16-16UN 17.5
03
24 59 – 98 { 6.0 – 10.0} 78 { 8.0} 18 – –
04 27 84 – 132 { 8.5 – 13.5} 103 {10.5} 22 13/16-16UN 20.6
05 32 128 – 186 {13.0 – 19.0} 157 {16.0} 24 1-14UNS 25.4
06 36 177 – 245 {18.0 – 25.0} 216 {22.0} 30 1-3/16-12UN 30.2
(10) 41 177 – 245 {18.0 – 25.0} 216 {22.0} 33 – –
(12) 46 197 – 294 {20.0 – 30.0} 245 {25.0} 36 – –
(14) 55 246 – 343 {25.0 – 35.0} 294 {30.0} 42 – –
6. 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 Width Tightening torque Nm {kgm} Face seal

diameter across Nominal No. – Thread diameter
of pipe flats Range Target Number of threads, (mm)
(mm) (mm) type of thread (Reference)
8 19 14 – 16 {1.4 – 1.6} 15 {1.5} 9/16-18UN 14.3
10 22 24 – 27 {2.4 – 2.7} 25.5 {2.6} 11/16-16UN 17.5
12 24 (27) 43 – 47 {4.4 – 4.8} 45 {4.6} 13/16-16UN 20.6
15 (16) 30 (32) 60 – 68 {6.1 – 6.8} 64 {6.5} 1-14UN 25.4
22 (20) 36 90 – 95 {9.2 – 9.7} 92.5 {9.4} 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
Thread size
Bolts and nuts
mm Nm kgm
6 10 ± 2 1.02 ± 0.20
8 24 ± 4 2.45 ± 0.41
10 43 ± 6 4.38 ± 0.61
12 77 ± 12 7.85 ± 1.22
14 — —
34 140E-5 Series
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 Tightening torque

mm Nm kgm
6 8±2 0.81 ± 0.20
8 10 ± 2 1.02 ± 0.20
10 12 ± 2 1.22 ± 0.20
12 24 ± 4 2.45 ± 0.41
14 36 ± 5 3.67 ± 0.51
9. Table of tightening torques for 102, 107 and 114 engine series (Taper screws)
a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114
engine series to the torque below.
Tightening torque
Material In cast iron or steel In aluminum
Thread size (inch) Nm kgm Nm kgm
1/16 15 ± 2 1.53 ± 0.20 5±1 0.51 ± 0.10
1/8 20 ± 2 2.04 ± 0.20 15 ± 2 1.53 ± 0.20
1/4 25 ± 3 2.55 ± 0.31 20 ± 2 2.04 ± 0.20
3/8 35 ± 4 3.57 ± 0.41 25 ± 3 2.55 ± 0.31
1/2 55 ± 6 5.61 ± 0.61 35 ± 4 3.57 ± 0.41
3/4 75 ± 8 7.65 ± 0.82 45 ± 5 4.59 ± 0.51
140E-5 Series 35
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 hori-
zontal 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 (B)

1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
(C)
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
(A)
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
36 140E-5 Series
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
Liters to U.S. Gallons

1 l = 0.2642 U.S.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
140E-5 Series 37
Liters to U.K. Gallons

1 l = 0.21997 U.K.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.699 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
kgm to ft.lb
1 kgm = 7.233 ft.lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
38 140E-5 Series
kg/cm2 to lb/in2
1 kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1,010 1,024 1,038 1,053 1,067 1,081 1,095 1,109 1,124
80 1,138 1,152 1,166 1,181 1,195 1,209 1,223 1,237 1,252 1,266
90 1,280 1,294 1,309 1,323 1,337 1,351 1,365 1,380 1,394 1,408
100 1,422 1,437 1,451 1,465 1,479 1,493 1,508 1,522 1,536 1,550
110 1,565 1,579 1,593 1,607 1,621 1,636 1,650 1,664 1,678 1,693
120 1,707 1,721 1,735 1,749 1,764 1,778 1,792 1,806 1,821 1,835
130 1,849 1,863 1,877 1,892 1,906 1,920 1,934 1,949 1,963 1,977
140 1,991 2,005 2,020 2,034 2,048 2,062 2,077 2,091 2,105 2,119
150 2,134 2,148 2,162 2,176 2,190 2,205 2,219 2,233 2,247 2,262
160 2,276 2,290 2,304 2,318 2,333 2,347 2,361 2,375 2,389 2,404
170 2,418 2,432 2,446 2,460 2,475 2,489 2,503 2,518 2,532 2,546
180 2,560 2,574 2,589 2,603 2,617 2,631 2,646 2,660 2,674 2,688
190 2,702 2,717 2,731 2,745 2,759 2,773 2,788 2,802 2,816 2,830
200 2,845 2,859 2,873 2,887 2,901 2,916 2,930 2,944 2,958 2,973
210 2,987 3,001 3,015 3,030 3,044 3,058 3,072 3,086 3,101 3,115
220 3,129 3,143 3,158 3,172 3,186 3,200 3,214 3,229 3,243 3,257
230 3,271 3,286 3,300 3,314 3,328 3,343 3,357 3,371 3,385 3,399
240 3,414 3,428 3,442 3,456 3,470 3,485 3,499 3,513 3,527 3,542
140E-5 Series 39
Temperature
Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centi-
grade temperature reading or vice versa is to enter the accompanying table in the center (boldface column)
of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahren-
heit temperatures and read the corresponding Centigrade temperature in the column at the left.
When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centi-
grade values, and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
–40.4 –40 –40.0 –11.7 11 51.8 7.8 46 114.8 27.2 81 177.8
–37.2 –35 –31.0 –11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
–34.4 –30 –22.0 –10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
–31.7 –25 –13.0 –10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
–28.9 –20 –4.0 –9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
–28.3 –19 –2.2 –8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

–27.8 –18 –0.4 –8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
–27.2 –17 1.4 –7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
–26.7 –16 3.2 –7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
–26.1 –15 5.0 –6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
–25.6 –14 6.8 –6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

–25.0 –13 8.6 –5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
–24.4 –12 10.4 –5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
–23.9 –11 12.2 –4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
–23.3 –10 14.0 –3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
–22.8 –9 15.8 –3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

–22.2 –8 17.6 –2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
–21.7 –7 19.4 –2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
–21.1 –6 21.2 –1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
–20.6 –5 23.0 –1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
–20.0 –4 24.8 –0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

–19.4 –3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
–18.9 –2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
–18.3 –1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
–17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
–17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

–16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
–16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
–15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
–15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
–14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

–13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
–13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
–12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
–12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
40 140E-5 Series
140E-5 Series 41
SEN00077-07
© 2009 KOMATSU
All Rights Reserved
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 Engine serial No. Machine models

PC600-8, PC600LC-8, PC600-8R, PC600LC-8R Hydraulic excavator
PC600-8E0, PC600LC-8E0, Hydraulic excavator
PC600-8R1, PC600LC-8R1, Hydraulic excavator
PC700-8E0, PC700LC-8E0 Hydraulic excavator
PC700-8R, PC700LC-8R, PC700LC-8R1 Hydraulic excavator
PC800-8, PC800SE-8, PC800LC-8 Hydraulic excavator
PC850-8, PC850SE-8 Hydraulic excavator
PC800-8R, PC800SE-8R, PC800LC-8R Hydraulic excavator
PC850-8R, PC850SE-8R Hydraulic excavator
PC800-8R1, PC800SE-8R1, PC800LC-8R1 Hydraulic excavator
SAA6D140E-5 PC850-8R1, PC850SE-8R1 Hydraulic excavator
PC800-8E0, PC800SE-8E0, PC800LC-8E0 Hydraulic excavator
PC850-8E0, PC850SE-8E0 Hydraulic excavator
D155AX-6, D155A-6 Bulldozer
D275AX-5E0, D275A-5R Bulldozer
WA500-6, WA500-6R Wheel loader
HD325-7, HD405-7, HD325-7R, HD405-7R Dump truck
HM350-2, HM350-2R Articulated dump truck
HM400-2, HM400-2R Articulated dump truck
HM400-3M0, HM400-3R Articulated dump truck
SDG400S-6B1 (HOKUETSU INDUSTRIES) Generator
2 140E-5 Series
01 Specification SEN00079-07
2. Outline of engine
(With EGR)
q The 140E-5 engine is a high-performance and 4) To secure the high output of the engine, the
high-efficiency engine, which passed strict twin cooling nozzle to cool the piston employed
emission regulations (USA: EPA Regulations for 140E-3 and after models is improved to
for 2006, EU: Regulations for 2006, Japan: increase the durability of the piston and lower
Construction machinery regulations for 2006) the back side temperature of the piston. As a
and attained low fuel consumption, low noise, result, the lubricating oil on the piston is not
better exhaust gas color, and high acceleration exposed to high temperature, thus it is not
performance. Accordingly, this newly devel- deteriorated. Since the high-pressure fuel
oped engine is suitable as a power source of injection system controlled electronically is
construction machinery and industrial machin- employed, less soot is produced and the drain-
ery used for various purposes. ing interval of the oil is lengthened. (While the
capacity of the oil pan is not changed, the oil
q The 140E-5 engine is the successor to the replacement interval of 500 hours is secured.)
140E-3 engine. While it is an in-line 6-cylinder,
water-cooled, common rail direct injection, 4- 5) The common rail high-pressure fuel injection
stroke diesel engine similar to 140E-3, it is system controlled electronically is employed
equipped with the cooled EGR system which is for all of 140E-3 and after models. This system
a new technology. can inject the fuel at high pressure of 120 MPa
{1,200 kg/cm2} from the low-speed range to the
1) The main components of the cooled EGR sys- high-speed range. In addition, this system can
tem are the EGR cooler of corrugated tube control the form of injection most properly by
type made of newly developed special stain- electronic control according to the speed and
less steel and the EGR valve driven hydrauli- load. The injection system of 140E-5 is further
cally and controlled electronically which improved to employ multiple injections and
KOMATSU developed by itself. The cooled increase the injection pressure up to 160 MPa
EGR system secures the optimum EGR rate {1,600 kg/cm2}. As a result, exhaust gas of the
from the low-speed range to the high-speed cleanest level in the world, good exhaust gas
range to attain both clean exhaust gas and low color, low fuel consumption, and low noise are
fuel consumption with the bypass assist circuit realized simultaneously.
consisting of the venturi system and bypass
valve which has the same function and struc- 6) As the injection pressure of the common rail
ture as those of the EGR valve. injection system employed for the 140E-3
engine and after models is increased (from
2) The special EGR oil pump is employed to gen- 120 to 160 MPa {from 1,200 to 1,600 kg/cm2}),
erate high oil pressure (1.47 MPa {15 kg/cm2}) the pressure resistance of the common rail,
as the drive power source of the EGR valve injector, and supply pump is improved for
driven hydraulically and controlled electroni- higher reliability.
cally. The engine oil pump has sufficient deliv-
ery for the EGR valve and increased output of 7) The main fuel filter of high efficiency and the
the engine. As a result, the reliability and dura- pre-fuel filter are installed as standard so that
bility of the engine are improved. the low grade fuel in the market (equivalent to
Class NAS13) can be used. In addition, the
3) While the 140E-3 engine has only 1 combina- delivery of the priming pump used to replace
tion filter of high performance and high effi- the filters is increased for higher serviceability.
ciency, the 140E-5 engine has 2 of the same
filter to meet the requirements of the EGR sys- 8) The high-quality piston made of cast iron which
tem and high-dispersion oil and improve the has been employed for the 140E-2 engine and
ability to capture the soot in the oil. In addition, after models is employed. This piston has a
the recommended sub-materials for operation less coefficient of thermal expansion, a reen-
(oil and fuel) are changed to improve the reli- trant combustion chamber, and a shaker cool-
ability and durability of the engine. ing gallery. As a result, clean exhaust gas,
good exhaust gas color, and low fuel consump-
tion are attained simultaneously, and high
durability and reliability are also obtained.
140E-5 Series 3
9) By using the above-mentioned high-pressure

fuel injection system controlled electronically,
the multiple injection and injection characteris-
tics are set most properly to improve the start-
ability 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 turbo-

charger 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 high-
speed 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
(EGR-less)
q The 140E-5 engine is a high-performance and 4) As the injection pressure of the common rail
high-efficiency engine, which attained low fuel injection system employed for the 140E-3
consumption and low noise. Accordingly, this engine and after models is increased, the pres-
newly developed engine is suitable as a power sure resistance of the common rail, injector,
source of construction machinery and indus- and supply pump is improved for higher reli-
trial machinery used for various purposes. ability.
q The 140E-5 engine is the successor to the 5) The main fuel filter of high efficiency and the
140E-3 engine. While it is an in-line 6-cylinder, pre-fuel filter are installed as standard so that
water-cooled, 4-stroke diesel engine, it is the low grade fuel in the market can be used.
equipped with the common rail direct injection In addition, the delivery of the priming pump
system. used to replace the filters is increased for
higher serviceability.
1) While the 140E-3 engine has only 1 combina-
tion filter of high performance and high effi- 6) The high-quality piston made of cast iron which
ciency, the 140E-5 engine has 2 of the same has been employed for the 140E-2 engine and
filter to meet the requirements of the high-dis- after models is employed. This piston has a
persion oil and improve the ability to capture less coefficient of thermal expansion, a reen-
the soot in the oil. In addition, the recom- trant combustion chamber, and a shaker cool-
mended sub-materials for operation (oil and ing gallery. As a result, clean exhaust gas,
fuel) are changed to improve the reliability and good exhaust gas color, and low fuel consump-
durability of the engine. tion are attained simultaneously, and high
durability and reliability are also obtained.
2) To secure the high output of the engine, the
twin cooling nozzle to cool the piston employed 7) By using the above-mentioned high-pressure
for 140E-3 and after models is improved to fuel injection system controlled electronically,
increase the durability of the piston and lower the multiple injection and injection characteris-
the back side temperature of the piston. As a tics are set most properly to improve the start-
result, the lubricating oil on the piston is not ability and reduce the white exhaust smoke
exposed to high temperature, thus it is not when the temperature is low.
deteriorated. Since the high-pressure fuel
injection system controlled electronically is 8) Since the controller is mounted on the engine
employed, less soot is produced and the drain- and equipped with the automatic high-altitude
ing interval of the oil is lengthened. (While the compensation function, the engine can be
capacity of the oil pan is not changed, the oil operated at high altitude without replacing the
replacement interval of 500 hours is secured.) controller. As a result, the serviceability is
improved.
3) The common rail high-pressure fuel injection
system controlled electronically is employed 9) The improved type of the KTR110 turbo-
for all of 140E-3 and after models. This system charger manufactured by KOMATSU which
can inject the fuel at high pressure of 120 MPa has been employed for the 140E-2 engine and
{1,200 kg/cm2} from the low-speed range to the after models and which has high reliability and
high-speed range. In addition, this system can high performance is mounted. Besides; the
control the form of injection most properly by efficiency of the blower impeller is heightened
electronic control according to the speed and and the strength of its material is improved to
load. The injection system of 140E-5 is further obtain higher efficiency and pressure ratio.
improved to employ multiple injections and Since the design of the shaft is improved to
increase the injection pressure. As a result, increase the reliability, high performance is
exhaust gas of the cleanest level in the world, obtained from the low-speed range to the high-
good exhaust gas color, low fuel consumption, speed range. As a result, the engine has high
and low noise are realized simultaneously. performance and consumes less fuel and
attains high reliability.
140E-5 Series 5
Specifications 1
Engine name SAA6D140E-5

PC600-8, PC600LC-8
Machine models PC600-8E0, PC600LC-8E0
PC700-8E0, PC700LC-8E0
Number of cylinders – Bore × Stroke mm 6 – 140 × 165
Total displacement l{cc} 15.2 {15,230}
Firing order — 1–5–3–6–2–4
Overall length mm 1,494
Dimensions
Overall width mm 1,151

Overall height (excluding exhaust pipe) mm 1,467
Overall height (including exhaust pipe) mm 1,863
kW{HP}/ 323 {433.3}/1,800 {1,800}
Rated horsepower
min-1{rpm} (Gross)
Nm{kgm}/ 1,944 {198.4}/1,400 {1,400}
Max. torque
Performance
min-1{rpm} (Gross)
Max. speed with no load
min-1{rpm} 1,950 ± 50 {1,950 ± 50}
(High idle speed)
Min. speed with no load
min-1{rpm} 800 ± 25 {800 ± 25}
(Low idle speed)
g/kW·h
Fuel consumption ratio at rated point 209 {156}
{g/HP·h}
Dry weight kg 1,845
Fuel supply pump — DENSO ECD-U2
Governor — Electronic control type
Quantity of lubricating oil (refill capacity) l 48 (40)
Quantity of coolant l 24
Alternator — 24V, 60A, 90A
Starting motor — 24V, 11kW
Battery — 12V, 170Ah × 2
Turbocharger — KOMATSU KTR110L
Air compressor — —
Others — With air-cooled aftercooler
With cooled EGR
6 140E-5 Series

PC600-8R, PC600LC-8R
Machine models PC600-8R1, PC600LC-8R1
PC700-8R, PC700LC-8R, PC700LC-8R1
Dimensions

kW{HP}/ 323 {433.3}/1,800 {1,800}
Rated horsepower
min-1{rpm} (Gross)
Nm{kgm}/ 1,944 {198.4}/1,400 {1,400}
Max. torque
Performance
min-1{rpm} (Gross)
min-1{rpm} 1,950 ± 50 {1,950 ± 50}
(High idle speed)
min-1{rpm} 800 ± 25 {800 ± 25}
(Low idle speed)
g/kW·h
{g/HP·h}
Dry weight kg 1,770
140E-5 Series 7

PC800-8, PC800SE-8, PC800LC-8,
PC850-8, PC850SE-8
Machine models
PC800-8E0, PC800SE-8E0, PC800LC-8E0,
PC850-8E0, PC850SE-8E0
Dimensions

kW{HP}/ 370 {496.4}/1,800 {1,800}
Rated horsepower
min-1{rpm} (Gross)
Nm{kgm}/ 2,195 {223.8}/1,350 {1,350}
Max. torque
Performance
min-1{rpm} (Gross)
min-1{rpm} 1,980 ± 50 {1,980 ± 50}
(High idle speed)
min-1{rpm} 825 ± 25 {825 ± 25}
(Low idle speed)
g/kW·h
{g/HP·h}
Dry weight kg 1,920
Quantity of coolant l 25 (In only engine)
With cooled EGR
8 140E-5 Series

PC800-8R, PC800SE-8R, PC800LC-8R,
PC850-8R, PC850SE-8R
Machine models
PC800-8R1, PC800SE-8R1, PC800LC-8R1
PC850-8R1, PC850SE-8R1
Dimensions

kW{HP}/ 370 {496.4}/1,800 {1,800}
Rated horsepower
min-1{rpm} (Gross)
Nm{kgm}/ 2,195 {223.8}/1,350 {1,350}
Max. torque
Performance
min-1{rpm} (Gross)
min-1{rpm} 1,980 ± 50 {1,980 ± 50}
(High idle speed)
min-1{rpm} 825 ± 25 {825 ± 25}
(Low idle speed)
g/kW·h
{g/HP·h}
Dry weight kg 1,850
140E-5 Series 9

Machine models D155AX-6
Dimensions

kW{HP}/ 268 {359.9}/1,900 {1,900}
Rated horsepower
min-1{rpm} (Gross)
Nm{kgm}/ 1,834 {187}/1,300 {1,300}
Max. torque
Performance
min-1{rpm} (Gross)
min-1{rpm} 2,100 (0/–50) {2,100 (0/–50)}
(High idle speed)
min-1{rpm} 740 (+40/0) {740 (+40/0)}
(Low idle speed)
g/kW·h
{g/HP·h}
Dry weight kg 1,800
Alternator — 24V, 60A, 75A, 90A
With cooled EGR
10 140E-5 Series

Machine models D155A-6
Dimensions

kW{HP}/ 268 {359.9}/1,900 {1,900}
Rated horsepower
min-1{rpm} (Gross)
Nm{kgm}/ 1,834 {187}/1,300 {1,300}
Max. torque
Performance
min-1{rpm} (Gross)
min-1{rpm} 2,100 (0/–50) {2,100 (0/–50)}
(High idle speed)
min-1{rpm} 740 (+40/0) {740 (+40/0)}
(Low idle speed)
g/kW·h
{g/HP·h}
Dry weight kg 1,725
Alternator — 24V, 60A, 75A, 90A
140E-5 Series 11

Machine models D275AX-5E0
Dimensions
Overall width mm 966

Overall height (including exhaust pipe) mm —
kW{HP}/ 337 {451.6}/2,000 {2,000}
Rated horsepower
min-1{rpm} (Gross)
Nm{kgm}/ 2,030 {207}/1,400 {1,400}
Max. torque
Performance
min-1{rpm} (Gross)
min-1{rpm} 2,200 ± 50 {2,200 ± 50}
(High idle speed)
min-1{rpm} 700 ± 50 {700 ± 50}
(Low idle speed)
g/kW·h
Fuel consumption ratio at rated point 218 {162.3}
{g/HP·h}
Dry weight kg 1,869
With cooled EGR
12 140E-5 Series

Machine models D275A-5R
Dimensions
Overall width mm 966

kW{HP}/ 337 {451.6}/2,000 {2,000}
Rated horsepower
min-1{rpm} (Gross)
Nm{kgm}/ 2,030 {207}/1,400 {1,400}
Max. torque
Performance
min-1{rpm} (Gross)
min-1{rpm} 2,200 ± 50 {2,200 ± 50}
(High idle speed)
min-1{rpm} 700 ± 50 {700 ± 50}
(Low idle speed)
g/kW·h
{g/HP·h}
Dry weight kg 1,800
140E-5 Series 13

Machine models WA500-6
Dimensions

kW{HP}/ 266 {356.9}/1,900 {1,900}
Rated horsepower
min-1{rpm} (Gross)
Nm{kgm}/ 1,803 {184}/1,250 {1,250}
Max. torque
Performance
min-1{rpm} (Gross)
min-1{rpm} 2,150 ± 50 {2,150 ± 50}
(High idle speed)
min-1{rpm} 700 ± 25 {700 ± 25}
(Low idle speed)
g/kW·h
Fuel consumption ratio at rated point 216.2 {161.3}
{g/HP·h}
Dry weight kg 1,750
With cooled EGR
14 140E-5 Series

Machine models WA500-6R
Dimensions

kW{HP}/ 266 {356.9}/1,900 {1,900}
Rated horsepower
min-1{rpm} (Gross)
Nm{kgm}/ 1,803 {184}/1,250 {1,250}
Max. torque
Performance
min-1{rpm} (Gross)
min-1{rpm} 2,150 ± 50 {2,150 ± 50}
(High idle speed)
min-1{rpm} 700 ± 25 {700 ± 25}
(Low idle speed)
g/kW·h
Fuel consumption ratio at rated point 211.4 {157.7}
{g/HP·h}
Dry weight kg 1,680
140E-5 Series 15

Machine models HD325-7, HD405-7
Dimensions

kW{HP}/ 386 {517.7}/2,000 {2,000}
Rated horsepower
min-1{rpm} (Gross)
Nm{kgm}/ 2,170 {221.3}/1,400 {1,400}
Max. torque
Performance
min-1{rpm} (Gross)
min-1{rpm} 2,300 ± 25 {2,300 ± 25}
(High idle speed)
min-1{rpm} 725 ± 25 {725 ± 25}
(Low idle speed)
g/kW·h
{g/HP·h}
Dry weight kg 1,810
With cooled EGR
16 140E-5 Series

Machine models HD325-7R, HD405-7R
Dimensions

kW{HP}/ 386 {517.7}/2,000 {2,000}
Rated horsepower
min-1{rpm} (Gross)
Nm{kgm}/ 2,170 {221.3}/1,400 {1,400}
Max. torque
Performance
min-1{rpm} (Gross)
min-1{rpm} 2,300 ± 25 {2,300 ± 25}
(High idle speed)
min-1{rpm} 725 ± 25 {725 ± 25}
(Low idle speed)
g/kW·h
{g/HP·h}
Dry weight kg 1,740
140E-5 Series 17

Machine models HM350-2
Dimensions

kW{HP}/ 304 {407.2}/2,000 {2,000}
Rated horsepower
min-1{rpm} (Gross)
Nm{kgm}/ 1,991 {203}/1,400 {1,400}
Max. torque
Performance
min-1{rpm} (Gross)
min-1{rpm} 2,200 (+50/0) {2,200 (+50/0)}
(High idle speed)
min-1{rpm} 725 ± 25 {725 ± 25}
(Low idle speed)
g/kW·h
{g/HP·h}
Dry weight kg 1,820
Battery — 12V 170Ah × 2
With cooled EGR
18 140E-5 Series

Machine models HM350-2R
Dimensions

kW{HP}/ 304 {407.2}/2,000 {2,000}
Rated horsepower
min-1{rpm} (Gross)
Nm{kgm}/ 1,991 {203}/1,400 {1,400}
Max. torque
Performance
min-1{rpm} (Gross)
min-1{rpm} 2,200 (+50/0) {2,200 (+50/0)}
(High idle speed)
min-1{rpm} 725 ± 25 {725 ± 25}
(Low idle speed)
g/kW·h
{g/HP·h}
Dry weight kg 1,750
Battery — 12V 170Ah × 2
140E-5 Series 19

Machine models HM400-2, HM400-3M0
Number of cylinders – Bore × Stroke mm 6-140 × 165
Dimensions

kW{HP}/ 338 {452.6}/2,000 {2,000}
Rated horsepower
min-1{rpm} (Gross)
Nm{kgm}/ 2,089 {213}/1,400 {1,400}
Max. torque
Performance
min-1{rpm} (Gross)
min-1{rpm} 2,200 (+50/0) {2,200 (+50/0)}
(High idle speed)
min-1{rpm} 725 ± 25 {725 ± 25}
(Low idle speed)
g/kW·h
{g/HP·h}
Dry weight kg 1,820
With cooled EGR
20 140E-5 Series

Machine models HM400-2R, HM400-3R
Number of cylinders – Bore × Stroke mm 6-140 × 165
Dimensions

kW{HP}/ 338 {452.6}/2,000 {2,000}
Rated horsepower
min-1{rpm} (Gross)
Nm{kgm}/ 2,089 {213}/1,400 {1,400}
Max. torque
Performance
min-1{rpm} (Gross)
min-1{rpm} 2,200 (+50/0) {2,200 (+50/0)}
(High idle speed)
min-1{rpm} 725 ± 25 {725 ± 25}
(Low idle speed)
g/kW·h
{g/HP·h}
Dry weight kg 1,750
140E-5 Series 21

SDG400S-6B1
Machine models
(HOKUETSU INDUSTRIES GENERATOR)
Dimensions

kW{HP}/ 357 {478}/1,800 {1,800}
Rated horsepower
min-1{rpm} (Net)
Nm{kgm}/ —
Max. torque
Performance
min-1{rpm} —
min-1{rpm} —
(High idle speed)
min-1{rpm} —
(Low idle speed)
g/kW·h
{g/HP·h}
Dry weight kg 1,950
Quantity of coolant (with radiator) l 53
Alternator — 24V, 35A
Starting motor — 24V, 7.5kW
Battery — —
With cooled EGR
22 140E-5 Series
140E-5 Series 23
General view 1
SAA6D140E-5 (Left side view of engine)
Machine model: PC600-8, PC600LC-8
a The shape is subject to machine models.
1. Center of crankshaft
2. Rear face of flywheel housing
24 140E-5 Series
SAA6D140E-5 (Front view of engine)

Machine model: PC600-8, PC600LC-8
2. Center of cylinder liner
140E-5 Series 25

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

a Corrosion resistor-less, Single cartridge and Manual priming pump are set for some models. (See the
PC700-8R, PC700LC-8R.)
26 140E-5 Series

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

a Corrosion resistor-less, Single cartridge and Manual priming pump are set for some models. (See the
PC700-8R, PC700LC-8R.)
140E-5 Series 27

Machine model: PC600-8E0, PC600LC-8E0, PC700-8E0, PC700LC-8E0
28 140E-5 Series

Machine model: PC600-8E0, PC600LC-8E0, PC700-8E0, PC700LC-8E0
140E-5 Series 29

Machine model: PC600-8R1, PC600LC-8R1,
PC700-8R, PC700LC-8R, PC700LC-8R1
30 140E-5 Series

Machine model: PC600-8R1, PC600LC-8R1,
PC700-8R, PC700LC-8R, PC700LC-8R1
140E-5 Series 31

Machine model: PC800-8, PC800SE-8, PC800LC-8, PC850-8, PC850SE-8
PC800-8E0, PC800SE-8E0, PC800LC-8E0, PC850-8E0, PC850SE-8E0
32 140E-5 Series

Machine model: PC800-8, PC800SE-8, PC800LC-8, PC850-8, PC850SE-8
140E-5 Series 33

Machine model: PC800-8R, PC800SE-8R, PC800LC-8R, PC850-8R, PC850SE-8R
34 140E-5 Series

Machine model: PC800-8R, PC800SE-8R, PC800LC-8R, PC850-8R, PC850SE-8R
140E-5 Series 35

Machine model: PC800-8R1, PC800SE-8R1, PC800LC-8R1, PC850-8R1,
PC850SE-8R1
36 140E-5 Series

Machine model: PC800-8R1, PC800SE-8R1, PC800LC-8R1, PC850-8R1,
PC850SE-8R1
140E-5 Series 37

Machine model: D275AX-5E0
38 140E-5 Series

Machine model: D275AX-5E0
140E-5 Series 39

Machine model: D275A-5R
40 140E-5 Series

Machine model: D275A-5R
140E-5 Series 41

Machine model: WA500-6
42 140E-5 Series

Machine model: WA500-6
140E-5 Series 43

Machine model: WA500-6R
44 140E-5 Series

Machine model: WA500-6R
140E-5 Series 45

Machine model: HD325-7, HD405-7
46 140E-5 Series

Machine model: HD325-7, HD405-7
140E-5 Series 47

Machine model: HD325-7R, HD405-7R
48 140E-5 Series

Machine model: HD325-7R, HD405-7R
140E-5 Series 49

Machine model: HM350-2, HM400-2
50 140E-5 Series

Machine model: HM350-2, HM400-2
140E-5 Series 51

Machine model: HM350-2R, HM400-2R
52 140E-5 Series

Machine model: HM350-2R, HM400-2R
140E-5 Series 53

Machine model: HM400-3M0
54 140E-5 Series

Machine model: HM400-3M0
140E-5 Series 55

Machine model: HM400-3R
56 140E-5 Series

Machine model: HM400-3R
140E-5 Series 57

Machine model: SDG400S-6B1 (HOKUETSU INDUSTRIES GENERATOR)
58 140E-5 Series

Machine model: SDG400S-6B1 (HOKUETSU INDUSTRIES GENERATOR)
140E-5 Series 59
Dimensions table 1
Unit: mm
Dimension of each part
Engine Machine model
A B C D E F G H
PC600-8, PC600LC-8 1,494 1,863 441 227 143 920 1,155 1,151
PC600-8E0, PC600LC-8E0
1,412 1,867 444 227 143 920 1,155 1,061
PC700-8E0, PC700LC-8E0
PC600-8R1, PC600LC-8R1,
1,482 1,863 411 227 143 920 1,155 1,151
PC700LC-8R1
PC800-8, PC800LC-8,
PC800SE-8,
PC850-8, PC850SE-8,
PC800-8E0,
PC800LC-8E0,
PC800SE-8E0,
PC850-8E0,
1,350 1,902 594 196 196 1,000 1,185 1,176
PC850SE-8E0,
PC800-8R, PC800LC-8R,
PC800SE-8R,
SAA6D140E-5 PC800-8R1, PC800LC-8R1,
PC800SE-8R1,
PC850-8R1, PC850SE-8R1
D155AX-6, D155A-6 1,477 1,950 419 14 14 918 1,090 1,109
D275AX-5E0 1,505 2,178 542 15 15 794 966 1,135
D275A-5R 1,461 2,178 542 15 15 794 966 1,180
WA500-6 1,477 1,727 419 150 150 815 945 1,094
WA500-6R 1,465 1,727 419 150 150 815 945 1,094
HD325-7, HD405-7,
1,775 1,604 542 80 80 875 1,005 1,025
HD325-7R, HD405-7R
HM350-2, HM350-2R,
1,724 1,496 542 147 147 815 945 1,250
HM400-2, HM400-2R
HM400-3M0 1,477 1,509 542 147 147 815 945 1,112
HM400-3R 1,451 1,509 542 147 147 815 945 1,112
SDG400S-6B1
(HOKUETSU INDUS- 1,785 1,523 403 213 213 877 956 1,242
TRIES GENERATOR)
a These dimensions are given for reference when the engine is set on a test bench.
60 140E-5 Series
Weight table 1
(With EGR)
Unit: kg
No. Item Main parts SAA6D140E-5
24 (Air-cooled) /
1 Turbocharger KOMATSU KTR110L
28 (Water-cooled)
Cylinder head, valve,
2 Cylinder head assembly 23 × 6
valve spring
Cylinder block, bearing, cap,
3 Cylinder block assembly 480
cylinder liner
4 Front cover 60
PC800-8, PC800SE-8, PC800LC-8
PC850-8, PC850SE-8
PC800-8E0, PC800SE-8E0, 36
PC800LC-8E0
PC850-8E0, PC850SE-8E0
PC600-8, PC600LC-8
PC600-8E0, PC600LC-8E0
PC700-8E0, PC700LC-8E0 30
5 Oil pan D155AX-6
WA500-6
D275AX-5E0
HD325-7, HD405-7
28
HM350-2, HM400-2
HM400-3M0
SDG400S-6B1 (HOKUETSU
62
INDUSTRIES GENERATOR)
PC600-8, PC600LC-8
PC800-8, PC800SE-8, PC800LC-8
PC850-8, PC850SE-8
PC800-8E0, PC800SE-8E0,
PC800LC-8E0 60
PC850-8E0, PC850SE-8E0
D155AX-6
6 Flywheel assembly Flywheel ring gear D275AX-5E0
WA500-6
HD325-7, HD405-7
HM350-2, HM400-2 47
HM400-3M0
SDG400S-6B1 (HOKUETSU
123
65
7 Flywheel housing assembly SDG400S-6B1 (HOKUETSU
63
8 Crankshaft assembly Crankshaft, crank gear 136
Camshaft, cam gear, thrust
9 Camshaft assembly 20
plate
Piston and connecting rod Piston, piston ring, piston
10 11 × 6
assembly pin, connecting rod
11 Oil pump 7
12 Fuel supply pump 13
13 Water pump 18
140E-5 Series 61
Unit: kg
24V, 35A 8
24V, 50A 11
14 Alternator 24V, 60A 11
24V, 75A 12.5
24V, 90A 19
24V, 7.5kW 15.5
15 Starting motor
24V, 11kW 18
16 EGR oil pump 6
17 EGR valve 10
18 Bypass valve 10
19 EGR cooler 10
62 140E-5 Series
(EGR-less)
Unit: kg
24 (Air-cooled) /
1 Turbocharger KOMATSU KTR110L
28 (Water-cooled)
Cylinder head, valve,
2 Cylinder head assembly 23 × 6
valve spring
Cylinder block, bearing, cap,
3 Cylinder block assembly 480
cylinder liner
4 Front cover 60
PC800-8R, PC800SE-8R,
PC800LC-8R
36
PC800-8R1, PC800SE-8R1
PC800LC-8R1
PC850-8R1, PC850SE-8R1
PC600-8R1, PC600LC-8R1
5 Oil pan
30
PC700LC-8R1
D155A-6
WA500-6R
D275A-5R
HD325-7R, HD405-7R
28
HM350-2R, HM400-2R
HM400-3R
PC600-8R1, PC600LC-8R1
PC700LC-8R1
PC800-8R, PC800SE-8R,
PC800LC-8R
60
PC800-8R1, PC800SE-8R1
6 Flywheel assembly Flywheel ring gear PC800LC-8R1
PC850-8R1, PC850SE-8R1
D155A-6
D275A-5R
WA500-6R
HD325-7R, HD405-7R
HM350-2R, HM400-2R 47
HM400-3R
7 Flywheel housing assembly 65
8 Crankshaft assembly Crankshaft, crank gear 136
Camshaft, cam gear,
9 Camshaft assembly 20
thrust plate
Piston and connecting rod Piston, piston ring, piston pin,
10 11 × 6
assembly connecting rod
11 Oil pump 7
12 Fuel supply pump 13
13 Water pump 18
140E-5 Series 63
Unit: kg
24V, 35A 8
24V, 50A 11
14 Alternator 24V, 60A 11
24V, 75A 12.5
24V, 90A 19
15 Starting motor 24V, 11kW 18
64 140E-5 Series
Engine performance curves 1
Engine Engine serial No. Machine model Page

PC600-8, PC600-8R,
PC600LC-8, PC600LC-8R
PC600-8E0, PC600-8R1,
PC600LC-8E0, PC600LC-8R1, 66
PC700-8E0, PC700LC-8E0,
PC700-8R, PC700LC-8R,
PC700LC-8R1
PC800-8, PC800LC-8,
PC800SE-8, PC800SE-8R
PC850-8, PC850-8R
PC800-8E0, PC800SE-8E0, 67
SAA6D140E-5 PC800LC-8E0,
PC850-8E0, PC850SE-8E0
PC800-8R1, PC800SE-8R1
PC800LC-8R1
PC850-8R1, PC850SE-8R1
D155AX-6, D155A-6 68
D275AX-5E0, D275A-5R 69
WA500-6, WA500-6R 70
HD325-7, HD325-7R
71
HD405-7, HD405-7R
HM350-2, HM350-2R 72
HM400-2, HM400-2R
73
HM400-3M0, HM400-3R
140E-5 Series 65
SAA6D140E-5
(Machine model: PC600-8, PC600LC-8, PC600-8R, PC600LC-8R, PC600-
8E0, PC600LC-8E0, PC600-8R1, PC600LC-8R1, PC700-8E0, PC700LC-8E0,
PC700-8R, PC700LC-8R, PC700LC-8R1)
Rated horsepower: 323 kW {433.3 HP}/1,800 min-1 {1,800 rpm} (Gross)
Max. torque: 1,944 Nm {198.4 kgm}/1,400 min-1 {1,400 rpm} (Gross)
66 140E-5 Series
SAA6D140E-5
(Machine model: PC800-8, PC800SE-8, PC850-8, PC850SE-8, PC800LC-8,
PC800-8E0, PC800SE-8E0, PC850-8E0, PC850SE-8E0, PC800LC-8E0,
PC800-8R, PC800SE-8R, PC800LC-8R, PC850-8R, PC850SE-8R, PC800-
8R1, PC800SE-8R1, PC800LC-8R1, PC850-8R1, PC850SE-8R1)
140E-5 Series 67
SAA6D140E-5 (Machine model: D155AX-6, D155A-6)

Max. torque: 1,834 Nm {187 kgm}/1,300 min-1 {1,300 rpm} (Gross)
68 140E-5 Series
SAA6D140E-5 (Machine model: D275AX-5E0, D275A-5R)

140E-5 Series 69
SAA6D140E-5 (Machine model: WA500-6, WA500-6R)

70 140E-5 Series
SAA6D140E-5 (Machine model: HD325-7, HD405-7, HD325-7R, HD405-7R)

140E-5 Series 71
SAA6D140E-5 (Machine model: HM350-2, HM350-2R)

72 140E-5 Series
SAA6D140E-5
(Machine model: HM400-2, HM400-2R, HM400-3M0, HM400-3R)
140E-5 Series 73
SEN00079-07
© 2012 KOMATSU
All Rights Reserved
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 SEN00081-08
Air intake and exhaust unit 1

a The above illustration shows the engine for PC600-8.
A: Air intake unit (Between air-cooled aftercooler and air intake manifold)
1. Electrical intake air heater (ribbon heater)

2. Diffuser
3. Air intake manifold
140E-5 Series 3
SAA6D140E-5 (Right side view of engine)
A: To EGR cooler
B: To turbocharger
C: From bypass valve
1. Exhaust manifold (rear)

2. Exhaust manifold (center)
3. Exhaust manifold (front)
4 140E-5 Series
Air cleaner 1
ERB type
[Air cleaner of automatic exhaust gas discharge type (radial seal type)]
A: Air inlet
B: To turbocharger (intake air)
C: To muffler (dust)
1. Pre-cleaner
2. Air cleaner casing
3. Outer element
4. Inner element
Machine Method of discharging

Engine Type Number of elements
model dust from pre-cleaner
D155AX-6,
D155A-6, Komaclone, multi-cyclone Automatic discharge Inner cylinder: 1,
SAA6D140E-5
D275AX-5E0 (ERB type) (Exhaust ejector) Outer cylinder: 1
D275A-5R
140E-5 Series 5
FRG type
[Air cleaner of cyclone pack type with evacuator valve (radial seal type)]
1. Inlet
2. Outlet
3. Guide vane
4. Primary element
5. Safety element
6. Evacuator valve
7. Dust pan
8. Guide plate (sleeve)
9. Body
10. Element
6 140E-5 Series
Number of
Engine Machine model Type Evacuator valve
elements
PC600-8, PC600-8R,
PC600LC-8, PC600LC-8R
PC600-8E0, PC600-8R1,
PC600LC-8E0, PC600LC-8R1,
PC700-8E0, PC700LC-8E0,
PC700-8R, PC700LC-8R,
PC700LC-8R1
PC800-8, PC800LC-8,
PC850-8, PC850-8R
PC850SE-8, PC850SE-8R FRG Automatic Inner cylinder: 1,
SAA6D140E-5
PC800-8E0, PC800LC-8E0, (radial seal type) discharge Outer cylinder: 1
PC800SE-8E0, PC850-8E0,
PC850SE-8E0
PC800-8R1, PC800LC-8R1,
PC800SE-8R1, PC850-8R1,
PC850SE-8R1
WA500-6, WA500-6R
HD325-7, HD325-7R
HD405-7, HD405-7R
HM350-2, HM350-2R,
HM400-2, HM400-2R
HM400-3M0, HM400-3R
Structure Operation
q The size of the body is reduced from the con- q Air containing dust is sucked in vertically
ventional type without changing the diameter through inlet (1) and the dust is separated by
of the element. the centrifugal effect of guide vane (3).
q Since the inlet is set in the tangential direction, q More than 99.9% of the dust is removed by pri-
air is given sufficient centrifugal force by the mary element (4) and clean air is sucked in the
simple spiral guide vane, not by the guide engine through safety element (5) and outlet
plate. (2).
q The dust and water separated by guide vane
(3) swirl along the inside wall of body (9) and
enter evacuator valve (6) and then are dis-
charged out automatically.
140E-5 Series 7
Turbocharger 1
(With EGR)
Air-cooled type
Model: KTR110L
PC600-8, PC600LC-8, PC600-8E0, PC600LC-8E0, PC700-8E0, PC700LC-8E0, HD325-7, HD405-7,
WA500-6, HM350-2, HM400-2, HM400-3M0,
SDG400S-6B1 (HOKUETSU INDUSTRIES GENERATOR)
8 140E-5 Series
A: Intake air inlet

B: Intake air outlet
C: Exhaust gas inlet
D: Exhaust gas outlet
E: Oil inlet
F: Oil outlet
1. Blower housing
2. V-band
3. Diffuser plate
4. Center housing
5. Shroud
6. Turbine housing
7. Blower impeller
8. Seal ring
9. Bearing metal
10. Journal bearing
11. Seal ring
12. Turbine impeller
Specifications
Model: KOMATSU KTR110L (air-cooled)
Overall length: 308 mm
Overall width: 305 mm
Overall height: 287 mm
Weight: 24 kg
140E-5 Series 9
(EGR-less)
Air-cooled type
Model: KTR110L
PC600-8R, PC600-8R1, PC600LC-8R, PC600LC-8R1, PC700-8R, PC700LC-8R, PC700LC-8R1, HD325-
7R, HD405-7R, WA500-6R, HM350-2R, HM400-2R, HM400-3R
10 140E-5 Series
A: Intake air inlet

E: Oil inlet
F: Oil outlet
1. Blower housing
2. V-band
3. Diffuser plate
4. Center housing
5. Shroud
6. Turbine housing
7. Blower impeller
8. Seal ring
9. Bearing metal
10. Journal bearing
11. Seal ring
Specifications
Model: KOMATSU KTR110L (air-cooled)
Weight: 24 kg
140E-5 Series 11
(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
A: Intake air inlet

E: Oil inlet
F: Oil outlet
G: Coolant
1. Blower housing
2. V-band
3. Diffuser plate
4. Center housing
(water-cooled center housing: standard for D275AX, D155AX and PC800, and
optional for other machine models)
5. Shroud
6. Turbine housing
7. Blower impeller
8. Seal ring
9. Bearing metal
10. Journal bearing
11. Seal ring
Specifications
Model: KOMATSU KTR110L (water-cooled)
Weight: 28 kg
140E-5 Series 13
(EGR-less)
Water-cooled type
Model: KTR110L
PC800-8R, PC800LC-8R, PC800SE-8R, PC850-8R, PC850SE-8R, PC800-8R1, PC800LC-8R1, PC800SE-
8R1, PC850-8R1, PC850SE-8R1, D155A-6, D275A-5R
14 140E-5 Series
A: Intake air inlet

E: Oil inlet
F: Oil outlet
G: Coolant
1. Blower housing
2. V-band
3. Diffuser plate
4. Center housing
(water-cooled center housing: standard for D275A, D155A and PC800, and
optional for other machine models)
5. Shroud
6. Turbine housing
7. Blower impeller
8. Seal ring
9. Bearing metal
10. Journal bearing
11. Seal ring
Specifications
Model: KOMATSU KTR110L (water-cooled)
Weight: 28 kg
140E-5 Series 15
Model: KTR110L
a The above illustration shows the air-cooled turbocharger.
16 140E-5 Series
Unit: mm
No. Check item Criteria Remedy

Standard Repair limit Replace thrust
1 End play (play in axial direction)
0.08 to 0.13 0.18 parts
Replace bearing
2 Radial play (play in radial direction) 0.43 to 0.68 0.84
parts
Clearance between blower housing and Replace bearing
3 Clearance limit (min.): 0.14
impeller parts
140E-5 Series 17
Turbocharger mounting

A: Intake air inlet

B: Intake air (between turbocharger and air-cooled aftercooler)
1. Muffler
2. Turbocharger
18 140E-5 Series
Aftercooler 1
Air-cooled type
SAA6D140E-5 (HD325-7, HD325-7R, HD405-7, HD405-7R)
a. Inlet/Outlet of intake air

(between turbocharger and air intake manifold)
1. Tank
2. Side support
3. Tube
4. Fin
140E-5 Series 19
Muffler 1
For PC600-8, PC600-8R, PC600LC-8, PC600LC-8R, PC600-8E0, PC600-8R1, PC600LC-8E0, PC600LC-
8R1, PC700-8E0, PC700-8R,PC700LC-8E0, PC700LC-8R, PC700LC-8R1
A: Exhaust gas inlet (from turbocharger)

B: Exhaust gas outlet
C: Water drain
20 140E-5 Series
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

C: Water drain
140E-5 Series 21
For PC800-8E0, PC800SE-8E0, PC800LC-8E0, PC850-8E0, PC850SE-8E0

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

C: Water drain
22 140E-5 Series
For D155AX-6, D155A-6

C: Water drain
D: From air cleaner (dust)
140E-5 Series 23
For D275AX-5E0, D275A-5R

C: Water drain
D: From air cleaner (dust)
24 140E-5 Series
EGR system 1
No. Component part Function

EGR valve • Controls the gas flow from the exhaust system to the air intake system.
1 (driven hydrauli- • Since the exhaust pressure (PEX) is higher than the boost pressure (PIN), the
cally) exhaust gas flows to the air intake valve.
• Opens the bypass valve when the boost pressure (PIN) is higher than the
exhaust pressure (PEX).
2 Bypass valve
• 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.
• Controls the EGR according to the operating condition.
5 Each sensor
• 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 trouble-
shooted, a serious trouble is prevented.
140E-5 Series 25
a The above illustration shows the engine for D155AX-6.
26 140E-5 Series
1. EGR valve
2. Bypass valve
3. EGR cooler
4. Venturi system
5. EGR valve position sensor
6. Bypass valve position sensor
7. Bypass piping
8. EGR piping
9. EGR oil pump
Operation
q The engine controller outputs signals for open-
ing EGR valve (1) most properly according to
the load on the engine to attain both clean
exhaust gas and low fuel consumption.
q If EGR valve (1) opens, a part of the exhaust
gas (EGR gas) flows from the exhaust mani-
fold through EGR piping (8) to EGR cooler (3).
q The exhaust gas cooled by EGR cooler (3)
flows through EGR valve (1) and mixes with
the intake air in venturi system (4), and then
flows in the air intake manifold.
q In the operating range where the boost pres-
sure is higher than the exhaust pressure on the
high load side, the EGR gas does not flow to
the air intake side easily. At this time, the
engine controller opens bypass valve (2).
q If bypass valve (2) opens, the intake air flows
through bypass piping (7). As a result, the
exhaust pressure rises and more EGR gas
mixes with the intake air.
140E-5 Series 27
EGR valve and bypass valve
A: Oil inlet 1. Stick prevention device

B: Oil outlet 2. Oil pressure control valve
C: EGR gas passage (EGR valve) 3. Solenoid
D: Boost air passage (bypass valve) 4. Position sensor
5. Hydraulic piston
6. Spring
7. Valve
Function q Valve (7) is closed by spring (6) but pushed

q The EGR valve controls the EGR gas. open by hydraulic piston (5) to an opening ratio
q This valve is driven hydraulically and its open- in proportion to the control oil pressure.
ing ratio is controlled electronically. q The valve opening ratio is sensed with position
sensor (4) installed to hydraulic piston (5) and
Operation set to the specified opening ratio by controlling
q The oil pressure (engine oil) of 1.47 MPa {15 the solenoid current.
kg/cm2} supplied to oil inlet (A) is reduced by q The bypass valve assists the EGR gas by
oil pressure control valve (2). increasing the exhaust pressure.
q Hydraulic piston (5) generates pressing force q The structure and operation of the EGR
from the reduced oil pressure. bypass valve are the same as those of the
q The control oil pressure can be changed with EGR valve.
the drive current of solenoid (3).
28 140E-5 Series
EGR cooler
A: EGR gas inlet D: Coolant outlet

B: EGR gas outlet E: Air bleeder
C: Coolant inlet
1. Heat exchange tube (corrugated tube)
Function
q The EGR cooler cools the high-temperature
EGR gas taken out of the exhaust gas to
increase the gas density, or the EGR effi-
ciency.
Structure
q The EGR cooler is a multi-tube heat
exchanger. When the high-temperature EGR
gas flows through heat exchange tube (1), it is
cooled by the coolant flowing outside of the
tube.
q Heat exchange tube (1) is made of corrosion-
resistant stainless steel and corrugated to
increase the cooling efficiency.
140E-5 Series 29
Venturi system
A: Air inlet 1. Venturi nozzle

B: EGR gas inlet 2. Throat
3. Diffuser
Structure
q The EGR gas and intake air mix together in the
venturi system.
q The venturi system consists of throat (2), ven-
turi nozzle (1), and diffuser (3).
Operation
q The boost pressure increased by the turbo-
charger is set negative temporarily with the
venturi effect of the throat to take the EGR gas
into the intake air through venturi nozzle (1).
q When the mixture of the EGR gas and intake
air flows through diffuser (3), its pressure is
increased again to the normal level and then it
flows in the intake manifold.
30 140E-5 Series
140E-5 Series 31
Cylinder head 1
32 140E-5 Series
A: Intake air
B: Exhaust gas
C: To fuel tank
D: To radiator
1. Rocker cover bolt

2. Cylinder head bolt
3. Air bleeding pipe from coolant
4. Fuel spill pipe
5. Rocker cover
6. Cylinder head
7. Injector connector
8. Injector assembly
9. Injector holder mounting bolt
10. Injector holder retainer
Specifications
Cylinder head
q Direct injection type
q 4-valve type
q Split-type 1-cylinder, 1-head
q Centralized cooling system for valve bridge
and injector
q Cylinder head bolt: Plastic-region tightening
Valve seat
q Valve seat inserts are press fitted to both
intake and exhaust valves
Rocker cover
q O-ring seal
Injector
q Installation: Dry type (without sleeve)
140E-5 Series 33
a Tighten the cylinder head mounting bolts in the order of (1) to (7).
Unit: mm
Strain of cylinder head mount- Tolerance Repair limit Correct by grinding

1 ing face or replace
0 to 0.06 0.09
Engine Standard Replace nozzle or
2 Projection of nozzle
gasket
SAA6D140E-5 2.3 to 2.9
Bolt No. Procedure Target(Nm{kgm}) Range(Nm{kgm})
Tightening torque for cylinder 1st stage 147{15} 137 to 157{14 to 16} Tighten in order
head mounting bolt (Apply shown above. If
3 molybdenum disulfide or
(1) to (6) 2nd stage 289{29.5} 284 to 294{29 to 30}
there are 5 punch
engine oil to threaded part) 3rd stage Retighten 90 deg. 90(+30/0) deg. marks, replace bolt.
(7) — 68.6{7} 58.8 to 73.5{6 to 7.5}
Tightening torque for injector Target(Nm{kgm}) Range(Nm{kgm})

4 holder mounting bolt 66.7{6.8} 58.8 to 73.5{6 to 7.5}
Tightening torque for fuel injec- Retighten
5 tion pipe
37.3{3.8} 34.3 to 40.2{3.5 to 4.1}
Tightening torque for head

6 cover mounting bolt
32.4{3.3} 29.4 to 34.3{3.0 to 3.5}
a 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.
34 140E-5 Series
140E-5 Series 35
Cylinder block 1
36 140E-5 Series
1. Front cover
2. Cylinder block
3. Cylinder liner
4. Clevis seal
5. Liner O-ring (water)
6. Liner O-ring (oil)
7. Thrust bearing metal
8. Main bearing metal
9. Main bearing metal cap
10. Main bearing metal cap bolt
11. Front oil seal
12. Piston cooling nozzle (front side)
13. Piston cooling nozzle (rear side)
Specifications
Cylinder block
q Crankshaft section: 7 bearings
q Camshaft section: High cam type, 7 bearings
q Main cap bolt: Plastic-region tightening
Front seal
q Single lip with dust seal
(lay-down seal)
Piston cooling
q With piston cooling nozzle
(2 pieces for each cylinder)
Cylinder liner
q Wet type
q Machining on inside: Plateau honing
Soft nitriding process
Liner ring
q Upper: Clevis seal
q Middle: O-ring (ethylene-propylene rubber)
q Lower: O-ring (silicone rubber)
140E-5 Series 37
Unit: mm
Strain of cylinder head mount- Tolerance Repair limit Correct by grinding

1 ing face or replace
0 to 0.09 0.135
Standard dimension Tolerance
Diameter of main bearing metal Replace main bear-
mounting hole +0.018 ing metal cap
127
–0.006
2
Thickness of main bearing –0.010
3.5 Replace bearing
metal –0.010
metal
Roundness of mounting hole Repair limit: 0.005
Standard dimension Tolerance Repair limit
Inside diameter of main bearing Replace bearing
3 metal +0.038 metal
120 120.15
–0.006
Diameter of cam bushing +0.030 Correct or replace
4 mounting hole
69
+0.030
—
block
+0.040 Replace cam bush-
5 Inside diameter of cam bushing 65
+0.040
65.15
ing
Level difference between
6 underside faces of cylinder Repair limit: 0.14 Reassemble
block and front cover
Procedure Target(Nm{kgm}) Range(Nm{kgm})
Tightening torque for main cap 1st stage 118{12} 108 to 127{11 to 13}
7 mounting bolt (Apply engine oil
to threads) 2nd stage 235{24} 230 to 240{23.5 to 24.5}
Retighten
3rd stage Retighten 90 deg. 90(+30/0) deg.
Tightening torque for crank pul-
8 ley mounting bolt
— 275{28} 245 to 309{25 to 31.5}
a Do not use a main cap mounting bolt more than 5 times.

38 140E-5 Series
Cylinder liner 1
Unit: mm

Replace cylinder liner or
1 Projection of cylinder liner Permissible range: 0.07 to 0.15
cylinder block
Rank Standard dimension Tolerance Repair limit
+0.020
S 140 140.12
Inside diameter of cylinder liner +0.020
+0.040
L 140 140.14
2 +0.021
Roundness of inside of cylinder
Repair limit: 0.02 Replace cylinder liner
liner
Cylindricality of inside of cylinder
Repair limit: 0.02
liner
Outside diameter of cylinder liner –0.10
170.2
3 –0.10
Clearance between cylinder liner Replace cylinder liner or
Standard clearance: 0 to 0.163
and block block
Outside diameter of cylinder liner +0.090 Replace cylinder liner
161.2
4 +0.050
Interference of cylinder liner and Standard interference Interference limit Replace or correct cylin-
block 0.02 to 0.12 Min. 0.02 der liner or block

Outside diameter of cylinder liner
–0.073 Replace cylinder liner
(at O-ring) 158
5 –0.103
Clearance between cylinder liner Replace cylinder liner or
Standard clearance: 0.024 to 0.089
and block (at O-ring) block
140E-5 Series 39
Main moving parts 1
1. Piston (FCD piston) 9. Connecting rod cap bolt

2. Piston pin 10. Connecting rod bearing metal
3. Connecting rod bushing 11. Crank gear (number of teeth: 36)
4. Top ring 12. Key (crank gear)
5. Second ring 13. Crankshaft
6. Oil ring 14. Vibration damper
7. Connecting rod 15. Pin (flange)
8. Connecting rod cap 16. Flange
40 140E-5 Series
Specifications
Crankshaft: Closed die forging
Journal, fillet
Induction hardening
Piston: 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): M-shaped steel, with coil

expander, nitrided surface
140E-5 Series 41
Crankshaft 1
Unit: mm

Standard value Repair limit Replace thrust bearing
1 End play metal or use oversize
0.140 to 0.315 0.50 metal
STD 120 119.88
Outside diameter of main jour- 0.25 US 119.75 119.63
nal –0.050
0.50 US 119.50 119.38 Use undersize journal or
–0.068
0.75 US 119.25 119.13 replace
2
1.00 US 119.00 118.88
Standard Repair limit
Roundness
0 to 0.009 0.020
Standard clearance Allowable clearance Replace main bearing
Clearance of main journal
0.044 to 0.106 0.27 metal

STD 90 89.88
Outside diameter of crank pin 0.25 US 89.75 89.63
journal –0.050
0.50 US 89.50 89.38 Use undersize journal or
–0.068
0.75 US 89.25 89.13 replace
3
1.00 US 89.00 88.88
Roundness
0 to 0.009 0.020
Standard clearance Allowable clearance Replace connecting rod
Clearance of crank pin journal
0.042 to 0.110 0.24 bearing metal
Standard clearance Repair limit

Coaxiallity of all main journals:
0.20 Use undersize crankshaft
4 Bend of crankshaft Max. 0.150
or replace
Coaxiallity of adjacent journals:
0.10
Max. 0.050
a US: Undersize
42 140E-5 Series
Camshaft 1
Unit: mm

1 End play Replace thrust plate
0.1 to 0.25 0.36
Outside diameter of camshaft
–0.016 Replace camshaft
journal 65
2 –0.036
Standard clearance Allowable clearance
Clearance of camshaft journal Replace cam bushing
0.016 to 0.096 0.15
3 Bend of camshaft Repair limit: 0.03 (Overall swing of indicator)
Cam Standard dimension Tolerance Repair limit
Replace camshaft
4 Height of cam Intake 55.48 ±0.1 55.08
Exhaust 55.75 ±0.1 55.35
140E-5 Series 43
Cam follower and push rod 1
Unit: mm

Diameter of cam follower shaft –0.021
22 21.92
1 –0.034
Diameter of cam follower shaft +0.021
22 22.07
hole +0.021
+0.05
2 Outside diameter of cam roller 31.7
+0.02
31.50
+0.038
Inside diameter of cam roller 12.7 12.78 Replace
3 +0.013
Diameter of cam roller pin 12.63 ±0.006 12.56
4 Diameter of push rod ball end –0.20
12.7
–0.20
Diameter of push rod socket –0.20
5 end
13.4
–0.20
6 Bend of push rod Repair limit: 0.3 (Overall swing of indicator)
44 140E-5 Series
140E-5 Series 45
Piston, piston ring and piston pin 1
46 140E-5 Series
Unit: mm

Rank Standard dimension Tolerance Repair limit
–0.120
S 140 139.830
1 Outside diameter of piston –0.135 Replace piston
–0.105
L 140 139.845
–0.120
No. Measuring point Standard dimension Tolerance
–0.015
2 No. 1 ring 2.9
–0.035
Thickness of piston ring –0.010 Replace piston ring
3 No. 2 ring 2.41
–0.035
–0.010
4 Oil ring 4
–0.030
2 No. 1 ring Judge using groove wear gauge (*1)
3 No. 2 ring Judge using groove wear gauge (*2)
Width of piston ring groove Replace piston
+0.040
4 Oil ring 4
+0.025
2 to 4 No. Measuring point Standard clearance Allowable clearance
Clearance between piston ring 2 No. 1 ring Replace piston or

Judge using groove wear gauge
and piston ring groove 3 No. 2 ring piston ring
4 Oil ring 0.035 to 0.060 0.14

0.42 to 0.57
2 No. 1 ring (Tension 16.5 to 23.5N 2.0
{1.68 to 2.40kg})
No. 2 ring 1.15 to 1.30
Replace piston ring
Closed gap of piston ring 3 (Identification: 2RN (Tension 16.2 to 24.2N 1.8
or cylinder liner
white mark) {1.65 to 2.47kg})
0.30 to 0.50
4 Oil ring (Tension 84.5 to 111.7N 1.0
{8.61 to 11.39kg})
Outside diameter of piston pin –0.006 Replace piston pin
52
–0.006
5 Diameter of piston pin hole 52
+0.045
Replace piston
+0.035
Clearance between piston pin Standard clearance Allowable clearance Replace piston or
and piston 0.035 to 0.051 0.10 piston pin
a *1: Part No. (groove wear gauge) 795-901-1150

a *2: Part No. (groove wear gauge) 795-901-1130
140E-5 Series 47
Connecting rod 1
Unit: mm
Inside diameter of connecting Standard dimension Tolerance Repair limit Replace bushing
rod small end bushing +0.049 (Spare is half
(Ream after press fitting) 52 52.09 worked)
+0.030
1
Clearance between connect- Standard clearance Allowable clearance
Replace bushing or
ing rod small end bushing and
0.030 to 0.055 0.11 piston pin
piston pin
Diameter of connecting rod Standard dimension Tolerance

Replace connecting
2 small end bushing mounting +0.030 rod
hole 57.4
+0.030
Inside diameter of connecting Replace bearing
3 rod large end bearing metal +0.042 metal
90 90.15
–0.008
Diameter of connecting rod
large end bearing metal
mounting hole +0.026 Replace connecting
95 —
(Before measuring, tighten –0.004 rod
4 connecting rod cap mounting
bolt to specified torque)
Thickness of connecting rod +0.002 Replace bearing
2.5 —
bearing metal –0.008 metal
Item Standard Repair limit
Parallelism and twist of con- Parallelism a 0.20 0.25 Replace connecting

5 necting rod rod
Twist b 0.30 0.35
Dimension c 264 —
Tightening torque for connect- Procedure Target(Nm{kgm}) Range(Nm{kgm})

ing rod cap mounting bolt 117.7 to 132.4
6 (Apply engine oil to bolt
1st stage 127.5{13}
{12.5 to 13.5}
Retighten
threads and nut seat)
2nd stage Retighten 90 deg. 90(+30/0) deg.
Permissible range: Dispersion of weight of connecting rods in one engine
— Weight of connecting rod Replace
must not exceed 154 g.
a Do not use a connecting rod cap mounting bolt more than 5 times.
48 140E-5 Series
Flywheel and flywheel housing 1
1. Rear seal
2. Ring gear
3. Flywheel
4. Engine speed sensor (for monitor)
5. Flywheel housing
6. Engine speed sensor
(NE sensor for engine control)
140E-5 Series 49
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: Tightening order of flywheel mounting bolts

B: Tightening order of flywheel housing mounting
bolts
50 140E-5 Series
Unit: mm

Facial runout of flywheel hous-
1 ing
Repair limit: 0.20
Radial runout of flywheel hous-

2 ing
Repair limit: 0.20 Reassemble
3 Facial runout of flywheel Repair limit: 0.20
4 Radial runout of flywheel Repair limit: 0.13

Tightening torque for flywheel Procedure Target(Nm{kgm}) Range(Nm{kgm})
Tighten in order
housing mounting bolt
5 (Apply engine oil to bolt threads
1st stage 191{19.5} 147 to 235{15 to 24} shown in above fig-
ure
and seat surface) 2nd stage 275{28.0} 245 to 309{25 to 31.5}
Tightening torque for flywheel Procedure Target(Nm{kgm}) Range(Nm{kgm}) Tighten and
mounting bolt retighten in order
6 (Apply engine oil to bolt threads
1st stage 118{12} 113 to 123{11.5 to 12.5}
shown in above fig-
and seat surface) 2nd stage Retighten 90 deg. 90(+30/0) deg. ure
a 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
Vibration damper 1
1. Adapter
2. Pin (between adapter and crankshaft pulley)
3. Vibration damper
4. Bolt (between adapter and vibration damper)
5. Bolt (between crankshaft and adapter)
6. Pin (between adapter and vibration damper)
52 140E-5 Series
140E-5 Series 53
Timing gear 1
(With EGR)
54 140E-5 Series
A: Timing mark
[Between crank gear and main idler gear (large)]
B: Timing mark
[Between main idler gear (small) and fuel supply pump drive gear]
C: Timing mark
[Between main idler gear (small) and cam gear]
1. Water pump drive gear (Number of teeth: 23)

2. Sub idler gear (Number of teeth: 42)
3. Main idler gear (large) (Number of teeth: 60)
4. Main idler gear (small) (Number of teeth: 40)
5. Cam gear (Number of teeth: 48)
6. Air compressor pulley drive gear (Number of teeth: 14)
7. Fuel supply pump drive gear (Number of teeth: 48)
8. EGR oil pump drive gear (Number of teeth: 22)
9. Crank gear (Number of teeth: 36)
10. Oil pump drive gear (Number of teeth: 20)
Unit: mm
Standard Tolerance Standard Allowable

Clearance between main idler dimension Shaft Hole clearance clearance
11 gear bushing and shaft
–0.016 +0.034 Replace bushing
56 0.025 to 0.063 0.20
–0.029 +0.009
Clearance between sub idler –0.016 +0.055
56
–0.029 +0.055
0.016 to 0.084 0.20

13 End play of main idler gear Replace thrust
0.06 to 0.24 0.4
bearing
14 End play of sub idler gear 0.11 to 0.23 0.4
Posi-
Measuring point Standard Repair limit
tion
15 Crank gear and main idler gear (large) 0.028 to 0.312
Main idler gear (small) and fuel supply
16 0.016 to 0.278
pump gear
17 Main idler gear (small) and cam gear 0.016 to 0.278
Main idler gear (large) and sub idler
18 0.028 to 0.313
— Backlash of each gear gear Replace
19 Sub idler gear and oil pump drive gear 0.080 to 0.417 0.6
Sub idler gear and water pump drive

20 0.095 to 0.346
gear
Cam gear and air conditioner drive
21 0.118 to 0.369
gear
Fuel supply pump gear and EGR oil
22 0.118 to 0.369
pump drive gear
140E-5 Series 55
(EGR-less)
56 140E-5 Series
A: Timing mark
[Between crank gear and main idler gear (large)]
B: Timing mark
[Between main idler gear (small) and fuel supply pump drive gear]
C: Timing mark
[Between main idler gear (small) and cam gear]

2. Sub idler gear (Number of teeth: 42)
3. Main idler gear (large) (Number of teeth: 60)
4. Main idler gear (small) (Number of teeth: 40)
6. Air compressor pulley drive gear (Number of teeth: 14)
7. Fuel supply pump drive gear (Number of teeth: 48)
8. Crank gear (Number of teeth: 36)
9. Oil pump drive gear (Number of teeth: 20)
Unit: mm
Standard Tolerance Standard Allowable

Clearance between main idler dimension Shaft Hole clearance clearance
–0.016 +0.034 Replace bushing
56 0.025 to 0.063 0.20
–0.029 +0.009
Clearance between sub idler –0.016 +0.055
56
–0.029 +0.055
0.016 to 0.084 0.20

12 End play of main idler gear Replace thrust
0.06 to 0.24 0.4
bearing
13 End play of sub idler gear 0.11 to 0.23 0.4
Posi-
Measuring point Standard Repair limit
tion
14 Crank gear and main idler gear (large) 0.141 to 0.425
Main idler gear (small) and fuel supply
15 0.129 to 0.391
pump gear
16 Main idler gear (small) and cam gear 0.129 to 0.391
— Backlash of each gear Main idler gear (large) and sub idler Replace
17 0.141 to 0.425
gear 0.6
18 Sub idler gear and oil pump drive gear 0.080 to 0.417
Sub idler gear and water pump drive
19 0.095 to 0.346
gear
Cam gear and air conditioner drive
20 0.118 to 0.369
gear
140E-5 Series 57
Valve system 1
58 140E-5 Series
A: Lubricating oil inlet Valve timing

2. Thrust plate
3. Camshaft
4. Cam roller
5. Cam roller pin
6. Cam follower shaft
7. Cam follower
8. Push rod
9. Rocker arm shaft
10. Locknut
11. Rocker arm adjustment screw
12. Rocker arm
13. Crosshead adjustment screw
14. Locknut
15. Crosshead
16. Valve retainer
17. Outer valve spring
18. Inner valve spring
19. Air intake valve
20. Valve guide
21. Spring seat
22. Exhaust valve
Specifications
Camshaft: Drawn steel bar (turning)
Journal and cam sections:
Induction hardening
140E-5 Series 59
Valve and valve guide 1
60 140E-5 Series
Unit: mm

Valve Standard dimension Tolerance Repair limit
Replace valve or valve
1 Sinking distance of valve Intake 0 ±0.10 0.70
seat
Exhaust 0 ±0.10 0.70
Valve Standard dimension Repair limit
2 Thickness of valve lip Intake 2.4 1.9 Replace valve
Exhaust 2.15 1.75
Valve Standard dimension Tolerance
Correct or replace valve
3 Valve seat angle Intake 30 deg. ±15 min.
or valve seat
Exhaust 45 deg. ±15 min.
–0.045
Intake 10
–0.060
Diameter of valve stem Replace valve
–0.074
Exhaust 10
–0.089
Before head is press +0.019
10
fitted +0.001
+0.008
Inside diameter of valve guide –0.009 Replace valve guide
4 (Press fitted part)
After head is press fitted
10 +0.011
–0.009
(Other than press
fitted part)
Valve Standard clearance Allowable clearance
Clearance between valve guide Replace valve or valve
Intake 0.036 to 0.068 0.22
and stem guide
Exhaust 0.065 to 0.097 0.24
Bend of valve stem Repair limit: 0.02 (Overall swing of indicator in 100) Replace valve
Standard Tolerance
5 Driving height of valve guide Correct
22.0 ±0.2
Spring Standard dimension Repair limit
Free length of valve spring Outer 81.7 —
Inner 72.0 —
Standard installed Allowable installed
Spring Installed length
load(N{kg}) load(N{kg})
6 Replace valve spring
424.3±21.6 377.3
Installed load of valve spring Outer 51.0
{43.3±2.2} {38.5}
215.6±10.8 192.1
Inner 46.0
{22.0±1.1} {19.6}
Perpendicularity of valve spring Repair limit: 2 deg. (both sides)
140E-5 Series 61
Rocker arm and shaft 1
Unit: mm

Diameter of rocker arm shaft Replace rocker arm shaft
32.0 ±0.0065
Inside diameter of rocker arm +0.087
1 bushing
32.0
+0.035
Replace rocker arm
Clearance between rocker arm Standard clearance Allowable clearance Replace rocker arm shaft
shaft and rocker arm 0.0285 to 0.0935 0.13 or rocker arm
Valve Standard Tolerance

2 Valve clearance (when cold) Intake 0.35 ±0.02 Adjust
Exhaust 0.57 ±0.02
Tightening torque for locknut of Target(Nm{kgm}) Range(Nm{kgm})

3 rocker arm adjustment screw
Tighten
58.8{6} 52.9 to 64.7{5.4 to 6.6}
62 140E-5 Series
Crosshead and guide 1
Unit: mm

Depth of crosshead stem
1 receiver +0.3
6.2 6.61
+0.3
Replace
Inside diameter of crosshead 11.04 ±0.02 11.17
2 Outside diameter of crosshead +0.011
11 10.95
guide +0.011
3 Projection of crosshead guide 49.0 ±0.25 — Correct
140E-5 Series 63
SEN00081-08
© 2012 KOMATSU
All Rights Reserved
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
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
140E-5 Series 3
Lubrication system 1
Lubrication system diagram 1
(With EGR)
a The layout of the oil filter, shapes of the oil pan and piping, etc. are subject to machine models.
4 140E-5 Series
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
(EGR-less)
a The layout of the oil filter, shapes of the oil pan and piping, etc. are subject to machine models.
6 140E-5 Series
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
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
Oil pump 1
A: From oil pan Specifications

B: To oil cooler Oil pump
C: Rotation direction Type: Gear pump
D: Pump mounting face Revolving speed: Engine speed × 1.8
1. Pump cover Main relief valve
2. Drive gear
Cracking pressure:
3. Pump body
600 ± 50 kPa {6.0 ± 0.5 kg/cm2}
4. Pump drive gear (Number of teeth: 20)
5. Driven gear
Sub relief valve
6. Main relief valve
7. Main valve spring Cracking pressure:
8. Sub relief valve 1,000 ± 50 kPa {10.0 ± 0.5 kg/cm2}
9. Sub valve spring
8 140E-5 Series
EGR oil pump 1
A: From main gallery Specifications

B: To EGR valve and bypass valve Oil pump
C: Rotation direction Type: Gear pump
Revolving speed: Engine speed × 1.09
1. Pump cover
2. Drive gear Main relief valve
3. Pump body
Cracking pressure:
4. Driven gear
1,430 ± 100 kPa {14.6 ± 1.0 kg/cm2}
5. Pump drive gear (Number of teeth: 22)
6. Main relief valve
Sub-relief valve
7. Main valve spring
8. Sub-relief valve Cracking pressure:
9. Sub-valve spring 1,800 ± 150 kPa {18.4 ± 1.5 kg/cm2}
140E-5 Series 9
Oil filter 1
Except SDG400S-6B1 (HOKUETSU INDUSTRIES GENERATOR)
A: Oil inlet Specifications

B: Oil outlet Oil filter
Filtration area: 0.44 m2 (full flow)
1. Safety valve
2. Filter head Safety valve
3. Cartridge
Cracking pressure: 343 ± 19.6 kPa {3.5 ± 0.2 kg/cm2}
10 140E-5 Series
For SDG400S-6B1 (HOKUETSU INDUSTRIES GENERATOR)
A: Oil inlet Specifications

B: Oil outlet Oil filter
Filtration area: 0.44 m2 (full flow)
1. Safety valve
2. Filter head Safety valve
3. Cartridge
Cracking pressure: 343 ± 19.6 kPa {3.5 ± 0.2 kg/cm2}
4. Clogging switch
Clogging switch
q Operating differential pressure:
147 +39 +0.4 2
+0 kPa {1.5 +0 kg/cm }
q Contact type: NO (Normal Open)
140E-5 Series 11
Oil cooler 1
12 140E-5 Series
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
Lift of thermostat at full opening Min. 8 mm (Before checking, leave valve in oil of 100°C for 4 to 5 minutes)
6 Check that valve closes fully when its temperature is lowered from 100°C Replace
Opening/Closing of thermostat for full opening to 85°C. (Before checking valve, leave it in oil for 4 to 5
minutes)
140E-5 Series 13
Fuel system 1
CRI system diagram 1
(With EGR)
a CRI is an abbreviation for common rail injection.
1. NE speed sensor 9C. Priming pump (sub)

2. Engine controller 9D. Feed pump
3. Injector 9E. Relief valve
4. Fuel cooler 9F. Bkup speed sensor (G sensor)
5. Fuel tank 10. Common rail
6. Pre-fuel filter 11. High-pressure injection pipe
7. Main fuel filter 12. Flow damper
8. Overflow valve 13. Pressure limiter
9. Fuel supply pump 14. Priming pump (main)
9A. PCV 15. Engine controller cooler
9B. High-pressure pump
14 140E-5 Series
(EGR-less)
a CRI is an abbreviation for common rail injection.
1. NE speed sensor 9C. Priming pump

2. Engine controller 9D. Feed pump
3. Injector 9E. Relief valve
4. Fuel cooler 9F. Bkup speed sensor (G sensor)
5. Fuel tank 10. Common rail
6. Pre-fuel filter 11. High-pressure injection pipe
7. Main fuel filter (double cartridges) 12. Flow damper
a Single cartridge is set for some models. 13. Pressure limiter
8. Overflow valve 14. Electric priming pump
9. Fuel supply pump a Manual priming pump is set for some models.
9A. PCV 15. Engine controller cooler
9B. High-pressure pump
140E-5 Series 15
Outline of CRI system 1

Outline 1. Fuel system
q The CRI system checks the condition of the
engine (engine speed, accelerator angle, cool-
ant 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 func-
tion which stops the engine when a certain
parts fail and a backup function which contin-
ues 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})
Configuration
q The CRI system is divided by the function into
the fuel system and control system.
q The fuel system distributes the high-pressure

fuel supplied by the fuel supply pump to the
cylinders through the common rail.
q The solenoid valve in the injector opens and
closes the nozzle needle valve to start and fin-
ish injection.
16 140E-5 Series
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 quan-
tity of fuel in proper timing.
q The control system is roughly divided by the
electric parts into the sensors, computer, and
actuators.
140E-5 Series 17
Structure and operation of CRI system 1
q The CRI system consists of the fuel supply q If the TWV is turned on (energized), the fuel
pump, common rail, injector, engine controller circuit is so changed that the high-pressure
to control them, and sensors. fuel in the control chamber will flow through the
q The fuel supply pump generates fuel pressure orifice. As a result, the needle valve is raised
in the common rail. The fuel pressure is con- to start fuel injection by the nozzle cracking
trolled by the fuel discharge rate of the supply pressure of the high-pressure fuel on the noz-
pump. zle side.
q The discharge rate is controlled by turning on q If the TWV is turned off (de-energized), the fuel
and off the PCV (pressure control valve) of the circuit is so changed that the high-pressure
fuel supply pump according to the electric sig- fuel will be applied to the control chamber
nals from the engine controller. through the orifice. As a result, the needle
q The common rail receives the pressurized fuel valve lowers and finishes fuel injection.
from the fuel supply pump and distributes it to q Accordingly, the fuel injection timing and fuel
the cylinders. injection rate are controlled respectively by the
q The fuel pressure is sensed by the common timing to turn on the TWV and the length of the
rail fuel pressure sensor installed to the com- turn-on time of the TWV.
mon rail.
q A feedback control is applied so that the actual
fuel pressure will match to the command pres-
sure set according to the engine speed and the
load on the engine.
q The fuel pressure in the common rail is applied
to the nozzle side of the injector and to the
control chamber through the fuel injection pipe
of each cylinder.
q The injector controls the fuel injection rate and
fuel injection timing by turning on and off the
TWV (2-way solenoid valve).
18 140E-5 Series
Structure and operation of component parts 1

1. Fuel supply pump
1. 3-head cam 6. No. 2 high-pressure pump

2. Overflow valve 7. Priming pump
3. Drive gear 8. Feed pump
4. No. 1 high-pressure pump 9. Gear for Bkup speed sensor (G sensor)
5. PCV (pressure control valve)
Outline q Since the number of the times of feeding fuel

q The fuel supply pump consists of priming to the common rail is the same as the number
pump (7), feed pump (8), and high-pressure of the times of fuel injection, the common rail
pumps (4) and (6). fuel pressure is smooth and stable.
q The function of the fuel supply pump is to gen- q The fuel fed by high-pressure pumps (4) and
erate common rail fuel pressure by controlling (6) to the common rail is divided as follows.
the fuel delivery. q No. 1 high-pressure pump (on the drive gear
side) (4) compensates for drop in the common
Structure rail fuel pressure caused by fuel injection into
q High-pressure pumps (4) and (6) have the the No. 1, 3, and 5 cylinders.
pressure feed systems similar to those of the q No. 2 high-pressure pump (on the feed pump
conventional in-line fuel injection pump and the side) (6) compensates for drop in the common
PCVs (pressure control valves) for each cylin- rail fuel pressure caused by fuel injection into
der to control the fuel delivery. the No. 2, 4, and 6 cylinders.
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.
140E-5 Series 19
Operation
q (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.
q (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.
q (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.
q (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 de-
energized, it opens and the low-pressure
fuel is sucked in the plunger chamber, or
the state of (A) starts again.
20 140E-5 Series
1) PCV (pressure control valve) 2) Feed pump

q The PCV adjusts the fuel delivery from the fuel q The feed pump built in the fuel supply pump
supply pump to adjust the common rail fuel assembly draws the fuel from the fuel tank and
pressure. The delivery from the fuel supply sends it through the fuel filter to the high-pres-
pump to the common rail is decided by the tim- sure pump chamber.
ing of energizing the PCV. 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.
140E-5 Series 21
2. Common rail
Structure When fuel is stopped

q Common rail (4) distributes the high-pressure q If the fuel flows out abnormally because of a
fuel from the high-pressure pump to the injec- burst of the piping, etc., piston (2) moves to the
tors of the cylinders. right stroke end.
q Common rail (4) is equipped with common rail q The tip of piston (2) contacts seat (b) to stop
fuel pressure sensor (2), flow dampers (1), and the fuel.
pressure limiter (3). q Once the fuel is stopped, piston (2) does not
q The fuel injection pipes are connected to flow return to the initial position until the engine is
dampers (1) to send the high-pressure fuel to stopped.
the injectors.
q The piping of the pressure limiter (3) is
returned to the fuel tank.
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

q 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.
22 140E-5 Series
2) Pressure limiter 3) Common rail fuel pressure sensor

q If abnormally high pressure is generated, the q The common rail fuel pressure sensor is
pressure limiter opens to release that pres- installed to the common rail to sense the fuel
sure. pressure.
q If the common rail fuel pressure reaches about q This sensor is a semiconductor pressure sen-
200 MPa {2,040 kg/cm2}, the pressure limiter sor, which utilizes the phenomenon that the
operates (opens). electric resistance of silicon changes according
q If the common rail fuel pressure lowers to 30 to pressure applied to it.
MPa {310 kg/cm2}, the pressure limiter resets
itself (closes) to maintain the pressure.
q Under the normal condition, the pressure lim-
iter does not reset itself (close) until the engine
is stopped.
1. Ball
2. Housing
3. Spring
4. Guide
5. Body
140E-5 Series 23
3. Injector
Outline
q The function of the injector is to inject the high-
pressure fuel from the common rail into each
combustion chamber of the engine in the opti-
mum timing, by the optimum quantity, at the
optimum injection rate, and under the optimum
spray condition.
q The TWV (2-way solenoid valve) controls the
start and finish of fuel injection by controlling
the pressure in the control chamber.
q The orifice limits the opening speed of the noz-
zle and controls the fuel injection rate.
q The hydraulic piston transmits the force gener-
ated by the pressure in the control chamber to
the needle valve of the nozzle.
q The nozzle sprays the fuel.
24 140E-5 Series
Structure
1. Inlet connector 7. Orifice (in)

2. Terminal 8. Pressure control chamber
3. Upper body 9. Control piston
4. Solenoid 10. Spring
5. Valve body 11. Pressure pin
6. Orifice (out) 12. Nozzle assembly
q The injector consists of the nozzle section, ori-

fice to control the fuel injection rate, hydraulic
piston section, and 2-way solenoid valve sec-
tion.
140E-5 Series 25
A: No fuel injection C: Finish of fuel injection

B: Start of fuel injection D: From common rail
1. Nozzle 5. Valve body

2. Control piston 6. Solenoid
3. Orifice (in) 7. Spring
4. Orifice (out) 8. Pressure control chamber
Operation
1) No fuel injection (A) 3) Finish of fuel injection (C)
q While solenoid (6) is not energized, valve body q If solenoid (6) is de-energized, valve body (5)
(5) is pressed down by spring (7). is lowered by spring (7) and the fuel passage is
q Since the high-pressure fuel is applied from closed.
the common rail to pressure control chamber q At this time, the high-pressure fuel in the com-
(8), nozzle (1) is closed and the fuel is not mon rail is applied to pressure control chamber
injected. (8) suddenly and nozzle (1) is closed quickly,
fuel injection is finished sharply.
2) Start of fuel injection (B)
q If solenoid (6) is energized, valve body (5) is
pulled up by the electromagnetic force and the
fuel passage is opened.
q Since the fuel in pressure control chamber (8)
flows out through orifices (3) and (4), nozzle
(1) rises and fuel injection pump starts.
q The fuel injection rate is increased gradually by
the function of orifices (3) and (4).
q If solenoid (6) is kept energized, the fuel injec-
tion rate is increased to the maximum.
26 140E-5 Series
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
28 140E-5 Series
Various controls
a Parts marked with * (3 places) are installed to only the engines with EGR.
q The CRI system controls the fuel injection rate 2. Fuel injection timing control function
and fuel injection timing more properly than the q The fuel injection timing control function is
mechanical governor or timer of the conven- employed instead of the function of the con-
tional fuel injection pump. ventional timer. It controls the fuel injection
q For the control of the system, calculations nec- timing most properly from the engine speed
essary to the engine controller are performed and fuel injection rate.
fr om th e si gn als se nt fr om the s en so rs
installed to the engine and machine.
q The energizing timing and energizing period of 3. Fuel injection pressure control func-
the injector are so controlled that the optimum tion (Common rail fuel pressure control
quantity of fuel will be injected in the optimum
function)
timing.
q The fuel injection pressure control function
(common rail fuel pressure control function) is
a function of measuring the fuel pressure with
1. Fuel injection rate control function
the common rail fuel pressure sensor and
q The fuel injection rate control function is
feeding it back to the engine controller to con-
employed instead of the function of the con-
trol the delivery of the fuel supply pump.
ventional governor. It controls the fuel injection
q This function performs pressure feedback con-
according to the signals of engine speed and
trol so that the fuel injection pressure will be
accelerator angle so that the fuel injection rate
the same as the optimum value (command
will be most proper.
value) set according to the engine speed and
fuel injection rate.
140E-5 Series 29
4. Various sensors and relays
a Nos. 1 to 13 in the above illustration correspond to title Nos. 1) to 13).

a The above illustration shows the engine for HD325-7.
a Parts *1, *3 and *4 are installed to only the engines with EGR.
30 140E-5 Series
140E-5 Series 31
1) EGR inlet pressure sensor (with EGR) 2) Fuel temperature sensor

q This sensor is used to sense the EGR pres- q The fuel temperature sensor senses the fuel
sure. temperature and sends it to the engine control-
ler. The sensor unit is a thermistor the resis-
tance of which changes according to the
temperature.
q The engine controller applies voltage to the
thermistor and senses the temperature by the
voltage divided by the resistance in the com-
puter and the resistance of the thermistor.
q The following graph shows the output charac-

teristics of the EGR inlet pressure sensor.
32 140E-5 Series
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

teristics of the position sensor.
140E-5 Series 33
5) Engine controller 7) Atmospheric pressure sensor

q This sensor is used to correct altitude.
6) NE speed sensor (crank angle sensor) (with EGR)
q If the signal hole made on the flywheel passes
the sensor, the magnetic line of force changes.
q If the magnetic line of force changes, the out-
put 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}

teristics of the atmospheric pressure sensor.
34 140E-5 Series
(EGR-less)
10) Bkup speed sensor (G sensor)

(Cylinder No. sensor)
q Similarly to the NE speed sensor, this sensor
utilizes the pulses of 0 – 5 V generated by the
change of the magnetic line of force crossing
the sensor unit.
q 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.
q In addition to the above teeth, one more tooth
is installed. Accordingly, 7 pulses are gener-
ated every 2 revolutions of the engine.
q The standard pulse of the No. 1 cylinder is rec-
ognized 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}

teristics of the atmospheric pressure sensor.
8) Common rail pressure sensor
9) Oil pressure sensor
140E-5 Series 35
11) Charge pressure sensor (EGR-less)

q This sensor is used to sense the charge pres-
sure (boost pressure).
(with EGR)
1. Sensor
2. O-ring

teristics 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

teristics of the charge pressure sensor.
36 140E-5 Series
12) Charge temperature sensor 13) Coolant temperature sensor

q The charge temperature sensor senses the q The coolant temperature sensor senses the
intake air temperature (boost temperature) and coolant temperature and sends it to the engine
sends it to the engine controller. controller.
q The sensor unit is a thermistor the resistance q The sensor unit is a thermistor the resistance
of which changes according to the tempera- of which changes according to the tempera-
ture. The engine controller applies voltage to ture. The engine controller applies voltage to
the thermistor and senses the temperature by the thermistor and senses the temperature by
the voltage divided by the resistance in the the voltage divided by the resistance in the
computer and the resistance of the thermistor. computer and the resistance of the thermistor.
140E-5 Series 37
Fuel piping 1
(with EGR)

Specifications A: Fuel inlet

Fuel supply pump B: To engine controller cooler
Manufacturer: DENSO CORPORATION C: To main fuel filter
Model: DENSO ECD-U2 D: From main fuel filter
Lubrication method: E: To injector
Forced lubrication with engine oil 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)
38 140E-5 Series

1. Fuel injection pipe (No. 1 cylinder) 11. Oil inlet pipe (for pump lubricating oil)
2. Fuel injection pipe (No. 2 cylinder) 12. Fuel supply pump
3. Fuel injection pipe (No. 3 cylinder) 13. Drive gear (Number of teeth: 48)
4. Fuel injection pipe (No. 4 cylinder) 14. Overflow valve
5. Fuel injection pipe (No. 5 cylinder) 15. PCV
6. Fuel injection pipe (No. 6 cylinder) 16. Priming pump (main)
7. Common rail 17. Pre-fuel filter
8. Fuel return pipe 18. Main fuel filter
9. Priming pump (sub)
10. Feed pump
140E-5 Series 39
(EGR-less)
a The above illustration shows the engine for D275A-5R.

Specifications A: Fuel inlet

Fuel supply pump B: To engine controller cooler
Manufacturer: DENSO CORPORATION C: To main fuel filter
Model: DENSO ECD-U2 D: From main fuel filter
Lubrication method: E: To injector
Forced lubrication with engine oil 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)
40 140E-5 Series
a The above illustration shows the engine for D275A-5R.

1. Fuel injection pipe (No. 1 cylinder) 11. Oil inlet pipe (for pump lubricating oil)
2. Fuel injection pipe (No. 2 cylinder) 12. Fuel supply pump
3. Fuel injection pipe (No. 3 cylinder) 13. Drive gear (Number of teeth: 48)
4. Fuel injection pipe (No. 4 cylinder) 14. Overflow valve
5. Fuel injection pipe (No. 5 cylinder) 15. PCV
6. Fuel injection pipe (No. 6 cylinder) 16. Electric priming pump
7. Common rail a Manual priming pump is set for some models.
8. Fuel return pipe (See the "with EGR".)
9. Priming pump 17. Pre-fuel filter
10. Feed pump 18. Main fuel filter (double cartridges)
a Single cartridge is set for some models.
19. Air bleeding valve for electric priming pump
140E-5 Series 41
Fuel cooler 1
(installed on the machine)
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
Fuel filter 1
Main fuel filter
(with EGR)
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
(EGR-less)
A: Fuel inlet
B: Fuel outlet

2. Filter head
3. Cartridge (double cartridges)
Specifications
Filtration area: 1.06 m2 x 2
44 140E-5 Series
Pre-fuel filter
A: Fuel inlet
B: Fuel outlet

2. Filter head
3. Cartridge
Specifications
Filtration area: 1.06 m2
with water separator
140E-5 Series 45
Priming pump 1
(with EGR)
1. Spring 9. Valve stopper

2. Cover 10. Packing
3. Shaft 11. Check valve body
4. Bushing 12. Lever pin
5. Diaphragm 13. E-ring
6. Diaphragm cover 14. Washer
7. Body 15. Bolt
8. Check valve 16. Lever
46 140E-5 Series
Electric priming pump 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
Engine controller cooler 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
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, PC800-
8, PC800SE-8, PC850-8, PC850SE-8, PC800LC-8, PC800-8E0, PC800SE-8E0, PC850-
8E0, PC850SE-8E0, PC800LC-8E0, D155AX-6, D275AX-5E0, WA500-6, HM400-3M0)
A: Oil inlet
B: Oil outlet
1. Radiator 6. Corrosion resistor

2. Thermostat a Corrosion resistor is not set for some models.
3. Oil cooler 7. Hydraulic cooling fan
4. Water pump 8. Hydraulic fan motor
5. EGR cooler
140E-5 Series 49
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
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
1. Radiator
2. Thermostat
3. Oil cooler
4. Water pump
5. EGR cooler
7. Engine-driven cooling fan
140E-5 Series 51
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
6. Engine-driven cooling fan
52 140E-5 Series
140E-5 Series 53
Water pump 1
SAA6D140E-5
54 140E-5 Series
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
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
Standard Tolerance Standard inter-
Interference between impeller and dimension Shaft Hole ference
10 shaft –0.082 –0.120
16 0.025 to 0.068
–0.095 –0.150
Interference between drive gear and +0.015 –0.023
11 shaft
28
+0.002 –0.055
0.025 to 0.070 Replace
+0.015 –0.023
12 Interference between flange and shaft 25
+0.002 –0.053
0.025 to 0.068
13 Clearance between impeller and body Standard clearance: 0.6 to 0.9 (including end play)
14 Wear of water seal ring Limits of size: 1.5
140E-5 Series 55
Water pump mounting 1

SAA6D140E-5

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
Thermostat 1
A: To radiator inlet Specifications

B: From radiator outlet Opening temperature: 76.5 ± 2°C
Full opening temperature: 90°C
1. Thermostat housing Lift at full opening: Min. 9 mm
2. Thermostat
Unit: mm
Min. 9 mm (Before checking, leave valve in water of 90°C for 4 to 5 min-
Lift of thermostat at full opening
utes)
3 Check that valve closes fully when its temperature is lowered from 90°C Replace
Opening/Closing of thermostat for full opening to 76.5°C. (Before checking valve, leave it in water for 4 to
5 minutes)
140E-5 Series 57
Corrosion resistor 1

A: Coolant inlet Specifications

B: Coolant outlet Filtration area 0.13m2 0.19m2 0.37m2
Quantity of anti-corrosion
1. Head agent
400g 600g 1,000g
2. Cartridge
3. Element
4. Inhibitor (solid anti-corrosion agent)
5. Spring
6. Stop valve
58 140E-5 Series
Corrosion resistor mounting

1. Tube (return from corrosion resistor)

2. Corrosion resistor head
3. Corrosion resistor cartridge
4. Tube (to corrosion resistor)
140E-5 Series 59
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)]
1. Crankshaft pulley 4. Fan belt

2. Tension pulley 5. Fan pulley
3. Adjustment bolt
Outside diameter of pulley

Unit: mm
Engine Machine model Crankshaft pulley Tension pulley Fan pulley
HD325-7, HD405-7,
166 120 322
HD325-7R, HD405-7R
HM350-2, HM350-2R 166 120 262
SAA6D140E-5 HM400-2, HM400-2R 166 120 262
SDG400S-6B1
(HOKUETSU INDUS- 203 120 277
TRIES GENERATOR)
60 140E-5 Series
Tension pulley
HM350-2R, HM400-2R,
1. Tension pulley
2. Spacer
3. Ball bearing
4. Tension shaft
5. Oil seal
6. Adjustment bolt
7. Bracket
140E-5 Series 61
Fan mounting case

HM350-2R, HM400-2R,
1. Fan pulley hub

2. Ball bearing
3. Shaft
4. Case
62 140E-5 Series
Accessories 1
Front PTO 1
1. Shaft
2. Pulley
3. Oil seal
4. Bearing (2 pieces)
5. Housing
6. O-ring
7. Gear (Number of teeth: 14)
8. Snap ring
9. Sleeve
140E-5 Series 63
Front PTO mounting
1. Front PTO (for driving air conditioner compressor)

2. O-ring
64 140E-5 Series
Electrical equipment 1
Alternator 1
1. Alternator with built-in regulator (open type, 35 A)
1. Alternator 6. Internal electric circuit diagram

2. Alternator pulley 6A. Field coil
3. Terminal B 6B. Regulator
4. Terminal E
5. Terminal R
140E-5 Series 65

3. Terminal B 6B. Initial excitation resistor
4. Terminal E 6C. Regulator
5. Terminal R
66 140E-5 Series

2. Alternator pulley 6A. Stator
4. Terminal E
5. Terminal R
140E-5 Series 67

5. Terminal R
68 140E-5 Series
Outside diameter
Engine Machine model Type Specification Weight (kg)
of pulley (mm)
PC600-8, PC600LC-8,
PC600-8R, PC600LC-8R,
PC600-8E0, PC600LC-8E0,
Open type (brushless)
PC600-8R1, PC600LC-8R1, 24V, 60A
manufactured by NIKKO DENKI
PC700-8E0, PC700LC-8E0,
PC700-8R, PC700LC-8R,
PC700LC-8R1
PC800-8, PC800LC-8, PC800-8R,
PC800LC-8R, PC800SE-8,
PC800SE-8R
PC850-8, PC850-8R, PC850SE-8,
PC850SE-8R
SAA6D140E-5 PC800-8E0, PC800SE-8E0, 24V, 60A
PC850-8E0, PC850SE-8E0,
PC800LC-8E0
PC800-8R1, PC800SE-8R1
PC850-8R1, PC850SE-8R1
PC800LC-8R1
D155AX-6, D155A-6 24V, 60A
HD325-7, HD325-7R Open type (brushless)
24V, 60A
HD405-7, HD405-7R manufactured by NIKKO DENKI
HM350-2, HM350-2R
HM400-2, HM400-2R 24V, 60A
HM400-3M0, HM400-3R
140E-5 Series 69

2. Alternator pulley 6A. Stator
4. Terminal E
5. Terminal R
Outside diameter of
pulley (mm)
D155AX-6, D155A-6 Open type (brushless) manufactured
24V, 75A
(If equipped) by SAWAFUJI DENKI
D275AX-5E0, Open type (brushless) manufactured
24V, 75A
D275A-5R by SAWAFUJI DENKI
Open type (brushless) manufactured
WA500-6, WA500-6R 24V, 75A
by SAWAFUJI DENKI
SAA6D140E-5 HD325-7, HD325-7R
Open type (brushless) manufactured
HD405-7, HD405-7R 24V, 75A
by SAWAFUJI DENKI
(If equipped)
HM350-2, HM350-2R
HM400-2, HM400-2R Open type (brushless) manufactured
24V, 75A
HM400-3M0, HM400-3R by SAWAFUJI DENKI
(If equipped)
70 140E-5 Series
140E-5 Series 71

5. Terminal R
72 140E-5 Series
Outside diameter
of pulley (mm)
PC600-8, PC600LC-8,
PC600-8R, PC600LC-8R,
PC600-8E0, PC600LC-8E0,
PC600-8R1, PC600LC-8R1, Open type (brushless)
24V, 90A
PC700-8E0, PC700LC-8E0, manufactured by NIKKO DENKI
PC700-8R, PC700LC-8R,
PC700LC-8R1
(If equipped)
PC800-8, PC800LC-8, PC800-8R,
PC800LC-8R, PC800SE-8,
PC800SE-8R
PC850-8, PC850-8R
SAA6D140E-5 PC800-8E0, PC800SE-8E0, Open type (brushless)
24V, 90A
PC850-8E0, PC850SE-8E0, manufactured by NIKKO DENKI
PC800LC-8E0
PC800-8R1, PC800SE-8R1
PC850-8R1, PC850SE-8R1
PC800LC-8R1
(If equipped)
D155AX-6, D155A-6 Open type (brushless)
24V, 90A
(If equipped) manufactured by NIKKO DENKI
D275AX-5E0, D275A-5R Open type (brushless)
24V, 90A
WA500-6, WA500-6R Open type (brushless)
24V, 90A
140E-5 Series 73
Alternator mounting
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
140E-5 Series 75
Starting motor 1
For 7.5kW (for SDG400S-6B1 (HOKUETSU INDUSTRIES GENERATOR))
E: To chassis ground 5. Terminal C

R: To alternator terminal R 6. Safety relay
S: To starting switch terminal C 7. External connection diagram
(2-pole connector type)
1. Pinion gear 7A. Safety relay section
2. Starting motor assembly 7B. Starting motor section
3. Magnetic switch 8. Jump start prohibition label
4. Terminal B 9. Jump start prevention cover
Number of Type of
pinion teeth connector
SDG400S-6B1
Water-resistant, oil-resistant
(HOKUETSU
SAA6D140E-5 type manufactured by 24V, 7.5kW 12 15.5 DT
INDUSTRIES
NIKKO DENKI
GENERATOR)
76 140E-5 Series
For 11kW (except SDG400S-6B1 (HOKUETSU INDUSTRIES GENERATOR))
E: To chassis ground 5. Terminal C

R: To alternator terminal R 6. Safety relay
S: To starting switch terminal C 7. External connection diagram
(2-pole connector type)
1. Pinion gear 7A. Safety relay section
2. Starting motor assembly 7B. Starting motor section
3. Magnetic switch 8. Jump start prohibition label
4. Terminal B 9. Jump start prevention cover
Number of Type of
pinion teeth connector
Water-resistant, oil-resistant
SAA6D140E-5 All machines type manufactured by 24V, 11kW 12 18 DT
NIKKO DENKI
140E-5 Series 77
Starting aid 1
Electric heater
For SAA6D140E-5
1. Body Specifications
2. Heater coil Type of heater: Electrical intake air heater
3. Terminal q Rated voltage: 22 V (DC)
4. Connection diagram q Load current: 175 A
78 140E-5 Series
Engine controller 1
Features
Mounting of engine controller on engine
q Since the engine controller is mounted on the
engine, the operator can service it easily in the
field.
q The engine controller cooler (if equipped) is
prepared to cool the engine controller with the
fuel to secure the reliability of the mounted
engine controller.
q Vibrations are damped by the vibration-proof
rubber.
Unified specifications of engine controller

q Engine controller CM850 developed by the
cooperation between KOMATSU and CUM-
MINS is employed.
140E-5 Series 79
SEN00082-06
© 2012 KOMATSU
All Rights Reserved
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
Standard service value table for testing, adjusting, and troubleshooting
Engine SAA6D140E-5
Performance Category
Standard value for

Item Measurement conditions Unit Repair limit
new machine
Max. speed with no load rpm 2,100(0/–50) 2,100(0/–50)

Speed
Min. speed with no load rpm 740(+40/0) 740(+40/0)
Necessary speed for At 0°C (without starting aid) rpm Min. 110 —
starting At –20°C (with starting aid) rpm Min. 85 —
kPa Max. 3.73 7.47
Air intake resistance Whole speed range
{mmH2O} {Max. 380} {762}
kPa Min. 117 100
Air boost pressure At rated horsepower
{mmHg} {Min. 880} {750}
kPa Min. 127 108
Exhaust pressure At rated horsepower
Air intake and exhaust system
{mmHg} {Min. 950} {810}

Exhaust temperature Whole speed range (20°C) °C 660 700
% (Bosch Max. 25 35
At sudden acceleration (Low  High)
index) (Max. 2.5) (3.5)
Bosch
Exhaust gas color At rated horsepower Max. 1.5 2.5
index
Bosch
At high idle Max. 1.0 2.0
index
Intake valve mm 0.35 —
Valve clearance
Exhaust valve mm 0.57 —
MPa Min. 1.18 Min. 1.18
At low idle
EGR valve and bypass {kg/cm2} {Min. 12} {Min. 12}
valve drive oil pressure MPa Min. 1.43 Min. 1.43
At high idle
{kg/cm2} {Min. 14.6} {Min. 14.6}
Engine oil temperature: 40 to 60°C MPa Min. 4.1 2.8
Compression pressure
Engine speed: 200 to 250 rpm {kg/cm2} {Min. 42} {29}
Body
At rated horsepower kPa Max. 2.94 3.92

Blow-by pressure
Engine coolant temperature: Min. 70°C {mmH2O} {Max. 300} {400}
At rated horsepower
MPa Min. 0.34 0.21
Engine oil temperature: SAE0W30EOS
Lubrication system
2
SAE5W40EOS {kg/cm } {Min. 3.5} {2.1}
Min. 80°C
Oil pressure SAE10W30DH
At low idle SAE15W40DH MPa Min. 0.10 0.08
Engine oil temperature: SAE30DH
{kg/cm2} {Min. 1.0} {0.8}
Min. 80°C
Oil temperature Whole speed range °C 90 to 110 120
Ratio to fuel consumption at continuous
Oil consumption % Max. 0.15 0.3
rated horsepower
Function of radiator Cracking pressure kPa
— —
pressure valve (Differential pressure) {kg/cm2}
Cooling system
Fan speed At rated speed rpm Hydraulically driven on machine side

Deflection under finger pressure of 98 N
Fan belt tension mm Hydraulically driven on machine side
{10 kg}
Alternator belt tension mm 13 to 16 13 to 16
{10 kg}
2 140E-5 Series
20 Standard value table SEN00147-07
Engine SAA6D140E-5
Standard value for

new machine
Max. speed with no load rpm 2,100(0/–50) 2,100(0/–50)

Speed
Min. speed with no load rpm 740(+40/0) 740(+40/0)
kPa Max. 3.73 7.47
{mmH2O} {Max. 380} {762}
kPa Min. 85 72
{mmHg} {Min. 640} {540}

kPa Min. 92 77
{mmHg} {Min. 690} {580}
Exhaust temperature Whole speed range (20°C) °C 670 720
% (Bosch Max. 30 40
index) (Max. 3.0) (4.0)
Bosch
index
Bosch
index
Valve clearance
Body

Blow-by pressure
At rated horsepower
MPa Min. 0.34 0.21
Lubrication system
SAE5W40EOS {kg/cm2} {Min. 3.5} {2.1}

Min. 80°C
{kg/cm2} {Min. 1.0} {0.8}
Min. 80°C
rated horsepower
— —
Cooling system

{10 kg}
{10 kg}
140E-5 Series 3
Engine SAA6D140E-5
Standard value for

new machine
Max. speed with no load rpm 2,200 ± 50 2,200 ± 50

Speed
Min. speed with no load rpm 700 ± 50 700 ± 50
kPa Max. 3.73 7.47
{mmH2O} {Max. 380} {762}
kPa Min. 169 144
{mmHg} {Min. 1,270} {1,080}
kPa Min. 169 144
{mmHg} {Min. 1,270} {1,080}

Exhaust temperature Whole speed range (20°C) °C Max. 620 670
% (Bosch Max. 25 35
index) (Max. 2.5) (3.5)
Bosch
index
Bosch
index
Valve clearance
MPa Min. 1.18 Min. 1.18
At low idle
At high idle
{kg/cm2} {Min. 14.6} {Min. 14.6}
Body

Blow-by pressure
At rated horsepower
SAE0W30EOS MPa Min. 0.34 0.21
Engine oil temperature:
{kg/cm2} {Min. 3.5} {2.1}
Lubrication system
Min. 80°C SAE5W40EOS

SAE30DH {kg/cm2} {Min. 1.0} {0.8}
Min. 80°C
rated horsepower
— —
Cooling system

{10 kg}
{10 kg}
4 140E-5 Series
Engine SAA6D140E-5
Standard value for

new machine

Speed
kPa Max. 3.73 7.47
{mmH2O} {Max. 380} {762}
kPa Min. 116 99
{mmHg} {Min. 870} {740}

kPa Min. 116 99
{mmHg} {Min. 870} {740}
% (Bosch Max. 40 50
index) (Max. 4.0) (5.0)
Bosch
index
Bosch
index
Valve clearance
Body

Blow-by pressure
At rated horsepower
{kg/cm2} {Min. 3.5} {2.1}
Lubrication system

SAE30DH {kg/cm2} {Min. 1.0} {0.8}
Min. 80°C
rated horsepower
— —
Cooling system

{10 kg}
{10 kg}
140E-5 Series 5
Engine SAA6D140E-5
PC600-8, PC600LC-8
Machine models PC600-8E0, PC600LC-8E0
PC700-8E0, PC700LC-8E0
Standard value for

new machine

Speed
kPa Max. 3.73 7.47
{mmH2O} {Max. 380} {762}
kPa Min. 147 125
{mmHg} {Min. 1,100} {940}
kPa Min. 145 128
{mmHg} {Min. 1,090} {930}

% (Bosch Max. 25 35
index) (Max. 2.5) (3.5)
Bosch
index
Bosch
index
Valve clearance
MPa Min. 1.18 Min. 1.18
At low idle
At high idle
{kg/cm2} {Min. 14.6} {Min. 14.6}
Body

Blow-by pressure
At rated horsepower
{kg/cm2} {Min. 3.5} {2.1}
Lubrication system

SAE30DH {kg/cm2} {Min. 1.0} {0.8}
Min. 80°C
rated horsepower
— —
Cooling system

{10 kg}
{10 kg}
6 140E-5 Series
Engine SAA6D140E-5
PC600-8R, PC600LC-8R,
PC600-8R1, PC600LC-8R1,
Machine models
PC700-8R, PC700LC-8R,
PC700LC-8R1
Standard value for

new machine

Speed
kPa Max. 3.73 7.47
{mmH2O} {Max. 380} {762}
kPa Min. 120 102
{mmHg} {Min. 900} {760}

kPa Min. 116 99
{mmHg} {Min. 870} {740}
% (Bosch Max. 30 40
index) (Max. 3.0) (4.0)
Bosch
index
Bosch
index
Valve clearance
Body

Blow-by pressure
At rated horsepower
{kg/cm2} {Min. 3.5} {2.1}
Lubrication system

SAE30DH {kg/cm2} {Min. 1.0} {0.8}
Min. 80°C
rated horsepower
— —
Cooling system

{10 kg}
{10 kg}
140E-5 Series 7
Engine SAA6D140E-5
PC800-8, PC800SE-8, PC800LC-8
PC850-8, PC850SE-8
Machine models PC800-8E0, PC800SE-8E0,
PC800LC-8E0
PC850-8E0, PC850SE-8E0
Standard value for

new machine

Speed
kPa Max. 3.73 7.47
{mmH2O} {Max. 380} {762}
kPa Min. 184 157
{mmHg} {Min. 1,380} {1,180}
kPa Min. 172 147
{mmHg} {Min. 1,290} {1,100}

% (Bosch Max. 25 35
index) (Max. 2.5) (3.5)
Bosch
index
Bosch
index
Valve clearance
MPa Min. 1.18 Min. 1.18
At low idle
At high idle
{kg/cm2} {Min. 14.6} {Min. 14.6}
Body

Blow-by pressure
At rated horsepower SAE0W30EOS MPa Min. 0.34 0.21
SAE5W40EOS {kg/cm2}
Lubrication system
{Min. 3.5} {2.1}

Min. 80°C
At low idle
SAE15W40DH MPa Min. 0.10 0.08
Engine oil temperature: 2
SAE30DH {kg/cm } {Min. 1.0} {0.8}
Min. 80°C
Oil consumption % Max. 0.15 Max. 0.3
rated horsepower
— —
Cooling system

{10 kg}
{10 kg}
8 140E-5 Series
Engine SAA6D140E-5
PC800-8R, PC800SE-8R,
PC800LC-8R
Machine models
PC800-8R1, PC800SE-8R1,
PC800LC-8R1, PC850-8R1,
PC850SE-8R1
Standard value for

new machine

Speed
kPa Max. 3.73 7.47
{mmH2O} {Max. 380} {762}
kPa Min. 128 108
{mmHg} {Min. 960} {810}

kPa Min. 113 96
{mmHg} {Min. 850} {720}
% (Bosch Max. 30 40
index) (Max. 3.0) (4.0)
Bosch
index
Bosch
index
Valve clearance
Body

Blow-by pressure
SAE5W40EOS {kg/cm2}
Lubrication system
{Min. 3.5} {2.1}

Min. 80°C
At low idle
SAE30DH {kg/cm2} {Min. 1.0} {0.8}
Min. 80°C
Oil consumption % Max. 0.15 Max. 0.3
rated horsepower
— —
Cooling system

{10 kg}
{10 kg}
140E-5 Series 9
Engine SAA6D140E-5
Standard value for

new machine

Speed
kPa Max. 3.73 7.47
{mmH2O} {Max. 380} {762}
kPa Min. 116 89
{mmHg} {Min. 870} {670}
kPa Min. 121 91
{mmHg} {Min. 910} {680}

% (Bosch Max. 25 35
index) (Max. 2.5) (3.5)
Bosch
index
Bosch
index
Valve clearance
MPa Min. 1.18 Min. 1.18
At low idle
At high idle
{kg/cm2} {Min. 14.6} {Min. 14.6}
Body

Blow-by pressure
At rated horsepower
MPa Min. 0.34 0.21
Lubrication system
SAE5W40EOS {kg/cm2} {Min. 3.5} {2.1}

Min. 80°C
{kg/cm2} {Min. 1.0} {0.8}
Min. 80°C
rated horsepower
— —
Cooling system

{10 kg}
{10 kg}
10 140E-5 Series
Engine SAA6D140E-5
Standard value for

new machine

Speed
Air intake kPa Max. 3.73 7.47
Whole speed range
resistance {mmH2O} {Max. 380} {762}
Air boost kPa Min. 89 76
At rated horsepower
pressure {mmHg} {Min. 670} {570}
Exhaust kPa Min. 101 85

At rated horsepower
pressure {mmHg} {Min. 760} {640}
Exhaust
Whole speed range (20°C) °C Max. 670 720
temperature
% (Bosch Max. 40 50
index) (Max. 4.0) (5.0)
Bosch
index
Bosch
index
Valve clearance
Body
Blow-by At rated horsepower kPa Max. 2.94 3.92

pressure Engine coolant temperature: Min. 70°C {mmH2O} {Max. 300} {400}
At rated horsepower
MPa Min. 0.34 0.21
Lubrication system
2
SAE5W40EOS {kg/cm } {Min. 3.5} {2.1}
Min. 80°C
{kg/cm2} {Min. 1.0} {0.8}
Min. 80°C
rated horsepower
Function of
Cracking pressure kPa
radiator — —
(Differential pressure) {kg/cm2}
Cooling system
pressure valve
{10 kg}
{10 kg}
140E-5 Series 11
Engine SAA6D140E-5
HD325-7
Machine models
HD405-7
Standard value for

new machine

Speed
kPa Max. 3.73 7.47
{mmH2O} {Max. 380} {762}
kPa Min. 183 156
{mmHg} {Min. 1,370} {1,170}
kPa Min. 163 139
{mmHg} {Min. 1,220} {1,040}

% (Bosch Max. 25 35
index) (Max. 2.5) (3.5)
Bosch
index
Bosch
index
Valve clearance
MPa Min. 1.18 Min. 1.18
At low idle
At high idle
{kg/cm2} {Min. 14.6} {Min. 14.6}
Body

Blow-by pressure
SAE5W40EOS {kg/cm2}
Lubrication system
{Min. 3.5} {2.1}

Min. 80°C
At low idle
SAE30DH {kg/cm2} {Min. 1.0} {0.8}
Min. 80°C
rated horsepower
— —
Cooling system
Fan speed At rated speed rpm 1,020 ± 30 1,020 ± 30

17 to 19
Deflection under finger pressure of 98 N 13 to 15
Fan belt tension mm (when retight-
{10 kg} (when new)
ened)
{10 kg}
12 140E-5 Series
Engine SAA6D140E-5
HD325-7R
Machine models
HD405-7R
Standard value for

new machine

Speed
kPa Max. 3.73 7.47
{mmH2O} {Max. 380} {762}
kPa Min. 135 115
{mmHg} {Min. 1,010} {860}

kPa Min. 121 103
{mmHg} {Min. 910} {770}
% (Bosch Max. 40 50
index) (Max. 4.0) (5.0)
Bosch
index
Bosch
index
Valve clearance
Body

Blow-by pressure
SAE5W40EOS {kg/cm2}
Lubrication system
{Min. 3.5} {2.1}

Min. 80°C
At low idle
Engine oil temperature: 2
SAE30DH {kg/cm } {Min. 1.0} {0.8}
Min. 80°C
rated horsepower
— —
Cooling system

17 to 19
{10 kg} (when new)
ened)
{10 kg}
140E-5 Series 13
Engine SAA6D140E-5
Standard value for

new machine
Max. speed with no load rpm 2,200(+50/0) 2,200(+50/0)

Speed
kPa Max. 3.73 7.47
{mmH2O} {Max. 380} {762}
kPa Min. 145 124
{mmHg} {Min. 1,090} {930}
kPa Min. 148 127
{mmHg} {Min. 1,110} {950}

% (Bosch Max. 25 35
index) (Max. 2.5) (3.5)
Bosch
index
Bosch
index
Valve clearance
MPa Min. 1.18 Min. 1.18
At low idle
At high idle
{kg/cm2} {Min. 14.6} {Min. 14.6}
Body

Blow-by pressure
SAE5W40EOS {kg/cm2}
Lubrication system
{Min. 3.5} {2.1}

Min. 80°C
At low idle
SAE30DH {kg/cm2} {Min. 1.0} {0.8}
Min. 80°C
rated horsepower
— —
Cooling system

17 to 19
{10 kg} (when new)
ened)
{10 kg}
14 140E-5 Series
Engine SAA6D140E-5
Standard value for

new machine

Speed
kPa Max. 3.73 7.47
{mmH2O} {Max. 380} {762}
kPa Min. 98 83
{mmHg} {Min. 730} {620}

kPa Min. 104 88
{mmHg} {Min. 780} {660}
% (Bosch Max. 40 50
index) (Max. 4.0) (5.0)
Bosch
index
Bosch
index
Valve clearance
Body

Blow-by pressure
At rated horsepower
{kg/cm2} {Min. 3.5} {2.1}
Lubrication system

SAE30DH {kg/cm2} {Min. 1.0} {0.8}
Min. 80°C
rated horsepower
— —
Cooling system

17 to 19
{10 kg} (when new)
ened)
{10 kg}
140E-5 Series 15
Engine SAA6D140E-5
Standard value for

new machine

Speed
kPa Max. 3.73 7.47
Air intake resistance Air intake resistance
{mmH2O} {Max. 380} {762}
kPa Min. 160 136
{mmHg} {Min. 1,200} {1,020}
kPa Min. 163 139
{mmHg} {Min. 1,220} {1,040}

% (Bosch Max. 25 35
index) (Max. 2.5) (3.5)
Bosch
index
Bosch
index
Valve clearance
MPa Min. 1.18 Min. 1.18
At low idle
At high idle
{kg/cm2} {Min. 14.6} {Min. 14.6}
Body

Blow-by pressure
Lubrication system
SAE5W40EOS {kg/cm2} {Min. 3.5} {2.1}

Min. 80°C
At low idle
SAE30DH {kg/cm2} {Min. 1.0} {0.8}
Min. 80°C
rated horsepower
— —
Cooling system

{10 kg}
{10 kg}
16 140E-5 Series
Engine SAA6D140E-5
Standard value for

new machine

Speed
kPa Max. 3.73 7.47
Air intake resistance Air intake resistance
{mmH2O} {Max. 380} {762}
kPa Min. 111 94
{mmHg} {Min. 830} {700}

kPa Min. 115 98
{mmHg} {Min. 860} {730}
% (Bosch Max. 40 50
index) (Max. 4.0) (5.0)
Bosch
index
Bosch
index
Valve clearance
Body

Blow-by pressure
Lubrication system
SAE5W40EOS {kg/cm2} {Min. 3.5} {2.1}

Min. 80°C
At low idle
SAE30DH {kg/cm2} {Min. 1.0} {0.8}
Min. 80°C
rated horsepower
— —
Cooling system

{10 kg}
{10 kg}
140E-5 Series 17
Engine SAA6D140E-5
SDG400S-6B1
Machine models
(HOKUETSU INDUSTRIES GENERATOR)
Standard value for

new machine

Speed
kPa Max. 3.73 7.47
{mmH2O} {Max. 380} {762}
kPa Min. 207 171
{mmHg} {Min. 1,550} {1,280}
kPa Min. 185 153
{mmHg} {Min. 1,390} {1,150}

% (Bosch — —
index) (—) (—)
Bosch
index
Bosch
index
Valve clearance
MPa Min. 1.18 Min. 1.18
At low idle
At high idle
{kg/cm2} {Min. 14.6} {Min. 14.6}
Body

Blow-by pressure
At rated horsepower
MPa Min. 0.34 0.21
Engine oil temperature: SAE0W30EOS 2
Lubrication system
SAE5W40EOS {kg/cm } {Min. 3.5} {2.1}

Min. 80°C
{kg/cm2} {Min. 1.0} {0.8}
Min. 80°C
rated horsepower
— —
Cooling system

Deflection under finger pressure of 98 N 13 to 15 17 to 19
Fan belt tension mm
{10 kg} (When new)
{10 kg}
18 140E-5 Series
Running-in standard and performance test standard 1

Running-in standard
Engine SAA6D140E-5
Procedure
Item
1 2 3 4 5
Running time min. 1 3 6 8 2
Speed rpm 740 1,197 1,501 1,729 1,900
Dynamometer load N{kg} 0{0} 747{76} 1,192{122} 1,552{158} 1,883{192}
Output kW{HP} 0{0} 67{90} 134{181} 201{270} 268{360}
a This table shows the values when the fan is not installed.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Performance test standard
Engine SAA6D140E-5
Test item Rated horsepower Max. torque High idle speed Low idle speed
Specification value 268 kW/1,900 rpm 1,834 Nm/1,300 rpm
— 2,100(0/–50) rpm 740(+40/0) rpm
(Gross value) {359.9 HP/1,900 rpm} {187 kgm/1,300 rpm}
Speed rpm 1,900 1,300 2,100(0/–50) 740(+40/0)
N 1,823 to 1,940 2,460 to 2,607
Dynamometer load — —
{kg} {186 to 198} {251 to 266}
kW 260 to 277
Output (Gross value) — — —
{HP} {349 to 371}
Nm 1,758 to 1,868
Torque (Gross value) — — —
{kgm} {179.4 to 190.6}
Fuel consumption sec/300cc Min. 16.0 — — —
Coolant temperature °C 70 to 90 70 to 90 70 to 90 70 to 90
Lubricating oil
°C 90 to 110 90 to 110 90 to 110 80 to 110
temperature
Lubricating oil kPa 340 to 490 340 to 490 340 to 490 Min. 120
pressure {kg/cm2} {3.5 to 5.0} {3.5 to 5.0} {3.5 to 5.0} {Min. 1.2}
Exhaust temperature °C Max. 650 Max. 650 — —
a This table shows the standard values obtained by using the JIS correction coefficients.
a Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.
a This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
a Use ASTM No.1 or No. 2 diesel fuel as fuel.
a Use SAE15W-40 as lubricating oil.
140E-5 Series 19
Running-in standard
Engine SAA6D140E-5
Procedure
Item
1 2 3 4 5
Speed rpm 740 1,197 1,501 1,729 1,900
Output kW{HP} 0{0} 67{90} 134{181} 201{270} 268{360}
Engine SAA6D140E-5
— 2,100(0/–50) rpm 740(+40/0) rpm
Speed rpm 1,900 1,300 2,100(0/–50) 740(+40/0)
N 1,823 to 1,940 2,482 to 2,635
{kg} {186 to 198} {253 to 269}
kW 260 to 277
{HP} {349 to 371}
Nm 1,778 to 1,888
{kgm} {181.4 to 192.6}
Lubricating oil
°C 90 to 110 90 to 110 90 to 110 80 to 110
temperature
20 140E-5 Series
Running-in standard
Engine SAA6D140E-5
Procedure
Item
1 2 3 4 5
Speed rpm 740 1,260 1,580 1,820 2,000
Output kW{HP} 0{0} 84{113} 168{226} 253{339} 337{452}
Engine SAA6D140E-5
— 2,200 ± 50 rpm 700 ± 50 rpm
Speed rpm 2,000 1,400 2,200 ± 50 700 ± 50
N 2,177 to 2,314 2,753 to 2,917
{kg} {222.0 to 236.0} {280.7 to 297.5}
Output kW 327 to 347
— — —
(Gross value) {HP} {438 to 465}
Nm 1,970 to 2,087
{kgm} {201 to 213}
Lubricating oil
°C 90 to 110 90 to 110 90 to 110 90 to 110
temperature
140E-5 Series 21
Running-in standard
Engine SAA6D140E-5
Procedure
Item
1 2 3 4 5
Speed rpm 740 1,260 1,580 1,820 2,000
Output kW{HP} 0{0} 84{113} 168{226} 253{339} 337{452}
Engine SAA6D140E-5
— 2,200 ± 50 rpm 700 ± 50 rpm
Speed rpm 2,000 1,400 2,200 ± 50 700 ± 50
N 2,177 to 2,314 2,753 to 2,917
{kg} {222.0 to 236.0} {280.7 to 297.5}
Output kW 327 to 347
— — —
(Gross value) {HP} {438 to 465}
Nm 1,970 to 2,087
{kgm} {201 to 213}
Lubricating oil
°C 90 to 110 90 to 110 90 to 110 90 to 110
temperature
22 140E-5 Series
Running-in standard
Engine SAA6D140E-5
PC600-8, PC600LC-8, PC600-8E0, PC600LC-8E0
Machine models
PC700-8E0, PC700LC-8E0
Procedure
Item
1 2 3 4 5
Speed rpm 800 1,134 1,422 1,638 1,800
Output kW{HP} 0{0} 81{108} 161{217} 242{324} 323{433}
Engine SAA6D140E-5
PC600-8, PC600LC-8, PC600-8E0, PC600LC-8E0
Machine models
PC700-8E0, PC700LC-8E0
323 kW/1,800 rpm 1,944Nm/1,400rpm
Specification value
— {433.3 HP/ {198.4 kgm/ 1,950 ± 50 rpm 800 ± 25 rpm
(Gross value)
1,800 rpm} 1,400 rpm}
Speed rpm 1,800 1,400 1,950 ± 50 800 ± 25
N 2,323 to 2,470 2,626 to 2,793
{kg} {237 to 252} {268 to 285}
kW 313 to 333
{HP} {420 to 447}
Nm 1,882 to 1,999
{kgm} {192 to 204}
Lubricating oil
°C 90 to 110 90 to 110 90 to 110 80 to 110
temperature
140E-5 Series 23
Running-in standard
Engine SAA6D140E-5
PC600-8R, PC600LC-8R,
Machine models PC600-8R1, PC600LC-8R1,
PC700-8R, PC700LC-8R, PC700LC-8R1
Procedure
Item
1 2 3 4 5
Speed rpm 800 1,134 1,422 1,638 1,800
Output kW{HP} 0{0} 81{108} 161{217} 242{324} 323{433}
Engine SAA6D140E-5
PC600-8R, PC600LC-8R,
Machine models PC600-8R1, PC600LC-8R1,
PC700-8R, PC700LC-8R, PC700LC-8R1
323 kW/1,800 rpm 1,944Nm/1,400rpm
Specification value
— {433.3 HP/ {198.4 kgm/ 1,950 ± 50 rpm 800 ± 25 rpm
(Gross value)
1,800 rpm} 1,400 rpm}
Speed rpm 1,800 1,400 1,950 ± 50 800 ± 25
N 2,323 to 2,470 2,626 to 2,793
{kg} {237 to 252} {268 to 285}
kW 313 to 333
{HP} {420 to 447}
Nm 1,882 to 1,999
{kgm} {192 to 204}
Lubricating oil
°C 90 to 110 90 to 110 90 to 110 80 to 110
temperature
24 140E-5 Series
Running-in standard
Engine SAA6D140E-5
PC800-8, PC800SE-8, PC800LC-8, PC850-8, PC850SE-8
Machine models
Procedure
Item
1 2 3 4 5
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}
Engine SAA6D140E-5
PC800-8, PC800SE-8, PC800LC-8, PC850-8, PC850SE-8
Machine models
370 kW/1,800 rpm 2,195 Nm/1,350 rpm
Specification value
— {496.4 HP/ {223.8 kgm/ 1,980 ± 50 rpm 825 ± 25 rpm
(Gross value)
1,800 rpm} 1,350 rpm}
Speed rpm 1,800 1,350 1,980 ± 50 825 ± 25
N 2,550 to 2,690 2,930 to 3,100
{kg} {260 to 274} {299 to 316}
kW 359 to 381
{HP} {481 to 512}
Nm 2,126 to 2,264
{kgm} {217 to 231}
Lubricating oil
°C 90 to 110 90 to 110 90 to 110 80 to 110
temperature
140E-5 Series 25
Running-in standard
Engine SAA6D140E-5
PC800-8R, PC800SE-8R, PC800LC-8R, PC850-8R, PC850SE-8R
Machine models
Procedure
Item
1 2 3 4 5
Speed rpm 825 1,134 1,422 1,638 1,800
Output kW{HP} 0{0} 92{124} 185{248} 277{372} 370{496}
Engine SAA6D140E-5
PC800-8R, PC800SE-8R, PC800LC-8R, PC850-8R, PC850SE-8R
Machine models
370 kW/1,800 rpm 2,195 Nm/1,350 rpm
Specification value
— {496.4 HP/ {223.8 kgm/ 1,980 ± 50 rpm 825 ± 25 rpm
(Gross value)
1,800 rpm} 1,350 rpm}
Speed rpm 1,800 1,350 1,980 ± 50 825 ± 25
N 2,550 to 2,690 2,969 to 3,162
{kg} {260 to 274} {303 to 323}
kW 359 to 381
{HP} {481 to 512}
Nm 2,126 to 2,264
{kgm} {217 to 231}
Lubricating oil
°C 90 to 110 90 to 110 90 to 110 80 to 110
temperature
26 140E-5 Series
Running-in standard
Engine SAA6D140E-5
Procedure
Item
1 2 3 4 5
Speed rpm 675 1,197 1,501 1,729 1,900
Output kW{HP} 0{0} 64{86} 128{172} 192{257} 266{357}
Engine SAA6D140E-5
— 2,150 ± 50 rpm 700 ± 25 rpm
(Gross value) {357 HP/1,900 rpm} {184 kgm/1,250 rpm}
Speed rpm 1,900 1,250 2,150 ± 50 700 ± 25
N 1,744 to 1,852 2,440 to 2,597
{kg} {178 to 189} {249 to 265}
kW 248 to 263
{HP} {333 to 353}
Nm 1,744 to 1,862
{kgm} {178 to 190}
Lubricating oil
°C 90 to 110 90 to 110 90 to 110 80 to 110
temperature
140E-5 Series 27
Running-in standard
Engine SAA6D140E-5
Procedure
Item
1 2 3 4 5
Speed rpm 675 1,197 1,501 1,729 1,900
Output kW{HP} 0{0} 64{86} 128{172} 192{257} 266{357}
Engine SAA6D140E-5
— 2,150 ± 50 rpm 700 ± 25 rpm
(Gross value) {357 HP/1,900 rpm} {184 kgm/1,250 rpm}
Speed rpm 1,900 1,250 2,150 ± 50 700 ± 25
N 1,814 to 1,922 2,440 to 2,597
{kg} {185 to 196} {249 to 265}
kW 258 to 274
{HP} {346 to 368}
Nm 1,744 to 1,862
{kgm} {178 to 190}
Lubricating oil
°C 90 to 110 90 to 110 90 to 110 80 to 110
temperature
28 140E-5 Series
Running-in standard
Engine SAA6D140E-5
HD325-7
Machine models
HD405-7
Procedure
Item
1 2 3 4 5
Speed rpm 725 1,260 1,580 1,820 2,000
Output kW{HP} 0{0} 97{129} 193{259} 290{388} 386{518}
Engine SAA6D140E-5
HD325-7
Machine models
HD405-7
— 2,300 ± 25 rpm 725 ± 25 rpm
(Gross value) {517.7 HP/2,000 rpm} {221.3 kgm/1,400 rpm}
Speed rpm 2,000 1,400 2,300 ± 25 725 ± 25
N 2,499 to 2,646 2,930 to 3,120
{kg} {255 to 270} {299 to 318}
kW 374 to 398
{HP} {502 to 533}
Nm 2,100 to 2,230
{kgm} {214 to 228}
Lubricating oil
°C 90 to 110 90 to 110 90 to 110 80 to 110
temperature
140E-5 Series 29
Running-in standard
Engine SAA6D140E-5
HD325-7R
Machine models
HD405-7R
Procedure
Item
1 2 3 4 5
Speed rpm 725 1,260 1,580 1,820 2,000
Output kW{HP} 0{0} 97{129} 193{259} 290{388} 386{518}
Engine SAA6D140E-5
HD325-7R
Machine models
HD405-7R
— 2,300 ± 25 rpm 725 ± 25 rpm
(Gross value) {517.7 HP/2,000 rpm} {221.3 kgm/1,400 rpm}
Speed rpm 2,000 1,400 2,300 ± 25 725 ± 25
N 2,499 to 2,646 2,930 to 3,120
{kg} {255 to 270} {299 to 318}
kW 374 to 398
{HP} {502 to 533}
Nm 2,100 to 2,230
{kgm} {214 to 228}
Lubricating oil
°C 90 to 110 90 to 110 90 to 110 80 to 110
temperature
30 140E-5 Series
Running-in standard
Engine SAA6D140E-5
Procedure
Item
1 2 3 4 5
Speed rpm 725 1,260 1,580 1,820 2,000
Output kW{HP} 0{0} 76{102} 152{204} 228{306} 304{407}
Engine SAA6D140E-5
— 2,200(+50/0) rpm 725 ± 25 rpm
Speed rpm 2,000 1,400 2,200(+50/0) 725 ± 25
N 1,960 to 2,087 2,695 to 2,862
{kg} {200 to 213} {275 to 292}
kW 295 to 315
{HP} {395 to 419}
Nm 1,931 to 2,048
{kgm} {197 to 209}
Lubricating oil tem-
°C 90 to 110 90 to 110 90 to 110 80 to 110
perature
Lubricating oil pres- kPa 340 to 490 340 to 490 340 to 490 Min. 120
sure {kg/cm2} {3.5 to 5.0} {3.5 to 5.0} {3.5 to 5.0} {Min. 1.2}
140E-5 Series 31
Running-in standard
Engine SAA6D140E-5
Procedure
Item
1 2 3 4 5
Speed rpm 725 1,260 1,580 1,820 2,000
Output kW{HP} 0{0} 76{102} 152{204} 228{306} 304{407}
Engine SAA6D140E-5
— 2,200(+50/0) rpm 725 ± 25 rpm
Speed rpm 2,000 1,400 2,200(+50/0) 725 ± 25
N 1,960 to 2,087 2,695 to 2,862
{kg} {200 to 213} {275 to 292}
kW 295 to 315
{HP} {395 to 419}
Nm 1,931 to 2,048
{kgm} {197 to 209}
Lubricating oil tem-
°C 90 to 110 90 to 110 90 to 110 80 to 110
perature
Lubricating oil pres- kPa 340 to 490 340 to 490 340 to 490 Min. 120
sure {kg/cm2} {3.5 to 5.0} {3.5 to 5.0} {3.5 to 5.0} {Min. 1.2}
32 140E-5 Series
Running-in standard
Engine SAA6D140E-5
Procedure
Item
1 2 3 4 5
Speed rpm 725 1,260 1,580 1,820 2,000
Output kW{HP} 0{0} 84{113} 169{227} 253{339} 338{453}
Engine SAA6D140E-5
— 2,200(+50/0) rpm 725 ± 25 rpm
Speed rpm 2,000 1,400 2,200(+50/0) 725 ± 25
N 2,185 to 2,313 2,832 to 2,999
{kg} {223 to 236} {289 to 306}
kW 327 to 348
{HP} {439 to 466}
Nm 2,029 to 2,146
{kgm} {207 to 219}
Lubricating oil
°C 90 to 110 90 to 110 90 to 110 80 to 110
temperature
140E-5 Series 33
Running-in standard
Engine SAA6D140E-5
Procedure
Item
1 2 3 4 5
Speed rpm 725 1,260 1,580 1,820 2,000
Output kW{HP} 0{0} 84{113} 169{227} 253{339} 338{453}
Engine SAA6D140E-5
— 2,200(+50/0) rpm 725 ± 25 rpm
Speed rpm 2,000 1,400 2,200(+50/0) 725 ± 25
N 2,185 to 2,313 2,832 to 2,999
{kg} {223 to 236} {289 to 306}
kW 327 to 348
{HP} {439 to 466}
Nm 2,029 to 2,146
{kgm} {207 to 219}
Lubricating oil
°C 90 to 110 90 to 110 90 to 110 80 to 110
temperature
34 140E-5 Series
Running-in standard
Engine SAA6D140E-5
Machine models SDG400S-6B1 (HOKUETSU INDUSTRIES GENERATOR)
Procedure
Item
1 2 3 4 5
Speed rpm 875 1,134 1,422 1,638 1,800
Output kW{HP} 0{0} 92{123} 185{248} 277{371} 371{498}
Engine SAA6D140E-5
Machine models SDG400S-6B1 (HOKUETSU INDUSTRIES GENERATOR)
Specification value 371 kW/1,800 rpm —
— 1,890 ± 50 rpm 875 ± 25 rpm
(Gross value) {498 HP/1,800 rpm} —
Speed rpm 1,800 — 1,890 ± 50 875 ± 25
N 2,695 to 2,813 —
{kg} {275 to 287} —
kW 360 to 382
{HP} {483 to 512}
Nm
Torque (Gross value) — — — —
{kgm}
Coolant temperature °C 70 to 90 — 70 to 90 70 to 90
Lubricating oil
°C 90 to 110 — 90 to 110 80 to 110
temperature
Lubricating oil kPa 340 to 490 — 340 to 490 Min. 120
pressure {kg/cm2} {3.5 to 5.0} {—} {3.5 to 5.0} {Min. 1.2}
Exhaust temperature °C Max. 670 — — —
140E-5 Series 35
SEN00147-07
© 2012 KOMATSU
All Rights Reserved
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) 1

Testing and adjusting tools list 1
Testing and Sym-

Part No. Part name Q'ty Remarks
adjusting item bol
Testing air boost 799-201-2202 Boost gauge kit 1 –101 – 200 kPa {–760 – 1,500 mmHg}
A
pressure 799-401-2220 Hose 1 I-coupler type (if necessary)
Testing exhaust
B 799-101-1502 Digital thermometer 1 –99.9 – 1,299°C
temperature
Adjusting valve Commercially Intake: 0.35 mm
C Clearance gauge 1
clearance available Exhaust: 0.57 mm
1 795-502-1590 Compression gauge 1 0 – 7 MPa {0 – 70 kg/cm2}
Testing compression
D 795-471-1330 Adapter 1
pressure 2 For 140E-5
6261-71-6150 Gasket 1
Testing blow-by
E 799-201-1504 Blow-by checker 1 0 – 5 kPa {0 – 500 mmH2O}
pressure
Pressure gauge:
Testing engine oil pres-
799-101-5002 Hydraulic tester 1 2.5, 6, 40, 60 MPa
sure 1 {25, 60, 400, 600 kg/cm2}
Testing EGR valve and F
bypass valve drive oil 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
pressure
2 799-401-2320 Hydraulic tester 1 Pressure gauge: 1 MPa {10 kg/cm2}
Pressure gauge:
1 {25, 60, 400, 600 kg/cm2}
Testing fuel pressure G 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
2 799-401-2320 Gauge 1 Pressure gauge: 1 MPa {10 kg/cm2}
795-471-1450 Adapter 1 8 × 1.25 mm o R1/8
3
07005-00812 Gasket 1
1 6151-51-8490 Spacer 1 Inside diameter: 14 mm
2 6206-71-1770 Joint 1 Inside diameter of joint: 10 mm
Commercially
3 Hose 1 ∅5mm × 2 – 3 m
available
Testing fuel return rate Commercially
and leakage
H 4 Hose 1 ∅15mm × 2 – 3 m
available
Commercially
5 Measuring cylinder 1
available
Commercially
6 Stopwatch 1
available
140E-5 Series 3
Testing and Sym-

adjusting item bol
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
For coolant temperature sensor
795-799-5530 T-adapter —
For fuel temperature sensor
Troubleshooting for
For EGR valve solenoid
controllers, sensors, J 799-601-9020 T-adapter —
For bypass valve solenoid
and actuators
For EGR valve stroke sensor
799-601-9030 T-adapter —
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)
799-601-9320 T-box —
For 24-pole type
799-601-9310 Plate —
799-601-4350 T-box — For 60-pole type
Checking coolant tem-
perature and oil temper- — 799-101-1502 Digital thermometer 1 –99.9 – 1,299°C
ature
Checking voltage and Commercially
— Tester 1
resistance available
21 mm deep socket
Commercially (MITOLOY 4ML 21 or equivalent)
Socket 1
available Applicable engine serial No.:
Removal and installa- 530056-534132
tion of engine coolant —
temperature sensor 19 mm deep socket
(MITOLOY 4ML 19 or equivalent)
795T-981-1010 Socket 1
Applicable engine serial No.:
534133 and up
4 140E-5 Series
Sketches of special tools 1

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
Socket
140E-5 Series 5
Testing air boost pressure 1
a Testing tools for air boost pressure

Symbol Part No. Part name
799-201-2202 Boost gauge kit
A
799-401-2220 Hose
k Be careful not to touch any hot part when

removing or installing the testing tools.
a The test point is subject to machine models.
1. Remove air boost pressure pickup plug (1)

from the bottom of the air intake connector.
4. 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 install-
ing.
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
2. Install nipple [1] of boost gauge kit A and con- iron.
nect it to gauge [2]. (*2): When air intake connector is made of
aluminum.
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 140E-5 Series
Testing exhaust temperature 1
a Testing tool for exhaust temperature

B 799-101-1502 Digital thermometer
k Remove and install the testing tools after

the exhaust manifold temperature has low-
ered.
1. Remove exhaust temperature pickup plug (1)

from the bottom of the exhaust manifold.
a You may measure at either front or rear
plug.
q Clean the thread of the removed plug and
apply seizure prevention compound to the
plug before installing.
2 Plug: Seizure prevention com-
pound (LC-G)
(NEVER-SEEZ (NEVER-SEEZ COM-
POUND CO, LTD) or equivalent).
3 Plug: 2.9 – 5.9 Nm {0.3 – 0.6 kgm}
2. Install sensor [1] of digital thermometer B and

connect it to thermometer [2].
3. Run the engine and test the exhaust tempera-

ture in the whole speed range.
machine.
140E-5 Series 7
Adjusting valve clearance 1 3. While fixing adjustment screw (3), loosen lock-
nut (4).
a Adjusting tool for valve clearance a After setting the No. 1 cylinder to the com-
pression top dead center, adjust the valve
Symbol Part No. Part name clearance of the No. 1 cylinder.
Commercially
C Clearance gauge
available
4. Insert clearance gauge C in the clearance
between rocker arm (5) and crosshead (6) and
1. Remove 6 cylinder head covers (1). adjust the valve clearance with adjustment
screw (3).
a With the clearance gauge inserted, turn
the adjustment screw to a degree that you
can move the thickness gauge lightly.
a Valve clearance
Intake valve: 0.35 mm, Exhaust valve:
0.57 mm
5. While fixing adjustment screw (3), tighten lock-

nut (4).
3 Locknut: 45.1 – 51.0 Nm {4.6 – 5.2 kgm}
a After tightening the locknut, check the
valve clearance again.
2. 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 compres-
sion 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. 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}
8 140E-5 Series
Testing compression pressure 1
a Testing tools for compression pressure

1 795-502-1590 Compression gauge
D 795-471-1330 Adapter
2
6261-71-6150 Gasket
k When measuring the compression pres-

sure, take care not to burn yourself on the
exhaust manifold, muffler, etc. or get
caught in a rotating part.
a Measure the compression pressure after the

engine is warmed up (Engine oil temperature: 4. Install adapter D2 to the mounting hole on the
40 – 60°C). injector and the compression gauge D1.
a Fit the gasket to the adapter end without
1. Remove cylinder head cover (1) of the cylinder fail.
to be tested for compression pressure. 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.”
2. Bring the cylinder to be tested to the compres-

sion top dead center and remove rocker arm
assembly (2).
3. Disconnect fuel high-pressure tube (3) and

injector wiring harness and remove injector (4).
a Disconnect the terminal of the injector wir-
ing 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 6. Connect the INSITE (bench test tool) to the
(Loosen the 2 terminal nuts alternately). engine and set the engine in the no-injection
a Pass a wire, etc. under the fuel path pro- cranking mode.
jected sideways and pull up the injector a When inspecting with the engine mounted
(Do not pry the injector top up). on the machine, set the engine in the no-
injection cranking mode by operating the
monitor panel.
k If the engine is not set in the no-injec-
tion cranking mode, it will start and will
be dangerous. Accordingly, be sure to
set the engine in this mode.
140E-5 Series 9
7. Rotate the engine with the starting motor and

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

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) tempo-
rarily.
2 Spherical part of washer: Engine oil
3) Tighten sleeve nut (15) of the fuel high-
pressure 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}
a Install the injector wiring harness accord-

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

93 – 103 Nm {9.5 – 10.5 kgm}
a Adjust the valve clearance. For details, see

“Adjusting valve clearance.”

29.4 – 34.3 Nm {3.0 – 3.5 kgm}
10 140E-5 Series
Testing blow-by pressure 1
a Testing tool for blow-by pressure

E 799-201-1504 Blow-by checker
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].

blow-by pressure.
machine.

140E-5 Series 11
Testing engine oil pressure 1
a Testing tools for engine oil pressure

799-101-5002 Hydraulic tester
1
F 790-261-1204 Digital hydraulic tester
2 799-401-2320 Hydraulic tester
1. Remove oil pressure pickup plug (1) from the

cylinder block.

ing.
sealant (LG-5)
3 Plug:
16.7 – 37.2 Nm {1.7 – 3.8 kgm}
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.
machine.
12 140E-5 Series
Testing EGR valve and bypass 3. Connect hydraulic tester [2] (Component part
valve drive oil pressure 1 of tool F1) to the nipple.
4. Start the engine and measure the oil pressure

a Testing instrument for EGR valve and bypass at low idle and high idle.
valve drive oil pressure
F 1
790-261-1204 Digital hydraulic tester
a The measuring point may be different from the

following explanation, depending on each
applicable machine.

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. 5. After finishing measurement, remove the mea-
suring instruments 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 seal-
ant (LG-5)
3 Plug: 9.8 – 19.6 Nm {1.0 – 2.0 kgm}
140E-5 Series 13
Handling fuel system parts 1 Releasing residual pressure in

fuel system 1
a Precautions for testing and maintaining fuel
system a Pressure is generated in the low-pressure cir-
The common rail fuel injection system (CRI) cuit and high-pressure circuit of the fuel sys-
consists of more precise parts than the con- tem while the engine is running.
ventional fuel injection pump and nozzle. If for- Low-pressure circuit:
eign matter enters this system, it can cause a Feed pump – Fuel filter – Supply pump
trouble. High-pressure circuit:
When testing and maintaining the fuel system, Supply pump – Common rail – Injector
take care more than the past. If dust, etc. a The pressure in both low-pressure circuit and
sticks to any part, wash that part thoroughly high-pressure circuit lowers to a safety level
with clean fuel. automatically 30 seconds after the engine is
a Precautions for replacing fuel filter cartridge stopped.
Be sure to use the Komatsu genuine fuel filter a Before the fuel circuit is tested and its parts are
cartridge. removed, the residual pressure in the fuel cir-
Since the common rail fuel injection system cuit must be released completely. Accordingly,
(CRI) consists of more precise parts than the observe the following.
conventional fuel injection pump and nozzle, it k Before testing the fuel system or removing
employs a high-efficiency special filter to pre- its parts, wait at least 30 seconds after stop-
vent foreign matter from entering it. If a filter ping the engine until the residual pressure
other than the genuine one is used, the fuel in the fuel circuit is released. (Do not start
system may have a trouble. Accordingly, the work just after stopping the engine
never use such a filter. since there is residual pressure.)
14 140E-5 Series
Testing fuel pressure 1 3. Run the engine at high idle and measure the
fuel pressure.
a If the fuel pressure is in the following
a Testing tools for fuel pressure range, it is normal.
799-101-5002 Hydraulic tester Engine speed Fuel pressure
1
790-261-1204 Digital hydraulic tester 0.15 – 0.3 MPa
High idle
G 2 799-401-2320 Gauge {1.5 – 3 kg/cm2}
795-471-1450 Adapter
3
07005-00812 Gasket
a Check the fuel pressure in only the low-pres-

sure circuit from the feed pump via the fuel fil-
ter to the supply pump.
k Since the pressure in the high-pressure cir-
cuit from the supply pump through the
common rail to the injector is very high, it
cannot be measured.
1. Remove fuel pressure pickup plug (1) from the

fuel filter head.

3 Plug: 7.8 – 9.8 Nm {0.8 – 1.0 kgm}
2. Install adapter G3, 90° elbow [1] of hydraulic

tester G1, and nipple [2] and connect them to
gauge G2.
140E-5 Series 15
Reduced cylinder mode No-injection cranking 1

operation 1
a No-injection cranking means to crank the
a Reduced cylinder mode operation means to engine with the starting motor while all the
run the engine with the fuel injectors of 1 or injections are stopped electrically. The pur-
more cylinders disabled electrically to reduce pose and effect of this operation are as follows.
the number of effective cylinders. The pur- q Before the engine is started after it or the
poses and effects of this operation are as fol- machine has been stored for a long period, the
lows. no-injection cranking is performed to lubricate
1. This operation is used to find out a cylinder the engine parts and protect them from sei-
which does not output power normally (or, zure.
combustion in it is abnormal). a Perform the no-injection operation with the
2. When a cylinder is selected for the reduced engine mounted on the machine or connected
cylinder mode operation, if the engine speed to INSITE (bench test tool). Before perform-
and output do not change from the normal ing, see Testing method in the shop manual for
operation (all-cylinder operation), that cylinder the machine or INSITE (bench test tool).
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
3. Since the common rail fuel injection system
controls the injector of each cylinder electroni-
cally, the operator can perform the reduced cyl-
inder mode operation easily with switches to
find out a defective cylinder.
a Perform the reduced cylinder mode opera-
tion with the engine mounted on the
machine or connected to INSITE (bench
test tool). Before performing, see Testing
method in the shop manual for the
machine or INSITE (bench test tool).
16 140E-5 Series
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 1. Preparation work

with the return block on it to return the fuel 1) Remove tube (3) between common rail (1)
spilling from the injector to the fuel tank, test and supply pump (2).
the fuel return rate and fuel leakage according 2) Insert spacer H1 on supply pump (2) side
to the following procedure (The figure shows and tighten the removed joint bolt again.
the engine for D155AX-6). a Connect the return pipe to the fuel
tank again, too.
a Testing tools for fuel return rate and leakage a Be sure to fit the gaskets to both ends
of the spacer.
1 6151-51-8490 Spacer
2 6206-71-1770 Joint
3 Commercially available Hose
H
5 Commercially available Measuring cylinder
6 Commercially available Stopwatch
a Prepare a receiving pan of about 20 l to

receive the fuel flowing out during the test.
140E-5 Series 17
a If the leakage from the pressure lim-

iter is in the following range, it is nor-
mal.
Leakage
Engine speed
(cc/min)
At rated output Max. 10
3) 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.
4) 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. 5) After finishing testing, stop the engine.
a The above is the preparation work for
testing the leakage from the pressure 3. Testing return rate from injector
limiter. a Keep the hose on the pressure limiter side
connected and keep its end in the receiv-
ing 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
from coming off.
2) Lay test hose H4 so that it will not slacken
and put its end in the receiving pan.
2. Testing leakage from pressure limiter

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. 3) Connect INSITE (bench test tool) to the
a You may test for 20 seconds and engine and set it so that it can check the
judge by multiplying the result by 3. engine speed.
18 140E-5 Series
4) Run the engine at the rated output.

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 injec-
tor is in the following range, it is nor-
mal.
Rated output Limit of return rate
speed (rpm) (spill) (cc/min)
1,600 960
1,700 1,020
1,800 1,080
1,900 1,140
2,000 1,200
6) After finishing testing, stop the engine.
4. 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
Bleeding air from fuel circuit 1
a 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.
a The locations of the fuel circuit parts are sub-
ject to machine models (The figure shows the
engine for D155AX-6).
1. 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).
2. Install fuel pre-filter (1) to the filter head.
a After filling the fuel pre-filter with fuel,
a Apply engine oil thinly over the packing on
remove the cap from part (a).
the fuel pre-filter side.
a If clean fuel is not available, do not
a After the packing of the fuel pre-filter
remove the fuel pre-filter but fill it with the
touches the sealing face of the filter head,
fuel by operating priming pump (4).
tighten the fuel pre-filter 3/4 turns.
a Do not add fuel to fuel main filter (2) from
outside.
20 140E-5 Series
6. 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.
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).
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.
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 21
Testing fuel system for leakage 1

9. Inspect the fuel piping and devices for fuel
k Very high pressure is generated in the high- leakage.
pressure circuit of the fuel system. If fuel a Inspect mainly around the high-pressure
leaks while the engine is running, it is dan- circuit parts coated with the color checker
gerous since it can catch fire. for fuel leakage.
After testing the fuel system or removing a If any fuel leakage is detected, repair it
its parts, test it for fuel leakage according and inspect again from step 1.
to the following procedure. a If no fuel leakage is detected, inspection is
a Clean and degrease the engine and the parts completed.
around it in advance so that you can test it eas-
ily 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.

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.

leakage.
for fuel leakage.
6. Run the engine at high idle.

leakage.
for fuel leakage.
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 140E-5 Series
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 alter-

nator (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
Testing and adjusting fan belt tension 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 Deflection: 15 – 17 mm (When new)
19 – 21 mm (When retightened)
Adjusting
1. Loosen lock bolt of tension pulley (3).
2. Move tension pulley (3) with adjustment bolt

(2) to adjust the belt tension.
3. Tighten lock bolt of tension pulley (3).
24 140E-5 Series
Handling controller high-voltage circuit 1
1. Before disconnecting or connecting the con-

nector 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 25
Testing and adjusting (EGR-less) 1

Testing and adjusting tools list 1
Testing and Sym-

adjusting item bol
Testing air boost 799-201-2202 Boost gauge kit 1 –101 – 200 kPa {–760 – 1,500 mmHg}
A
pressure 799-401-2220 Hose 1 I-coupler type (if necessary)
Testing exhaust
B 799-101-1502 Digital thermometer 1 –99.9 – 1,299°C
temperature
Adjusting valve Commercially Intake: 0.35 mm
C Clearance gauge 1
clearance available Exhaust: 0.57 mm
1 795-502-1590 Compression gauge 1 0 – 7 MPa {0 – 70 kg/cm2}
Testing compression
D 795-471-1330 Adapter 1
pressure 2 For 140E-5
6261-71-6150 Gasket 1
Testing blow-by
E 799-201-1504 Blow-by checker 1 0 – 5 kPa {0 – 500 mmH2O}
pressure
Pressure gauge:
Testing engine oil pres- 1 {25, 60, 400, 600 kg/cm2}
F
sure
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}
Pressure gauge:
1 {25, 60, 400, 600 kg/cm2}
Testing fuel pressure G 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
2 799-401-2320 Gauge 1 Pressure gauge: 1 MPa {10 kg/cm2}
795-471-1450 Adapter 1 8 × 1.25 mm o R1/8
3
07005-00812 Gasket 1
1 6151-51-8490 Spacer 1 Inside diameter: 14 mm
2 6206-71-1770 Joint 1 Inside diameter of joint: 10 mm
Commercially
3 Hose 1 ∅5mm × 2 – 3 m
available
Testing fuel return rate Commercially
and leakage
H 4 Hose 1 ∅15mm × 2 – 3 m
available
Commercially
5 Measuring cylinder 1
available
Commercially
6 Stopwatch 1
available
26 140E-5 Series
Testing and Sym-

adjusting item bol
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
Troubleshooting for For coolant temperature sensor
795-799-5530 T-adapter —
controllers, sensors, J For fuel temperature sensor
and actuators 799-601-9430 T-adapter — For supply pump PCV
799-601-9020 T-adapter — For injector
799-601-9320 T-box —
For 24-pole type
799-601-9310 Plate —
799-601-4350 T-box — For 60-pole type
Checking coolant tem-
perature and oil temper- — 799-101-1502 Digital thermometer 1 –99.9 – 1,299°C
ature
Checking voltage and Commercially
— Tester 1
resistance available
21 mm deep socket
Commercially (MITOLOY 4ML 21 or equivalent)
Socket 1
available Applicable engine serial No.:
Removal and installa- 530056-534132
tion of engine coolant —
temperature sensor 19 mm deep socket
(MITOLOY 4ML 19 or equivalent)
795T-981-1010 Socket 1
Applicable engine serial No.:
534133 and up
140E-5 Series 27

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
Socket
28 140E-5 Series
Testing air boost pressure 1
a Testing tools for air boost pressure

799-201-2202 Boost gauge kit
A
799-401-2220 Hose
k Be careful not to touch any hot part when

removing or installing the testing tools.
1. Remove air boost pressure pickup plug (1)

from the bottom of the air intake connector.

ing.
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
2. Install nipple [1] of boost gauge kit A and con- iron.
nect it to gauge [2]. (*2): When air intake connector is made of
aluminum.

air boost pressure.
machine.
140E-5 Series 29
Testing exhaust temperature 1
a Testing tool for exhaust temperature

B 799-101-1502 Digital thermometer
k Remove and install the testing tools after

the exhaust manifold temperature has low-
ered.
1. Remove the heat insulation cover.
2. Remove exhaust temperature pickup plug (1)

from the bottom of the exhaust manifold.
q Clean the thread of the removed plug and
apply seizure prevention compound to the
plug before installing.
2 Plug: Seizure prevention com-
pound (LC-G)
(NEVER-SEEZ (NEVER-SEEZ COM-
POUND CO, LTD) or equivalent).
3 Plug: 2.9 – 5.9 Nm {0.3 – 0.6 kgm}
3. Install sensor [1] of digital thermometer B and

connect it to thermometer [2].
4. Run the engine and test the exhaust tempera-

ture in the whole speed range.
machine.
30 140E-5 Series
Adjusting valve clearance 1 3. While fixing adjustment screw (3), loosen lock-
nut (4).
a Adjusting tool for valve clearance a After setting the No. 1 cylinder to the com-
pression top dead center, adjust the valve
Symbol Part No. Part name clearance of the No. 1 cylinder.
Commercially
C Clearance gauge
available
4. Insert clearance gauge C in the clearance
between rocker arm (5) and crosshead (6) and
1. Remove 6 cylinder head covers (1). adjust the valve clearance with adjustment
screw (3).
a With the clearance gauge inserted, turn
the adjustment screw to a degree that you
can move the thickness gauge lightly.
a Valve clearance
Intake valve: 0.35 mm, Exhaust valve:
0.57 mm
5. While fixing adjustment screw (3), tighten lock-

nut (4).
3 Locknut: 45.1 – 51.0 Nm {4.6 – 5.2 kgm}
2. 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 compres-
sion 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. 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.
29.4 – 34.3 Nm {3.0 – 3.5 kgm}
140E-5 Series 31
Testing compression pressure 1
a Testing tools for compression pressure

1 795-502-1590 Compression gauge
D 795-471-1330 Adapter
2
6261-71-6150 Gasket
k When measuring the compression pres-

sure, take care not to burn yourself on the
exhaust manifold, muffler, etc. or get
caught in a rotating part.
a Measure the compression pressure after the

engine is warmed up (Engine oil temperature: 4. Install adapter D2 to the mounting hole on the
40 – 60°C). injector and the compression gauge D1.
a Fit the gasket to the adapter end without
1. Remove cylinder head cover (1) of the cylinder fail.
to be tested for compression pressure. a Fix the adapter with the injector holder.
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}
2. Bring the cylinder to be tested to the compres-

sion top dead center and remove rocker arm
assembly (2).
3. Disconnect fuel high-pressure tube (3) and

injector wiring harness and remove injector (4).
a Disconnect the terminal of the injector wir-
ing 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 6. Connect the INSITE (bench test tool) to the
(Loosen the 2 terminal nuts alternately). engine and set the engine in the no-injection
a Pass a wire, etc. under the fuel path pro- cranking mode.
jected sideways and pull up the injector a When inspecting with the engine mounted
(Do not pry the injector top up). on the machine, set the engine in the no-
injection cranking mode by operating the
monitor panel.
k If the engine is not set in the no-injec-
tion cranking mode, it will start and will
be dangerous. Accordingly, be sure to
set the engine in this mode.
32 140E-5 Series
7. Rotate the engine with the starting motor and

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

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) tempo-
rarily.
2 Spherical part of washer: Engine oil
3) Tighten sleeve nut (15) of the fuel high-
pressure 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}
a Install the injector wiring harness accord-

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

93 – 103 Nm {9.5 – 10.5 kgm}
a Adjust the valve clearance. For details, see

“Adjusting valve clearance.”

29.4 – 34.3 Nm {3.0 – 3.5 kgm}
140E-5 Series 33
Testing blow-by pressure 1
a Testing tool for blow-by pressure

E 799-201-1504 Blow-by checker
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].

blow-by pressure.
machine.

34 140E-5 Series
Testing engine oil pressure 1
a Testing tools for engine oil pressure

1
F 790-261-1204 Digital hydraulic tester
2 799-401-2320 Hydraulic tester

cylinder block.

ing.
sealant (LG-5)
3 Plug:
16.7 – 37.2 Nm {1.7 – 3.8 kgm}
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.
machine.
140E-5 Series 35
Handling fuel system parts 1 Releasing residual pressure in

fuel system 1
a Precautions for testing and maintaining fuel
system a Pressure is generated in the low-pressure cir-
The common rail fuel injection system (CRI) cuit and high-pressure circuit of the fuel sys-
consists of more precise parts than the con- tem while the engine is running.
ventional fuel injection pump and nozzle. If for- Low-pressure circuit:
eign matter enters this system, it can cause a Feed pump – Fuel filter – Supply pump
trouble. High-pressure circuit:
When testing and maintaining the fuel system, Supply pump – Common rail – Injector
take care more than the past. If dust, etc. a The pressure in both low-pressure circuit and
sticks to any part, wash that part thoroughly high-pressure circuit lowers to a safety level
with clean fuel. automatically 30 seconds after the engine is
a Precautions for replacing fuel filter cartridge stopped.
Be sure to use the Komatsu genuine fuel filter a Before the fuel circuit is tested and its parts are
cartridge. removed, the residual pressure in the fuel cir-
Since the common rail fuel injection system cuit must be released completely. Accordingly,
(CRI) consists of more precise parts than the observe the following.
conventional fuel injection pump and nozzle, it k Before testing the fuel system or removing
employs a high-efficiency special filter to pre- its parts, wait at least 30 seconds after stop-
vent foreign matter from entering it. If a filter ping the engine until the residual pressure
other than the genuine one is used, the fuel in the fuel circuit is released. (Do not start
system may have a trouble. Accordingly, the work just after stopping the engine
never use such a filter. since there is residual pressure.)
36 140E-5 Series
Testing fuel pressure 1 3. Run the engine at high idle and measure the
fuel pressure.
a If the fuel pressure is in the following
a Testing tools for fuel pressure range, it is normal.
799-101-5002 Hydraulic tester Engine speed Fuel pressure
1
790-261-1204 Digital hydraulic tester 0.15 – 0.3 MPa
High idle
G 2 799-401-2320 Gauge {1.5 – 3 kg/cm2}
795-471-1450 Adapter
3
07005-00812 Gasket
a Check the fuel pressure in only the low-pres-

sure circuit from the feed pump via the fuel fil-
ter to the supply pump.
k Since the pressure in the high-pressure cir-
cuit from the supply pump through the
common rail to the injector is very high, it
cannot be measured.
1. Remove fuel pressure pickup plug (1) from the

fuel filter head.

3 Plug: 7.8 – 9.8 Nm {0.8 – 1.0 kgm}
2. Install adapter G3, nipple [1] of hydraulic tester

G1, and connect them to gauge G2.
140E-5 Series 37
Reduced cylinder mode operation1 No-injection cranking 1
a Reduced cylinder mode operation means to a No-injection cranking means to crank the
run the engine with the fuel injectors of 1 or engine with the starting motor while all the
more cylinders disabled electrically to reduce injections are stopped electrically. The pur-
the number of effective cylinders. The purpose and effect of this operation are as follows.
poses and effects of this operation are as fol- q Before the engine is started after it or the
lows. machine has been stored for a long period, the
1. This operation is used to find out a cylinder no-injection cranking is performed to lubricate
which does not output power normally (or, the engine parts and protect them from sei-
combustion in it is abnormal). zure.
2. When a cylinder is selected for the reduced a Perform the no-injection operation with the
cylinder mode operation, if the engine speed engine mounted on the machine or connected
and output do not change from the normal to INSITE (bench test tool). Before perform-
operation (all-cylinder operation), that cylinder ing, see Testing method in the shop manual for
has 1 or more defects. The possible defects the machine or INSITE (bench test tool).
are as follows.
q Leakage of compression through cylinder
head gasket
q Defective injection
q Defective piston, piston ring, or cylinder
liner
q Defective valve mechanism (Moving valve
system)
q Defect in electrical system
3. Since the common rail fuel injection system
controls the injector of each cylinder electroni-
cally, the operator can perform the reduced cyl-
inder mode operation easily with switches to
find out a defective cylinder.
a Perform the reduced cylinder mode opera-
tion with the engine mounted on the
machine or connected to INSITE (bench
test tool). Before performing, see Testing
method in the shop manual for the
machine or INSITE (bench test tool).
38 140E-5 Series
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 1. Preparation work

with the return block on it to return the fuel 1) Remove tube (3) between common rail (1)
spilling from the injector to the fuel tank, test and supply pump (2).
the fuel return rate and fuel leakage according 2) Insert spacer H1 on supply pump (2) side
to the following procedure (The figure shows and tighten the removed joint bolt again.
the engine for WA500-6R). a Connect the return pipe to the fuel
tank again, too.
a Testing tools for fuel return rate and leakage a Be sure to fit the gaskets to both ends
of the spacer.
1 6151-51-8490 Spacer
2 6206-71-1770 Joint
H
5 Commercially available Measuring cylinder
6 Commercially available Stopwatch
a Prepare a receiving pan of about 20 l to

receive the fuel flowing out during the test.
140E-5 Series 39
a If the leakage from the pressure lim-

iter is in the following range, it is nor-
mal.
Leakage
Engine speed
(cc/min)
At rated output Max. 10
3) 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.
4) Connect test hose H3 to the end of joint
H2.
from coming off. 5) After finishing testing, stop the engine.
a The above is the preparation work for
testing the leakage from the pressure 3. Testing return rate from injector
limiter. a Keep the hose on the pressure limiter side
connected and keep its end in the receiv-
ing 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
from coming off.
2. Testing leakage from pressure limiter

2) Connect INSITE (bench test tool) to the
engine and set it so that it can check the
engine speed.
3) Start the engine and keep its speed to
rated output.
the leakage in 1 minute with measuring
cylinder H5. 3) Connect INSITE (bench test tool) to the
a You may test for 20 seconds and engine and set it so that it can check the
judge by multiplying the result by 3. engine speed.
40 140E-5 Series
4) Run the engine at the rated output.

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 injec-
tor is in the following range, it is nor-
mal.
Rated output Limit of return rate
speed (rpm) (spill) (cc/min)
1,600 960
1,700 1,020
1,800 1,080
1,900 1,140
2,000 1,200
6) After finishing testing, stop the engine.
4. 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
Bleeding air from fuel circuit 1 4. Turn “ON” switch (3) of electric priming pump
(2) installed to the chassis.
Reference: The electric priming pump switch is a The electric priming pump operates and
installed to the chassis. lamp (4) blinks.
a Manual priming pump is set for some models.
(See the "with EGR".)
a Bleed air from the fuel circuit in the following
cases according to this procedure.
q When the fuel filter is replaced
q When fuel is used up
q When the engine is started for the first
time after the fuel piping or supply pump is
replaced
a If the fuel filter was replaced, do not fill the
main filter and prefilter with the fuel.
1. Turn the starting switch to the “OFF” position.
2. Check that the fuel valve on the fuel tank side a The electric priming pump has a timer in it
is open. to start and stop itself automatically (See
the following figure).
3. Turn lever (1) of the air bleeding piping to the a The electric priming pump stops while the
parallel position with the piping to open the cir- lamp is blinking. This phenomenon is not
cuit valve. abnormal, however.
a If the switch is turned to the “OFF” position
while the lamp is blinking, the lamp goes
off and the electric priming pump stops.
k While the electric priming pump is
operating, pressure is applied to the
fuel circuit. Do not loosen the air
bleeding plug at this time, since the
fuel may spout out.
Reference: The operating procedure sticker is

stuck near the air bleeding piping lever.
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.
42 140E-5 Series
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 cir-
cuit valve.
9. Start the engine with the starting motor.

a Do not operate the starting motor continu-
ously 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 bleed-
ing 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 operat-
ing, crank the engine.
q If the engine does not start, repeat the
above operation.
a Do not operate the starting motor continu-
ously 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
Testing fuel system for leakage 1

k Very high pressure is generated in the high- leakage.
pressure circuit of the fuel system. If fuel a Inspect mainly around the high-pressure
leaks while the engine is running, it is dan- circuit parts coated with the color checker
gerous since it can catch fire. for fuel leakage.
After testing the fuel system or removing a If any fuel leakage is detected, repair it
its parts, test it for fuel leakage according and inspect again from step 1.
to the following procedure. a If no fuel leakage is detected, inspection is
a Clean and degrease the engine and the parts completed.
around it in advance so that you can test it eas-
ily 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.

leakage.
for fuel leakage.
4. Run the engine at low idle.

leakage.
for fuel leakage.
6. Run the engine at high idle.

leakage.
for fuel leakage.
8. Run the engine at high idle and load it.

a When testing the engine mounted on the
relieve the oil from the hydraulic pump.
44 140E-5 Series
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 Deflection (a): 13 – 16 mm (1 piece)
Adjusting
1. Loosen mounting bolts (2), (3) and (4) of alter-

nator (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).
140E-5 Series 45
Testing and adjusting fan belt tension 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 Deflection: 15 – 17 mm (When new)
19 – 21 mm (When retightened)
Adjusting
1. Loosen lock bolt of tension pulley (3).
2. Move tension pulley (3) with adjustment bolt

(2) to adjust the belt tension.
3. Tighten lock bolt of tension pulley (3).
46 140E-5 Series
Handling controller high-voltage

circuit 1
1. Before disconnecting or connecting the con-

nector 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
© 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 1

k When troubleshooting a machine, stop it in a level ground, and check that the lock pin, chocks,
and parking brake are securely fitted.
k 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.
k 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.
k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
k When disconnecting wiring, always disconnect the negative (-) terminal of the battery first.
k 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 con-
nect 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 ques-
tions to form some idea of possible causes of the failure that would produce the reported symptoms.
1. When carrying out troubleshooting, do not 3) Check other inspection items, if neces-
hurry to disassemble the components. sary.
If components are disassembled immediately 4) Some other maintenance items can be
after any failure occurs: checked externally, so check any item that
q Parts that have no connection with the fail- is considered to be necessary.
ure or other unnecessary parts will be dis- 5) Check the controller for display of an error.
assembled.
q It will become impossible to find the cause 4. Confirming failure
of the failure. Confirm the extent of the failure yourself, and
It will also cause a waste of manhours, parts, judge whether to handle it as a real failure or
or oil or grease, and at the same time, will also as a problem with the method of operation, etc.
lose the confidence of the user or operator. a When operating the machine or engine to
For this reason, when carrying out troubleshoot- reenact the troubleshooting symptoms, do
ing, it is necessary to carry out thorough prior not carry out any investigation or mea-
investigation and to carry out troubleshooting in surement that may make the problem
accordance with the fixed procedure. worse.
2. Points to ask user or operator 5. Troubleshooting

1) Have any other problems occurred apart Use the results of the investigation and inspec-
from the problem that has been reported? tion in Items 2 – 4 to narrow down the causes
2) Was there anything strange about the of failure, then use the troubleshooting matrix
machine before the failure occurred? to locate the position of the failure exactly.
3) Did the failure occur suddenly, or were a The basic procedure for troubleshooting is
there problems with the machine condition as follows.
before this? 1) Start from the simple points.
4) Under what conditions did the failure 2) Start from the most likely points.
occur? 3) Investigate other related parts or informa-
5) Had any repairs been carried out before tion.
the failure? When were these repairs car-
ried out? 6. Measures to remove root cause of failure
6) Has the same kind of failure occurred Even if the failure is repaired, if the root cause
before? of the failure is not repaired, the same failure
will occur again. To prevent this, always inves-
3. Check before troubleshooting tigate why the problem occurred. Then,
1) Check for symptoms of any abnormality in remove the root cause.
the machine and engine.
2) Be sure to check the CHECKS BEFORE
STARTING items.
2 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
Normal display mode Error code display mode
Item (While starting switch is ON or engine is running) (While starting switch is ON and engine is stopped)
When normal When error occurs When error occurs
Diagnosis lamp
indication selector OFF ON
switch
R Error code is indicated by number of flashes.
Lamp off Either lamp lights up
Y Lamp off
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
Indication in normal display mode (when diagnosis lamp indication selector switch is OFF)
q The normal display mode means the state in which the diagnosis lamp indication selector switch is kept
OFF while the starting switch is ON or the engine is running.
q While the engine controller system is operating normally in the normal state, the red lamp and yellow
lamp are turned OFF. If the system has an error, either lamp is turned ON.
Indication in error code display mode (when diagnosis lamp indication selector switch is ON)
q The error code display mode means the state in which the diagnosis lamp indication selector switch is
kept ON while the engine is stopped (with the starting switch is ON).
q In this state, the red lamp indicates the error code by the number of flashes. The yellow lamp is kept
turned OFF at this time.
q When starting the engine, turn the diagnosis lamp indication selector switch OFF. Do not turn the diag-
nosis lamp indication selector switch ON while the engine is running.
4 140E-5 Series
Error codes and failure codes list 1

For construction equipment
Machine failure
INSITE error code Failure phenomenon Reference document No.
code
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
Troubleshooting of
263 CA263 Fuel Temp. Sensor High Error electrical system
265 CA265 Fuel Temp. Sensor Low Error (E-mode), Part 1
SEN00153-02
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
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 5
Machine failure
INSITE error code Failure phenomenon Reference document No.
code
449 CA449 Rail Press. High Error 2
451 CA451 Rail Press. Sensor High Error
452 CA452 Rail Press. Sensor Low Error
553 CA553 Rail Press. High Error 1
554 CA554 Rail Press Sensor In Range Error
559 CA559 No-pressure Feed By Supply pump 1
689 CA689 Eng. Ne Speed Sensor Error
731 CA731 Eng. Bkup Speed Sensor Phase Error
757 CA757 All Engine Controller Data Lost Error
778 CA778 Eng. Bkup Speed Sensor Error
1228 CA1228 EGR Valve Servo Error 1
1625 CA1625 EGR Valve Servo Error 2
1626 CA1626 Bypass Valve Solenoid Drive Short Circuit Error
1627 CA1627 Bypass Valve Solenoid Drive Open Error
1628 CA1628 Bypass Valve Servo Error 1
1629 CA1629 Bypass Valve Servo Error 2 Troubleshooting of
electrical system
1631 CA1631 Bypass Valve Lift Sensor High Error
(E-mode), Part 2
1632 CA1632 Bypass Valve Lift Sensor Low Error SEN00154-02
1633 CA1633 KOMNET Error
1642 CA1642 EGR Inlet Press Sensor Low Error
1653 CA1653 EGR Inlet Press Sensor High Error
2185 CA2185 Throttle Sens. Sup. Volt. High Error
2186 CA2186 Throttle Sens. Sup. Volt. Low Error
2249 CA2249 No-pressure Feed By Supply pump 2
2271 CA2271 EGR Valve Lift Sensor High Error
2272 CA2272 EGR Valve Lift Sensor Low Error
2351 CA2351 EGR Valve Solenoid Drive Short Error
2352 CA2352 EGR Valve Solenoid Drive Open Error
2555 CA2555 Intake Air Heater Relay Open Error
2556 CA2556 Intake Air Heater Relay Short Error
(143) B@BAZG Eng. Oil Press Low Torque Derate
(146) B@BCNS Eng. Overheat
(415) B@BAZG Eng. Oil Press. Low Speed Derate
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.
a 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
For generator
Machine failure
Failure phenomenon Reference document No.
code
A8 Speed Adj. Vol. High (Isochronous) A8
A9 Speed Adj. Vol. Low (Isochronous) A9
AA Speed Adj. Vol. High (Droop) AA
AB Speed Adj. Vol. Low (Droop) AB
AF KOMNET Error (CR710) AF
b6 Droop Rate Adj. Vol. High b6
b7 Droop Rate Adj. Vol. Low b7 –
b8 Low Idle Speed Adj. Vol. High b8
b9 Low Idle Speed Adj. Vol. Low b9
bc Speed Adj. Vol. High (Default) bc
bd Speed Adj. Vol. Low (Default) bd
bE Ramptime Adj. Vol. High bE
bF Ramptime Adj. Vol. Low bF
CA111 Engine Controller Internal Failure
CA115 Eng. Ne and Bkup Speed Sensor Error
CA122 Charge (boost) Air Press Sensor High Error
CA123 Charge (boost) Air Press Sensor Low Error
CA135 Oil Press. Sensor High Error
CA141 Oil Press. Sensor Low Error
CA144 Coolant Temp. Sensor High Error
CA145 Coolant Temp. Sensor Low Error
CA153 Charge (boost) Air Temp. Sensor High Error
CA154 Charge (boost) Air Temp. Sensor Low Error
CA187 Sensor Sup. 2 Volt. Low Error
CA221 Ambient Air Press. Sensor High Error
Troubleshooting of
CA222 Ambient Air Press. Sensor Low Error electrical system
CA227 Sensor Sup. 2 Volt. High Error (E-mode), Part 1
SEN00153-02
CA234 Eng. Overspeed
CA238 Ne Speed Sensor Sup. Volt. Error
CA263 Fuel Temp. Sensor High Error
CA265 Fuel Temp. Sensor Low Error
CA271 PCV1 Short Error
CA272 PCV1 Open Error
CA273 PCV2 Short Error
CA274 PCV2 Open Error
CA322 Injector #1 System Open/Short Error
140E-5 Series 7
Machine failure
Failure phenomenon Reference document No.
code
CA342 Engine Controller Data Matching Error
Troubleshooting of
CA351 INJ. Drive Circuit Error electrical system
CA352 Sensor Sup. 1 Volt. Low Error (E-mode), Part 1
SEN00153-02
CA386 Sensor Sup. 1 Volt. High Error
CA441 Supply Voltage Low Error
CA442 Supply Voltage High Error
CA449 Rail Press. High Error 2
CA451 Rail Press. Sensor High Error
CA452 Rail Press. Sensor Low Error
CA553 Rail Press. High Error 1
CA559 No-pressure Feed By Supply pump 1
CA689 Eng. Ne Speed Sensor Error
CA731 Eng. Bkup Speed Sensor Phase Error
CA757 All Engine Controller Data Lost Error
CA778 Eng. Bkup Speed Sensor Error
CA1228 EGR Valve Servo Error 1
CA1625 EGR Valve Servo Error 2 Troubleshooting of
electrical system
CA1633 KOMNET Error
(E-mode), Part 2
CA2185 Throttle Sens. Sup. Volt. High Error SEN00154-02
CA2186 Throttle Sens. Sup. Volt. Low Error
CA2249 No-pressure Feed By Supply pump 2
CA2271 EGR Valve Lift Sensor High Error
CA2272 EGR Valve Lift Sensor Low Error
CA2351 EGR Valve Solenoid Drive Short Error
CA2352 EGR Valve Solenoid Drive Open Error
CA2555 Intake Air Heater Relay Open Error
CA2556 Intake Air Heater Relay Short Error
CA143 Eng. Oil Press Low Torque Derate
CA146 Eng. Overheat
8 140E-5 Series
140E-5 Series 9
Information in troubleshooting table 1

a The following information is summarized in the troubleshooting table and the related electrical circuit
diagram. Before carrying out troubleshooting, understand that information fully.
Error code Failure code

Display on Trouble Trouble in engine
Display on INSITE
applicable machine
Contents of trouble Contents of trouble detected by engine controller
Action taken by engine controller to protect system or devices when engine controller
Action of controller
detects trouble
Problem that appears
Problem that appears on engine as a result of action taken by engine controller (shown above)
on machine
Related information Information related to detected trouble or troubleshooting
Cause Standard value in normal state/Remarks on troubleshooting

<Contents of description>
• Standard value in normal state to judge possible causes
• Remarks on judgment
1
<Troubles in wiring harness>
• Disconnection
Connector is connected imperfectly or wiring harness is
broken.
• Ground fault
Wiring harness which is not connected to chassis
ground circuit is in contact with chassis ground circuit.
• Hot short
Wiring harness which is not connected to power source
(24 V) circuit is in contact with power source (24 V) cir-
2 cuit.
• Short circuit
Independent wiring harnesses are in contact with each
Possible causes and other abnormally.
Possible causes of trouble
standard value in (Given numbers are refer-
normal state ence numbers, which do not <Precautions for troubleshooting>
indicate priority) 1) Method of indicating connector No. and handling of T-
adapter
Insert or connect T-adapter as explained below for trou-
3 bleshooting, unless otherwise specified.
• If connector No. has no marks of “male” and
“female”, disconnect connector and insert T-adapters
in both male side and female side.
• If connector No. has marks of “male” and “female”,
disconnect connector and connect T-adapter to only
male side or female side.
2) Entry order of pin Nos. and handling of tester leads
Connect positive (+) lead and negative (–) lead of tester
as explained below for troubleshooting, unless other-
4 wise specified.
• Connect positive (+) lead to pin No. or wiring harness
entered on front side.
• Connect negative (–) lead to pin No. or harness entered
on rear side.
10 140E-5 Series
Related circuit diagram
This drawing is a part of the electric circuit diagram related to trouble-

shooting.
• 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
Connection table for connector pin numbers (Rev. 2009.04)
a The terms of male and female refer to the pins, while the terms of male housing and female housing
refer to the mating portion of the housing.
12 140E-5 Series
140E-5 Series 13
14 140E-5 Series
140E-5 Series 15
16 140E-5 Series
140E-5 Series 17
18 140E-5 Series
140E-5 Series 19
20 140E-5 Series
140E-5 Series 21
22 140E-5 Series
140E-5 Series 23
24 140E-5 Series
140E-5 Series 25
26 140E-5 Series
140E-5 Series 27
28 140E-5 Series
140E-5 Series 29
30 140E-5 Series
140E-5 Series 31
32 140E-5 Series
140E-5 Series 33
34 140E-5 Series
140E-5 Series 35
36 140E-5 Series
140E-5 Series 37
38 140E-5 Series
140E-5 Series 39
40 140E-5 Series
140E-5 Series 41
42 140E-5 Series
140E-5 Series 43
44 140E-5 Series
140E-5 Series 45
46 140E-5 Series
140E-5 Series 47
T- branch box and T- branch adapter table 1

(Rev. 2009.03)
a The vertical column indicates a part number of T-branch box or T-branch adapter while the horizontal
column indicates a part number of harness checker assembly.
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol
799-601-2600 T-box (for ECONO) 21 q q q q q

799-601-3100 T-box (for MS) 37 q
799-601-3200 T-box (for MS) 37 q
799-601-3380 Plate for MS (14-pin) q
799-601-3410 Adapter for BENDIX (MS) 24 MS-24P q
799-601-3470 Case q
799-601-2710 Adapter for MIC 5 MIC-5P q q q
799-601-2720 Adapter for MIC 13 MIC-13P q q q
799-601-2730 Adapter for MIC 17 MIC-17P q q q q q q
799-601-2740 Adapter for MIC 21 MIC-21P q q q q q q
799-601-2950 Adapter for MIC 9 MIC-9P q q q q
799-601-2750 Adapter for ECONO 2 ECONO2P q q
799-601-2810 Adapter for DLI 8 DLI-8P q q
799-601-2840 Extension cable (ECONO type) 12 ECONO12P q q q
799-601-2850 Case q
799-601-4350 T-box (for DRC 60, ECONO) 60 q
799-601-4360 Case q
799-601-7010 Adapter for X (T-adapter) 1 q q
799-601-7020 Adapter for X 2 X2P q q q q
799-601-7050 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 q
799-601-7070 Adapter for SWP 14 SW14P q q
799-601-7320 Adapter for SWP 16 SW16P q
799-601-7080 Adapter for M (T-adapter) 1 q q
799-601-7090 Adapter for M 2 M2P q q q q
48 140E-5 Series
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol

799-601-7340 Adapter for M 8 M8P q
799-601-7140 Adapter for S 8 S8P q q q q
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 q
799-601-7330 Adapter for S (White) 16 S16PW q
799-601-7350 Adapter for S (White) 12 S12PW q
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
799-601-7240 Case q q
799-601-7270 Case q
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 — q
799-601-9010 Adapter for DTM 2 DTM2 q q
799-601-9020 Adapter for DT 2 DT2 q q q q
799-601-9030 Adapter for DT 3 DT3 q q
799-601-9040 Adapter for DT 4 DT4 q 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
799-601-9310 Plate for HD30 (24-pin) q q q
799-601-9320 T-box (for ECONO) 24 q q q
140E-5 Series 49
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol
799-601-9330 Case q
799-601-9340 Case q
799-601-9350 Adapter for DRC 40 DRC-40 q
799-601-9360 Adapter for DRC 24 DRC-24 q
799-601-9410* Socket for engine (CRI-T2) 2 G q
Adapter for engine (CRI-T2)
799-601-9420 Adapter for engine (CRI-T3) PFUEL 3 A3 q q
Oil pressure sensor
Socket for engine (CRI-T2)
799-601-9430* 2 P q q
Socket for engine (CRI-T3) PCV
799-601-9440* Socket for engine (CRI-T2) 3 1,2,3 q
795-799-5520* Socket for engine (HPI-T2) 2 S q
Socket for engine (HPI-T2)
795-799-5530* Socket for engine (CRI-T3) 2 C q q
Temperature sensor
Socket for engine (HPI-T2)
795-799-5540* 2 A q q
Socket for engine (CRI-T3) TIM
795-799-5460 Cable for engine (HPI-T2) 3 — q
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
799-601-4140 3 FCIG q q
Atomosphere pressure
799-601-4150 Adapter for engine (CRI-T3) POIL 3 FCIB q q
799-601-4160 2 4160 q q
Oil pressure switch
799-601-4180 Adapter for engine (CRI-T3) PEVA 3 4180 q q
799-601-4190* 3 1,2,3L q q
Commonrail pressure
799-601-4230* 4 1,2,3,4C q q
Air intake pressure/temperature
799-601-4240* Socket for engine (CRI-T3) PAMB 3 1,2,3A q q
799-601-4250* Socket for engine (CRI-T3) PIM 3 1,2,3B q q
799-601-4330* Socket for engine (CRI-T3) G 3 1,2,3,G q q
799-601-4340* 2 2,PA q q
Pump actuator
Socket for engine (CRI-T3)(95)
799-601-4380* 4 1,2,3,4T q
Air intake pressure/temperature
799-601-4260 Adapter for controller (ENG) 4 DTP4 q q
799-601-4211 Adapter for controller (ENG) 50 DRC50 q
799-601-4220 Adapter for controller (ENG) 60 DRC60 q
799-601-4390* Socket for controller (95 ENG) 60 — q
799-601-4280* Box for controller (PUMP) 121 — q
799-601-9720 Adapter for controller (HST) 16 HST16A q
799-601-9710 Adapter for controller (HST) 16 HST16B q
799-601-9730 Adapter for controller (HST) 26 HST26A q
2,
Multi-adapter for
799-601-9890 3, — q
DT2 – 4 and DTM2
4,
“*” Shows not T-adapter but socket.
50 140E-5 Series
140E-5 Series 51
SEN00151-04
© 2009 KOMATSU
All Rights Reserved
52
SEN00152-03
ENGINE 1SHOP MANUAL
140E-5 Series
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
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
140E-5 Series 3
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
140E-5 Series 5
<Example of troubleshooting> Exhaust gas color is black (incomplete combustion)

Let us assume that a trouble of “Exhaust gas color is black” occurred and we checked the [Questions] and
[Check items] and found the following 3 items to be the causal symptoms; [Color of exhaust gas gradually
became black], [Power was lost gradually], and [Dust indicator is red].
6 140E-5 Series
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
S-1 Starting performance is poor 1

General causes why starting performance is poor Causes
• Defective electrical system
Cracked EGR cooler (Coolant in exhaust pipe)

• Insufficient supply of fuel
Leaking or clogged fuel piping, entry of air

Clogged air breather hole of fuel tank cap
Defective alternator (generator section)

Defective alternator (regulator section)
• Insufficient intake of air
Defective contact of valve, vale seat
Stuck, seized supply pump plunger
Defective intake air heater system

Clogged feed pump gauze filter
Defective, deteriorated battery

• Improper selection of fuel
Clogged air cleaner element
Clogged fuel filter, element

Worn piston ring, cylinder
• Coolant in exhaust pipe ("with EGR" only)
a The common rail fuel injection system (CRI) controls the fuel
Defective injector
["with EGR" only]
injection timing electrically. Accordingly, even if the starting
operation is carried out, the engine may not start until the crank-
shaft revolves 2 turns at maximum. This phenomenon does not
indicate a trouble, however.
Confirm recent repair history

Degree of use of
machine
Operated for long period E E EE E
Became worse gradually Q Q ww QQ
Starting performance
Engine starts easily when warm w w
Questions
Non-specified fuel is being used QQQQ

Replacement of filters has not been carried out according to Operation and Main-
tenance Manual w wwQQ
Engine oil must be added more frequently w
When engine is preheated or when temperature is low, preheating monitor does
not indicate normally (if monitor is installed) w
During operation, charge level monitor indicates abnormal charge (if monitor is
installed) ww
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 Q
When priming pump is operated, it makes no reaction or it is heavy wQQ
Starting motor cranks engine slowly Q w
If air bleeding plug of fuel filter is removed, fuel does not
While engine is
flow out ww
cranked with starting
w
Check items
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 w
Engine does not pick up smoothly and combustion is irregular QQ w
There is hunting from engine (rotation is irregular) QwQQ
Blow-by gas is excessive w
Inspect air cleaner directly q
When EGR cooler outlet gas piping is removed, coolant containing antifreeze
flows out (*1) ["with EGR" only] q
When compression pressure is measured, it is found to be low qq
When air is bled from fuel system, air comes out q
q
Troubleshooting
Inspect fuel filter, element directly

Inspect feed pump gauze filter directly q
Carry out troubleshooting according to “No-pressure feed by supply pump (*2)” in
E-mode q
When a cylinder is cut out for reduced cylinder mode operation, engine speed
does not change q
When starting switch is turned to HEAT, intake air heater mount does not become
warm q
Is voltage 20 – 30 V between alternator terminal B and terminal E with Yes q
engine at low idle? No q
When specific gravity of electrolyte and voltage of battery are measured, they are
low q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Clean
Clean
Clean
Clean
Remedy
8 140E-5 Series
*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, how-
ever, it is not a problem.
*2: Code [559/CA559] and code [2249/CA2249] in E-mode
140E-5 Series 9
S-2 Engine does not start 1
a) Engine does not turn Causes
Cracked EGR cooler (Coolant in exhaust pipe)

General causes why engine does not turn
Defective starting motor (safety relay section)

• Internal parts of engine seized
Defective connection of battery terminal
Defective starting motor (motor section)

→ See “S-4 Engine stops during operations.”
Defective or deteriorated battery
Defective starting circuit wiring

• Water hammer caused by coolant which entered cylinder
Broken flywheel ring gear
Defective starting switch

• Defective electrical system
Defective battery relay

• Problem in drive devices on applicable machine side
["with EGR" only]

→ Carry out troubleshooting for devices on applicable machine

Questions
Degree of use of
machine
Operated for long period E EE
Condition of horn when Horn does not sound Q Q w
starting switch is turned
ON Horn volume is low w
Battery electrolyte is low w
Battery terminal is loose w
When starting switch is turned ON, there is no operating sound from battery relay Q w
When starting switch is turned to START, starting pinion does not move out Q Q w
Check items
Speed of rotation is low Q w

When starting switch is
turned to START, start- Makes grating noise w w
ing pinion moves out, Soon disengages again w
but
Makes rattling noise and does not turn w Q Q w
Carry out troubleshooting on applicable machine side

When EGR cooler outlet gas piping is removed, coolant containing antifreeze flows out (*1).
["with EGR" only]
q
Inspect flywheel ring gear directly q
When specific gravity of electrolyte and voltage of battery are measured, they are low q
Troubleshooting
There is not voltage (20 – 30 V) between battery relay terminal B and

terminal E
q
When terminal B and terminal C of starting switch are connected,

Turn starting switch
engine starts
q
OFF, connect cord, and
carry out troubleshoot- When terminal B and terminal C at safety relay outlet are connected,
ing at ON engine starts
q
Even if terminal B and terminal C at safety relay outlet are connected,

engine does not start
q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Remedy —
10 140E-5 Series

140E-5 Series 11
b) Engine turns but no exhaust smoke comes out Causes
Defective operation of overflow valve (Does not close)

General causes why engine turns but no exhaust smoke comes out
• Fuel is not being supplied

Wrong connection of supply pump PCV

• Supply of fuel is extremely small
Seized, abnormally worn feed pump
Defective operation of flow damper

Broken supply pump shaft, key

• Improper selection of fuel (particularly in winter)
Defective supply pump PCV

Clogged fuel filter element
Insufficient fuel in tank
Defective fuel injector

Use of improper fuel
Degree of use of
Questions
machine
Operated for long period EEE
Exhaust smoke suddenly stopped coming out (when starting again) wQwww EE
Replacement of filters has not been carried out according to Operation and Main-
tenance Manual
ww E Q
When fuel tank is inspected, it is found to be empty w
Rust and water are found when fuel tank is drained QQQ QQ
When fuel filter is removed, there is not fuel in it w w
Fuel is leaking from fuel piping w
Check items
When priming pump is operated, it makes no reaction or it is heavy [“with EGR”

only]
wQQ
If air bleeding plug of fuel filter is removed, fuel does not flow
While engine is Q Q wQ
cranked with start- out
ing motor If spill hose from injector is disconnected, little fuel spills Q wwww Q
Inspect fuel filter directly q
Troubleshooting
Inspect feed pump directly q

Carry out troubleshooting according to “No-pressure feed by supply pump (*1)” in
E-mode
qq q q
Carry out troubleshooting according to “Abnormality in PCV1 (*2) or Abnormality in
PCV2 (*3)” in E-mode
q
Inspect overflow valve directly q
Engine can be started in reduced cylinder mode qq
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Clean
Clean
Remedy
Add

12 140E-5 Series
c) Exhaust smoke comes out but engine does not start (fuel is being injected) Causes
Worn dynamic valve system (Valve, rocker lever, etc.)
Defective coolant temperature sensor, wiring harness

General causes why exhaust smoke comes out but engine does not start
Leaking or clogged fuel system, entry of air

• Lack of rotating force due to defective electrical system

Defective intake air heater system

Clogged injector, defective spray
Worn piston ring, cylinder liner
Defective, deteriorated battery

Clogged fuel filter, strainer

Use of improper fuel

Degree of use of machine Operated for long period E EE E
Suddenly failed to start w w Q
Questions
Non-specified fuel is being used QQ

Replacement of filters has not been carried out according to Operation and Maintenance
Manual
w ww
Engine oil must be added more frequently w
When engine is preheated or when temperature is low, preheating monitor does not indicate
normally (if monitor is installed)
w
Air breather hole of fuel tank cap is clogged Q
Rust and water are found when fuel tank is drained ww
When fuel filter is removed, there is not fuel in it w
When priming pump is operated, it makes no reaction or it is heavy wQQ
Starting motor cranks engine slowly w
When engine is cranked, abnormal sound is generated around cylinder head w
Check items
While engine is cranked If air bleeding plug of fuel filter is removed, fuel does not flow out Q ww
with starting motor, If spill hose from injector is disconnected, little fuel spills w
When exhaust manifold is touched immediately after starting engine, temperature of some
cylinders is low
w

Inspect dynamic valve system directly q
When compression pressure is measured, it is found to be low q
Troubleshooting
Inspect fuel filter, strainer directly q

Carry out troubleshooting according to “No-pressure feed by supply pump (*1)” in E-mode q
When injector unit is tested, spray condition is bad q
When specific gravity of electrolyte and voltage of battery are measured, they are low q
Coolant temperature gauge does not indicate normally (if coolant temperature gauge is
installed)
q
When starting switch is turned to HEAT, intake air heater mount does not become warm q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Clean
Clean
Remedy
140E-5 Series 13
S-3 Engine does not pick up smoothly 1

General causes why engine does not pick up smoothly Causes
Seized turbocharger, interference of turbocharger

q Insufficient intake of air
q Insufficient supply of fuel
q Defective condition of fuel spray

Defective contact of valve and valve seat
q Improper selection of fuel
Defective EGR valve or bypass valve

q Controller is controlling in derate mode

Defective operation of flow damper
Clogged injector, defective spray

(limiting injection rate (output) because of an error in

electrical system)
(Large leakage from injector)


q EGR valve is stuck open ["with EGR" only]
Improper valve clearance

(There is much EGR gas and intake of air is insuffi-
cient)
["with EGR" only]

Degree of use of machine Operated for long period E E E E E E
Questions
Engine pick-up suddenly became worse Q w Q Q Q

Non-specified fuel is being used w w w w
Replacement of filters has not been carried out according to Operation and
Maintenance Manual w w w
Oil must be added more frequently w

Rust and water are found when fuel tank is drained w w
When priming pump is operated, it makes no reaction or it is heavy w Q Q
When exhaust manifold is touched immediately after starting engine, tempera-
ture of some cylinders is low Q w
Blue under light load w

Color of exhaust gas
w Q w w
Check items
Black
When engine is cranked, interference sound is generated around turbocharger w
High idle speed under no load is normal, but speed suddenly drops when load is
applied Q w w
There is hunting from engine (rotation is irregular) Q Q w Q

Blow-by gas is excessive w w

Carry out troubleshooting according to “Abnormality in EGR valve servo (*1)” in q
E-mode or “Abnormality in bypass valve servo (*1)” in E-mode ["with EGR" only]
When compression pressure is measured, it is found to be low q q
Troubleshooting
Inspect valve clearance directly q

When turbocharger is rotated by hand, it is found to be heavy q
Carry out troubleshooting according to “No-pressure feed by supply pump (*2)” q
in E-mode
When a cylinder is cut out for reduced cylinder mode operation, engine speed q q
does not change
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Clean
Clean
Clean
Clean
Remedy
*1: Code [1228/CA1228] and code [1625/CA1625] or code [1628/CA1628] and code [1629/CA1629] in E-
mode
14 140E-5 Series
S-4 Engine stops during operations 1

General causes why engine stops during operations Causes
Broken dynamic valve system (valve, rocker arm, etc.)
Problem in drive devices on applicable machine side

q Seized parts inside engine
Broken auxiliary equipment (pump, compressor, etc.)

q Insufficient supply of fuel
Defective engine controller power supply wiring

q There is overheating
q Problem in drive devices on applicable machine

side
Broken, seized piston, connecting rod

o Requires troubleshooting on applicable

Broken, seized crankshaft bearing
machine side.
Defective starting switch wiring

Broken supply pump shaft, key
Leaking, clogged fuel piping
Broken, seized feed pump

Broken, seized gear train
Degree of use of machine Operated for long period E E
Abnormal noise was heard and engine
w w w w Q w Q w w
stopped suddenly
Questions
Condition when engine Engine overheated and stopped w Q Q

stopped
Engine stopped slowly 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 Q
Replacement of filters has not been carried out according to Operation
w w
and Maintenance Manual
Fuel level monitor indicates low level (if monitor is installed) w
Rust and water are found when fuel tank is drained w w
w w w
Check items
Metal particles are found when oil is drained

Does not turn at all w w
When engine is cranked Turns in opposite direction w
by hand 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 w

Inspect piston, connecting rod directly q
Inspect crankshaft bearing directly q
on applicable machine side
Carry out troubleshooting
Inspect gear train directly q

Troubleshooting

Inspect feed pump directly q
Carry out troubleshooting according to “No-pressure feed by supply
q q
pump (*1)” in E-mode
Engine rotates when pump auxiliary equipment (pump, compressor, etc.)
is removed q
Inspect controller power supply wiring q

Inspect starting switch wiring q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Clean
Clean
Clean
Add
Remedy —
140E-5 Series 15
S-5 Engine does not rotate smoothly 1

General causes why engine does not rotate smoothly Causes
Defective operation of flow damper (Large leakage from injector)

q Air in fuel system
q Defective speed sensor
(Error at degree that it is not indicated)
q Defective EGR valve ["with EGR" only]
Defective operation of bypass valve ["with EGR" only]

Defective operation of EGR valve ["with EGR" only]
q Defective bypass valve ["with EGR" only]
Clogged injector, defective spray (dirt in injector)
Defective Bkup speed sensor, wiring harness

Defective Ne speed sensor, wiring harness

Low setting of low idle speed

Degree of use of machine Operated for long period E E E E
Occurs at a certain speed range Q Q Q Q Q
Questions
Occurs at low idle w Q Q Q Q Q Q Q

Condition of hunting
Occurs even when speed is raised Q Q Q Q Q
Occurs on slopes w Q Q
Replacement of filters has not been carried out according to Operation and Mainte-
nance Manual w w

w
Check items
Air breather hole of fuel tank cap is clogged

Rust and water are found when fuel tank is drained Q Q
Carry out troubleshooting according to “Abnormality in EGR valve servo (*1)” in E-mode q
["with EGR" only]
Carry out troubleshooting according to “Abnormality in bypass valve servo (*2)” in E-
q
mode ["with EGR" only]
Troubleshooting

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 q

E-mode
Carry out troubleshooting according to “Abnormality in engine Bkup speed sensor (*4)”
q
in E-mode
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Clean
Add
Remedy

*3: Code [689/CA689] in E-mode
*4: Code [778/CA778] in E-mode
16 140E-5 Series
S-6 Engine lacks output (or lacks power) 1

General causes why engine lacks output Causes
Defective installation of charge (boost) pressure sensor (air leakage)

Defective charge (boost) pressure sensor, wiring harness

• Defective spray condition of fuel
Defective fuel temperature sensor, wiring harness

Clogged injector, defective spray (dirt in injector)

Defective drive of injector (signal, solenoid)

• There is overheating

→ See “S-14 Coolant temperature becomes too high (Overheating)”
Air leakage from air intake piping

Leaking, clogged fuel piping

• Controller is controlling in derate mode (limiting injection rate (out-

put) because of an error in electrical system)

Degree of use of
machine
Operated for long period E E E E E
Q Q Q Q
Questions
Suddenly
Power was lost
Gradually Q Q Q Q Q Q Q
Non-specified fuel is being used Q Q
Replacement of filters has not been carried out according to Operation and Mainte-
nance Manual
w
Engine oil must be added more frequently Q Q Q
Output becomes insufficient after short stop of operation w
Black w w w
When exhaust manifold is touched immediately after starting engine, temperature of
some cylinders is low
w
w
Check items
When engine is cranked, interference sound is generated around turbocharger

High idle speed is too low Q
High idle speed under no load is normal, but speed suddenly drops when load is
applied
w w Q
Engine does not pick up smoothly and combustion is irregular w Q Q w
There is hunting from engine (rotation is irregular) Q Q Q Q
Inspect air intake piping directly q
When boost pressure is measured, it is found to be low q q q
Troubleshooting

Carry out troubleshooting according to “No-pressure feed by supply pump (*1)” in E-
mode
q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does
not change
q q
Inspect charge (boost) pressure sensor mount directly q
Carry out troubleshooting according to “Abnormality in charge pressure sensor (*2)” in
E-mode
q
Carry out troubleshooting according to “Abnormality in fuel temperature sensor (*3)” in
E-mode
q

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
*2: Code [122/CA122] and code [123/CA123] in E-mode Remedy

Adjust
Clean
Clean
Clean
140E-5 Series 17
S-7 Exhaust smoke is black (incomplete combustion) 1

General causes why exhaust smoke is black Causes
q Insufficient intake of air
Leakage of air between turbocharger and cylinder head

Defective EGR valve or bypass valve ["with EGR" only]
q Excessive injection of fuel

q Defective condition of fuel injection
Clogged fuel spill piping (on cylinder head side)

q Improper selection of fuel
EGR gas piping is clogged ["with EGR" only]

q There is overheating

o See “S-14 Coolant temperature becomes too high

(Overheating)”
Improper fuel injection pressure

q Controller is controlling in derate mode (limiting

injection rate (output) because of an error in electri-
Crushed, clogged muffler
Abnormally worn injector
Improper injection timing

Clogged, seized injector
cal 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)
Degree of use of
machine
Suddenly became black w Q Q Q Q
Questions

Gradually became black w w Q Q Q
color
Suddenly w Q Q Q
Power was lost
Gradually Q Q Q Q
Muffler is crushed w
Air leaks between turbocharger and cylinder head, clamp is loosened w
Engine is operated in low-temperature mode at normal temperature Q Q Q
When exhaust manifold is touched immediately after starting engine, temperature of
Q w
some cylinders is low
Check items

Torque converter stall speed or pump relief speed is high (Fuel is injected exces- Q Q
sively)
Exhaust noise is abnormal Q w Q
Engine does not pick up smoothly and combustion is irregular Q Q Q Q Q Q w
If spill hose from injector is disconnected, abnormally much fuel spills w

When turbocharger is rotated by hand, it is fount to be heavy q
Carry out troubleshooting according to “Abnormality in EGR valve servo (*1)” in E-
q
mode or “Abnormality in bypass valve servo (*1)” in E-mode ["with EGR" only]
Inspect EGR gas piping directly (*2) ["with EGR" only] q
Troubleshooting

When muffler is removed, exhaust color improves q
Carry out troubleshooting according to “No-pressure feed by supply pump (*3)” in E-
q q
mode
When a cylinder is cut out for reduced cylinder mode operation, engine speed does
q
not change
Inspect fuel spill piping (on cylinder head side) directly q
Carry out troubleshooting according to “Abnormality in coolant temperature sensor
q
(*4)” in E-mode
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Adjust
Adjust
Clean
Remedy
18 140E-5 Series
*1: Code [1228/CA1228] and code [1625/CA1625] or code [1628/CA1628] and code [1629/CA1629] in E-
mode
*2: EGR inlet pressure pipings
Remove 2 EGR inlet pressure pipings (2) and check their inside for clogging.
Reference: EGR inlet pressure sensor is applied to only machines Serial No. up to 530896.

140E-5 Series 19
S-8 Oil consumption is excessive (or exhaust smoke is blue) 1
General causes why oil consumption is excessive Causes
Turbocharger
Oil leakage from EGR valve stem ["with EGR" only]

• Abnormal consumption of oil
• Long-time operation of engine at low idle or high idle (Do not run engine
Oil leakage from oil pan, cylinder head, etc.

Worn, damaged valve (stem, guide, seal)
at idle for more than 20 minutes continuously)
• External leakage of oil
Dust sucked in from intake system
Clogged breather, breather hose

Worn seal at turbocharger end
Oil leakage from oil drain plug

• Wear of parts in lubrication system
Worn, damaged rear oil seal
Oil leakage from oil cooler
Oil leakage from oil piping

Worn seal at blower end
Oil leakage from oil filter

Broken piston ring
Broken oil cooler

Degree of use of
EEEE E
Questions
Operated for long period

machine
Oil consumption suddenly increased w Q
Oil must be added more frequently Q w Q
Oil becomes contaminated quickly Q Q w
Outside of engine is dirty with oil w w w w w
There are loose piping clamps in intake system w
Inside of turbocharger intake outlet pipe is dirty with oil w
Inside of turbocharger exhaust outlet pipe is dirty with oil Q w
Check items
There is oil in coolant w

Oil level in clutch chamber or damper chamber is high w
Exhaust smoke is blue under light load Q w w
Amount of blow-by Excessive Q Q w w
gas None w
When intake manifold is removed, dust is found inside q
When intake manifold is removed, inside is found to be dirty abnor-
q
mally
q q
Troubleshooting
Excessive play of turbocharger shaft

When EGR valve is removed, exhaust port is found to be dirty with oil
q
["with EGR" only]
Check breather and breather hose directly q
Inspect rear oil seal directly q
Pressure-tightness test of oil cooler shows there is leakage q q
There is external leakage of oil from engine q q q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
20 140E-5 Series
S-9 Oil becomes contaminated quickly 1
General causes why oil becomes contaminated quickly Causes
Clogged turbocharger lubrication drain tube

• Entry of exhaust gas into oil due to internal wear
Worn EGR valve guide ["with EGR" only]

Defective turbocharger turbine side seal
• Clogging of lubrication passage
Clogged breather, breather hose

• Use of improper fuel
Defective oil filter safety valve

• Use of improper oil
Worn valve, valve guide
Exhaust smoke is bad

• Operation under excessive load
Clogged oil cooler

Clogged oil filter
Degree of use of
Operated for long period EEEE
Questions
machine
Non-specified fuel is being used Q
Engine oil must be added more frequently Q w
Even when engine oil temperature rises, oil filter clogging monitor indi-
w Q
cates clogging (if monitor is installed)
Metal particles are found when oil is drained Q Q
Inside of exhaust pipe is dirty with oil w
Engine oil temperature rises quickly w
w
Check items
Color of exhaust gas Blue under light load

color Black w
Excessive Q Q w
Amount of blow-by gas
None w
Excessive play of turbocharger shaft q
When EGR valve is removed, exhaust port is found to be dirty with oil
q
Troubleshooting
["with EGR" only]

See S-7
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 q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Clean
Clean
Remedy —
140E-5 Series 21
S-10 Fuel consumption is excessive 1
General causes why fuel consumption is excessive Causes

• Leakage of fuel
• Defective condition of fuel injection (fuel pressure, injection timing)
• Excessive injection of fuel
Fuel leakage from fuel filter, piping, etc.
Defective common rail pressure

Fuel leakage inside head cover
Defective supply pump plunger
Defective operation of injector

Improper fuel injection timing
Defective feed pump oil seal
Defective spray by injector

Degree of use of
EE E
Questions
Operated for long period

machine
More than for other machines of same model Q Q Q Q
Condition of fuel
Gradually increased Q Q
consumption
Suddenly increased Q Q
There is external leakage of fuel from engine w
Combustion is irregular w
Engine oil level rises and oil smells of diesel fuel w w
When exhaust manifold is touched immediately after starting engine, tempera-
w
ture of some cylinders is low
Check items
Low idle speed is high Q

Torque converter stall speed or pump relief speed is high Q
Exhaust smoke Black Q Q Q Q
color White Q
Remove and inspect head cover directly q
Inspect feed pump oil seal directly q
Troubleshooting
Carry out troubleshooting according to “No-pressure feed by supply pump (*2)”

q
in E-mode
q
does not change
If spill hose from injector is disconnected, much fuel spills q
Carry out troubleshooting according to “Abnormality in coolant temperature
q
sensor (*2)” in E-mode
Confirm with INSITE or with monitoring function on applicable machine side q q
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Remedy

22 140E-5 Series
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)1
General causes why oil is in coolant Causes
Broken hydraulic oil cooler or power train oil cooler on applicable machine side
• Internal leakage in lubrication system
• Internal leakage in cooling system
Damaged cylinder liner O-ring, holes caused by pitting

Insufficient protrusion of cylinder liner
Broken cylinder head, head gasket
Internal cracks in cylinder block
Broken oil cooler core, O-ring

E E
Questions
Degree of use of machine Operated for long period

Suddenly increased Q Q Q
Oil level
Gradually increased Q Q
Hard water is being used as coolant Q Q
Oil level has risen and oil is milky Q Q w
There are excessive air bubbles in radiator, coolant spurts back w w
Check items
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

Carry out troubleshooting on
Pressure-tightness test of cylinder head shows there is leakage q

applicable machine side
Troubleshooting
Inspect cylinder block, liner directly q q
Inspect cylinder liner directly q
Pressure-tightness test of oil cooler shows there is leakage q

Replace
Replace
Replace
Replace
Replace
Remedy —
140E-5 Series 23
S-12 Oil pressure drops 1
General causes why oil pressure drops Causes
Leaking EGR hydraulic piping ["with EGR" only]

• Leakage, clogging, wear in lubrication system
Defective oil pressure sensor, wiring harness

Leaking, crushed, clogged hydraulic piping
Defective EGR oil pump ["with EGR" only]
Defective oil level sensor, wiring harness

• Defective oil pressure control
• Selection of oil by the temperature etc. specified in the Operation and Main-
tenance Manual is not observed.
Clogged, broken pipe in oil pan
Defective oil pump relief valve

• Deterioration of oil due to overheating
Clogged strainer in oil pan

Worn journal of bearing
Lack of oil in oil pan
Defective oil pump

Coolant, fuel in oil
Clogged oil filter

Degree of use of
Operated for long period E E E
Questions
machine
Oil pressure monitor indicates low oil pressure (if monitor is installed) Q w
Non-specified oil is being used Q Q
Replacement of filters has not been carried out according to Operation and
w
Maintenance Manual
Indicates pressure drop at low idle w Q Q
Oil pressure Indicates pressure drop at low, high idle Q w w w Q Q Q
monitor
Indicates pressure drop on slopes w
(if installed)
Sometimes indicates pressure drop w Q Q
Oil level monitor indicates oil level drop (if monitor is installed) w w
Oil level in oil pan is low w
External hydraulic piping is leaking, crushed w w
Check items
Oil is milky or smells of diesel oil w

Metal particles are found when oil pan is drained w
Metal particles are found when oil filter is drained w Q Q
Metal particles are found in oil filter q

Inspect oil pan strainer, pipe directly q q
Oil pump rotation is heavy, there is play in oil pump q
Troubleshooting
Valve and spring of oil pump relief valve are fatigued, damaged q
See S-13
Inspect oil filter directly q

Relief valve of EGR oil pump is damaged, oil leaks from it ["with EGR" only] q
Inspect EGR hydraulic piping directly ["with EGR" only] q
Carry out troubleshooting according to “Abnormality in oil pressure sensor
q
(*1)” in E-mode
If oil level sensor is replaced, oil pressure monitor indicates normally q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Clean
Clean
Remedy —
Add
24 140E-5 Series
S-13 Oil level rises (Entry of coolant/fuel) 1
General causes why oil level rises Causes
Clogged water pump drain hole (breather hole), defective seal

• Coolant in oil (milky)
Defective seal of auxiliary equipment (pump, compressor)

Cracked EGR cooler (Entry of coolant) ["with EGR" only]
• Fuel in oil (smells diluted diesel fuel)
Damaged cylinder liner O-ring, holes caused by pitting

a If oil is in coolant, carry out troubleshooting for “S-11 Oil is in coolant”

Fuel leakage inside head cover
Broken oil cooler core, O-ring

Worn, damaged rear oil seal
Cracks inside cylinder block
Defects in supply pump

Questions
Degree of use of
Operated for long period EE E E
machine
Fuel must be added more frequently w w
Coolant must be added more frequently Q Q
There is oil in coolant Q Q Q w
Oil smells of diesel fuel w w
Oil is milky Q Q
When engine is started, drops of water come from muffler Q Q
When radiator cap is removed and engine is run at low idle, an abnormal number of
w Q
bubbles appear, or coolant spurts back
Check items
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]
Troubleshooting
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
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Remedy
140E-5 Series 25

26 140E-5 Series
S-14 Coolant temperature becomes too high (overheating) 1
General causes why coolant temperature becomes too high Causes
External leakage of coolant from EGR cooler ["with EGR" only]
Rise in power train oil temperature on applicable machine side

• Lack of cooling air (deformation, damage of fan)
• Drop in heat dissipation efficiency
Damaged cylinder liner O-ring, hole caused by pitting

• Problem in coolant circulation system
• Rise in oil temperature in power train
Defective radiator cap (pressure valve)

→ Carry out troubleshooting for machine
Defective coolant temperature gauge

Defective operation of thermostat
Slipping fan belt, worn fan pulley

Clogged, crushed radiator fins
Clogged, broken oil cooler
Clogged radiator core

Broken water pump
Lack of coolant
Degree of use of
Questions
machine
Condition of Sudden overheated Q Q w Q
overheating Always tends to overheat Q w w Q
Coolant temperature Rises quickly Q w
gauge (if installed) Does not go down from red range w
Radiator coolant level monitor indicates drop of coolant level (if monitor is installed) Q w
Engine oil level has risen, oil is milky w Q
Fan belt tension is low w
When fan pulley is turned, it has play w
Milky oil is floating on coolant w
There are excessive air bubbles in radiator, coolant spurts back w
When light bulb is held behind radiator core, no light passes through w
Check items
Radiator shroud, inside of underguard on applicable machine side are clogged with
w w
dirt or mud
Coolant is leaking because of cracks in hose or loose clamps w
Coolant flows out from radiator overflow hose w
Fan belt whines under sudden acceleration w
Power train oil temperature enters red range faster than engine coolant temperature
w
(if oil temperature gauge and coolant temperature gauge are installed)
Inspect EGR cooler for coolant leakage ["with EGR" only] q

Carry out troubleshooting on applicable machine

Inspect cylinder liner directly q
Inspect oil cooler directly q
Troubleshooting
Temperature difference between upper and lower tanks of radiator is large q

When operation of thermostat is carried out, it does not open at cracking tempera-
q
ture
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
When coolant temperature is measured, it is fount to be normal q

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Remedy —
Add
140E-5 Series 27
S-15 Abnormal noise is made 1
General causes why abnormal noise is made Causes
Defective inside of muffler (dividing board out of position)
Deformed cooling fan, loose fan belt, interference of fan

Leakage of air between turbocharger and cylinder head
• Abnormality due to defective parts
Cracked, leaking EGR gas piping ["with EGR" only]

Broken dynamic valve system (valve, rocker lever)
Interference of turbocharger, seized turbocharger
• Abnormal combustion
(abnormality in coolant temperature sensor)

Excessive wear of piston ring, cylinder liner
• Air sucked in from intake system
Removed, seized gear train bushing

a Judge if the noise is an internal noise or an external noise before
starting troubleshooting.
Improper fuel injection timing

Improper gear train backlash
a The engine is operated in the low-temperature mode while it is not
Clogged, seized injector

warmed up sufficiently. Accordingly, the engine sound becomes a
Dirt caught in injector

little larger. This does not indicate abnormality, however.
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 sec-
onds. This does not indicate abnormality, however.
belt
Degree of use of
Operated for long period E
Questions
machine
Condition of Gradually occurred Q Q
abnormal noise Sudden occurred Q Q Q Q
Non-specified fuel is being used Q
Metal particles are found when oil filter is drained w w
Air leaks between turbocharger and cylinder head w
When engine is cranked, abnormal sound is generated around EGR gas piping
w
["with EGR" only]
When engine is cranked, abnormal sound is generated around cylinder head w w
When engine is cranked, beat noise is generated around muffler w
Check items
When exhaust manifold is touched immediately after starting engine, temperature

w Q
of some cylinders is low
Color of exhaust Blue under light load w
gas Black Q w Q
Engine does not pick up smoothly and combustion is irregular w
Abnormal noise is loud when engine is accelerated Q Q Q Q
Blow-by gas is excessive w
When turbocharger is rotated by hand, it is fount to be heavy q
Inspect EGR gas piping directly ["with EGR" only] q
When muffler is removed, abnormal noise disappears q
Troubleshooting

Inspect gear train directly q q
Inspect fan and fan belt directly q
q q
does not change
Abnormal noise is heard only when engine is started q
Confirm with INSITE or with monitoring function on applicable machine side q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Remedy
28 140E-5 Series
S-16 Vibration is excessive 1
General causes why vibration is excessive Causes
Misalignment between engine and devices on applicable machine side

• Defective parts (abnormal wear, breakage)
Broken output shaft, parts in damper on applicable machine side

• Misalignment between engine and chassis
• Abnormal combustion
a If abnormal noise is made and vibration is excessive, carry out trou-

bleshooting for “S-15 Abnormal noise is made”, too.
Stuck dynamic valve system (valve, rocker lever)
Loose engine mounting bolts, broken cushions

Worn main bearing, connecting rod bearing
Worn front support spigot joint portion

Improper gear train backlash
Worn camshaft bushing
Degree of use of
Questions
Operated for long period EE E

machine
Condition of Suddenly increased Q Q
vibration Gradually increased Q Q Q Q
Metal particles are found when oil filter is drained w w
Metal particles are found when oil pan is drained w w
Oil pressure is low at low idle Q Q
Check items
Vibration occurs at mid-range speed Q Q

Vibration follows engine speed Q Q Q Q Q
Exhaust smoke is black w

Inspect main bearing and connecting rod bearing directly q
Troubleshooting
Inspect gear train directly q

Inspect camshaft bushing directly q
Inspect engine mounting bolts and cushions directly q
When alignment is checked, radial runout or facial runout is detected q
Inspect front support spigot joint portion directly q
Inspect output shaft or inside of damper directly Q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Adjust
Remedy
140E-5 Series 29
SEN00152-03
© 2009 KOMATSU
All Rights Reserved
30
SEN00153-03
ENGINE 1SHOP MANUAL
140E-5 Series
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
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-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
Troubleshooting of electrical system (E-mode), Part 1 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

q CA123: Charge air pressure sensor low error (for "EGR-less" only)
q CA222: Ambient pressure sensor low error
Procedure
1. Measure and record resistance of pressure sensor unit.
1) Disconnect pressure sensor connector (1) and connect socket (2) to the sensor.
2) Measure resistances R1 and R2 between pins.
a If tester probes polarities to apply are reversed, measured values may change. Therefore, when
measuring resistances, apply the same tester probe polarities to the pressure sensor in steps 1 and
2.
a If measured value is infinite, take measurements with tester probes polarities exchanged each oth-
er and record the finite value obtained as a measured value.
a Since measured values may be different from each other, take several measurements. Cause of
the differences appears to be that the sensor may be charged by the tester. Take several measure-
ment in both steps 1 and 2. Take the fact into consideration this differences when determining
whether the wiring harness is disconnected in step 3.
2. Measure and record resistance with wiring harness between pressure sensor and engine controller
connected
1) Since 5 V power supply to pressure sensor is supplied to other sensors, disconnect the other sensor
connectors first.(*)
2) Connect the pressure sensor to be measured, disconnect connector (3) on engine controller side, and
connect T-adapter (4) to wiring harness side.
3) Connect T-box (5) to T-adapter (4) and measure respective pins for resistances R1' and R2'.
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
a "Apparent difference" means a difference of 10 or more times.
List of pressure sensor measuring locations and reference values

Internal resistance of measured
Measuring location at
Sensor sensor Remarks
sensor pin
(Reference value)
R2: Between (1) and (3) Approx. 2.9kz Sensor is common to engine mod-
Charge pressure
els 140 for EGR-less, 125, 170 and
sensor R1: Between (2) and (3) Approx. 4.3kz 12V140
Sensor is common to engine mod-
R2: Between (1) and (3) Approx. 3.2kz
els 95, 125, 140, 170 and 12V140
Ambient pressure R1: Between (2) (+) and
Approx. 4.6kz
sensor (1) (-) If polarities are reversed, resis-
R1: Between (1) (+) and tance value changes.
Approx. 2.9kz
(2) (-)
*: When measuring R2', disconnect the following connectors. (See circuit diagram related to code [187/
CA187])
q When measuring R2' of charge pressure sensor
(CA123)
Connectors of resistance RES, engine oil pressure sensor, ambient pressure sensor, and G sensor
q When measuring R2' of ambient pressure sen-
sor (CA222)
Connectors of charge pressure sensor, resistance RES, engine oil pressure sensor, and G sensor
4 140E-5 Series
Measurement record (For measuring locations, see circuit diagram related to each code)
Sensor + Wiring harness
Sensor unit (Measuring
(Measuring location on
Sensor location on sensor pin Measured value Measured value
wiring harness side of
side)
engine controller)
R1: Between (1) (+) and
R2: Between (1) and (3)
Charge pressure (2) (-)
sensor R1': Between (44) and
(47)
R2': Between (37) and
(38) (*)
Ambient pressure R1: Between (2) (+) and R1': Between (3) (+)
sensor (1) (-) and (38) (-)
R1: Between (1) (+) and R1': Between (38) (+)
(2) (-) and (3) (-)
140E-5 Series 5
E-1 Code [111/CA111] Engine Controller Internal Failure 1

Trouble Abnormality in engine controller
111 CA111
Contents of trouble • Abnormality occurred in controller.
Action of controller • None in particular.
• 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.

Check fuse or circuit breaker on machine side directly for
defect.
1 Defective fuse
(If fuse is broken or circuit breaker is turned OFF, circuit proba-
bly has ground fault.)
a Prepare with starting switch OFF, then carry out trouble-
Disconnection in wiring har- shooting without turning starting switch ON.
ness (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)
Possible causes and Resistance Max. 1 z
(1), (2) – chassis ground
standard value in
normal state
shooting 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
E-2 Code [115/CA115] Eng. Ne and Bkup Speed Sensor Error 1

Trouble Abnormality in engine Ne and Bkup sensors
115 CA115
Contents of trouble • Abnormality occurred in Ne speed sensor circuit and Bkup speed sensor circuit simultaneously.
Problem that appears • Engine cannot be started (if engine has been stopped).
on machine • Engine stops (if engine has been running).
Related information

Defective Ne speed sensor
1 Carry out troubleshooting for code [689/CA689].
system
Defective Bkup speed sen-
2 Carry out troubleshooting for code [778/CA778].
sor system
Defective mount of Ne Check mount of Ne speed sensor directly for defect (defective
Possible causes and 3
speed sensor installation of sensor, internal trouble of flywheel, etc.)
standard value in
normal state Defective mount of Bkup Check mount of Bkup speed sensor directly for defect (defec-
4
speed sensor tive installation of sensor, internal trouble of supply pump, etc.)
Defective connection Check Ne speed sensor and Bkup speed sensor directly for
5
(Wrong connection) defective connection (wrong connection).
If causes 1 – 5 are not detected, engine controller may be
6 Defective engine controller defective. (Since trouble is in system, troubleshooting cannot
be carried out.)
140E-5 Series 7
E-3 Code [122/CA122] Charge (boost) Air Press Sensor High Error 1
a For “with EGR”

Trouble Abnormally high level in charge (boost) pressure sensor
122 CA122
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.
• Acceleration performance of engine drops.
on machine
• If sensor connector is disconnected, code [123/CA123] for "Low Error" is displayed, even in
Related information
normal condition.

Defective sensor power If code [187/CA187] or [227/CA227] is indicated, carry out trou-
1
supply system bleshooting for it first.
1. Turn starting switch to OFF position.
2. Disconnect connector PIM.
Defective charge boost 3. Turn starting switch to ON position.
2
pressure sensor
If code changes from [122/CA122] to [123/CA123], charge
(boost) pressure sensor is defective.
1. Turn starting switch to OFF position, then perform trouble-
shooting.
Possible causes and Short circuit in wiring har- 2. Disconnect connectors ENG and PIM, and connect T-adapter
3
standard value in ness to female side of ENG.
normal state Between ENG (female) (37) and (44) Resistance Min. 1 Mz
2. Disconnect connector PIM, and connect T-adapter to female
Hot short circuit in wiring side or insert T-adapter into connector ENG.
4 harness 3. Turn starting switch to ON position (with connector PIM
(contact with 24 V circuit) disconnected).
Between PIM (female) (3) and (2), or
Voltage Max. 1 V
between ENG (44) and (47)
If no failure is found by above checks, engine controller is defec-
Defective engine control-
5 tive. (Since this is an internal failure, troubleshooting cannot be
ler
performed.)
8 140E-5 Series
Circuit diagram related to charge (boost) pressure sensor

140E-5 Series 9
a For “EGR-less”

Trouble Abnormally high level in charge (boost) pressure sensor
122 CA122
Contents of trouble • Signal voltage in charge (boost) pressure sensor circuit is abnormally high.
on machine
• If sensor connector is disconnected, code [123/CA123] for "Low Error" is displayed, even in
Related information
normal condition.

1
2. Disconnect connector PIM.
Defective charge boost 3. Turn starting switch to ON position.
2
pressure sensor
If code changes from [122/CA122] to [123/CA123], charge
(boost) pressure sensor is defective.
shooting.
Possible causes and Short circuit in wiring har- 2. Disconnect connectors ENG and PIM, and connect T-adapter
standard value in 3
ness to female side of ENG.
normal state
Between ENG (female) (37) and (44) Resistance Min. 1 Mz
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
Between ENG (44) and (47) Voltage Max. 1 V
ler
performed.)
10 140E-5 Series

140E-5 Series 11
E-4 Code [123/CA123] Charge (boost) Air Press Sensor Low Error 1

Trouble Abnormally low level in charge (boost) pressure sensor
123 CA123
Contents of trouble • Signal voltage in charge (boost) pressure sensor circuit is abnormally low.
on machine
Related information • If sensor connector is disconnected, this code is displayed.
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 Power 4.75 –
Voltage
(2) input 5.25 V
2. Disconnect connectors ENG and PIM and connect T-
adapters to each female side.
Open circuit in wiring har- Between ENG (female) (37) and PIM Resis- Max.
ness (female) (1) tance 1z
2
(wire breakage or defective
contact of connector) Between ENG (female) (44) and PIM Resis- Max.
(female) (3) tance 1z
Between ENG (female) (47) and PIM Resis- Max.
(female) (2) tance 1z
Possible causes and 1. Turn starting switch to OFF position.
standard value in 2. Disconnect connectors ENG and PIM.
Short circuit in wiring har- 3. Connect T-adapter to female side of ENG.
normal state 3
ness
Resis- Min.
Between ENG (female) (44) and (47)
tance 1 Mz
shooting.
Ground fault in wiring har- 2. Disconnect connectors ENG and PIM, and connect T-
4 ness adapters to either female side.
(contact with ground circuit)
Between ENG (female) (44) or PIM Resis- Min.
(female) (3) and ground tance 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 defec-
tive.
Defective boost pressure 1. Turn starting switch to OFF position.
5 2. Insert T-adapter into connector ENG or PIM.
sensor
Between ENG (44) and (47), or Sensor 0.3 – 4.7
Voltage
between PIM (3) and (2) output V
If no failure is found by above checks, engine controller is
6 Defective engine controller defective. (Since this is an internal failure, troubleshooting
cannot be performed.)
12 140E-5 Series

a For "with EGR"
140E-5 Series 13
a For "EGR-less"
Defective power supply sys-
If code [187/CA187] or [227/CA227] is indicated, carry out
1 tem of charge pressure sen-
sor (boost pressure sensor)
2. Disconnect connectors ENG and PIM.
2
ness
Resis- Min.
tance 1 Mz
1. Turn starting switch to OFF position, then carry out trouble-
shooting.
Ground fault in wiring har- 2. Disconnect connectors ENG and PIM, and connect T-
3 ness adapter to female side of ENG.
Possible causes and (contact with ground circuit)
standard value in Resis- Min.
Between ENG (female) (44) and ground
normal state tance 1 Mz
Disconnection in wiring har- If cause is not found by the above checks, wiring harness may
4
ness be disconnected. (*)
a If causes 1 - 4 are not the cause for the trouble and check
result of cause 5 is abnormal, sensor is defective.
Defective charge pressure 1. Turn starting switch to OFF position.
(boost pressure) sensor 2. Connect T-adapter to connector ENG.
5
(lmproper input voltage of 3. Turn starting switch to ON position.
engine controller)
Sensor 0.3 – 4.7
Between ENG (44) and (47) Voltage
output V
If no abnormality is found by the above checks, the engine
controller is defective.
(Since the failure is in it, troubleshooting cannot be per-
formed.)
*: Refer to "Troubleshooting method for disconnected wiring harness of pressure sensor system."
14 140E-5 Series

a For "EGR-less"
140E-5 Series 15
E-5 Code [131/CA131] Throttle Sensor High Error 1

Throttle sensor of accelerator pedal type (Case of HD325/405-7)

Trouble Abnormally high level in throttle sensor
131 CA131
Contents of trouble • 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).
• Different problems occur on different machine models.
on machine

Defective sensor power If code [2185/CA2185] or [2186/CA2186] is indicated, carry
1
supply system out troubleshooting for it first.
Accelerator
WAS1 Voltage
pedal
All range
Between (1) – (3) 4.75 – 5.25 V
(Power supply)
Defective accelerator pedal
2 (9 ± 2% of source
(Internal trouble) 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.
Disconnection in wiring har- Wiring harness between E02 (female)
Resistance Max. 1 z
ness (Disconnection in wir- (22) – WAS1 (female) (1)
3
ing or defective contact in Wiring harness between E02 (female)
connector) Resistance Max. 1 z
Possible causes and (9) – WAS1 (female) (2)
standard value in Wiring harness between E02 (female)
normal state Resistance Max. 1 z
(23) – WAS1 (female) (3)
Wiring harness between E02 (female)
(22) – WAS1 (female) (1) and chassis Resistance Min. 1 Mz
Ground fault in wiring har- ground
4 ness (Short circuit with GND Wiring harness between E02 (female)
circuit) (9) – WAS1 (female) (2) and chassis Resistance Min. 1 Mz
ground
ground
Accelerator
E02 Voltage
pedal
All range
5 Defective engine controller Between (22) – (23) 4.75 – 5.25 V
(Power supply)
(9 ± 2% of source
Released
voltage)
Between (9) – (23)
(73 ± 2% of source
Pressed
voltage)
16 140E-5 Series
Circuit diagram related to throttle sensor of accelerator pedal type (Case of HD325/405-7)
140E-5 Series 17
1
Throttle sensor of fuel control dial type (Case of PC800/800SE/850/850SE/850LC-8)

Trouble Abnormally high level in throttle sensor
131 CA131
Contents of trouble • Signal voltage in throttle sensor circuit is abnormally high.
each model).
on machine

Defective sensor power If code [2185/CA2185] or [2186/CA2186] is indicated, carry
1
supply system out troubleshooting for it first.
Defective fuel control dial P20 (male) Resistance

2
(Internal trouble) Between (1) – (3) 4.0 – 6.0 kz
Between (2) – (1) 0.25 – 5.0 kz
Between (2) – (3) 0.25 – 5.0 kz
Resistance Max. 1 z
ness (Disconnection in wir- (22) – P20 (female) (1)
3
(9) – P20 (female) (2)
Possible causes and Wiring harness between E02 (female)
standard value in Resistance Max. 1 z
(23) – P20 (female) (3)
normal state
(22) – P20 (female) (1) and chassis Resistance Min. 1 Mz
circuit) (9) – P20 (female) (2) and chassis Resistance Min. 1 Mz
ground
(23) – P20 (female) (3) and chassis Resistance Min. 1 Mz
ground
5 Defective engine controller E02 Voltage
Between (22) – (23) Power supply 4.75 – 5.25 V
Between (9) – (23) Signal 0.5 – 4.5 V
18 140E-5 Series
Circuit diagram related to throttle sensor of fuel control dial type

(Case of PC800/800SE/850/850SE/850LC-8)
140E-5 Series 19
E-6 Code [132/CA132] Throttle Sensor Low Error 1

Trouble Abnormally low level in throttle sensor
132 CA132
Contents of trouble • Signal voltage in throttle sensor circuit is abnormally low.
each model).
on machine
Related information
Possible causes and Cause Standard value in normal state/Remarks on troubleshooting

standard value in
normal state Carry out troubleshooting for E-5 Code [131/CA131].
20 140E-5 Series
140E-5 Series 21
E-7 Code [135/CA135] Oil Press. Sensor High Error 1

Trouble Abnormally high level in oil pressure sensor
135 CA135
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.
on machine
Related information

1
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.
2. Disconnect connectors ENG and POIL, and connect T-
Short circuit in wiring har- adapters to either female side.
Possible causes and 3
ness
standard value in Between ENG (female) (13) and (37), or
normal state between POIL (female) (1) and (3)
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
Between ENG (female) (13) and (47), or
Voltage Max. 1 V
between POIL (female) (3) and (2)
ler
performed.)
22 140E-5 Series
Circuit diagram related to oil pressure sensor

a There is connector PEVA only for serial No. up to 530896.
140E-5 Series 23
E-8 Code [141/CA141] Oil Press. Sensor Low Error 1

Trouble Abnormally low level in oil pressure sensor
141 CA141
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.
on machine
Related information

If code [187/CA187] or [227/CA227] is displayed, carry out
Defective power supply sys-
2. Disconnect connector POIL and connect T-adapter to
1 tem of engine oil pressure
female side.
sensor
Between POIL (female) (1) and Power 4.75 –
Voltage
(2) input 5.25V
2. Disconnect connectors ENG and POIL and connect T-
adapters to each female side.
a If power supply input in checks on
cause 1 is normal, this check is not re-
Resis-
quired. Max. 1 z
Open circuit in wiring har- tance
Between ENG (female) (37) and POIL
ness (female) (1)
2
(wire breakage or defective
contact of connector) a If power supply input in checks on
cause 1 is normal, this check is not re-
Resis-
quired. Max. 1 z
tance
Between ENG (female) (47) and POIL
Possible causes and (female) (2)
standard value in
Between ENG (female) (13) and POIL Resis-
normal state Max. 1 z
(female) (3) (Sensor output) tance
Ground fault of wiring har- 2. Disconnect connectors ENG and POIL, and connect T-
3 ness adapters to either female side.
(contact with ground circuit) Between ENG (female) (13) or POIL Resis- Min.
(female) (3) and ground tance 1 Mz
2. Disconnect connectors ENG and POIL, and connect T-
Short circuit in wiring har- adapters to either female side.
4
ness
Between ENG (female) (13) and (47), or Resis- Min.
between POIL (female) (2) and (3) tance 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.
Defective engine oil pres- 1. Turn starting switch to OFF position.
5 sure sensor (improper input 2. Insert T-adapter into connector ENG or POIL.
voltage to engine controller) 3. Turn starting switch to ON position.
Between ENG (13) and (47), or Sensor 0.3 – 4.7
Voltage
between POIL (3) and (2) output V
6 Defective engine controller defective. (Since this is an internal failure, troubleshooting can-
not be performed.)
24 140E-5 Series
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
E-9 Code [144/CA144] Coolant Temp. Sensor High Error 1

Trouble Abnormally high level in coolant temperature sensor
144 CA144
Contents of trouble • Signal voltage in coolant temperature sensor circuit is abnormally high.
Action of controller • Fixes coolant temperature (90°C) and continues operation.
• Engine starting performance decreases during low temperature.
on machine
• This failure code is generated if temperature sensor connector is disconnected.
• Because troubleshooting "socket" for this sensor features female connector alone, it is not
Related information
connectable to female connector of sensor wiring harness, and thus not usable for checking
open circuit (not designed as a T-adapter).

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.
30 –
0 °C Resistance
37 kz
Defective coolant tempera-
1 9.3 –
ture sensor 25 °C Resistance
Between TWTR (male) (A) 10.7 kz
and (B) 3.2 –
50 °C Resistance
a Coolant temperature -Re- 3.8 kz
Possible causes and sistaure characteristics 1.0 –
standard value in 80 °C Resistance
1.3 kz
normal state
700 –
95 °C Resistance
800 z
2. Disconnect connector ENG and connect T-adapter to
female side.
Open or short circuit in wir- Between ENG (female) (15) and (38)
2 (Coolant temperature: Min. 0 °C)
ing harness
a The resistance is the same as that 700 z –
Resistance
shown in the resistance character- 37 kz
istics table of the coolant tempera-
ture sensor of cause 1.
26 140E-5 Series
Circuit diagram related to coolant temperature sensor

a There are not connector SBP and line to the SBP for “EGR-less” in above figure.
140E-5 Series 27
E-10 Code [145/CA145] Coolant Temp. Sensor Low Error 1

Trouble Abnormally low level in coolant temperature sensor
145 CA145
Contents of trouble • Signal voltage in coolant temperature sensor circuit is abnormally low.
Action of controller • Fixes coolant temperature (90°C) and continues operation.
on machine
• If temperature sensor connector is disconnected, this failure code is not generated but code
Related information
[144/CA144] for "High Error" is generated.

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.
Resis- 30 –
0 °C
tance 37 kz
Resis- 9.3 –
25 °C
Between TWTR (male) (A) and tance 10.7 kz
Defective coolant tempera-
1 (B) Resis- 3.2 –
ture sensor 50 °C
a Coolant temperature-Resis- tance 3.8 kz
taure characteristics Resis- 1.0 –
80 °C
tance 1.3 kz
Resis- 700 –
95 °C
tance 800 z
Whole
Possible causes and coolant
standard value in Resis- Min.
Between (B) and ground tempera-
normal state tance 1 Mz
ture
range
female side.
Short circuit in wiring har- Between ENG (female) (15) and (38)
2 (Coolant temperature: Min. 0 °C)
ness
a The resistance is the same as that Resis- 700 z –
shown in the resistance characteristics tance 37 kz
table of the coolant temperature sen-
sor of cause 1.
Ground fault of wiring har- 2. Disconnect connectors ENG and TWTR, and connect T-
(contact with ground circuit) Resis- Min.
tance 1 Mz
not be performed.)
28 140E-5 Series
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
E-11 Code [153/CA153] Charge (boost) Air Temp. Sensor High Error 1

Trouble Abnormally high level in charge (boost) temperature sensor
153 CA153
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.
on machine
• Because troubleshooting "socket" for this sensor features female connector alone, it is not con-
nectable to female connector of sensor wiring harness, and thus not usable for checking open
Related information
circuit (not designed as a T-adapter).

2. Disconnect connector TIM and connect socket to male side.
a If temperature sensor has resistance of 280 z - 382 kz, re-
gard boost temperature sensor as normal.
291 –
-40 °C Resistance
382 kz
85 –
-20 °C Resistance
109 kz
Defective boost tempera- 29 –
1 0 °C Resistance
ture sensor Between TIM (male) (A) and 36 kz
(B) 7.3 –
30 °C Resistance
a Boost temperature-Resis- 8.8 kz
tance characteristic 2.3 –
Possible causes and 60 °C Resistance
standard value in 2.7 kz
normal state 860 –
90 °C Resistance
970 z
280 –
130 °C Resistance
320 z
female side.
2
ing harness a The resistance is the same as that
280 z –
shown in the resistance character- Resistance
382 kz
not be performed.)
30 140E-5 Series
Circuit diagram related to charge (boost) temperature sensor

a Pin number of connector PIM is not "2" but "3" for “EGR-less” in above figure.
140E-5 Series 31
E-12 Code [154/CA154] Charge (boost) Air Temp. Sensor Low Error 1

Trouble Abnormally low level in charge (boost) temperature sensor
154 CA154
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.
on machine
• If temperature sensor connector is disconnected, this failure code is not generated but code
Related information
[153/CA153] for "High Error" is generated.

2. Disconnect connector TIM and connect socket to male side
of.
a If temperature sensor has resistance of 280 z - 382 kz, re-
gard boost temperature sensor as normal.
Resis- 291 –
-40 °C
tance 382 kz
Resis- 85 –
-20 °C
tance 109 kz
Defective boost tempera- Resis- 29 –
1 0 °C
ture sensor tance 36 kz
Between TIM (male) (A) and
(B) Resis- 7.3 –
30 °C
a Boost temperature-Resis- tance 8.8 kz
tance characteristic Resis- 2.3 –
60 °C
tance 2.7 kz
Possible causes and Resis- 860 –

90 °C
standard value in tance 970 z
normal state Resis- 280 –
130 °C
tance 320 z
female side.
2
ness a The resistance is the same as that
Resis- 280 z –
shown in the resistance characteristics
tance 382 kz
sor of cause 1.
Ground fault of wiring har- 2. Disconnect connectors ENG and TIM and connect T-
tance 1 Mz
not be performed.)
32 140E-5 Series
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
E-13 Code [187/CA187] Sensor Sup. 2 Volt. Low Error 1

Trouble Abnormally low level in sensor power supply 2 circuit
187 CA187
Contents of trouble • Signal voltage in sensor power supply 2 (5 V) circuit is abnormally low.
• 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 opera-
tion.
• Fixes charge (boost) pressure sensor value (400 kPa {4.08 kg/cm2}) and continues operation.
Action of controller • Sets EGR inlet pressure sensor to default value (102 kPa {1.04 kg/cm2}) and continues opera-
tion. ["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]
• Output drops.
on machine
Related information

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 posi-
tion.
If this failure code is not displayed when a connector is discon-
nected, that sensor or engine wiring harness is defective.
a Other failure codes are displayed, too. This is because the
connector is disconnected. Ignore codes other than [187/
CA187].
Defective sensor or wiring
1 Sensor or harness Connector
harness
Bkup speed sensor G connector
Oil pressure sensor POIL connector
Possible causes and
standard value in Boost pressure sensor PIM connector
normal state 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
2 Defect in related system
it.
2. Disconnect connector ENG and connect T-adapter to male
side.
3 Defective engine controller 3. Turn starting switch to ON position with connector ENG
disconnected.
4.75 –
Between ENG (male) (37) and (47) Voltage
5.25 V
*: "with EGR" only

**: "only early model of "with EGR", serial No. up to 530896.
34 140E-5 Series
Circuit diagram related to sensor power supply 2 (5 V)

a For serial No. up to 530896 "with EGR"
140E-5 Series 35

a For serial No. and up 530897 "with EGR"
36 140E-5 Series

a For "EGR-less"
140E-5 Series 37
E-14 Code [221/CA221] Ambient Air Press. Sensor High Error 1


Trouble Abnormally high level in atmospheric pressure sensor
221 CA221
Contents of trouble • Signal voltage in atmospheric pressure sensor circuit is abnormally high.
• Sets atmospheric pressure to default value (52.44 kPa {0.53 kg/cm2}) and continues opera-
tion.
• Output drops.
on machine
Related information

1
2. Disconnect connector PAMB.
Defective ambient pres- 3. Turn starting switch to ON position.
2
sure sensor
If code changes from [221/CA221] to [222/CA222], sensor is
defective.
Possible causes and Short circuit in wiring har- 2. Disconnect connector ENG and PAMB, and connect T-
standard value in 3 adapter to female side of ENG.
ness
normal state Between ENG (female) (37) and (3) Resistance Min. 1 Mz
2. Disconnect connector PAMB.
Hot short circuit in wiring 3. Insert T-adapter into connector ENG.
4 harness 4. Turn starting switch to ON position (with connector PAMB
Between ENG (3) and (38) Voltage Max. 1 V
ler
performed.)
38 140E-5 Series
Circuit diagram related to atmospheric pressure sensor

140E-5 Series 39
E-15 Code [222/CA222] Ambient Air Press. Sensor Low Error 1

Trouble Abnormally low level in atmospheric pressure sensor
222 CA222
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.
• Output drops.
on machine
• 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
Related information
T-adapter).
• If sensor connector is disconnected, this failure code is generated.

Defective power supply line If failure code [187/CA187] or [227/CA227] is displayed, per-
1
of ambient pressure sensor form troubleshooting for it first.
2. Disconnect connectors PAMB and ENG.
2
ness
Resis- Min.
tance 1 Mz
Ground fault in wiring har- 2. Disconnect connectors PAMB and ENG and connect T-
Possible causes and (contact with ground circuit) Resis- Min.
standard value in Between ENG (female) (3) and ground
tance 1 Mz
normal state
Open circuit in wiring har- If no failure is found by above checks, wiring harness may have
4
ness 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.
age to engine controller) 3. Turn starting switch to ON position.
Sensor 0.3 – 4.7
Between ENG (3) and (38) Voltage
output V
not be performed.)
*: Refer to "Troubleshooting method for open circuit in wiring harness of pressure sensor system".
40 140E-5 Series
Circuit diagram related to atmospheric pressure sensor

a For "with EGR"
140E-5 Series 41
E-16 Code [227/CA227] Sensor Sup. 2 Volt. High Error 1

Trouble Abnormally high level in sensor power supply 2 circuit
227 CA227
Contents of trouble • 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 opera-
tion.
• Fixes charge (boost) pressure sensor value (400 kPa {4.08 kg/cm2}) and continues operation.
Action of controller • Sets EGR inlet pressure sensor to default value (102 kPa {1.04 kg/cm2}) and continues opera-
tion. ["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]
• Output drops.
on machine

standard value in
normal state 1 Carry out troubleshooting for code [187/CA187].
E-17 Code [234/CA234] Eng. Overspeed 1

Trouble Engine overspeed
234 CA234
Contents of trouble • Engine speed is above operating range.
Action of controller • Limits fuel injection rate until engine speed lowers to operating range.
• Engine speed fluctuates.
on machine
Related information

1 Defective related system If another failure code is indicated, carry out troubleshooting for it.
Possible causes and
standard value in 2 Improper way of use Way of use may be improper. Teach proper way of use to operator.
normal state If causes 1 – 2 are not detected, engine controller may be
be carried out.)
42 140E-5 Series
140E-5 Series 43
E-18 Code [238/CA238] Ne Speed Sensor Sup. Volt. Error 1

Trouble Abnormality in Ne speed sensor power supply
238 CA238
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).

a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
Defective Ne speed sen- Disconnect devices at right

1 in order. If error code disap-
sor (Internal trouble) Ne speed
pears when a device is dis- NE connector
sensor
connected, that device has
a defect in it.
a Prepare with starting switch OFF, then carry out troubleshoot-
Disconnection in wiring ing without turning starting switch ON.
harness (Disconnection Wiring harness between ENG (female)
in wiring or defective con- (16) – NE (female) (1)
tact in connector) Wiring harness between ENG (female)
Resistance Max. 1 z
(48) – NE (female) (2)
Possible causes and
standard value in a Prepare with starting switch OFF, then carry out troubleshoot-
normal state ing without turning starting switch ON.
Ground fault in wiring
Wiring harness between ENG (female)
3 harness (Short circuit Resistance Min. 1 Mz
(16) – NE (female) (1) and chassis ground
with GND circuit)
Short circuit in wiring har- ing without turning starting switch ON.
4 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)
Defective engine control- and carry out troubleshooting.
5
ler ENG Voltage
Between (16) – (48) 4.75 – 5.25 V
44 140E-5 Series
Circuit diagram related to Ne speed sensor power supply
140E-5 Series 45
E-19 Code [263/CA263] Fuel Temp. Sensor High Error 1

Trouble Abnormally high level in fuel temperature sensor
263 CA263
Contents of trouble • Signal voltage in fuel temperature sensor circuit is abnormally high.
• Uses signals from coolant temperature sensor to perform fuel injection rate correction based
Action of controller on fuel temperature.
• Fixes fuel temperature (90°C) and continues operation.
on machine
• Because troubleshooting "socket" for this sensor features female connector alone, it is not
Related information
connectable to female connector of sensor wiring harness, and thus not usable for checking
open circuit (not designed as a T-adapter).

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 tem-
perature sensor as normal.
30 –
0 °C Resistance
37 kz
Defective fuel temperature
1 9.3 –
sensor 25 °C Resistance
Between TFUEL (male)(A) 10.7 kz
and (B) 3.2 –
50 °C Resistance
a Fuel temperature-Resis- 3.8 kz
Possible causes and tance characteristics 1.0 –
standard value in 80 °C Resistance
1.3 kz
normal state
700 –
95 °C Resistance
800 z
female side.
2 (Fuel temperature: Min. 0 °C)
ing harness
a The resistance is the same as that 700 z –
Resistance
shown in the resistance character- 37 kz
46 140E-5 Series
Circuit diagram related to fuel temperature sensor

a Pin number of connector PIM is not "2" but "3" for “EGR-less” in above figure.
140E-5 Series 47
E-20 Code [265/CA265] Fuel Temp. Sensor Low Error 1

Trouble Abnormally low level in fuel temperature sensor
265 CA265
Contents of trouble • Signal voltage in fuel temperature sensor circuit is abnormally low.
• Uses signals from coolant temperature sensor to perform fuel injection rate correction based
Action of controller on fuel temperature.
• Fixes fuel temperature (90°C) and continues operation.
on machine
• If temperature sensor connector is disconnected, this code is not generated but code [263/
Related information
CA263] for "High Error" is generated.

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 tem-
perature sensor as normal.
Resis- 30 –
0 °C
tance 37 kz
Resis- 9.3 –
25 °C
Defective fuel temperature Between TFUEL (male)(A) and tance 10.7 kz
1
sensor (B) Resis- 3.2 –
50 °C
a Fuel temperature-Resis- tance 3.8 kz
tance characteristic Resis- 1.0 –
80 °C
tance 1.3 kz
Resis- 700 –
95 °C
tance 800 z
Possible causes and All fuel
standard value in tempera- Resis- Min.
Between (B) and ground
normal state ture tance 1 Mz
range
female side.
2 (Fuel temperature: Min. 0 °C)
ness
a The resistance is the same as that Resis- 700 z –
shown in the resistance characteristics tance 37 kz
sor of cause 1.
Ground fault in wiring har- 2. Disconnect connector TFUEL, and connect T-adapter to
3 ness female side of ENG.
tance 1 Mz
not be performed.)
48 140E-5 Series
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
E-21 Code [271/CA271] PCV1 Short Error 1

Trouble Short circuit in PCV1
271 CA271
Contents of trouble • There is short circuit in PCV1 circuit of supply pump.
on machine

Defective supply pump PCV1 (male) Resistance
1
PCV1 (Internal trouble) Between (1) – (2) 2.3 – 5.3 z
Between (1), (2) –
Min. 1 Mz
chassis ground
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)
Possible causes and (female) (5) – PCV1 (female) (2) and Resistance Min. 1 Mz
standard value in chassis ground
normal state a Prepare with starting switch OFF, then turn starting switch
Hot short (Short circuit with
(female) (4) – PCV1 (female) (1) and Voltage Max. 1 V
3 24V circuit) in wiring har-
chassis ground
ness
chassis ground
ENG (female) Resistance
Between (4) – (5) 2.3 – 5.3 z
Between (4), (5) –
Min. 1 Mz
chassis ground
50 140E-5 Series
Circuit diagram related to supply pump PCV1
140E-5 Series 51
E-22 Code [272/CA272] PCV1 Open Error 1

Trouble Disconnection in PCV1
272 CA272
Contents of trouble • There is disconnection in PCV1 circuit of supply pump.
on machine

1 PCV1 (Internal disconnec-
tion) Between (1) – (2) 2.3 – 5.3 z
Between (1), (2) –
Min. 1 Mz
chassis ground
ness (Disconnection in wir- Wiring harness between ENG
ing or defective contact in (female) (4) – PCV1 (female) (1)
connector) Wiring harness between ENG
Resistance Max. 1 z
Possible causes and (female) (5) – PCV1 (female) (2)
standard value in a Prepare with starting switch OFF, then carry out trouble-
normal state shooting without turning starting switch ON.
chassis ground
circuit)
chassis ground
Between (4) – (5) 2.3 – 5.3 z
Between (4), (5) –
Min. 1 Mz
chassis ground
52 140E-5 Series
140E-5 Series 53
E-23 Code [273/CA273] PCV2 Short Error 1

Trouble Short circuit in PCV2
273 CA273
Contents of trouble • There is short circuit in PCV2 circuit of supply pump.
on machine

1
PCV2 (Internal trouble) Between (1) – (2) 2.3 – 5.3 z
Between (1), (2) –
Min. 1 Mz
chassis ground
chassis ground
circuit)
Possible causes and (female) (10) – PCV2 (female) (2) and Resistance Min. 1 Mz
standard value in chassis ground
normal state a Prepare with starting switch OFF, then turn starting switch
Hot short (Short circuit with
3 24V circuit) in wiring har-
chassis ground
ness
chassis ground
Between (9) – (10) 2.3 – 5.3 z
Between (9), (10) –
Min. 1 Mz
chassis ground
54 140E-5 Series
140E-5 Series 55
E-24 Code [274/CA274] PCV2 Open Error 1

Trouble Disconnection in PCV2
274 CA274
Contents of trouble • There is disconnection in PCV2 circuit of supply pump.
on machine

Defective supply pump shooting without turning starting switch ON.
1 PCV2 (Internal disconnec-
PCV2 (male) Resistance
tion)
Between (1) – (2) 2.3 – 5.3 z
ing or defective contact in (female) (9) – PCV2 (female) (1)
Resistance Max. 1 z
(female) (10) – PCV2 (female) (2)
Possible causes and a Prepare with starting switch OFF, then carry out trouble-
standard value in shooting without turning starting switch ON.
normal state
chassis ground
circuit)
chassis ground
Between (9) – (10) 2.3 – 5.3 z
Between (9), (10) –
Min. 1 Mz
chassis ground
56 140E-5 Series
140E-5 Series 57
E-25 Code [322/CA322] Injector #1 System Open/Short Error 1

Trouble Disconnection or short circuit in injector #1 system
322 CA322
Contents of trouble • There is disconnection or short circuit in injector #1 circuit.
Problem that appears • Output drops.
on machine • Rotation is unstable.
• While engine is running normally, pulse voltage of about 70 V is applied to positive (+) side of
Related information injector. This pulse voltage cannot be measured with circuit tester.
• Different machine models may have different connector Nos.

Defective injector #1 (Inter- CN1 (male) Resistance
1
nal trouble) Between (1) – (2) 0.4 – 1.1 z
Between (1), (2) –
Min. 1M z
chassis ground
ing or defective contact in (female) (45) – CN1 (female) (1)
Resistance Max. 1 z
(female) (53) – CN1 (female) (2)
normal state
(female) (45) – CN1 (female) (1) and Resistance Min. 1 Mz
chassis ground
circuit)
chassis ground
Defective injector or wiring If failure code of another cylinder is displayed, carry out trou-
4
harness of another cylinder bleshooting for it, too.
Between (45) – (53) 0.4 – 1.1 z
Between (45), (53) –
Min. 1 Mz
chassis ground
58 140E-5 Series
Circuit diagram related to injector #1

q Improper installation of injector wiring harness

(H)
Q: Injector wiring harness (H) is in good condition x: Injector wiring harness (H) is in bad condition
being laid close to injector (N) without being laid close to injector (N)
a: Injector wiring harness (H) may interfere with
rocker arm.
140E-5 Series 59

323 CA323

1
Between (1), (2) –
Min. 1 Mz
chassis ground
Resistance Max. 1 z
normal state
chassis ground
circuit)
chassis ground
4
Between (46) – (60) 0.4 – 1.1 z
Between (46), (60) –
Min. 1 Mz
chassis ground
60 140E-5 Series


(H)
rocker arm.
140E-5 Series 61

324 CA324

1
Between (1), (2) – chassis
Min. 1M z
ground
Resistance Max. 1 z
normal state
chassis ground
circuit)
chassis ground
4
Between (55) – (52) 0.4 – 1.1 z
Between (55), (52) –
Min. 1M z
chassis ground
62 140E-5 Series


(H)
rocker arm.
140E-5 Series 63

325 CA325

1
Between (1), (2) –
Min. 1 Mz
chassis ground
Resistance Max. 1 z
normal state
chassis ground
circuit)
chassis ground
4
Between (57) – (59) 0.4 – 1.1 z
Between (57), (59) –
Min. 1 Mz
chassis ground
64 140E-5 Series


(H)
rocker arm.
140E-5 Series 65

331 CA331

1
Between (1), (2) –
Min. 1 Mz
chassis ground
Resistance Max. 1 z
normal state
chassis ground
circuit)
chassis ground
4
Between (54) – (51) 0.4 – 1.1 z
Between (54), (51) –
Min. 1 Mz
chassis ground
66 140E-5 Series


(H)
rocker arm.
140E-5 Series 67

332 CA332

1
Between (1), (2) –
Min. 1 Mz
chassis ground
Resistance Max. 1 z
normal state
chassis ground
circuit)
chassis ground
4
Between (56) – (58) 0.4 – 1.1 z
Between (56), (58) –
Min. 1 Mz
chassis ground
68 140E-5 Series


(H)
rocker arm.
140E-5 Series 69
E-31 Code [342/CA342] Engine Controller Data Matching Error 1

Trouble Matching error in engine controller data
342 CA342
Contents of trouble • Matching error occurred in engine controller data.
Problem that appears • Engine continues operation normally, but it may stop during operation or may not be able to
on machine start.
Related information

standard value in
70 140E-5 Series
140E-5 Series 71
E-32 Code [351/CA351] INJ. Drive Circuit Error 1

Trouble Abnormality in injector drive circuit
351 CA351
Contents of trouble • Abnormality occurred in injector drive circuit.
Action of controller • Limits output and continues operation (Limits common rail pressure).
• Output drops.
on machine

If another failure code (code of abnormality in injector system)
1 Defective related system
is indicated, carry out troubleshooting for it.
Check fuse or circuit breaker on machine side directly for
defect.
2 Defective fuse
(If fuse is broken or circuit breaker is turned OFF, circuit proba-
bly has ground fault.)
ness (Disconnection in wir- Wiring harness between E03 (female)
ing or defective contact in (3), (4) – battery (+)
Possible causes and
connector) Wiring harness between E03 (female)
normal state (1), (2) – chassis ground
4 ness (Short circuit with GND Resistance Min. 1 Mz
(3), (4) – battery (+) and chassis ground
circuit)
(1), (2) – chassis ground
E03 Voltage
Between (3), (4) – (1), (2) 20 – 30 V
72 140E-5 Series
Circuit diagram related to controller power supply
140E-5 Series 73
E-33 Code [352/CA352] Sensor Sup. 1 Volt. Low Error 1

Trouble Abnormally low level in sensor power supply 1 circuit
352 CA352
Contents of trouble • Signal voltage in sensor power supply (5 V) circuit is abnormally low.
• Limits output of common rail pressure sensor and continues operation (Limits common rail
pressure).
• Output drops.
on machine
Related information

standard value in
74 140E-5 Series
E-34 Code [386/CA386] Sensor Sup. 1 Volt. High Error 1

Trouble Abnormally high level in sensor power supply 1 circuit
386 CA386
Contents of trouble • Signal voltage in sensor power supply (5 V) circuit is abnormally high.
• Limits output of common rail pressure sensor and continues operation (Limits common rail
pressure).
• Output drops.
on machine

1 Defective related system If another failure code is indicated, carry out troubleshooting for it.
Disconnect devices at
Defective sensor (Inter- right in order. If error
2
nal trouble) code disappears when a Common rail
PFUEL connector
device is disconnected, pressure sensor
that device has a defect
in it.
a Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring without turning starting switch ON.
in wiring or defective (33) – PFUEL (female) (1)
contact in connector) Wiring harness between ENG (female)
Resistance Max. 1 z
Possible causes and (47) – PFUEL (female) (3)
standard value in a Prepare with starting switch OFF, then carry out troubleshooting
normal state without turning starting switch ON.
(33) – PFUEL (female) (1) and chassis Resistance Min. 1 Mz
4 harness (Short circuit
ground
with GND circuit)
Wiring harness between CE01 (female)
ground
Short circuit in wiring without turning starting switch ON.
5 harness (with another Wiring harness between ENG (female)
wiring harness) (33) – PFUEL (female) (1) and between Resistance Min. 1 Mz
ENG (female) (47) – PFUEL (female) (3)
Defective engine control- and carry out troubleshooting.
6
ler ENG Voltage
Between (33) – (47) 4.75 – 5.25 V
140E-5 Series 75

a There are not connect for PEVA and line to the PEVA for serial No. 530897 and up.
76 140E-5 Series

140E-5 Series 77
E-35 Code [431/CA431] Idle Validation Switch Error 1


Trouble Abnormality in idle validation switch
431 CA431
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).
on machine

WAS1 Signal name Voltage
Defective accelerator pedal
1 Between (5) – (4) Signal 1
(Internal trouble) See Fig. 1
Between (6) – (4) Signal 2
If voltage is abnormal, check wiring harness and controller,
too, for another cause of trouble, and then judge.
Resistance Max. 1 z
ness (Disconnection in wir- (32) – WAS1 (female) (4)
2
(11) – WAS1 (female) (5)
Resistance Max. 1 z
(1) – WAS1 (female) (6)
Possible causes and shooting without turning starting switch ON.
standard value in
normal state
circuit) (11) – WAS1 (female) (5) and chassis Resistance Min. 1 Mz
ground
ground
(32) – WAS1 (female) (4) and chassis Voltage Max. 1 V
Hot short (Short circuit with ground
4 24V circuit) in wiring har- Wiring harness between E02 (female)
ness (11) – WAS1 (female) (5) and chassis Voltage Max. 1 V
ground
(1) – WAS1 (female) (6) and chassis Voltage Max. 1 V
ground
78 140E-5 Series

Possible causes and ON and carry out troubleshooting.
standard value in nor-
5 Defective engine controller E02 Signal name Voltage
mal state
See Fig. 1
Fig. 1
Throttle: Signal voltage of throttle sensor
Idle validation: Signal voltage of idle validation
switch
Operating range: Operating range of accelerator
pedal
140E-5 Series 79
E-36 Code [432/CA432] Idle Validation Process Error 1

Trouble Abnormality in processing of idle validation
432 CA432
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).
on machine
Related information

standard value in
80 140E-5 Series
E-37 Code [441/CA441] Supply Voltage Low Error 1

Trouble Abnormally low power supply voltage
441 CA441
Contents of trouble • Power supply voltage is abnormally low.
on machine start.
Related information

standard value in
E-38 Code [442/CA442] Supply Voltage High Error 1

Trouble Abnormally high power supply voltage
442 CA442
Contents of trouble • Power supply voltage is abnormally high.
on machine start.
Related information

standard value in
140E-5 Series 81
SEN00153-03
© 2010 KOMATSU
All Rights Reserved
82
SEN00154-02
ENGINE 1SHOP MANUAL
140E-5 Series
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
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
Troubleshooting of electrical system (E-mode), Part 2 1

E-39 Code [449/CA449] Rail Press. High Error 2 1

Trouble Abnormally high common rail pressure 2
449 CA449
Contents of trouble • Common rail pressure sensor circuit detected abnormally high pressure (level 2).
• Output drops.
on machine
Related information

standard value in
140E-5 Series 3
E-40 Code [451/CA451] Rail Press. Sensor High Error 1

Trouble Abnormally high level in common rail pressure sensor
451 CA451
Contents of trouble • Signal voltage in common rail pressure sensor circuit is abnormally high.
• Output drops.
on machine

1
supply bleshooting for it first.
or start engine and carry out troubleshooting.
PFUEL Voltage
Defective common rail
Between (1) – (3) Power supply 4.75 – 5.25 V
2 pressure sensor (Internal
trouble) Between (2) – (3) Signal 0.25 – 4.6 V
ing without turning starting switch ON.
Disconnection in wiring Wiring harness between ENG (female)
Resistance Max. 1 z
harness (Disconnection (33) – PFUEL (female) (1)
3
in wiring or defective con- Wiring harness between ENG (female)
tact in connector) Resistance Max. 1 z
(25) – PFUEL (female) (2)
Resistance Max. 1 z
(47) – PFUEL (female) (3)
Possible causes and
Ground fault in wiring ground
4 harness (Short circuit Wiring harness between ENG (female)
with GND circuit) (25) – PFUEL (female) (2) and chassis Resistance Min. 1 Mz
ground
ground
(33) – PFUEL (female) (1) and between Resistance Min. 1 Mz
Short circuit in wiring har- ENG (female) (25) – PFUEL (female) (2)
harness) (33) – PFUEL (female) (1) and between Resistance Min. 1 Mz
(25) – PFUEL (female) (2) and between Resistance Min. 1 Mz
4 140E-5 Series

Possible causes and or start engine and carry out troubleshooting.
standard value in Defective engine control-
6 ENG Voltage
normal state ler
Between (33) – (47) 4.75 – 5.25 V
Between (25) – (47) 0.25 – 4.6 V
Circuit diagram related to common rail pressure sensor

140E-5 Series 5
Circuit diagram related to common rail pressure sensor

6 140E-5 Series
E-41 Code [452/CA452] Rail Press. Sensor Low Error 1

Trouble Abnormally low level in common rail pressure sensor
452 CA452
Contents of trouble • Signal voltage in common rail pressure sensor circuit is abnormally low.
• Output drops.
on machine
Related information

standard value in
140E-5 Series 7
E-42 Code [553/CA553] Rail Press. High Error 1 1

Trouble Abnormally high common rail pressure 1
553 CA553
Contents of trouble • Common rail pressure sensor circuit detected abnormally high pressure (level 1).
• Output drops.
on machine
Related information

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
Common rail pressure sensor may have electric trouble. Carry
3 of common rail pressure
Possible causes and out troubleshooting for code [451/CA451] (E-40).
sensor
standard value in
normal state Defective mechanical sys-
Check mechanical system of common rail pressure sensor
4 tem of common rail pres-
directly.
sure sensor
Check overflow valve directly for broken spring, worn seat, and
5 Defective overflow valve
stuck ball.
6 Clogging of overflow piping Check overflow piping directly for clogging.
7 Defective pressure limiter Check pressure limiter directly for mechanical defect.
8 140E-5 Series
E-43 Code [554/CA554] Rail Press Sensor In Range Error 1

Trouble In-range error in common rail pressure sensor
554 CA554
Contents of trouble • In-range error occurred in common rail pressure sensor circuit.
• Output drops.
on machine
Related information

standard value in
140E-5 Series 9
E-44 Code [559/CA559] No-pressure Feed By Supply pump 1 1

Trouble No-pressure feed by supply pump 1
559 CA559
Contents of trouble • Supply pump does not feed fuel (level 1).
Action of controller • Limits common rail pressure.
• Output drops.
on machine
Related information

it.
2 Use of improper fuel Check fuel used directly (for high viscosity).
a For contents of troubleshooting, see Note 1. For check of
pressure in fuel low-pressure circuit, see TESTING AND
ADJUSTING, Testing fuel pressure.
Defective low-pressure cir-
3 Pressure in fuel low-pressure
cuit device
circuit 0.15 – 0.3 MPa
(At high idle or equivalent to {1.5 – 3.0 kg/cm2}
rated load [by models])
4 Clogging of filter/strainer a For contents of troubleshooting, see Note 2.
Supply pump PCV may have electric trouble. Carry out trou-
Defective electrical system bleshooting for following codes;
5
of supply pump PCV [271/CA271] (E-21), [272/CA272] (E-22), [273/CA273] (E-23),
[274/CA274] (E-24)
Possible causes and Defective common rail pres- Common rail pressure sensor may be defective. Check wiring
6
standard value in sure sensor harness for damage.
normal state 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 opera- Max. 10 cc/min
tion [by models])
a For testing of return (spill) limit from injector, see Testing and
adjusting, “Testing fuel return rate and leakage.”
Speed equivalent to rated Return (Spill) limit from
output (stall load) injector
8 Defective 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 defec-
9 Defective supply pump
tive.
<How to use check sheet>

Carry out the above troubleshooting and take a record of the contents of the attached “Check sheet for no-
pressure feed”.
10 140E-5 Series
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
Check sheet for no-pressure feed

Model Work No.
Machine serial No. # Date of check / /
Engine Service meter h
Engine serial No. # Worker's name
A. Visual check Good NG

1 Fuel leakage to outside
2 Clogging of fuel tank breather
B. Check with machine monitor (Fault history function, monitoring function, and reduced cylinder mode function) Good NG
3 Check of error/failure code / / / /
Check of monitoring information
Standard value
Code Displayed item Checking condition Unit Measured value Good NG
(Reference value)
Low idle rpm <By models>
*1 Engine speed High idle rpm <By models>
Equivalent to rating <By models> rpm <By models>
Low idle % 0
*2 Throttle opening
High idle % 100
Fuel injection com-
*3 Equivalent to rating <By models> mm3 — — —
mand
4 Common rail pres-
*4 Equivalent to rating <By models> MPa
sure command
Common rail fuel
*5 Equivalent to rating <By models> MPa
pressure
Low idle CA — — —
Fuel injection tim-
*6 High idle CA — — —
ing command
Equivalent to rating <By models> CA — — —
*7 Boost pressure Equivalent to rating <By models> kPa — — —
Engine coolant tem-
*8 Low idle °C — — —
perature
*9 Fuel temperature Low idle °C — — —
Check of reduced cylinder mode operation (Engine speed)
Standard value
Function Reduced cylinder Checking condition Unit Measured value Good NG
(Reference value)
No. 1 cylinder Low idle rpm — — —
5 No. 2 cylinder Low idle rpm — — —
*10
Standard value
C. Check of fuel circuit pressure Checking condition Unit Measured value Good NG
(Reference value)
Fuel low-pressure circuit pres- High idle or equivalent to rated load MPa 0.15 – 0.3
6
sure [by models]) {kg/cm2} {1.5 – 3.0}
D. Check of strainers and filters Good NG

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 Standard value

Checking condition Unit Measured value Good NG
return rate (Reference value)
Leakage through pressure lim-
11 Equivalent to rated output [by models]) cc/min Max. 10
iter
Equivalent to rating<By models>1,600 rpm cc/min 960 Speed:
Equivalent to rating<By models>1,700 rpm cc/min 1,020
12 Return rate from injector Equivalent to rating<By models>1,800 rpm cc/min 1,080
Equivalent to rating<By models>1,900 rpm cc/min 1,140 Return rate:
Equivalent to rating<By models>2,000 rpm cc/min 1,200
12 140E-5 Series
*1 – *10:
When inspecting with INSITE (bench test tool), see Operation and Maintenance Manual (Testing method).
When inspecting with the monitoring function of the machine, use the codes specified for each machine
model.
Equivalent to rating <By models>:

When inspecting the engine unit on the bench, operate it under a load equivalent to the rating. When the
engine is installed to the machine, however, the operation load equivalent to the rating depends on the
machine model.
140E-5 Series 13
E-45 Code [689/CA689] Eng. Ne Speed Sensor Error 1

Trouble Abnormality in engine Ne speed sensor
689 CA689
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).

Defective sensor power If code [238/CA238] is indicated, carry out troubleshooting for it
1
supply system first.
Resistance Max. 1 z
harness (Disconnection (16) – NE (female) (1)
2
(48) – NE (female) (2)
Resistance Max. 1 z
(27) – NE (female) (3)
Ground fault in wiring Resistance Min. 1 Mz
with GND circuit) Wiring harness between ENG (female)
Possible causes and Resistance Min. 1 Mz
standard value in
normal state a Prepare with starting switch OFF, then carry out troubleshoot-
(16) – NE (female) (1) and between Resistance Min. 1 Mz
Short circuit in wiring har- ENG (female) (48) – NE (female) (2)
harness) (16) – NE (female) (1) and between Resistance Min. 1 Mz
ENG (female) (27) – NE (female) (3)
(48) – NE (female) (2) and between Resistance Min. 1 Mz
ENG (female) (27) – NE (female) (3)
Defective mount of sen- Check Ne speed sensor directly for defective mount (defective
5 sor or defective rotation clearance) or check rotation sensing part (flywheel) directly for
sensing part defect.
If causes 1 – 5 are not detected, engine Ne speed sensor may
Defective engine Ne
6 be defective. (Since trouble is in system, troubleshooting cannot
speed sensor
be carried out.)
If causes 1 – 6 are not detected, engine controller may be defec-
7 tive. (Since trouble is in system, troubleshooting cannot be car-
ler
ried out.)
14 140E-5 Series
Circuit diagram related to engine Ne speed sensor
140E-5 Series 15
E-46 Code [731/CA731] Eng. Bkup Speed Sensor Phase Error 1

Trouble Abnormality in engine Bkup speed sensor phase
731 CA731
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

Possible causes and Defective engine Ne speed Engine Ne speed sensor may be defective. Carry out trouble-
1
standard value in sensor system shooting for [689/CA698] (E-45).
normal state Defective engine Bkup Engine Bkup speed sensor may be defective. Carry out trou-
2
speed sensor system bleshooting for [778/CA778] (E-48).
E-47 Code [757/CA757] All Engine Controller Data Lost Error 1

Trouble Loss of all data in engine controller
757 CA757
Contents of trouble • All data in engine controller are lost.
on machine start.
Related information

standard value in
16 140E-5 Series
140E-5 Series 17
E-48 Code [778/CA778] Eng. Bkup Speed Sensor Error 1

Trouble Abnormality in engine Bkup speed sensor
778 CA778
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).

1
Resistance Max. 1 z
harness (Disconnection (37) – G (female) (1)
2
(47) – G (female) (2)
Resistance Max. 1 z
(26) – G (female) (3)
(37) – G (female) (1) and chassis ground
with GND circuit) Wiring harness between ENG (female)
Possible causes and Resistance Min. 1 Mz
standard value in
normal state a Prepare with starting switch OFF, then carry out troubleshoot-
(37) – G (female) (1) and between ENG Resistance Min. 1 Mz
Short circuit in wiring har- (female) (47) – G (female) (2)
harness) (37) – G (female) (1) and between ENG Resistance Min. 1 Mz
(female) (26) – G (female) (3)
(47) – G (female) (2) and between ENG Resistance Min. 1 Mz
(female) (26) – G (female) (3)
Defective mount of sen- Check Bkup speed sensor directly for defective mount (defective
5 sor or defective rotation clearance) or check rotation sensing part (in supply pump)
sensing part directly for defect.
If causes 1 – 5 are not detected, engine Bkup speed sensor may
Defective engine Bkup
6 be defective. (Since trouble is in system, troubleshooting cannot
speed sensor
be carried out.)
If causes 1 – 6 are not detected, engine controller may be defec-
7 tive. (Since trouble is in system, troubleshooting cannot be car-
ler
ried out.)
18 140E-5 Series
Circuit diagram related to engine Bkup speed sensor

140E-5 Series 19
Circuit diagram related to engine Bkup speed sensor

20 140E-5 Series
E-49 Code [1228/CA1228] EGR Valve Servo Error 1 1

a This code applies to only “with EGR”.

Trouble Abnormality in EGR valve servo 1
1228 CA1228
Contents of trouble • Abnormality (level 1) occurred in EGR valve servo.
Action of controller • Performs open control.
on machine
Related information

it.
a For measurement of EGR valve drive pressure, see Testing
and adjusting, “Measuring EGR valve and bypass valve
drive oil pressure”.
Improper EGR valve drive Engine speed EGR valve drive pressure
2
pressure Low idle 1.18 MPa {12 kg/cm2}
High idle 1.43 MPa {14.6 kg/cm2}
If EGR valve drive pressure is abnormal, check causes 3 and
4.
a For check of engine oil pressure, see TESTING AND
ADJUSTING, Testing engine oil pressure.
Possible causes and
Engine speed Engine oil pressure
standard value in Defective engine oil pres-
normal state 3 Low idle 0.08 MPa {0.8 kg/cm2}
sure system (main circuit)
If engine oil pressure is abnormal, carry out troubleshooting for
mechanical system (S-12 Oil pressure lowers).
Defective oil pump for EGR
4 Check oil pump and relief valve for EGR valve circuit directly.
valve
Defective oil feed piping for
5 Check oil feed piping for EGR valve circuit directly.
EGR valve
Defective oil return piping
6 Check oil return piping for EGR valve circuit directly.
for EGR valve
7 Defective EGR valve Check mechanical section of EGR valve directly.
be carried out.)
140E-5 Series 21
E-50 Code [1625/CA1625] EGR Valve Servo Error 2 1


Trouble Abnormality in EGR valve servo 2
1625 CA1625
Contents of trouble • Abnormality (level 2) occurred in EGR valve servo.
• Limits output and continues operation.
• Closes EGR valve and bypass valve.
• Output drops.
on machine
Related information

standard value in
22 140E-5 Series
E-51 Code [1626/CA1626] Bypass Valve Solenoid Drive Short Circuit

Error 1

Trouble Short circuit in bypass valve solenoid drive circuit
1626 CA1626
Contents of trouble • There is short circuit in drive circuit of bypass valve solenoid.
• Output drops.
on machine

Defective bypass valve ing without turning starting switch ON.
1
solenoid (Internal trouble) BP (male) Resistance
Between (1) – (2) 10 – 21 z
in wiring or defective con- (31) – BP (female) (1)
Resistance Max. 1 z
(11) – BP (female) (2)
Possible causes and ing without turning starting switch ON.
standard value in Ground fault in wiring
Wiring harness between ENG (female) (31)
normal state 3 harness (Short circuit Resistance Min. 1 Mz
– BP (female) (1) and chassis ground
with GND circuit)
Hot short (Short circuit
4 with 24V circuit) in wiring Voltage Max. 1 V
harness
Voltage Max. 1 V
Defective engine control- ing without turning starting switch ON.
5
ler ENG (female) Resistance
Between (31) – (11) 10 – 21 z
140E-5 Series 23
Circuit diagram related to bypass valve solenoid & lift sensor
24 140E-5 Series
E-52 Code [1627/CA1627] Bypass Valve Solenoid Drive Open Error 1


Trouble Disconnection in bypass valve solenoid drive circuit
1627 CA1627
Contents of trouble • There is disconnection in drive circuit of bypass valve solenoid.
• Output drops.
on machine
Related information

standard value in
140E-5 Series 25
E-53 Code [1628/CA1628] Bypass Valve Servo Error 1 1


Trouble Abnormality in bypass valve servo 1
1628 CA1628
Contents of trouble • Abnormality (level 1) occurred in bypass valve servo.
Action of controller • Performs open control.
on machine
Related information

If another failure code is indicated, carry out troubleshooting
for it.
a For measurement of EGR valve drive pressure, see Testing
and adjusting, “Measuring EGR valve and bypass valve
drive oil pressure”.
Improper EGR valve drive Engine speed Bypass valve drive pressure
2
pressure Low idle 1.18 MPa {12 kg/cm2}
If EGR valve drive pressure is abnormal, check causes 3 and
4.
a For check of engine oil pressure, see TESTING AND
ADJUSTING, Testing engine oil pressure.
Possible causes and
Engine speed Engine oil pressure
standard value in Defective engine oil pres-
normal state 3 Low idle 0.08 MPa {0.8 kg/cm2}
sure system (main circuit)
If engine oil pressure is abnormal, carry out troubleshooting
for mechanical system (S-12 Oil pressure lowers).
Defective oil pump for Check oil pump and relief valve for bypass valve circuit
4
bypass valve directly.
Defective oil feed piping for
5 Check oil feed piping for bypass valve circuit directly.
bypass valve
Defective oil return piping
6 Check oil return piping for bypass valve circuit directly.
for bypass valve
7 Defective bypass valve Check mechanical section of bypass valve directly.
be carried out.)
26 140E-5 Series
E-54 Code [1629/CA1629] Bypass Valve Servo Error 2 1


Trouble Abnormality in bypass valve servo 2
1629 CA1629
Contents of trouble • Abnormality (level 2) occurred in bypass valve servo.
• Output drops.
on machine
Related information

standard value in
140E-5 Series 27
E-55 Code [1631/CA1631] Bypass Valve Lift Sensor High Error 1


Trouble Abnormally high level in bypass valve lift sensor
1631 CA1631
Contents of trouble • Signal voltage in bypass valve lift sensor circuit is abnormally high.
• Output drops.
on machine

Defective sensor power If code [187/CA187] or [227/CA227] is indicated, carry out trouble-
1
supply shooting for it first.
a Prepare with starting switch OFF, then turn starting switch ON or
start engine and carry out troubleshooting.
SBP Voltage
Defective bypass valve Between (1) – (2) Power supply 4.75 – 5.25 V
2 lift sensor (Internal trou- Between (3) – (2) Signal 0.8 – 1.2 V
ble)
Between (4) – (2) Signal 0.8 – 1.2 V
Accordingly, if voltage is abnormal, check wiring harness and con-
troller, too, for another cause of trouble, and then judge.
without turning starting switch ON.
Resistance Max. 1 z
harness (Disconnection (37) – SBP (female) (1)
3
in wiring or defective Wiring harness between ENG (female)
contact in connector) Resistance Max. 1 z
(38) – SBP (female) (2)
Possible causes and Wiring harness between ENG (female)
Resistance Max. 1 z
standard value in (29) – SBP (female) (3), (4)
normal state
Ground fault in wiring – SBP (female) (1) and chassis ground
4 harness (Short circuit Wiring harness between ENG (female) (38)
with GND circuit) Resistance Min. 1 Mz
– SBP (female) (2) and chassis ground
(29) – SBP (female) (3), (4) and chassis Resistance Min. 1 Mz
ground
(37) – SBP (female) (1) and between ENG Resistance Min. 1 Mz
Short circuit in wiring (female) (38) – SBP (female) (2)
5 harness (with another Wiring harness between ENG (female)
wiring harness) (37) – SBP (female) (1) and between ENG Resistance Min. 1 Mz
(female) (29) – SBP (female) (3), (4)
(38) – SBP (female) (2) and between ENG Resistance Min. 1 Mz
(female) (29) – SBP (female) (3), (4)
28 140E-5 Series

Possible causes and a Prepare with starting switch OFF, then turn starting switch ON or
standard value in Defective engine con- start engine and carry out troubleshooting.
normal state 6
troller ENG Voltage
Between (37) – (38) 4.75 – 5.25 V
Circuit diagram related to bypass valve solenoid & lift sensor
140E-5 Series 29
E-56 Code [1632/CA1632] Bypass Valve Lift Sensor Low Error 1


Trouble Abnormally low level in bypass valve lift sensor
1632 CA1632
Contents of trouble • Signal voltage in bypass valve lift sensor circuit is abnormally low.
• Output drops.
on machine
Related information

standard value in
E-57 Code [1633/CA1633] KOMNET Error 1

Trouble Abnormality in KOMNET
1633 CA1633
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.
on machine
Related information

Possible causes and This fault is detected and indicated when KOMNET communi-
standard value in Carry out troubleshooting cation with machine monitor or controller on the machine side
normal state 1
on machine side is abnormal. Accordingly, contents of troubleshooting depends
on machine model. See Shop manual for machine.
30 140E-5 Series
E-58 Code [1642/CA1642] EGR Inlet Press Sensor Low Error 1


Trouble Abnormally low level in EGR inlet pressure sensor
1642 CA1642
Contents of trouble • Signal voltage in EGR inlet pressure sensor circuit is abnormally low.
• Sets EGR inlet pressure to default value (102 kPa {1.04 kg/cm2}) and continues operation.
• Output drops.
on machine
Related information

standard value in
140E-5 Series 31
E-59 Code [1653/CA1653] EGR Inlet Press Sensor High Error 1


Trouble Abnormally high level in EGR inlet pressure sensor
1653 CA1653
Contents of trouble • Signal voltage in EGR inlet pressure sensor circuit is abnormally high.
• Sets EGR inlet pressure to default value (102 kPa {1.04 kg/cm2}) and continues operation.
• Output drops.
on machine

1
supply bleshooting for it first.
or start engine and carry out troubleshooting.
Defective EGR inlet pres- PEVA Voltage
2 sure sensor (Internal Between (1) – (2) Power supply 4.75 – 5.25 V
trouble)
Resistance Max. 1 z
harness (Disconnection (37) – PEVA (female) (1)
3
tact in connector) Resistance Max. 1z
(47) – PEVA (female) (2)
Resistance Max. 1 z
(20) – PEVA (female) (3)
Possible causes and ing without turning starting switch ON.
standard value in Wiring harness between ENG (female) (37)
normal state Ground fault in wiring Resistance Min. 1 Mz
– PEVA (female) (1) and chassis ground
with GND circuit) Wiring harness between ENG (female) (47)
(37) – PEVA (female) (1) and between Resistance Min. 1 Mz
Short circuit in wiring har- ENG (female) (47) – PEVA (female) (2)
harness) (37) – PEVA (female) (1) and between Resistance Min. 1 Mz
ENG (female) (20) – PEVA (female) (3)
(47) – PEVA (female) (2) and between Resistance Min. 1 Mz
ENG (female) (20) – PEVA (female) (3)
Defective engine control- or start engine and carry out troubleshooting.
6
ler ENG Voltage
Between (37) – (47) 4.75 – 5.25 V
32 140E-5 Series
Circuit diagram related to EGR inlet pressure sensor
140E-5 Series 33
E-60 Code [2185/CA2185] Throttle Sens. Sup. Volt. High Error 1


Trouble Abnormally high level in throttle sensor power supply
2185 CA2185
Contents of trouble • Signal voltage in throttle sensor power supply (5 V) circuit is abnormally high.
• Sets throttle angle with signal other than throttle sensor signal and continues operation
(depending on each model).
• Depends on machine model.
on machine

Defective accelerator Disconnect devices at right

1 in order. If error code dis-
pedal (Internal trouble) Accelerator
appears when a device is WAS1 connector
pedal
disconnected, that device
has a defect in it.
harness (Disconnection Wiring harness between E02 (female) (22)
in wiring or defective – WAS1 (female) (1)
contact in connector) Wiring harness between E02 (female) (23)
Resistance Max. 1 z
– WAS1 (female) (3)
Possible causes and
Wiring harness between E02 (female) (22)
– WAS1 (female) (1) and chassis ground
with GND circuit)
– WAS1 (female) (3) and chassis ground
4 harness (with another Wiring harness between E02 (female) (22)
wiring harness) – WAS1 (female) (1) and between E02 Resistance Min. 1 Mz
(female) (23) – WAS1 (female) (3)
Defective engine con- and carry out troubleshooting.
5
troller E02 Voltage
Between (22) – (23) 4.75 – 5.25 V
34 140E-5 Series
Circuit diagram related to throttle sensor of accelerator pedal type (Case of HD325/405-7)
140E-5 Series 35
Throttle sensor of fuel control dial type (Case of PC800/800SE/850/850SE/850LC-8)

Trouble Abnormally high level in throttle sensor power supply
2185 CA2185
Contents of trouble • Signal voltage in throttle sensor power supply (5 V) circuit is abnormally high.
on machine

Defective fuel control Disconnect devices at right

1 in order. If error code dis-
dial (Internal trouble) Fuel control
appears when a device is P20 connector
dial
disconnected, that device
has a defect in it.
harness (Disconnection Wiring harness between E02 (female) (22)
in wiring or defective – P20 (female) (1)
contact in connector) Wiring harness between E02 (female) (23)
Resistance Max. 1 z
– P20 (female) (3)
Possible causes and
– P20 (female) (1) and chassis ground
with GND circuit)
– P20 (female) (3) and chassis ground
4 harness (with another Wiring harness between E02 (female) (22)
wiring harness) – P20 (female) (1) and between E02 Resistance Min. 1 Mz
(female) (23) – P20 (female) (3)
Defective engine con- and carry out troubleshooting.
5
troller E02 Voltage
Between (22) – (23) 4.75 – 5.25 V
36 140E-5 Series
Circuit diagram related to throttle sensor of fuel control dial type (Case of PC800/800SE/850/850SE/
850LC-8)
140E-5 Series 37
E-61 Code [2186/CA2186] Throttle Sens. Sup. Volt. Low Error 1

Trouble Abnormally low level in throttle sensor power supply
2186 CA2186
Contents of trouble • Signal voltage in throttle sensor power supply (5 V) circuit is abnormally low.
on machine
Related information

standard value in
E-62 Code [2249/CA2249] No-pressure Feed By Supply pump 2 1

Trouble No-pressure feed by supply pump 2
2249 CA2249
Contents of trouble • Supply pump does not feed fuel (level 2).
Action of controller • Limits common rail pressure.
• Output drops.
on machine
Related information

standard value in
38 140E-5 Series
E-63 Code [2271/CA2271] EGR Valve Lift Sensor High Error 1


Trouble Abnormally high level in EGR valve lift sensor
2271 CA2271
Contents of trouble • Signal voltage in EGR valve lift sensor circuit is abnormally high.
• Output drops.
on machine

Defective sensor If code [187/CA187] or [227/CA227] is indicated, carry out trouble-
1
power supply shooting for it first.
a Prepare with starting switch OFF, then turn starting switch ON or
start engine and carry out troubleshooting.
SEGR Voltage
Defective EGR valve Between (1) – (2) Power supply 4.75 – 5.25V
2 lift sensor (Internal Between (3) – (2) Signal 0.8 – 1.2 V
trouble)
Between (4) – (2) Signal 0.8 – 1.2 V
Accordingly, if voltage is abnormal, check wiring harness and con-
troller, too, for another cause of trouble, and then judge.
Disconnection in wiring Wiring harness between ENG (female) (37)
harness (Disconnec- Resistance Max. 1 z
– SEGR (female) (1)
3 tion in wiring or defec-
tive contact in Resistance Max. 1 z
connector) – SEGR (female) (2)
Possible causes and
– SEGR (female) (3), (4)
normal state
– SEGR (female) (1) and chassis ground
with GND circuit) Wiring harness between ENG (female) (47)
– SEGR (female) (2) and chassis ground
Wiring harness between ENG (female) (19) –
SEGR (female) (3), (4) and chassis ground
– SEGR (female) (1) and between ENG Resistance Min. 1 Mz
Short circuit in wiring (female) (47) – SEGR (female) (2)
5 harness (with another Wiring harness between ENG (female) (37)
wiring harness) – SEGR (female) (1) and between ENG Resistance Min. 1 Mz
(female) (19) – SEGR (female) (3), (4)
– SEGR (female) (2) and between ENG Resistance Min. 1 Mz
(female) (19) – SEGR (female) (3), (4)
140E-5 Series 39

Possible causes and a Prepare with starting switch OFF, then turn starting switch ON or
standard value in Defective engine con- start engine and carry out troubleshooting.
normal state 6
troller ENG Voltage
Between (37) – (47) 4.75 – 5.25 V
Circuit diagram related to EGR valve solenoid & lift sensor
40 140E-5 Series
E-64 Code [2272/CA2272] EGR Valve Lift Sensor Low Error 1


Trouble Abnormally low level in EGR valve lift sensor
2272 CA2272
Contents of trouble • Signal voltage in EGR valve lift sensor circuit is abnormally low.
• Output drops.
on machine
Related information

standard value in
140E-5 Series 41
E-65 Code [2351/CA2351] EGR Valve Solenoid Drive Short Error 1


Trouble Short circuit in drive circuit of EGR valve solenoid
2351 CA2351
Contents of trouble • There is short circuit in drive circuit of EGR valve solenoid.
• Output drops.
on machine

Defective EGR valve ing without turning starting switch ON.
1
solenoid (Internal trouble) EGR (male) Resistance
Between (1) – (2) 10 – 21 z
in wiring or defective con- (22) – EGR (female) (1)
Resistance Max. 1 z
(11) – EGR (female) (2)
Possible causes and Ground fault in wiring
standard value in 3 harness (Short circuit Resistance Min. 1 Mz
– EGR (female) (1) and chassis ground
normal state with GND circuit)
– EGR (female) (2) and chassis ground
Hot short (Short circuit
(22) – EGR (female) (1) and chassis Voltage Max. 1 V
4 with 24V circuit) in wiring
ground
harness
(11) – EGR (female) (2) and chassis Voltage Max. 1 V
ground
Defective engine control- ing without turning starting switch ON.
5
ler ENG (female) Resistance
Between (22) – (11) 10 – 21 z
42 140E-5 Series
Circuit diagram related to EGR valve solenoid & lift sensor
140E-5 Series 43
E-66 Code [2352/CA2352] EGR Valve Solenoid Drive Open Error 1


Trouble Disconnection in drive circuit of EGR valve solenoid
2352 CA2352
Contents of trouble • There is disconnection in drive current of EGR valve solenoid.
• Output drops.
on machine
Related information

standard value in
normal state Carry out troubleshooting E-65 Code [2351/CA2351].
44 140E-5 Series
E-67 Code [2555/CA2555] Intake Air Heater Relay Open Error 1

Trouble Disconnection in intake air heater relay
2555 CA2555
Contents of trouble • There is disconnection in intake air heater relay.
• Engine does not start easily at low temperature.
on machine
Related information

standard value in
normal state Carry out troubleshooting E-68 Code [2556/CA2556].
140E-5 Series 45
E-68 Code [2556/CA2556] Intake Air Heater Relay Short Error 1

Trouble Short circuit in intake air heater relay
2556 CA2556
Contents of trouble • There is short circuit in intake air heater relay.
• Engine does not start easily at low temperature.
on machine
• Condition for driving heater relay depends on machine.
Related information

Defective intake air ing without turning starting switch ON.
1 heater relay (Internal
R18 (male) Resistance
trouble)
Between (1) – (2) 200 – 400 z
harness (Disconnection Wiring harness between E02 (female)
in wiring or defective con- (40) – R18 (female) (1)
tact in connector) Wiring harness between E02 (female)
Resistance Max. 1 z
(42) – R18 (female) (2)
Possible causes and
– R18 (female) (1) and chassis ground
with GND circuit)
– R18 (female) (2) and chassis ground
E02 Heater relay Voltage
4 Under operating
ler Max. 1 V
condition
Between (40) – (42)
Under stopping
20 – 30 V
condition
46 140E-5 Series
Circuit diagram related to intake air heater (Case of PC800/800SE/850/850SE/850LC-8)
140E-5 Series 47
E-69 Code [(143)/B@BAZG] Eng. Oil Press Low Torque Derate 1

Trouble Derating of torque by engine oil pressure reduction
(143) B@BAZG
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).
• Output drops.
on machine
Related information

Possible causes and
standard value in nor- This fault is indicated on only machine side when detected.
mal state 1 Accordingly, contents of troubleshooting depends on machine
on machine side
model. See Shop manual for machine.
E-70 Code [(146)/B@BCNS] Eng. Overheat 1

Trouble Engine overheat
(146) B@BCNS
Contents of trouble • Engine coolant temperature is above operating range.
Action of controller • Limits output and continues operation.
• Output drops.
on machine
Related information

Possible causes and
standard value in nor- This fault is indicated on only machine side when detected.
mal state 1 Accordingly, contents of troubleshooting depends on machine
on machine side
48 140E-5 Series
E-71 Code [(415)/B@BAZG] Eng. Oil Press. Low Speed Derate 1

Trouble Derating of speed by engine oil pressure reduction
(415) B@BAZG
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).
• Output drops.
on machine
Related information

Possible causes and
standard value in This fault is indicated on only machine side when detected.
normal state 1 Accordingly, contents of troubleshooting depends on machine
on machine side
140E-5 Series 49
SEN00154-02
© 2007 KOMATSU
All Rights Reserved
50
SEN00156-05
ENGINE 1SHOP MANUAL
140E-5 Series

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 Removal

q Special tools which are necessary for q In “Removal” section, the work procedures,
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 precautions and know-how to do the work, and
described as A1, ••• X1 etc. and their part the amount of oil and coolant to be drained are
numbers, part names and quantities are described.
described in the special tool list. q Common tools that are necessary for removal
q Also the following information is de- are described as [1], [2]••• etc. and their part
scribed in the special tool list. numbers, part names and quantities are not
1) Necessity described.
t : Special tools that cannot be substi- q Various symbols used in “Removal” section are
tuted and should always be used explained and listed below.
q : Special tools that will be useful if avail-
able and are substitutable with tools k : Precautions related to work safety
available on the market a : Guidance or precautions for the work
2) Distinction of new and existing special [*1] : This mark shows that instructions or precau-
tools tions for parts installation work are given in
N: Tools newly developed for this “Installation” section.
model. They have a new part num- 6 : Amount of oil or coolant to be drained
4:
ber respectively. Weight of part or component
R: Tools made available by redesign-
ing the existing tools which were
Installation
developed for other models. Each
of them has a new part number q Unless otherwise instructed, installation of
assigned by setting forward the parts is to be done in the reverse order to
part number of the existing tool. removal.
Blank : Tools already available for other q Instructions and precautions for parts installa-
models. They can be used without tion is shown with the mark ([*1], [*2]...) which
any modification. corresponds to the mark in “Removal” section.
3) Circle mark Q in sketch column: q Common tools that are necessary for installa-
q The sketch of the special tool is pre- tion are described as [1], [2]••• etc. and their
sented in the section of “Sketches of part numbers, part names and quantities are
special tools”. not described.
q Part No. of special tools starting with q Marks shown in the “Installation” section stand
for the following.
79 T-
* *** ****
- :
means that they are not available
from Komatsu Ltd. (i.e. tools to be k : Precautions related to work safety
made locally). a : Guidance or precautions for the work
2 : Type of coating material
3 : Tightening torque
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 SEN00156-05
2. Disassembly and assembly of assemblies
Special tools Disassembly

q Special tools which are necessary for dis- q In “Disassembly” section, the work procedures,
assembly and assembly of parts are precautions and know-how to do the work, and
described as A1, ••• X1 etc. and their part the amount of oil and coolant to be drained are
numbers, part names and quantities are described.
described in the special tool list. q Common tools that are necessary for disas-
q Also the following information is described sembly are described as [1], [2]••• etc. and
in the special tool list. their part numbers, part names and quantities
1) Necessity are not described.
t : Special tools that cannot be substi- q The meanings of the symbols used in “Disas-
tuted and should always be used. sembly” section are as follows.
q : Special tools that will be useful if avail-
able and are substitutable with tools k : Precautions related to work safety
available on the market. a : Guidance or precautions for the work
2) Distinction of new and existing special 6 : Amount of oil or coolant drained
tools
N: Tools newly developed for this
model. They have a new part num- Assembly
ber respectively. q In “Assembly” section, the work procedures,
R: Tools made available by redesign- precautions and know-how to do the work, and
ing the existing tools which were the amount of oil and coolant to be replenished
developed for other models. Each are described.
of them has a new part number q Common tools that are necessary for assem-
assigned by setting forward the bly are described as [1], [2]••• etc. and their
part number of the existing tool. part numbers, part names and quantities are
Blank : Tools already available for other not described.
models. They can be used without q The meanings of the symbols used in “Assem-
any modification. bly” section are as follows.
3) Circle mark Q in sketch column:
k
q The sketch of the special tool is pre- : Precautions related to work safety
sented in the section of “Sketches of a : Guidance or precautions for the work
2 : Type of coating material
special tools”.
3 : Tightening torque
q Part No. of special tools starting with
* *** ****
79 T- - :
means that they are not available
5 : Amount of oil or coolant to be replenished
from Komatsu Ltd. (i.e. tools to be
made locally).
Sketches of special tools
q Various special tools are illustrated for the local
manufacture.
140E-5 Series 3
Coating materials list 1

(Rev. 2009.02)
a The recommended coating materials such as adhesives, gasket sealants, and greases used for disas-
sembly and assembly are listed below.
a For coating materials not listed below, use the equivalent of products shown in this manual.
Cate- Komatsu
Part number Q'ty Container Main features and applications
gory code
• Used to prevent rubber gaskets, rubber cush-
LT-1A 790-129-9030 150 g Tube
ions, and cork plugs from coming out.
• Used for plastic (except polyethylene,
polypropylene, tetrafluoroethylene and vinyl
20 g Polyethylene
LT-1B 790-129-9050 chloride), rubber, metal, and non-metal parts
(2 pcs.) container
which require immediate and strong adhe-
sion.
Polyethylene • Features: Resistance to heat and chemicals.
LT-2 09940-00030 50 g
container • Used to fix and seal bolts and plugs.
790-129-9060
Adhesive: 1 kg • Used to stick and seal metal, glass, and plas-
LT-3 (Set of adhesive Can
Hardener: 500 g tics.
and hardener)
Adhesive
Polyethylene
LT-4 790-129-9040 250 g • Used to seal plugs.
container
Holtz MH 705 790-129-9120 75 g Tube • Heat-resistant seal used to repair engines.
• Quick-setting adhesive.
ThreeBond Polyethylene • Setting time: Within 5 sec. to 3 min.
790-129-9140 50 g
1735 container • Used mainly to stick metals, rubbers, plastics,
and woods.
• Quick-setting adhesive.
• Quick-setting type.
Aron-alpha Polyethylene
790-129-9130 2g (max. strength is obtained after 30 minutes)
201 container
• Used mainly to stick rubbers, plastics, and
metals.
• Features: Resistance to heat and chemicals.
Loctite Polyethylene
79A-129-9110 50 cc • Used for fitted portions used at high tempera-
648-50 container
tures.
• Used to seal various threaded portions, pipe
Polyethylene joints, and flanges.
LG-5 790-129-9080 1 kg
container • Used to seal tapered plugs, elbows, and nip-
ples of hydraulic piping.
• Features: Silicon-based heat and cold-resis-
tant sealant.
Gasket sealant
LG-6 790-129-9160 200 g Tube • Used to seal flange surfaces and threaded
portions.
• Used to seal oil pan, final drive case, etc.
• Features: Silicon-based quick-setting sealant.
LG-7 790-129-9170 1 kg Tube • Used to seal flywheel housing, intake mani-
fold, oil pan, thermostat housing, etc.
• Features: Silicon-based, heat and cold-resis-
LG-8
tant, vibration-resistant, impact-resistant seal-
ThreeBond 419-15-18131 100 g Tube
ant.
1207B
• Used to seal transfer case, etc.
4 140E-5 Series
Cate-
Komatsu code Part number Q'ty Container Main features and applications
gory
• Used for rough surfaces such as the circle gear
LG-9 top seal which does not need to be clamped,
ThreeBond 790-129-9310 200 g Tube water resistance of the clearance at the welded
1206D area, etc.
• Can be coated with paint.
Gasket sealant
LG-10 • Used as lubricant/sealant when the radiator

ThreeBond 790-129-9320 200 g Tube hoses are inserted.
1206E • Can be coated with paint.
LG-11 • Feature: Can be used together with gaskets.
ThreeBond 790-129-9330 200 g Tube • Used for covers of the transmission case and
1121 steering case etc.
ThreeBond
790-129-9090 100 g Tube • Gasket sealant used to repair engine.
1211
• Used to prevent scuffing and seizure of press-fit-
ted portions, shrink-fitted portions, and threaded
LM-P 09940-00040 200 g Tube
portions.
Molybdenum
• Used to lubricate linkages, bearings, etc.

lubricant
disulfide
• Spray type
• Thin molybdenum disulphide films are made on
metal surfaces to prevent the metals from scuff-
— 09995-00250 190 g Can
ing each other.
• Applicable for the drive shaft splines, needle
bearings, pins and bolts of various links, etc.
• Feature: Seizure and scuffing prevention com-
compound
prevention
pound with metallic super-fine-grain, etc.

Seizure
LC-G
— — Can • Used for the mounting bolt in the high tempera-
NEVER-SEEZ
ture area of the exhaust manifold and the turbo-
charger, etc.
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
G2-LI • Feature: Lithium grease with extreme pressure
SYG2-160LI
G0-LI Various Various lubrication performance.
SYGA-160CNLI
*: For cold district • General purpose type.
SYG0-400LI-A (*)
SYG0-160CNLI
(*)
• Used for parts under heavy load.
Caution:
Molybdenum SYG2-400M 400 g x 10 Bellows-type • Do not apply grease to rolling bearings like
disulfide grease SYG2-400M-A 400 g x 20 container swing circle bearings, etc. and spline.
Grease
LM-G (G2-M) SYGA-16CNM 16 kg Can • The grease should be applied to work equipment
pins at their assembly only, not applied for
greasing afterwards.
• Seizure resistance, heat resistance and water
Hyper White SYG2-400T-A
400 g Bellows-type resistance higher than molybdenum disulfide
Grease G2-T, SYG2-16CNT
container grease.
G0-T (*) SYG0-400T-A (*)
16 kg Can • Not conspicuous on machine since color is
*: For cold district SYG0-16CNT (*)
white.
Biogrease SYG2-400B
G2-B, G2-BT (*) SYGA-16CNB 400 g Bellows-type • Since this grease is decomposed by natural bac-
*: For use at high SYG2-400BT (*) container teria in short period, it has less effects on micro-
temperature and SYGA-16CNBT 16 kg Can organisms, animals, and plants.
under high load (*)
140E-5 Series 5
Cate-
Komatsu code Part number Q'ty Container Main features and applications
gory
• Feature: Silicone grease with wide using tem-
G2-S perature range, high resistance to thermal-oxi-
ThreeBond — 200 g Tube dative degradation and performance to prevent
1855 deterioration of rubber and plastic parts.
Grease
• Used for oil seals of the transmission, etc.

• Feature: Urea (organic system) grease with heat
G2-U-S resistance and long life. Enclosed type.
427-12-11871 2 kg Can
ENS grease • Used for rubber, bearing and oil seal in damper.
Caution: Do not mix with lithium grease.
SUNSTAR • Used as primer for cab side.
Glass
PAINT PRIMER 20 ml (Using limit: 4 months after date of manu-
container
580 SUPER facture)
SUNSTAR 417-926-3910
• Used as primer for glass side.
GLASS Glass
20 ml (Using limit: 4 months after date of manu-
PRIMER 580 container
facture)
Adhesive for cab glass

SUPER
• Used as primer for painted surface on cab
SUNSTAR
Glass side.
Primer
PAINT PRIMER 22M-54-27230 20 ml

container (Using limit: 4 months after date of manu-
435-95
facture)
• Used as primer for black ceramic-coated
SUNSTAR
surface on glass side and for hard polycar-
GLASS
22M-54-27240 150 ml Can bonate-coated surface.
PRIMER
(Using limit: 4 months after date of manu-
435-41
facture)
SUNSTAR • Used as primer for sash (Almite).
Glass
SASH PRIMER 22M-54-27250 20 ml (Using limit: 4 months after date of manu-
container
GP-402 facture)
SUNSTAR • “S” is used for high-temperature season
PENGUINE and “W” for low-temperature season as
Polyethylene
SEAL 580 417-926-3910 320 ml adhesive for glass.
container
SUPER “S” or (Using limit: 4 months after date of manu-
“W” facture)
Adhesive
• Used as adhesive for glass.

Sika Japan, Polyethylene
20Y-54-39850 310 ml (Using limit: 6 months after date of manu-
Sikaflex 256HV container
Adhesive for cab glass
facture)
SUNSTAR Ecocart • Used as adhesive for glass.
PENGUINE 22M-54-27210 320 ml (Special (Using limit: 6 months after date of manu-
SUPER 560 container) facture)
SUNSTAR • Used to seal joints of glass parts.
Polyethylene
PENGUINE 417-926-3920 320 ml (Using limit: 4 months after date of manu-
container
SEAL No. 2505 facture)
Caulking material
SEKISUI • Used to seal front window.

Polyethylene
SILICONE 20Y-54-55130 333 ml (Using limit: 6 months after date of manu-
container
SEALANT facture)
• Used to seal joint of glasses.
GE TOSHIBA
Translucent white seal.
SILICONES 22M-54-27220 333 ml Cartridge
(Using limit: 12 months after date of manu-
TOSSEAL 381
facture)
6 140E-5 Series
Special tools list 1

a Tools with part number 79*T-***-**** means that they are not available from Komatsu Ltd. (i.e. tools to be
made locally).
a 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
a New/Redesign: N ............ Tools newly developed for this model. They have a new part number respec-
tively.
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 for-
ward the part number of the existing tool.
Blank ..... Tools already available for other models. They can be used without any mod-
ification.
a Tools marked with Q in the sketch column are presented in the sketches of the special tools (See
“Sketches of special tools”).
New / Remodel
Necessity
Symbol
Sketch
Q'ty
Work item Part No. Part name Remarks
Disassembly and assembly of engine 1 790-501-2001 Engine repair stand t 1

A
assembly 2 790-901-1261 Bracket t 1
Removal and installation of cylinder
C 795-102-2103 Spring pusher t 1
head valve spring
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
Removal of oil
L 795-931-1100 Seal puller t 1
seal
795T-521-1111 Push tool t 1 N Q
Press fitting of
1 01050-31655 Bolt t 3
engine front seal
M 01050-31635 Bolt t 3
795T-521-1150 Push tool t 1 N Q Press fitting of
2 engine front seal
01050-31635 Bolt t 3 (sleeve type)
Removal and installation of engine front 795T-421-1260 Push tool t 1 N Q
seal and engine rear seal Press fitting of
1 01050-31640 Bolt t 4 engine rear seal
(standard type)
01643-31645 Washer t 8
795T-421-1240 Push tool t 1 N Q
N 2 01050-31645 Bolt t 4
01643-31645 Washer t 4 Press fitting of
engine rear seal
795T-421-1231 Push tool t 1 N Q (sleeve type)
3 01050-31645 Bolt t 4
01643-31645 Washer t 8
795-630-5500 Standard puller t 1
Used to remove
Removal of fuel supply pump P 01010-81090 Bolt t 2
pump unit
01643-31032 Washer t 2
Press fitting of valve stem seal Q 795-130-1720 Push tool t 1
140E-5 Series 7

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
drawings.
N1. Push tool
N2. Push tool
140E-5 Series 9
drawings.
N3. Push tool
10 140E-5 Series
140E-5 Series 11
SEN00156-05
© 2011 KOMATSU
All Rights Reserved
12
SEN00157-05
ENGINE 1SHOP MANUAL
140E-5 Series

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
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 assem-
bly.
a Before cleaning the engine, carefully seal
or remove the openings, electric parts,
and wiring connectors so that water will
not enter them. 4. Air cleaner bracket
1) Disconnect wiring harness clamp (1).
2. Setting engine assembly 2) Remove air cleaner bracket (2).
1) Prepare stable engine stands (Blocks [1]) a The type of the bracket depends on
and place the engine assembly on them the applicable machines.
4 Air cleaner bracket: 30 kg
so that it will not tip over.
a The weight depends on the applica-
ble machines.
4 Engine assembly: 2,000 kg
5. EGR cover
1) Remove covers (1), (2), and (3).
2) Drain the engine coolant and engine oil.
a The quantity of the oil depends on the
applicable machines.
6 Engine oil: Approx. 53 l
3. Starting motor assembly

1) Disconnect wiring harness (1) and con-
nector (2).
2) Remove 3 mounting bolts (3) and remove
starting motor assembly (4).
2 140E-5 Series
2) Remove covers (4), (5), (6), and (7). 8. Clamp and bracket
a Cover (6) is not installed to all the 1) Remove clamp (1) and brackets (2) and
models. (3).
2) Remove bracket (4).
6. Tube clamp and bracket

1) Remove clamps (1), (2), (3), and (4). 9. Bypass valve assembly
a The clamps hold the tubes from the 1) Remove the wiring harness clamp and
front and rear. disconnect connectors SBP (1) and BP
2) Remove brackets (5), (6), and (7). (2).
2) Remove clamps (3), (5), and (11) and

7. Bracket remove tubes (6) and (7).
Remove brackets (1), (2), and (3). 3) Remove bolts (8) and (9) and remove
bypass valve assembly (10).
140E-5 Series 3
10. EGR valve assembly 12. EGR tube

1) Remove the wiring harness clamp and 1) Remove EGR inlet pressure sensor tube
disconnect connectors SEGR (1) and (1).
EGR (2). Reference: EGR inlet pressure sensor is
applied to only machines Serial No. up to
530896.
2) Remove EGR tube (2).
2) Remove tubes (3) and (4).

3) 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) Remove turbocharger drain tube clamps

(6).
4) Remove air vent tube (7), bracket (8), and
EGR cooler inlet tube (9).
5) Remove EGR cooler coolant inlet tube
(10).
4 140E-5 Series
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).
3) Remove wiring harness (4) and 4 turbo-
charger lubrication tube clamps (5) and
remove turbocharger lubrication tube (6).
15. EGR valve bracket

Remove EGR valve bracket (1).
4) Remove the 4 nuts and remove air inlet
4 Bracket: 20 kg pipe and turbocharger assembly (7).
4 Air inlet pipe and turbocharger
assembly: 30 kg
140E-5 Series 5
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 adjust-
ment 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
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 thermo-
stat 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
22. Oil filter, fuel filter, and corrosion resistor 25. Oil filter head
Remove oil filter (1), pre-fuel filter (2), main fuel 1) Remove oil tubes (1) and (2) and the block
filter (3), and corrosion resistor (4). on the cylinder block side as a unit.
a Pre-fuel filter (2) may be installed on the 2) Remove oil filter head (3).
applicable machine side. a The type of the oil filter head depends
a Corrosion resistor is not set for some on the applicable machines.
models.
23. EGR valve and bypass valve oil drain tube

Remove drain tube (5).
26. Fuel filter head

1) Remove fuel tube (1).
2) Remove fuel filter head (2) and bracket (3)
as a unit.
24. Controller cover and oil filler
a The wiring harness clamp and the
1) Remove controller cover (1).
bracket are fixed together.
2) Remove the clamp and oil filler (2).
a The type of the fuel filter head
a The position of the oil filler depends
depends on the applicable machines.
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
6) 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.

1) Sling the air intake manifold temporarily.
2) Disconnect the clamps of connectors
TFUEL (1), TIM(2), PIM (3), and wiring
harness (4).
28. Air intake connector assembly 3) Disconnect fuel tube (5).
1) Disconnect EGR inlet pressure sensor 4) Remove wiring harness clamp (6) and
connector PEVA (1) and clamp of wiring tube clamp (7).
harness (2). 5) Remove clamp (8) of the high-pressure
Reference: EGR inlet pressure sensor is pipe.
applied to only machines Serial No. up to a Remove the 5 high-pressure pipe
clamps above the air intake manifold,
530896.
too.
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
6) Disconnect clamps (9), (10), (11), (12),

and (13) of the high-pressure pipe.
7) Remove the mounting bolts and air intake
manifold (14).
4 Air intake manifold: 45 kg
a When replacing the air heater,
remove connector (4).
8 140E-5 Series
30. Engine controller 33. Common rail and high-pressure pipe

Disconnect connector (1) and remove engine a Before removing the high-pressure pipe,
controller (2). loosen all of the clamps, brackets, and
sleeve nuts to give the high-pressure pipe
freedom.

1) Disconnect fuel hose (1).
a Fuel hose (1) may not be installed. 2) Remove 6 cylinder head covers (3).
2) Remove engine controller cooler (2). a At this time, the clamp of wiring har-
ness (4) comes off.
32. Plate 3) Remove clamps (5), (6), (7), (8), (9), (10),
Remove plate (3). and (11).
4) 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.
5) 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.
140E-5 Series 9
6) Disconnect fuel pressure sensor connec- 35. EGR oil pump assembly
tor PFUEL (15) and POIL (16). Remove the bolts and EGR oil pump assembly
7) Remove clamp (17) and the eye joint of (1).
tube (18) on the common rail side.
8) Remove special bolts (19) and remove
common rail (20).
36. Corrosion resistor tube and blow-by tube

1) Remove corrosion resistor tubes (1) and
(2).
34. Wiring and piping of fuel supply pump a Corrosion resistor is not set for some
assembly models.
1) Disconnect sensor connectors PCV1 (1), 2) Remove breather remote tube (3).
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.
37. Wiring harness assembly and sensor con-

nector
1) Disconnect the clamps of coolant temper-
ature sensor connector TWTR (1) and wir-
ing harnesses (2) and (3) and remove
bracket (4).
10 140E-5 Series
2) Disconnect the connectors of Ne sensor 38. Oil pan

NE (6), and atmospheric pressure sensor 1) Move the blocks which are supporting the
PAMB (7). engine to positions where you can remove
3) Remove the 6 injector connectors and the oil pan mounting bolts.
remove the wiring harness assembly. 2) While supporting oil pan (1) on a pallet lift,
4) Remove bracket (8). etc., remove the mounting bolts and oil
pan (1).
a Move lock [1] of the housing of con-

nector (7) in the direction of the arrow,
push down lock [2], and pull out con- 39. Suction tube
nector (7). Remove bracket (1) and suction tube (2).
5) Disconnect the injector connector accord- a After removing the suction tube, sling the
ing to the following procedure. engine. Set stable blocks at the front,
1] Apply flat-head screwdriver [1] to the rear, right, and left under the cylinder
stepped part (part (a)). block and place the engine on them.
2] While pressing stopper (1a), move a Arrange the above blocks so that you can
flat-head screwdriver [1] in direction rotate the crankshaft.
(X) to disconnect the connector.
40. Flywheel
1) Using sling [1], lift up flywheel (1) tempo-
rarily.
2) Remove the 8 mounting bolts and lift off
the flywheel.
a Take care that the flywheel will not
contact the Ne sensor on the back
side.
4 Flywheel: 65 kg
140E-5 Series 11
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 adjust-
ment 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
46. Push rod

Remove push rod (1).
6) Loosen the bolt of holder (8) of fuel injec-

tor (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 injec-
tor.
4) Disassemble the cylinder head assembly
1] Using tool C, compress the valve
spring and remove cotter (1).
2] Remove upper seat (2), outer spring
(3), and inner spring (4).
140E-5 Series 13
3] Remove valve stem seal (5) and 49. Front support

lower seat (6). Lift up front support (1) temporarily, remove the
4] Raise the cylinder head and remove mounting bolts, and lift off the front support.
valve (7). a The shape and weight of the front support
4 Front support: 65 kg
48. Damper assembly

Lift up damper assembly (1) temporarily,
remove the 6 mounting bolts (2), and lift off the
damper assembly. 50. Cam follower assembly
a The fan drive pulley may be installed. 1) Remove the 3 cover mounting bolts and
4
remove cover (1).
Damper assembly: 40 kg
2) Remove mounting bolts (3) and cam fol-
lower (2).
3) Remove snap rings (4) and remove lever

assembly (5) from shaft (6).
14 140E-5 Series
51. Front cover 4) Remove pump mounting bolts (4), bracket

1) Install eyebolts [1] and lift up the front (5), and fuel supply pump assembly (6).
cover temporarily. a While supporting the fuel supply
2) Remove the mounting bolts and sling front pump assembly, remove the mount-
cover (1). Remove the front cover by moving bolts.
ing it forward.
4 Front cover: 70 kg
54. Camshaft
1) Match the holes of cam gear (1) to mount-
52. Front oil seal ing bolts (2) and remove bolts (2).
Remove front oil seal (1) from the front cover.
2) Sling camshaft (3) temporarily. Pull out

the camshaft while turning it so that the
53. Fuel supply pump assembly and drive gear
cam bushing will not be damaged.
4 Camshaft: 20 kg
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 15
55. Oil pump assembly and sub idler gear 58. Piston cooling nozzle
1) Remove oil pump assembly (1). Remove the mounting bolts and piston cooling
2) Remove sub idler gear (2). nozzles (1) and (2).
a Be sure to remove the piston cooling noz-
zles before pulling out the piston.
56. Main idler gear

Remove mounting bolt (1) and main idler gear
(2). 59. Piston and connecting rod assembly
a Before removing the piston and connect-
ing rod assembly, measure its end play
with dial gauge [1], if necessary.
57. Setting of engine repair stand and under-

frame
1) Install tool A2 to the cylinder block. Sling
the engine and set it to tool A1. 1) Check the stamped No. of the connecting
2) Remove the 4 mounting bolts from each of rod cap.
2 underframes (1) and remove the under- q The cap No. and cylinder No. must be
frames. the same.
a The number of underframes (1) q The cap No. must be stamped on the
depends on the applicable machines. cam side.
a If the No. is not stamped, stamp it
before removing the connecting rod.
2) Rotate the crankshaft and bring the piston
to be removed to the bottom dead center.
3) Scrub the carbon off the top wall of the cyl-
inder liner with fine sandpaper.
4) Remove connecting rod cap mounting
bolts (1).
5) 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.
16 140E-5 Series
8) 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.
6) Push in and remove the piston and con-

necting rod assembly with a wood bar, etc.
from the oil pan side, while supporting pis-
ton (6) on the cylinder head side.
a Take care not to damage the inside of
the cylinder with a corner of the con-
necting rod.
7) Remove the other piston and connecting
3] Using tool D, remove piston ring (7).
rod assemblies according to the above
a Keep the piston, connecting rod, con-
procedure.
necting rod bearing, piston rings, and
a Take care not to damage the sliding
piston pin by cylinder.
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.
60. Crankshaft
a Before removing the crankshaft, measure
its end play with dial gauge [1], if neces-
sary.
140E-5 Series 17
1) Remove mounting bolts (2) of main cap 4) Remove upper thrust bearing (5).
(1).
2) Insert the bolts in the bolt holes of the
main cap and remove the cap, while shak-
ing it.
5) 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
a The No. 7 main cap has lower thrust to them and arrange them by journal
bearing (3). No.
3) Lift off crankshaft (4).

a When removing the crankshaft, take
care not to hit its sliding surfaces 61. Cylinder liner
against the cylinder block. a Before removing the cylinder liner, mea-
4 Crankshaft: 140 kg sure its projection with tool H, if necessary.
18 140E-5 Series
62. Using tool E, remove cylinder liner (1).
140E-5 Series 19
General assembly of engine 1 2) Before inserting the cylinder liners, pre-

pare the cylinder block according to the
a The shapes, quantity, locations, etc. of the following procedure.
parts depend on each applicable machine. 1] Remove the rust and scales from
Take care. faces A and B with sandpaper, etc.
a Clean each part carefully, and check it for until the machined surfaces are
bruise, flaw, cavity, etc. Make sure each oil or exposed.
coolant path is through. 2] Polish part R with sandpaper of about
No. 60 until it becomes a smooth
Tightening bolts by plastic-region turning angle rounded surface.
method 3] Polish parts R and h with sandpaper
a Bolts tightened by plastic-region turning angle of about No. 60 until they become
method smooth.
q Cylinder head mounting bolt If part R is sharp or has burrs, finish it
q Main cap mounting bolt with a scraper or sandpaper.
q Connecting rod cap mounting bolt Finish this surface particularly
q Flywheel mounting bolt smoothly so that it will not damage
a If the plastic-region turning angle method is the O-ring.
applied, the tightened bolts have permanent 4] If face B is so pitted that it cannot be
strain. Accordingly, the allowable number of repaired, replace the cylinder block.
using times of each bolt is limited. Observe 5] If faces A and R are pitted, finish
the following precautions. them smoothly.
q Before tightening each bolt, measure its 6] Check the counterbored part and
stem length and make sure that the result remove burrs. If chips or dust is on
is less than the using limit. If the stem is face C, the liner does not fit and cool-
longer than the using limit, do not reuse it ant may leak and the projection of the
but replace it. liner may become improper conse-
q Check each mounting bolt head for punch quently.
marks. If there are punch marks more a If the counterbored part is droop-
than the specified number, do not reuse it ing, corroded, or pitted, repair it.
but replace it.
1. Cylinder block
1) Install tool A2 to the cylinder block, and
then sling the cylinder block and set it to
tool A1.
4 Cylinder block: 390 kg
20 140E-5 Series
2. Cylinder liner 3) After fitting the liner O-ring, check it for

a Replace the O-ring and clevis seal with twist. If it is twisted, correct it with a
new ones. smooth rod (about 10 mm in diameter).
1) Check that the cylinder liner O-ring groove
and periphery of the liner are not rough-
ened 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 4) Apply gasket sealant to the parts of the
for distinction. cylinder block and cylinder liner which will
q O-ring (3): The whole ring is red. fit to the counterbored parts.
2 Clevis seal and O-ring:
a Wipe off dirt and oil with cloth from
Rubber lubricant (RF-1) the contact faces of the counterbored
a RF-1: DAIDO CHEMICAL INDUSTRY parts of the cylinder block and liner
CO., LTD. flange.
2 Cylinder block:
If RF-1 is not available, apply clean
engine oil SAE No. 30. Gasket sealant (LG-6)
a Since the clevis seal and O-ring are q Gasket sealant:
swollen and deteriorated by oil, apply 2 – 3 mm in diameter
a small amount of oil to them thinly q Overlap (a) of gasket sealant:
with a brush just before fitting them. 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.
140E-5 Series 21
5) Insert cylinder liner (1) in the cylinder 10) Using tool H, measure the projection of
block slowly, taking care not to damage the cylinder liner.
the O-ring. a When measuring the projection of the
6) Push in cylinder liner (1) further with both liner, tighten the liner with a plate so
hands. that it will not be lifted by the O-ring.
a If the liner does not enter the cylinder q Projection of liner: 0.07 – 0.15 mm
smoothly, the O-ring may be broken. a If the gasket sealant is projected from
In this case, check the cylinder block the fitting parts of the cylinder block
for burrs. and cylinder liner up to the top of the
7) Using tool F, press fit cylinder liner (1) to cylinder block, wipe it off.
the cylinder block.
8) To prevent the gasket sealant from pro- 3. Crankshaft

jecting through the clearance between the 1) Fit upper main bearing (6) to the cylinder
block and liner after the cylinder head is block, matching the projection of the
tightened, tighten the cylinder head tem- former to the cut of the latter.
porarily with the used head gasket a An oil hole is made on the upper main
inserted. bearing.
a At this time, observe the following a Before fitting the bearing, make sure
tightening torque and tightening that its back side is free from foreign
order. matter.
3 Temporary tightening torque: 2 Inside of bearing: Engine oil (EO30)
137 – 157 Nm {14 – 16 kgm}
9) Remove the cylinder head and wipe off 2) Drive the dowel pin so that it will be pro-
the gasket sealant projected from the jected by 2.7 – 3.4 mm from the block end
counterbored part. and then install upper thrust bearing (5) to
a Be sure to perform steps 8) and 9) the No. 7 journal.
above since the projected gasket a Install the thrust bearing with the
sealant can deform the grommet of grooved surface on the crankshaft
the head gasket. side.
22 140E-5 Series
3) Sling crankshaft (4) and install it to the cyl- 6) Make sure that the journal No. stamped at
inder block. the center of main cap (2) and the journal
a When replacing the crank gear, heat it No. of the cylinder block are the same and
with a bearing heater (30 A) (Set tem- then install the main cap.
perature: 150°C) and fit it just after it a Install the main cap with the cast let-
is heated. ter (F) toward the front of the engine.
a When installing the crankshaft, take
care not to hit its sliding surfaces
against the cylinder block.
4 Crankshaft: 140 kg
2 Cylinder block journal:
Engine oil (EO30)
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:
4) Fit the lower main bearing to the main cap,
Min. 176.3 mm
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 mat-
ter.
5) Drive the dowel pin of cap No. 7 so that it
will be projected by 2.7 – 3.4 mm from the
cap end and then install thrust bearings
(3) to both sides.
a Install each thrust bearing with the
grooved surface on the crankshaft
side.
140E-5 Series 23
8) Tighten main cap mounting bolts (1) 10) Check that the crankshaft turns smoothly.
according to the following procedure. 11) Measure the end play of the crankshaft
a Tighten the bolts from the center one with dial gauge [1].
to the outer ones in order. a End play: 0.140 – 0.315 mm
2 Threaded portion of mounting bolt a If the end play is out of the standard,
and washer: correct it. For details, see “Structure,
Engine oil (EO30) function and maintenance standard”.
3 Mounting bolt
1st time:
108 – 128 Nm {11 – 13 kgm}
2nd time:
230 – 240 Nm {23.5 – 24.5 kgm}
3rd time:
Using tool J, tighten the bolt by
90° (+30°/0).
4. 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
a When not using tool J, make 1) Using tool D, fit piston rings (7) to the pis-
marks (b) on the main cap and ton.
bolt with paint, then tighten the a Fit the top ring and second ring to the
bolt by 90° (+30°/0). piston with the stamped mark side up.
9) Make punch mark (c) on the mounting bolt q Stamp on top ring: 1RS
head. q Stamp on second ring: 2RX
a When a new bolt is used, do not a Take the expander out of the oil ring
make a punch mark on its head. 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.
24 140E-5 Series
2) Set the abutment joint of each piston ring 7) Insert piston and connecting rod assembly
as shown in the following figure. (8) in the cylinder block so that the cast
a Adjust oil ring so that the joint of the part number on the connecting rod will be
expander will be at 180° to the abut- directed to the front of the engine (the
ment joint of the oil ring. stamped cylinder number will be on the
camshaft side).
a Referring to step 2), check the abut-
ment joint of each piston ring again.
2 Inside of connecting rod bearing and
inside of cylinder:
Engine oil (EO30)
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 direc-
tion, then insert piston pin (5) to
assemble connecting rod (4) and pis-
ton (6).
4) Fit snap rings (3) on both sides of the pis-
ton pin to secure the piston pin.
8) Using tool G, reduce the piston ring and

push in the piston head with a wood bar,
etc. into the cylinder block.
5) Fit the upper bearing to the connecting
rod, matching the projection of the former
to the cut of the latter.
ter.
6) Set the crankshaft so that the cylinder to
be installed will be at the bottom dead
center.
140E-5 Series 25
9) 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.
is 5.)
Min. 95.0 mm
10) Fit lower bearing (9) to the connecting rod

cap, matching the projection of the former
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 connect-

ing rod (4), matching yellow marks (a) on
them to each other.
ter.
2 Inside of connecting rod cap bearing:
Engine oil (EO30)
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).
26 140E-5 Series
13) After tightening the bolt, make a punch 2) Install piston cooling nozzles (1) and (2) to
mark (c) on its head. each cylinder in order.
a When a new bolt is used, do not a Install the piston cooling nozzles hav-
make a punch mark on its head. ing the stamps of (F1) to the front side
of the cylinder and install those hav-
ing the stamps of (N1) to the rear side
of the cylinder.
a Push in each piston cooling nozzle
with the hand until its flange touches
the cylinder block and then tighten the
mounting bolt.
a Take care not to mistake the hexago-
nal part of the nozzle for the mounting
bolt.
3 Mounting bolt:
59 – 74 Nm {6.0 – 7.5 kgm}
14) Turn the crankshaft to check that it rotates

normally.
15) Measure the side clearance of the con-
necting rod with dial gauge [1].
a Side clearance: 0.100 – 0.274 mm
a If the side clearance is out of the stan-
dard, correct it. For details, see
“Structure, function and maintenance
standard”.
6. Underframe
Install underframes (1).
a The number of the underframes depends

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.
140E-5 Series 27
7.Main idler gear

1) Install bearing (3) and shaft (2) to the out-
side of main idler gear (1) and install bear-
ing (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 crank-
shaft gear to that of main idler gear (1),
tighten mounting bolt (5).
3 Mounting bolt:
784 ± 44.1 Nm {80 ± 4.5 kgm}
9. Camshaft
1) Install camshaft (1) to the cylinder block,
turning it so that it will not damage the
cam bushing.
a If the cam gear is replaced, heat the
new gear in an electric oven, etc. and
heat it at 220 – 240°C for 30 – 60
minutes and then install it by shrink
fit.
4 Camshaft: 20 kg
2 Camshaft journal surface:
8. Sub idler gear and oil pump assembly
Engine oil (EO30)
1) Install sub idler gear (2), shaft (4) and
plate (3) together.
a Direct the stamp of TOP on shaft (4)
up and direct the chamfered inside
edge toward the gear.
3 Sub idler gear mounting bolt:
377.6 – 426.6 Nm {38.5 – 43.5 kgm}
2) Install oil pump assembly (1).
3 Oil pump assembly mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
28 140E-5 Series
2) Matching the stamped (C) of the camshaft 4) Fit the O-ring and install cover (3).
gear to that of the main idler gear, tighten 3 Mounting bolt:
mounting bolt (2). 9.8 – 12.7 Nm {1.0 – 1.3 kgm}
3 Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}

1) Fit the key to the shaft of fuel supply pump
10. Cam follower assembly
assembly (6) and install them to the cylin-
1) Install 2 lever assemblies (5) to shaft (6).
der block.
a Insert the cam followers so that the
2) Tighten mounting bolts (4) and install
ball end of the shaft will be directed
bracket (5).
2 Mounting bolt: Adhesive (LT-2)
toward the rear of the engine.
2) Install snap rings (4).
3) Install cam follower assembly (1), match-

ing it to the dowel pin, and then tighten
mounting bolts (2).
3 Mounting bolt:
44.1 – 58.8 Nm {4.5 – 6.0 kgm}
140E-5 Series 29
3) Install fuel supply pump drive gear (3) to q Standard backlash of each gear
the fuel supply pump shaft and tighten
Position Range (mm)
mounting nut (1).
a When installing to the fuel supply A 0.141 – 0.425
pump shaft, set stamp (B) of fuel sup- B 0.129 – 0.391
ply pump drive gear (3) to stamp (B) C 0.129 – 0.391
of the main idler gear (circled in the
D 0.141 – 0.425
figure).
3 Mounting nut: E 0.080 – 0.417
176 – 196 Nm {18 – 20 kgm} F 0.095 – 0.346
G 0.118 – 0.369
q Standard end play of each gear

Position Range (mm)
1 0.1 – 0.25
2 0.06 – 0.24
3 0.11 – 0.23
a If the end play is out of the standard, cor-

rect 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.
30 140E-5 Series
14. Front cover and front support 1) Set large inside diameter side (a) of plas-
a The front cover and front support are tic inside cylinder (2) to the end of crank-
installed with the same mounting bolts. shaft (3).
1) Fit the gasket and install front cover (1) a Take care not to mistake the direction
temporarily, using eyebolt [1]. of the plastic inside cylinder.
2) 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.
3) Tighten the front cover mounting bolts per-
manently.
2) Push the metal ring of front seal (1)

evenly as if you are passing over the large
inside diameter side of plastic inside cylin-
der.
a Hit the metal ring of front seal with
plastic hammer evenly.
Do not hit it strongly.
3) After pushing in the seal, remove plastic
inside cylinder (2).
a When removing the inside cylinder,
take care not to damage the seal lip.
15. Front oil seal
Install front oil seal (1) according to the follow-
ing 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.
140E-5 Series 31
4) 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 55-
mm bolts with the 35-mm bolts and
tighten them.
a Seal driving distance (a) from crank-
shaft: 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) Fit inner spring (4) and outer spring (3)

and then install upper seat (2).
5) 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 fit-
ted 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).
32 140E-5 Series
7) Before tightening the cylinder head

is 5.)
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)
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 Mounting bolt:
a Tighten the mounting bolts according
to the following procedure.
1st time:
137 – 157 Nm {14 – 16 kgm}
2nd time:
284 – 294 Nm {29.0 – 30.0 kgm}
3rd time:
90° (+30°/0).
140E-5 Series 33
18. Crosshead 3) Insert holder (2) in fuel injector (1), then

Install crosshead (1). insert them simultaneously, directing the
a Adjust the crosshead according to the fol- injector connector (5) to the hole to insert
lowing procedure. the fuel high-pressure pipe.
1] Loosen the locknut and return the 4) Fit the ball washer to bolt (3) and tighten
adjustment screw. holder (2) temporarily.
2] Holding the top of the crosshead 2 Ball washer: Engine oil (EO30)
lightly, tighten the adjustment screw. 5) Insert high-pressure pipe sleeve (4) in the
3] After the adjustment screw touches hole to insert the fuel high-pressure pipe
the valve stem, tighten it further by and fix it temporarily, matching it to injector
20°. connector (5).
4] Tighten the locknut at this point. a Tighten the sleeve nut on the com-
3 Locknut: mon rail side temporarily, too, to pre-
58.7 ± 5.9 Nm {6.0 ± 0.6 kgm} vent the high-pressure pipe from
leaning.
6) Tighten holder (2) permanently.
a While pulling the high-pressure pipe
in the opposite direction to the injec-
tor, tighten bolt (3).
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 fol-
lower.
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 injec-
tor.
34 140E-5 Series
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 connect-
ing 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) 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 O-
ring (4) is not projected from the end
of the sleeve.
a 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
1) Secure common rail (1) temporarily with
and then tighten it with the spanner.
special bolts (2).
a If sleeve nut (5) does not catch the
2) Fit O-ring (4) to high-pressure pipe sleeve
threads, press its end with a small rod,
(3). Matching them to the injector connec-
etc. toward the injector and turn the span-
tor, tighten sleeve nut (5) and sleeve nut
ner.
(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.)
3) Tighten special bolts (2) permanently.
3 Special bolt:
59 – 74 Nm {6.0 – 7.5 kgm}
140E-5 Series 35
5) Tighten clamps and brackets (7), (8), (9), 22. Rocker arm and shaft assembly
(10), (11) and (12) with the hand first, then Install rocker arm and shaft assembly (1) and
tighten clamp side permanently. tighten mounting bolts (2), (3) and (4).
3 Clamp bolt: a Note that the lengths of the mounting bolts
9.8 ± 1.0 Nm {1.0 ± 0.1 kgm} are different.
6) Tighten clamps and brackets (7), (8), (9), Mounting bolt (2): Stem length; 120 mm
(10), (11) and (12) of bracket side perma- Mounting bolt (3): Stem length; 90 mm
nently. Mounting bolt (4): Stem length; 75 mm
7) Install covers (13) and (14) to the sleeve a Before tightening the mounting bolts,
nut. check that the ball of the adjustment screw
a Direct the cut of cover (13) down and is fitted to the socket of the push rod.
direct the cut of cover (14) toward the 3 Mounting bolt:
cylinder block. 93 – 103 Nm {9.5 – 10.5 kgm}
8) Tighten clamps and brackets (15), (16),

(17), (18), (19) and (20) with the hand.
23. Adjusting valve clearance
9) Tighten clamp (21) and frame (22) with the
a Adjust the clearance between the cross-
hand.
head and rocker arm to the following
10) Tighten clamp (21) permanently.
3 Clamp bolt:
value.
a Valve clearance (when cold)
9.8 ± 1.0 Nm {1.0 ± 0.1 kgm}
11) Tighten frame (22) permanently. Unit: mm
12) Tighten clamps and brackets (15), (16), Air intake valve Exhaust valve
(17), (18), (19) and (20) of clamp side per-
0.35 ± 0.02 0.57 ± 0.02
manently.
3 Clamp bolt:
a Rotate the crankshaft and adjust the valve
9.8 ± 1.0 Nm {1.0 ± 0.1 kgm}
clearance of each cylinder in the firing
order of 1 – 5 – 3 – 6 – 2 – 4.
(17), (18), (19) and (20) of bracket side
1) Rotate the crankshaft forward and match
permanently.
stamped line of “1.6 TOP” (a) on vibration
damper (1) to pointer (2), watching the
movement of the valve.
36 140E-5 Series
2) Insert thickness gauge I between rocker 2 Threaded portion and seat of

arm (3) and crosshead (4) and tighten bolt: Engine oil (EO30)
adjustment screw (5) to the degree that 4 Flywheel housing: 75 kg
the thickness gauge can be moved lightly.
3) Tighten locknut (6) to secure adjustment
screw (5).
3 Locknut:
53 – 64.7 Nm {5.4 – 6.6 kgm}
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 tempo- a Tighten the flywheel housing mount-
rarily. ing bolts in the following order in 2
3 Mounting bolt: steps.
29.4 – 34.3 Nm {3.0 – 3.5 kgm} 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}

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 2) After installing the flywheel housing, mea-
care not to damage the oil seal. sure its facial runout and radial runout with
2 Mating face:
dial gauge [1].
Gasket sealant (LG-7) q Radial runout: Max. 0.30 mm
q Facial runout: Max. 0.30 mm
140E-5 Series 37
26. Rear oil seal 1. Procedure for installing standard seal

a Check the Teflon seal (Laydown lip seal) a When installing rear seal (4), do not apply
by checking the wear of the shaft and oil or grease to the shaft and seal lip.
replace it with the "standard seal" or 1) Set large inside diameter side (b) of guide
"sleeved seal". (8) of rear seal (4) to the end of crankshaft
If the shaft is worn to the degree of luster (6).
(If wear which you feel with your finger is a Take care extremely not to mistake
less than 10 mm) and does not have any the direction of the plastic inside cylin-
flaw, install "standard seal A". In other der.
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
2) 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
3) After pushing in the seal, remove guide
(8).
a Clean, degrease, and dry the contact sur-

face against the flywheel housing.
a Clean, degrease, and dry the seal lip sur-
face (periphery of the crankshaft).
a Check that the end corners and lip sliding
surfaces of the crankshaft are free from
flaw, burr, and rust of the housing.
38 140E-5 Series
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)
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 crank-
shaft (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 2) Set sleeve (7) of the rear seal to the end of
not to damage the lip with the tool set crankshaft (6) and tighten the 4 bolts
etc. evenly to press fit sleeve and rear seal
a After press fitting the seal, remove the assembly (9) until the end of tool N2
red sealant layer from its periphery. reaches the end of crankshaft (6).
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).
140E-5 Series 39
4) Tighten the 4 bolts evenly to press fit 2nd time: Using tool J, tighten the bolts by 90°
sleeve and rear seal assembly (9) until the (+30°/0) in the order of (1) – (8).
end of tool N3 reaches the end of crank-
shaft (6).
seal) first until the bolt without washer
stops and then tighten the bolt with 2
washers.
a Rear seal driving depth:
13.2 ± 0.2 mm from end
of crankshaft

(f) on the flywheel with paint, then
tighten the bolts by 90° (+30°/0) in the
order of (1) – (8).
a After tightening each bolt, make punch
mark (g) on its head to show the number
of tightening times.
a When a new bolt is used, do not make a
punch mark on its head.
a 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 fly-
wheel (1) and install it to the crankshaft and
a When installing the flywheel, match the
dowel pin of the crankshaft to the hole of
the flywheel.
a Take care not to bring the flywheel in con-
tact with the speed sensor.
2 Threaded portion and seat of bolt:
Engine oil (EO30)
4 Flywheel: 60 kg
a After installing the flywheel, measure its
facial runout and radial runout with dial
gauge [1].
q Radial runout: Max. 0.13 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}
40 140E-5 Series
28. Suction pipe 2] Install holder (3) to connector (1) and

Install the O-ring to oil pump and install suction push in connector (1) to the position
tube (1), then install bracket (2) to the cylinder where the O-ring is fitted.
block. 3] Fix holder (3) with mounting bolt (4).
4] Insert spring clamp (8) in the injector

29. Oil pan connector and secure wiring harness
1) Install the gasket and push up oil pan (1) clamp (9) with bolt (10).
with a pallet lift, etc. and tighten the 5] Install wiring harness terminal (6) to
mounting bolts. fuel injector (5) and tighten 2 nuts (7).
a Apply gasket sealant to the joint part. a Stretch the wiring harness with-
2Joint part: Gasket sealant (LG-7) out slack and press it against the
2) Connect the level sensor connector. 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 sen-

sor connector
1) Install the engine wiring harness assem-
bly.
2) Install the injector wiring harness assem-
bly.
a Since the wiring harness assembly fit-
ted with the O-ring is difficult to insert
from inside, install it according to the
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.
140E-5 Series 41
3) Install bracket (11). 32. Piping and wiring of supply pump

4) Connect NE sensor connector NE (13), 1) Install bracket (1).
and atmospheric pressure sensor connec- 2) Install high-pressure pipes (2) and (3).
tor PAMB (14). 3 Sleeve nut of tube:
(Pump side)
39.2 – 49 Nm {4 – 5 kgm}
(Common rail side)
39.2 – 58.8 Nm {4 – 6 kgm}
3) Install the splash prevention cover and
install clamps (4), (5), and (6).
a Direct the cut of the splash prevention
cover on the supply pump side toward
the block and direct that on the com-
mon rail side down.
a Tighten clamps (4), (5) and (6) with
the hand first, and then tighten them
permanen tly. (Tightening order:
(4)o(5)o(6))
5) Install bracket (15) and install the clamps 3 Clamping bolt:
of wiring harnesses (16) and (17). 9.8 ± 1.0 Nm {1.0 ± 0.1 kgm}
6) Connect coolant temperature sensor con- 4) Install fuel tubes (7) and (8).
nector TWTR (18). 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}
31. EGR oil pump assembly 3 Sleeve nut of tube (11):
Install EGR oil pump assembly (1). 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}
42 140E-5 Series
7) Connect sensor connectors PCV2 (18),

PCV1 (19) and G (20).
35. Engine controller

Install engine controller (2) and connect con-
33. Breather remote tube and corrosion resis- nector (1).
tor tube
1) Install breather remote tube (1).
2) Install corrosion resistor tubes (2) and (3)
temporarily.
models.

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.
34. Engine controller cooler 3 Mounting bolt:
1) Install the O-ring and plate (1). 58.8 – 73.5 Nm {6.0 – 7.5 kgm}
2) Install engine controller cooler (2) and fuel
hose (3).
a Install the hose on the engine control-
ler 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 43
2) Install brackets (7), (8), (9), (10) and (11). 37. Air intake connector assembly
3) Install brackets (2), (3), (4), (5) and (6). 1) Install joint housing (6) to bracket (7).
2) Install venturi nozzle, air heater (5) and
connector (4) to joint housing (6).
a Direct the terminal of the air heater
toward the original direction of the
engine. (The direction of the terminal
depends on the applicable
machines.)
4) Tighten clamp (12) of the high-pressure

pipe.
3 Clamp bolt:
9.8 ± 1.0 Nm {1.0 ± 0.1 kgm}
5) Tighten corrosion resistor tube clamp (13)
and wiring harness clamp (14) temporarily.
a The type of the corrosion resistor
depends on the applicable machines. 3) Fit the gasket and install air intake con-
a Corrosion resistor is not set for some nector (3) to the air intake manifold and
models. joint housing.
6) Install the clamps of sensor connectors 4) Install EGR inlet pressure sensor PEVA
TFUEL (15), TIM (16), PIM (17) and wiring (1).
harness (18). Reference: EGR inlet pressure sensor is
7) Install fuel tube (19). applied to only machines Serial No. up to
3 Joint bolt: 530896.
(Head side) 5) Install the clamp of wiring harness (2).
9.8 – 12.7 Nm {1.0 – 1.3 kgm}
(Block side)
19.6 – 29.4 Nm {2.0 – 3.0 kgm}
44 140E-5 Series
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 appli-
cable machines.
models.
1) Install corrosion resistor head (10), fuel fil-
ter 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 tem-
porarily in step 33-2).
a Tighten the clamp on the cylinder
block side, too. 40. Oil filter head
3 Tube joint bolt: a The type of the oil filter head depends on
24.5 – 34.3 Nm {2.5 – 3.5 kgm} the applicable machines.
3) Install fuel tube (3). 1) Install oil filter head (3).
3 Tube joint bolt: 2) Fit the O-ring and install oil tubes (2) and
(Pump side) (1).
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).
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
2) Install controller cover (1).
39. Pre-fuel filter head

1) Install pre-fuel filter head (2) and bracket
(3) as a unit.
3 Fuel tube joint bolt (Filter side):
43 – 47 Nm {4.4 – 4.8 kgm}
a The type of the pre-fuel filter head
140E-5 Series 45
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).
models.
a Pre-fuel filter (2) may not be installed.
2) Install bypass tube (4) fitted with thermo-

stat (3) and O-ring to thermostat housing
(2).

Using eyebolts [1] and guide bolt [2], fit the
gasket, install oil cooler assembly (1) and
tighten the 16 mounting bolts.
3) Fit the gasket and install thermostat

assembly (5).
4) Insert bypass tube (4) in the water pump
assembly and install snap ring (6).
5) Tighten the water pump assembly mount-
ing bolts permanently.
6) Fit the gasket and install tubes (7) and (8).
7) Install alternator drive pulley (9).
44. Water pump assembly and thermostat

assembly
1) Fit the O-ring, install water pump assem-
bly (1) and tighten the mounting bolts tem-
porarily.
a The mounting bolts are also used to
secure the front cover.
46 140E-5 Series
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).

1) Fit the gasket and install tube (8).
2) Fit the gasket and install air inlet pipe and
turbocharger assembly (7).
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.
3) Fit the gasket and install lubrication tube
(6) and 4 clamps (5).
a Tighten the 3 bolts of (1) – (3) tempo-
3 Tube joint bolt:
rarily first in the numerical order, and
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
tighten the bolts (4) – (24) temporarily
4) Install wiring harness (4).
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 47
5) Fit the gasket and install turbocharger oil 2) Install bracket (8).
drain tube (2). 3) Fit the O-ring and the gasket and install
6) Install exhaust connector (3) and heat EGR cooler coolant inlet tube (10).
insulation cover (1). 3 Rubber hose:
(Nut of tube clamp U-bolt)
10.8 – 26.5 Nm {1.1 – 2.7 kgm}
4) Fit the gasket and install EGR cooler gas
inlet tube (9).
3 Mounting bolt:
44.1 – 53.9 Nm {4.5 – 5.5 kgm}
5) Install air vent tube (7).
3 Joint bolt:
19.6 – 29.4 Nm {2.0 – 3.0 kgm}
6) Install turbocharger drain tube clamps (6).
48. EGR valve bracket

Fit the gasket to the joint housing and sling and
install bracket (1).
4 Bracket: 20 kg
7) 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}
8) 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.
48 140E-5 Series
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 pres-
sure sensor tube (1).
Reference: EGR inlet pressure sensor is
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}
140E-5 Series 49
4) Connect wiring harness connectors BP (2) 57. Bracket and tube clamp
and SBP (1) and install the clamp. 1) Install brackets (7), (6) and (5).
2) Install clamps (4), (3), (2) and (1).
55. Bracket and clamp

1) Install brackets (4), (3) and (2). 58. EGR cover
2) Install clamp (1). 1) Install covers (7), (6), (5) and (4).
a Cover (6) may not be installed.
56. Bracket 2) Install covers (3), (2) and (1).

Install brackets (3), (2) and (1).
50 140E-5 Series
59. Starting motor assembly 61. Tightening torque for sensor

1) Fit the gasket and install starting motor If a sensor is replaced, tighten the new sensor
assembly (4) with bolts (3). to the following torque.
2) Install wiring harness (1) and alternator a The engine speed sensor may not be
connector terminal R (2). installed.
Sensor name Tightening torque
NE 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}
7.3 – 12.7 Nm {0.7 – 1.3 kgm}
(Big bolt)
Atmospheric pressure
4.1 – 9.5 Nm {0.4 – 1.0 kgm}
(Small bolt)
Fuel pressure Never disassemble.
60. Air cleaner bracket and wiring harness
1) Install air cleaner bracket (2).
(*): Reference: EGR inlet pressure sensor is
a The type of the bracket depends on
the applicable machines.
530896.
2) Install wiring harness clamp (1).
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 fol-
lowing procedure.
3) After assembling, check the installing con-

dition of the wiring harness clamp.
140E-5 Series 51
a 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 injec-
tor, and joints of the high-pressure piping.
2) Run the engine at speed below 1,000 rpm
and stop it after its speed is stabilized.
3) Check the fuel piping and devices for fuel
leakage.
a Check mainly around the high-pres-
sure circuit parts coated with the color
checker for fuel leakage.
a If any fuel leakage is detected, repair
it and check again from step 2).
4) Run the engine at low idle.
leakage.
6) Run the engine at high idle.
leakage.
8) Run the engine at high idle and load it.
a When checking while the components
to be checked are mounted on the
relieve the hydraulic pump.
leakage.
a If no fuel leakage is detected, check
is completed.
52 140E-5 Series
140E-5 Series 53
SEN00157-05
© 2011 KOMATSU
All Rights Reserved
54
SEN00158-05
ENGINE 1SHOP MANUAL
140E-5 Series

(EGR-less)
Disassembly and assembly, Part 2 (EGR-less) .............................................................................................. 2
General disassembly of engine............................................................................................................ 2
General assembly of engine .............................................................................................................. 18
140E-5 Series 1
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 assem-
bly.
a Before cleaning the engine, carefully seal
or remove the openings, electric parts,
and wiring connectors so that water will
not enter them. 4. Air cleaner bracket
1) Disconnect wiring harness clamp (1).
2. Setting engine assembly 2) Remove air cleaner bracket (2).
1) Prepare stable engine stands (Blocks [1]) a The type of the bracket depends on
and place the engine assembly on them the applicable machines.
so that it will not tip over.
a The weight depends on the applica-
ble machines.
4 Engine assembly: 1,900 kg
5. Heat insulation cover

1) Remove covers (1), (2), (3), (4) and (5).
2) Drain the engine coolant and engine oil.
a The quantity of the oil depends on the
applicable machines.
6 Engine oil: Approx. 53 l
3. Starting motor assembly

1) Disconnect wiring harness (1) and con-
nector (2).
2) Remove 3 mounting bolts (3) and remove
starting motor assembly (4).
2 140E-5 Series
6. Bracket 2) Remove wiring harness (3) and turbo-

Remove brackets (1) and (2), stay (3), brack- charger lubrication tube clamp (4) and
ets (4) and (5). remove turbocharger lubrication tube (5).
3) Sling turbocharger assembly (6) and

7. Front plate exhaust connector (7).
Remove front plate (1). 4) Remove the mounting nuts to remove the
4
turbocharger and connector assembly.
4 Turbocharger and intake connector
Bracket: 20 kg
assembly: 40 kg
1) Remove heat insulation cover (1) and oil 9. Exhaust manifold
drain tube (2). Remove the 24 mounting bolts and exhaust
manifold (1).
140E-5 Series 3
10. Alternately assembly 12. Water pump assembly

1) Disconnect terminal B (1) and terminal R 1) Remove alternator drive pulley (1).
(2). 2) Remove tubes (2) and (3).
2) Remove cover (3). 3) Remove water pump assembly (4).
3) Loosen alternator mounting bolt (4) and
clamping bolt (5).
4) Loosen locknut (6) and tension adjust-
ment nut (7) and remove V-belt (8).
5) Remove mounting bolt (4) and clamping
bolt (5) and remove alternator assembly
(9).

1) Using eyebolts [1], sling the oil cooler
assembly temporarily.
2) Remove the 16 mounting bolts and oil
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 140E-5 Series
14. Corrosion resistor, oil filter and fuel filter 16. Fuel filter head
1) Remove corrosion resistor. 1) Remove fuel tube clamp (1), then remove
2) Remove oil filters (1) and main fuel filters fuel tubes (2) and (3).
(2). 2) Remove fuel tube (4).
a The locations of the fuel filter and oil filter 3) Remove fuel filter head (5).
may be different from the photo, depend-
ing on the applicable machine.
models.
17. Plates, electric priming pump cover and oil

filler
a Manual priming pump is set for some
models. (See the procedure of "with
15. Controller cover and oil filler head EGR" )
1) Remove controller cover (1). 1) Remove plates (1), (2) and (3).
2) Remove oil filter head (2). 2) Remove electric priming pump cover (4).
a The type of the filter head depends on 3) Remove the clamp and oil filler (5).
3) Remove oil tubes (3) and (4) and the block
on the cylinder block side as a unit.
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).
140E-5 Series 5
2) Remove high-pressure pipe bracket

mounting bolts (7).
19. Electric priming pump

a Electric priming pump is not set for some 3) Remove the mounting bolts and remove
models. air intake connector (1) and joint housing
1) Remove joint bolts (1) and fuel tube (2). (8) together.
2) Remove joint bolt (3) and fuel tube (4). 4 Air intake connector assembly:
3) Remove joint bolts (5) and (6) and fuel 40 kg
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.
a When replacing air heater (9),

remove connector (10).
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).

1) Sling the air intake manifold temporarily.
2) Disconnect the clamps of connectors
TFUEL (1), TIM (2), PIM (3), and wiring
harness (4).
6 140E-5 Series
3) Remove wiring harness clamp (5) and

high-pressure pipe clamp (6). 22. Engine controller
Disconnect connector (1) and remove engine
controller (2).
4) Remove wiring harness clamps (7), (8),

(9), (10) and (11) at the top of the air
intake manifold.
5) Remove fuel tube (12). 23. Engine controller cooler
1) Disconnect fuel hose (1).
2) Remove engine controller cooler (2).
24. Plate
Remove plate (3).
6) Disconnect clamps (13), (14), (15), (16),

(17), and (18) of the high-pressure pipe.
7) Remove the mounting bolts and air intake
manifold (19).
140E-5 Series 7

a Before removing the high-pressure pipe,
loosen all of the clamps, brackets, and
sleeve nuts to give the high-pressure pipe
freedom.
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
2) Remove 6 cylinder head covers (3).
(10).
a At this time, the clamp of wiring har-
4) Remove oil tube (11).
ness (4) comes off.
5) Remove fuel tubes (12), (13), (14) and
3) Remove clamps (5), (6), (7), (8), (9), (10),
(15).
and (11).
a Before removing the supply pump
4) Remove all the splash prevention covers
unit, remove the front cover.
of the high-pressure pipe.
a When removing the cylinder head
cover, remove the high-pressure pipe
covers on the injector side, too.
5) 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.
27. Blow-by tube

Remove breather remote tube (1).
6) Disconnect fuel pressure sensor connec-

tor PFUEL (15) and POIL (16).
7) Remove clamp (17) and the eye joint of
tube (18) on the common rail side.
8) Remove special bolts (19) and remove
common rail (20).
8 140E-5 Series
28. Wiring harness assembly and sensor con- a Move lock [1] of the housing of con-
nector nector (6) in the direction of the arrow,
1) Disconnect the clamps of coolant temper- push down lock [2], and pull out con-
ature sensor connector TWTR (1) and wir- nector (6).
ing harnesses (2) and (3) and remove
bracket (4).
a Move lock [1] of the housing of con-

nector (7) in the direction of the arrow,
2) Disconnect the connectors of Ne sensor push down lock [2], and pull out con-
NE (6), and atmospheric pressure sensor nector (7).
PAMB (7).
5) Disconnect the injector connector accord-

4) Remove 6 injector connectors (9) and 1] Apply flat-head screwdriver [1] to the
remove the wiring harness assembly. stepped part (part (a)).
2] While pressing stopper (1a), move
flat-head screwdriver [1] in direction
(X) to disconnect the connector.
140E-5 Series 9
29. Oil pan 31. Flywheel

1) Move the blocks which are supporting the 1) Using sling [1], lift up flywheel (1) tempo-
engine to positions where you can remove rarily.
the oil pan mounting bolts. 2) Remove the 8 mounting bolts and lift off
2) While supporting oil pan (1) on a pallet lift, the flywheel.
etc., remove the mounting bolts and oil a Take care that the flywheel will not
pan (1). contact the Ne sensor on the back
side.
4 Flywheel: 65 kg
30. Suction tube

Remove bracket (1) and suction tube (2).
Lift up housing (1) temporarily and remove the
mounting bolts and the housing.
4 Housing: 75 kg
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.
a Arrange the above blocks so that you can
33. Rear oil seal
rotate the crankshaft.
Remove rear oil seal (1) from the flywheel
housing.
10 140E-5 Series
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.
6) Remove holder (8) of fuel injector (1).

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 ten-
sion will not be applied the rocker arm and
rocker shaft assembly mounting bolts
when the rocker arm and rocker shaft
assembly is removed. 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 injec-
tor.
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.
140E-5 Series 11
37. Push rod 4] Raise the cylinder head and remove

Remove push rod (1). valve (7).
38. Cylinder head assembly and crosshead 39. Damper assembly

1) Remove crosshead (1). Lift up damper assembly (1) temporarily,
2) Remove mounting bolts (2), auxiliary remove the 6 mounting bolts (2), and lift off the
bolts, and cylinder head assembly (3). damper assembly.
3) Remove each cylinder head gasket. a The fan drive pulley may be installed.
4 Damper assembly: 40 kg
4) Disassemble the cylinder head assembly

1] Using tool C, compress the valve 40. Front support
spring and remove cotter (1). Lift up front support (1) temporarily, remove the
2] Remove upper seat (2), outer spring mounting bolts, and lift off the front support.
(3), and inner spring (4). a The shape and weight of the front support
3] Remove valve stem seal (5) and

lower seat (6).
12 140E-5 Series
41. Cam follower assembly 43. Front oil seal

1) Remove the 3 cover mounting bolts and Remove front oil seal (1) from the front cover.
remove cover (1).
2) Remove mounting bolts (3) and cam fol-
lower (2).

1) Remove nut (1).
2) Set tool P to gear (3).
3) Remove snap rings (4) and remove lever
3) Tighten center bolt [1] of tool P and
assembly (5) from shaft (6).
remove gear (3).
4) Remove pump mounting bolts (4), bracket

42. Front cover
(5), and fuel supply pump assembly (6).
1) Install eyebolts [1] and lift up the front
a While supporting the fuel supply
cover temporarily.
pump assembly, remove the mount-
2) Remove the mounting bolts of front cover
ing bolts.
(1) and sling the front cover. Remove the
front cover by moving it forward.
140E-5 Series 13
45. Camshaft
1) Match the holes of cam gear (1) to mount-
ing bolts (2) and remove bolts (2).
48. Setting of engine repair stand and under-

frame
1) Install tool A2 to the cylinder block. Sling
2) Sling camshaft (3) temporarily. Pull out
the engine and set it to tool A1.
the camshaft while turning it so that the
2) Remove the 4 mounting bolts from each of
cam bushing will not be damaged.
4 Camshaft: 20 kg
2 underframes (1) and remove the under-
frames.
a The number of underframes (1)
46. Oil pump assembly and sub idler gear

1) Remove oil pump assembly (1).
2) Remove sub idler gear (2).
Remove the mounting bolts and piston cooling
nozzles (1) and (2).
a Be sure to remove the piston cooling noz-
zles before pulling out the piston.
47. Main idler gear

Remove mounting bolt (1) and main idler gear
(2).
14 140E-5 Series
50. Piston and connecting rod assembly 6) Push in and remove the piston and con-
a Before removing the piston and connect- necting rod assembly with a wood bar, etc.
ing rod assembly, measure its end play from the oil pan side, while supporting pis-
with dial gauge [1], if necessary. ton (6) on the cylinder head side.
a Take care not to damage the inside of
the cylinder with a corner of the con-
necting rod.
7) Remove the other piston and connecting
rod assemblies according to the above
procedure.
a Take care not to damage the sliding
portions of the pistons and bearings.
a Assemble each connecting rod and
cap temporarily so that they will not
be assembled with other ones and
keep them and the bearing together.
1) 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.
2) Rotate the crankshaft and bring the piston
to be removed to the bottom dead center.
3) Scrub the carbon off the top wall of the cyl-
inder liner with fine sandpaper.
4) Remove connecting rod cap mounting
bolts (1). 8) Disassemble the piston and connecting
5) Hit connecting rod cap (2) with a plastic rod assembly according to the following
hammer so lightly that the threads of the procedure.
connecting rod bolts will not be damaged 1] Remove 2 snap rings (3).
and remove connecting rod cap (2) and 2] While supporting connecting rod (4),
connecting rod bearing as a unit. remove piston pin (5) to disconnect
piston (6) and connecting rod.
140E-5 Series 15
3] Using tool D, remove piston ring (7). a The No. 7 main cap has lower thrust
a Keep the piston, connecting rod, con- bearing (3).
necting rod bearing, piston rings, and
piston pin by cylinder.
3) Lift off crankshaft (4).

a When removing the crankshaft, take
51. Crankshaft against the cylinder block.
a Before removing the crankshaft, measure 4 Crankshaft: 140 kg
its end play with dial gauge [1], if neces-
sary.
1) Remove mounting bolts (2) of main cap 4) Remove upper thrust bearing (5).
(1).
2) Insert the bolts in the bolt holes of the
main cap and remove the cap, while shak-
ing it.
16 140E-5 Series
5) 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, mea-
sure its projection with tool H, if necessary.
53. Using tool E, remove cylinder liner (1).
140E-5 Series 17
General assembly of engine 1 2) Before inserting the cylinder liners, pre-

pare the cylinder block according to the
a The shapes, quantity, locations, etc. of the following procedure.
parts depend on each applicable machine. 1] Remove the rust and scales from
Take care. faces A and B with sandpaper, etc.
a Clean each part carefully, and check it for until the machined surfaces are
bruise, flaw, cavity, etc. Make sure each oil or exposed.
coolant path is through. 2] Polish part R with sandpaper of about
No. 60 until it becomes a smooth
Tightening bolts by plastic-region turning angle rounded surface.
method 3] Polish parts R and h with sandpaper
a Bolts tightened by plastic-region turning angle of about No. 60 until they become
method smooth.
q Cylinder head mounting bolt If part R is sharp or has burrs, finish it
q Main cap mounting bolt with a scraper or sandpaper.
q Connecting rod cap mounting bolt Finish this surface particularly
q Flywheel mounting bolt smoothly so that it will not damage
a If the plastic-region turning angle method is the O-ring.
applied, the tightened bolts have permanent 4] If face B is so pitted that it cannot be
strain. Accordingly, the allowable number of repaired, replace the cylinder block.
using times of each bolt is limited. Observe 5] If faces A and R are pitted, finish
the following precautions. them smoothly.
q Before tightening each bolt, measure its 6] Check the counterbored part and
stem length and make sure that the result remove burrs. If chips or dust is on
is less than the using limit. If the stem is face C, the liner does not fit and cool-
longer than the using limit, do not reuse it ant may leak and the projection of the
but replace it. liner may become improper conse-
q Check each mounting bolt head for punch quently.
marks. If there are punch marks more a If the counterbored part is droop-
than the specified number, do not reuse it ing, corroded, or pitted, repair it.
but replace it.
1. Cylinder block
1) Install tool A2 to the cylinder block, and
then sling the cylinder block and set it to
tool A1.
4 Cylinder block: 390 kg
18 140E-5 Series
2. Cylinder liner 3) After fitting the liner O-ring, check it for

a Replace the O-ring and clevis seal with twist. If it is twisted, correct it with a
new ones. smooth rod (about 10 mm in diameter).
1) Check that the cylinder liner O-ring groove
and periphery of the liner are not rough-
ened 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 4) Apply gasket sealant to the parts of the
for distinction. cylinder block and cylinder liner which will
q O-ring (3): The whole ring is red. fit to the counterbored parts.
2 Clevis seal and O-ring:
a Wipe off dirt and oil with cloth from
Rubber lubricant (RF-1) the contact faces of the counterbored
a RF-1: DAIDO CHEMICAL INDUSTRY parts of the cylinder block and liner
CO., LTD. flange.
2 Cylinder block:
If RF-1 is not available, apply clean
engine oil SAE No. 30. Gasket sealant (LG-6)
a Since the clevis seal and O-ring are q Gasket sealant:
swollen and deteriorated by oil, apply 2 – 3 mm in diameter
a small amount of oil to them thinly q Overlap (a) of gasket sealant:
with a brush just before fitting them. 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 min-
utes.
140E-5 Series 19
5) Insert cylinder liner (1) in the cylinder 10) Using tool H, measure the projection of
block slowly, taking care not to damage the cylinder liner.
the O-ring. a When measuring the projection of the
6) Push in cylinder liner (1) further with both liner, tighten the liner with a plate so
hands. that it will not be lifted by the O-ring.
a If the liner does not enter the cylinder q Projection of liner: 0.07 – 0.15 mm
smoothly, the O-ring may be broken. a If the gasket sealant is projected from
In this case, check the cylinder block the fitting parts of the cylinder block
for burrs. and cylinder liner up to the top of the
7) Using tool F, press fit cylinder liner (1) to cylinder block, wipe it off.
the cylinder block.
8) To prevent the gasket sealant from pro- 3. Crankshaft

jecting through the clearance between the 1) Fit upper main bearing (6) to the cylinder
block and liner after the cylinder head is block, matching the projection of the
tightened, tighten the cylinder head tem- former to the cut of the latter.
porarily with the used head gasket a An oil hole is made on the upper main
inserted. bearing.
a At this time, observe the following a Before fitting the bearing, make sure
tightening torque and tightening that its back side is free from foreign
order. matter.
3 Temporary tightening torque: 2 Inside of bearing: Engine oil (EO30)
137 – 157 Nm {14 – 16 kgm}
9) Remove the cylinder head and wipe off 2) Drive the dowel pin so that it will be pro-
the gasket sealant projected from the jected by 2.7 – 3.4 mm from the block end
counterbored part. and then install upper thrust bearing (5) to
a Be sure to perform steps 8) and 9) the No. 7 journal.
above since the projected gasket a Install the thrust bearing with the
sealant can deform the grommet of grooved surface on the crankshaft
the head gasket. side.
20 140E-5 Series
3) Sling crankshaft (4) and install it to the cyl- 6) Make sure that the journal No. stamped at
inder block. the center of main cap (2) and the journal
a When replacing the crank gear, heat it No. of the cylinder block are the same and
with a bearing heater (30 A) (Set tem- then install the main cap.
perature: 150°C) and fit it just after it a Install the main cap with the cast let-
is heated. ter (F) toward the front of the engine.
a When installing the crankshaft, take
against the cylinder block.
4 Crankshaft: 140 kg
2 Cylinder block journal:
Engine oil (EO30)
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.
is 5.)
4) Fit the lower main bearing to the main cap,
Min. 176.3 mm
matching the projection of the former to
the cut of the latter.
ter.
5) Drive the dowel pin of cap No. 7 so that it
will be projected by 2.7 – 3.4 mm from the
cap end and then install thrust bearings
(3) to both sides.
a Install each thrust bearing with the
grooved surface on the crankshaft
side.
140E-5 Series 21
8) Tighten main cap mounting bolts (1) 10) Check that the crankshaft turns smoothly.
according to the following procedure. 11) Measure the end play of the crankshaft
a Tighten the bolts from the center one with dial gauge [1].
to the outer ones in order. a End play: 0.140 – 0.315 mm
2 Threaded portion of mounting bolt a If the end play is out of the standard,
and washer: correct it. For details, see “Structure,
Engine oil (EO30) function and maintenance standard”.
3 Mounting bolt
1st time:
108 – 128 Nm {11 – 13 kgm}
2nd time:
230 – 240 Nm {23.5 – 24.5 kgm}
3rd time:
90° (+30°/0).
4. 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
a When not using tool J, make 1) Using tool D, fit piston rings (7) to the pis-
marks (b) on the main cap and ton.
bolt with paint, then tighten the a Fit the top ring and second ring to the
bolt by 90° (+30°/0). piston with the stamped mark side up.
9) Make punch mark (c) on the mounting bolt q Stamp on top ring: 1RS
head. q Stamp on second ring: 2RX
a When a new bolt is used, do not a Take the expander out of the oil ring
make a punch mark on its head. 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.
22 140E-5 Series
2) Set the abutment joint of each piston ring 7) Insert piston and connecting rod assembly
as shown in the following figure. (8) in the cylinder block so that the cast
a Adjust oil ring so that the joint of the part number on the connecting rod will be
expander will be at 180° to the abut- directed to the front of the engine (the
ment joint of the oil ring. stamped cylinder number will be on the
camshaft side).
a Referring to step 2), check the abut-
ment joint of each piston ring again.
2 Inside of connecting rod bearing and
inside of cylinder:
Engine oil (EO30)
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 direc-
tion, then insert piston pin (5) to
assemble connecting rod (4) and pis-
ton (6).
4) Fit snap rings (3) on both sides of the pis-
ton pin to secure the piston pin.
8) Using tool G, reduce the piston ring and

push in the piston head with a wood bar,
etc. into the cylinder block.
5) Fit the upper bearing to the connecting
rod, matching the projection of the former
ter.
6) Set the crankshaft so that the cylinder to
be installed will be at the bottom dead
center.
140E-5 Series 23
9) Before tightening the connecting rod cap

is 5.)
Min. 95.0 mm
10) Fit lower bearing (9) to the connecting rod

cap, matching the projection of the former
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 connect-

ing rod (4), matching yellow marks (a) on
them to each other.
ter.
2 Inside of connecting rod cap bearing:
Engine oil (EO30)
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).
24 140E-5 Series
13) After tightening the bolt, make a punch 2) Install piston cooling nozzles (1) and (2) to
mark (c) on its head. each cylinder in order.
a When a new bolt is used, do not a Install the piston cooling nozzles hav-
make a punch mark on its head. ing the stamps of (F1) to the front side
of the cylinder and install those hav-
ing the stamps of (N1) to the rear side
of the cylinder.
a Push in each piston cooling nozzle
with the hand until its flange touches
the cylinder block and then tighten the
mounting bolt.
a Take care not to mistake the hexago-
nal part of the nozzle for the mounting
bolt.
3 Mounting bolt:
59 – 74 Nm {6.0 – 7.5 kgm}
14) Turn the crankshaft to check that it rotates

normally.
15) Measure the side clearance of the con-
necting rod with dial gauge [1].
a Side clearance: 0.100 – 0.274 mm
a If the side clearance is out of the stan-
dard, correct it. For details, see
“Structure, function and maintenance
standard”.
6. Underframe
Install underframes (1).
a The number of the underframes depends

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.
140E-5 Series 25
7.Main idler gear

1) Install bearing (3) and shaft (2) to the out-
side of main idler gear (1) and install bear-
ing (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 crank-
shaft gear to that of main idler gear (1),
tighten mounting bolt (5).
3 Mounting bolt:
784 ± 44.1 Nm {80 ± 4.5 kgm}
9. Camshaft
1) Install camshaft (1) to the cylinder block,
turning it so that it will not damage the
cam bushing.
a If the cam gear is replaced, heat the
new gear in an electric oven, etc. and
heat it at 220 – 240°C for 30 – 60
minutes and then install it by shrink
fit.
4 Camshaft: 20 kg
2 Camshaft journal surface:
8. Sub idler gear and oil pump assembly
Engine oil (EO30)
1) Install sub idler gear (2), shaft (4) and
plate (3) together.
a Direct the stamp of TOP on shaft (4)
up and direct the chamfered inside
edge toward the gear.
3 Sub idler gear mounting bolt:
377.6 – 426.6 Nm {38.5 – 43.5 kgm}
2) Install oil pump assembly (1).
3 Oil pump assembly mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
26 140E-5 Series
2) Matching the stamped (C) of the camshaft 4) Fit the O-ring and install cover (3).
gear to that of the main idler gear, tighten 3 Mounting bolt:
mounting bolt (2). 9.8 – 12.7 Nm {1.0 – 1.3 kgm}
3 Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}

1) Fit the key to the shaft of fuel supply pump
10. Cam follower assembly
assembly (6) and install them to the cylin-
1) Install 2 lever assemblies (5) to shaft (6).
der block.
a Insert the cam followers so that the
2) Tighten mounting bolts (4) and install
ball end of the shaft will be directed
bracket (5).
2 Mounting bolt: Adhesive (LT-2)
toward the rear of the engine.
2) Install snap rings (4).
3) Install fuel supply pump drive gear (3) to

3) Install cam follower assembly (1), match-
the fuel supply pump shaft and tighten
ing it to the dowel pin, and then tighten
mounting nut (1).
mounting bolts (2).
a When installing to the fuel supply
3 Mounting bolt:
pump shaft, set stamp (B) of fuel sup-
44.1 – 58.8 Nm {4.5 – 6.0 kgm}
ply 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}
140E-5 Series 27
a If the end play is out of the standard, cor-

rect 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].
13. Removal from engine repair stand
a Install the water pump drive gear tempo-
1) Remove the engine from the engine repair
rarily to measure their backlash and end
stand and set it on stable blocks.
play.
2) Remove the adapter from the engine.
a Set the air compressor drive gear (on the
right side of the camshaft gear) according
14. Front cover and front support
to the applicable machines.
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].
q 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
q Standard end play of each gear

Position Range (mm)
1 0.1 – 0.25
2 0.06 – 0.24
3 0.11 – 0.23
28 140E-5 Series
2) Sling and install front support (2) and

a The shape and weight of the front
support depends on the applicable
machines.
3) Tighten the front cover mounting bolts per-
manently.
2) Push the metal ring of front seal (1)

evenly as if you are passing over the large
inside diameter side of plastic inside cylin-
der.
a Hit the metal ring of front seal with
3) After pushing in the seal, remove plastic
15. Front oil seal take care not to damage the seal lip.
Install front oil seal (1) according to the follow-
ing 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.
the replacement seal before installing the
seal.
1) Set large inside diameter side (a) of plas-

tic inside cylinder (2) to the end of crank-
shaft (3).
a Take care not to mistake the direction
of the plastic inside cylinder.
140E-5 Series 29
4) Using tool M1, tighten the 3 bolts evenly to

press fit seal (3) until the end of tool M1
tighten them.
shaft: 9.1 – 10.1 mm
the tool set etc.
4) Fit inner spring (4) and outer spring (3)

and then install upper seat (2).
5) 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 fit-
ted 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).
30 140E-5 Series
7) Before tightening the cylinder head

is 5.)
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)
(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 Mounting bolt:
a Tighten the mounting bolts according
to the following procedure.
1st time:
137 – 157 Nm {14 – 16 kgm}
2nd time:
284 – 294 Nm {29.0 – 30.0 kgm}
3rd time:
90° (+30°/0).
140E-5 Series 31
18. Crosshead 20. Fuel injector

Install crosshead (1). a Check that the inside of the injector sleeve
a Adjust the crosshead according to the fol- is free from dirt.
lowing procedure. 1) Referring to step 21, install the common
1] Loosen the locknut and return the rail temporarily.
adjustment screw. 2 O-ring: Engine oil (EO30)
2] Holding the top of the crosshead 2) Fit the gasket and O-ring to the fuel injec-
lightly, tighten the adjustment screw. tor.
3] After the adjustment screw touches 3) Insert holder (2) in fuel injector (1), then
the valve stem, tighten it further by insert them simultaneously, directing the
20°. injector connector (5) to the hole to insert
4] Tighten the locknut at this point. the fuel high-pressure pipe.
3 Locknut: 4) Fit the ball washer to bolt (3) and tighten
58.7 ± 5.9 Nm {6.0 ± 0.6 kgm} 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 com-
mon rail side temporarily, too, to pre-
vent the high-pressure pipe from
leaning.
6) Tighten holder (2) permanently.
a While pulling the high-pressure pipe
in the opposite direction to the injec-
tor, tighten bolt (3).
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
19. Push rod a After tightening the holder, remove
Install push rod (1). the high-pressure pipe and install the
a Check that the push rod is in the cam fol- other injectors in order according to
lower. the above procedure.
32 140E-5 Series
1) Secure common rail (1) temporarily with

special bolts (2).
2) Fit O-ring (4) to high-pressure pipe sleeve
(3). Matching them to the injector connec-
tor, tighten sleeve nut (5) and sleeve nut
(6) on the common rail side temporarily.
(Tighten the sleeve nuts temporarily in the
order of No. 4, No. 5, No. 2, No. 3, No. 1,
and No. 6.)
3) Tighten special bolts (2) permanently.
3 Special bolt:
59 – 74 Nm {6.0 – 7.5 kgm}

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 connect-
ing 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) 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 O-
ring (4) is not projected from the end
of the sleeve.
a 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.
140E-5 Series 33
a If sleeve nut (5) does not catch the 13) Tighten clamps and brackets (15), (16),
threads, press its end with a small rod, (17), (18), (19) and (20) of bracket side
etc. toward the injector and turn the span- permanently.
ner.

5) Tighten clamps and brackets (7), (8), (9),
Install rocker arm and shaft assembly (1) and
(10), (11) and (12) with the hand first, then
tighten mounting bolts (2), (3) and (4).
tighten clamp side permanently.
a Note that the lengths of the mounting bolts
3 Clamp bolt:
are different.
9.8 ± 1.0 Nm {1.0 ± 0.1 kgm}
Mounting bolt (2): Stem length; 120 mm
6) Tighten clamps and brackets (7), (8), (9),
(10), (11) and (12) of bracket side perma-
nently.
a Before tightening the mounting bolts,
7) Install covers (13) and (14) to the sleeve
check that the ball of the adjustment
nut.
screw is fitted to the socket of the push
a Direct the cut of cover (13) down and
rod.
3 Mounting bolt:
direct the cut of cover (14) toward the
cylinder block.
93 – 103 Nm {9.5 – 10.5 kgm}

(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.
(17), (18), (19) and (20) of clamp side per-
manently.
3 Clamp bolt:
9.8 ± 1.0 Nm {1.0 ± 0.1 kgm}
34 140E-5 Series
23. Adjusting valve clearance 24. Cylinder head cover

a Adjust the clearance between the cross- Fit the O-ring and install cylinder head cover
head and rocker arm to the following (1).
value. a Since the bolt at the front on the air intake
a Valve clearance (when cold) manifold side is also used to secure the
wiring harness clamp, tighten it tempo-
Unit: mm
rarily.
Air intake valve Exhaust valve 3 Mounting bolt:
0.35 ± 0.02 0.57 ± 0.02 29.4 – 34.3 Nm {3.0 – 3.5 kgm}
a Rotate the crankshaft and adjust the valve

clearance of each cylinder in the firing
order of 1 – 5 – 3 – 6 – 2 – 4.
1) 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.

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:
2) Insert thickness gauge I between rocker Gasket sealant (LG-7)
arm (3) and crosshead (4) and tighten 2 Threaded portion and seat of
adjustment screw (5) to the degree that bolt: Engine oil (EO30)
the thickness gauge can be moved lightly. 4 Flywheel housing: 75 kg
3) Tighten locknut (6) to secure adjustment
screw (5).
3 Locknut:
53 – 64.7 Nm {5.4 – 6.6 kgm}
140E-5 Series 35
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)
a Tighten the flywheel housing mount-
from rear seal (4) before installing the rear
ing bolts in the following order in 2
seal.
steps.
a Handle rear seal (4) and sleeve (7) as an
a When tightening the bolts for the 1st
time, tighten bolts 1, 4 and 2, 9 twice.
3 Flywheel housing mounting bolt:
each other.
1st time:
147 – 235 Nm {15 – 24 kgm}
2nd time:
245 – 309 Nm {25 – 31.5 kgm}
a Clean, degrease, and dry the contact sur-

face against the flywheel housing.
2) After installing the flywheel housing, mea- a Clean, degrease, and dry the seal lip sur-
sure its facial runout and radial runout with face (periphery of the crankshaft).
dial gauge [1]. a Check that the end corners and lip sliding
q Radial runout: Max. 0.30 mm surfaces of the crankshaft are free from
q Facial runout: Max. 0.30 mm flaw, burr, and rust of the housing.
36 140E-5 Series
1. Procedure for installing standard seal 4) Tighten the 4 bolts evenly to press fit rear
a When installing rear seal (4), do not apply seal (4) until the end of tool N1 (for press
oil or grease to the shaft and seal lip. fitting the seal) reaches the end of crank-
1) Set large inside diameter side (b) of guide shaft (6).
(8) of rear seal (4) to the end of crankshaft a Tighten tool N1 (for press fitting the
(6). seal) first until the bolt without washer
a Take care extremely not to mistake stops and then tighten the bolt with 2
the direction of the plastic inside cylin- washers.
der. a When press fitting the seal, take care
not to damage the lip with the tool set
etc.

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 2. Procedure for installing sleeved seal
plastic hammer evenly. a When installing the rear seal, do not apply
Do not hit it strongly. oil or grease to the shaft, inside cylinder
3) After pushing in the seal, remove guide surface (C) of the sleeve (7) and seal lip.
(8). 1) Set sleeve and rear seal assembly (9) to
a When removing the inside cylinder, tool N2 (for fitting the sleeved seal).
take care not to damage the seal lip. 2 Sleeve inside cylinder surface (C):
Gasket sealant (LG-7)
140E-5 Series 37
2) Set sleeve (7) of the rear seal to the end of 27. Flywheel
crankshaft (6) and tighten the 4 bolts Using eyebolt [1] (12 mm, P = 1.75), sling fly-
evenly to press fit sleeve and rear seal wheel (1) and install it to the crankshaft and
assembly (9) until the end of tool N2 tighten the mounting bolts.
reaches the end of crankshaft (6). a When installing the flywheel, match the
a Tighten tool N2 (for press fitting the dowel pin of the crankshaft to the hole of
sleeved seal) until the bolt with the flywheel.
washer stops. a Take care not to bring the flywheel in con-
tact with the speed sensor.
Engine oil (EO30)
4 Flywheel: 60 kg

fitting the seal).
4) Tighten the 4 bolts evenly to press fit
sleeve and rear seal assembly (9) until the a Tighten the mounting bolts according to
end of tool N3 reaches the end of crank- the following procedure.
shaft (6). 3 Flywheel mounting bolt:
a Tighten tool N3 (for press fitting the 1st time: 118 ± 4.9 Nm {12 ± 0.5 kgm}
seal) first until the bolt without washer 2nd time: Using tool J, tighten the bolts by 90°
stops and then tighten the bolt with 2 (+30°/0) in the order of (1) – (8).
washers.
of crankshaft

(f) on the flywheel with paint, then
tighten the bolts by 90° (+30°/0) in the
order of (1) – (8).
a After tightening each bolt, make punch
mark (g) on its head to show the number
of tightening times.
a When a new bolt is used, do not make a
punch mark on its head.
a If there are 5 punch marks on the head of
a bolt, do not reuse that bolt but replace it.
38 140E-5 Series
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
30. Engine wiring harness assembly and sen-

sor connector
1) Install the engine wiring harness assem-
bly.
2) Install the injector wiring harness assem-
bly.
a Since the wiring harness assembly fit-
ted with the O-ring is difficult to insert
from inside, install it according to the
1] Remove O-ring (2) from connector (1)
and pass the wiring harness out from
28. Suction pipe
inside of the cylinder head and then fit
Install the O-ring to the oil pump and install
the O-ring.
suction tube (1), then install bracket (2) to the
cylinder block.
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] Insert spring clamp (8) in the injector

connector and secure wiring harness
clamp (9) with bolt (10).
140E-5 Series 39
5] Install wiring harness terminal (6) to 6) Connect coolant temperature sensor con-
fuel injector (5) and tighten 2 nuts (7). nector TWTR (18).
a Stretch the wiring harness with-
out slack and press it against the
injector body.
a Tighten the nuts alternately.
3 Terminal nut:
2 ± 0.2 Nm {0.2 ± 0.02 kgm}
3) Install bracket (11).

4) Connect NE sensor connector NE (13),
and atmospheric pressure sensor connec-
tor PAMB (14).
5) Install bracket (15) and install the clamps

of wiring harnesses (16) and (17).
40 140E-5 Series
31. Piping and wiring of supply pump 9) Connect sensor connectors PCV2 (20),
1) Install bracket (1). PCV1 (21) and G (22).
2) Install fuel high-pressure pipings (2) and
(3).
3 Sleeve nut of tube:
(Pump side)
39.2 – 49 Nm {4 – 5 kgm}
(Common rail side)
39.2 – 58.8 Nm {4 – 6 kgm}
3) Install the splash prevention cover and
install clamps (4), (5), and (6).
a Direct the cut of the splash prevention
cover on the supply pump side toward
the block and direct that on the com-
mon rail side down.
a Tighten clamps (4), (5) and (6) with
the hand first, and then tighten them
permanently. 32. Electric priming pump and air bleeding
a Tighten the clamps permanently in valve
the order of (4), (5) and (6). a Manual priming pump is set for some
3 Clamping bolt: models. (See the procedure of "with
9.8 ± 1 Nm {1.0 ± 0.1 kgm} EGR" )
4) Install fuel tubes (7), (8) and (9). 1) Install the assembly of electric priming
3 pump (1) and bracket (2).
q Joint bolt of tube (7) 2) Install oil filler bracket (3).
(Pump side) 3) Install the assembly of air bleeding valve
14.8 – 19.6 Nm {1.5 – 2.0 kgm} (4) and bracket (5).
(Common rail side) 4) Install fuel tube (6).
17.7 – 22.6 Nm {1.8 – 2.3 kgm} a Fuel tube (6) was installed tempo-
q Joint bolt of tube (8) rarily in the previous step.
(Pump side) 3 Joint bolt of tube (6)
14.8 – 19.6 Nm {1.5 – 2.0 kgm} (Supply pump side)
q Sleeve nut of tube (8) 14.8 – 19.6 Nm {1.5 – 2.0 kgm}
(Fuel cooler side) (Electric priming pump side)
43 – 47 Nm {4.4 – 4.8 kgm} 19.6 – 29.4 Nm {2.0 – 3.0 kgm}
q Joint bolt of tube (9) 5) Install fuel tube (7).
(Pump side) 3 Joint bolt of tube (7)
14.8 – 19.6 Nm {1.5 – 2.0 kgm} 19.6 – 29.4 Nm {2.0 – 3.0 kgm}
5) Install fuel tube (10) temporarily. 6) Install fuel tubes (8) and (9).
a After installing the electric priming a Fuel tubes (8) and (9) were installed
pump, tighten the joint bolt to the temporarily in the previous step.
specified torque. 3
6) Install oil tube (11). q Joint bolt of tube (8), (9)
3 Joint bolt of tube (11): (Supply pump side)
(Pump side) 14.8 – 19.6 Nm {1.5 – 2.0 kgm}
7.9 – 12.7 Nm {0.8 – 1.3 kgm} q Sleeve nut of tube (8)
(Cylinder block side) (Electric priming pump side)
9.8 – 12.7 Nm {1.0 – 1.3 kgm} 43 – 47 Nm {4.4 – 4.8 kgm}
7) Tighten clamps (12), (13), (14), (15), (17) 7) Install fuel tubes (10) and (11).
and (18) with the hand first, and then 3 Joint bolt of tubes (10) and (11).
tighten them permanently. 19.6 – 29.4 Nm {2.0 – 3.0 kgm}
3 Mounting bolt of clamps (12), (13),
(14): 9.8 ± 1.0 Nm {1.0 ± 0.1 kgm}
8) Install fuel tube (19) temporarily.
a After installing the electric priming
pump, tighten the joint bolt and sleeve
nut to the specified torque.
140E-5 Series 41
33. Breather remote tube and corrosion resis- 35. Engine controller
tor tube Install engine controller (2) and connect con-
1) Install breather remote tube (1). nector (1).
2) Install corrosion resistor tubes (2) and (3)
temporarily.
models.

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.
1) Install the O-ring and plate (1).
3 Mounting bolt:
2) Install engine controller cooler (2) and fuel
hose (3).
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
a Install the hose on the engine control-
ler cooler outlet side when installing
the fuel filter head.
3) Connect fuel pressure sensor connector
PFUEL (4) and engine oil pressure sensor
connector POIL (5).
42 140E-5 Series
2) Install brackets (7), (8), (9), (10) and (11). 37. Air intake connector assembly
3) Install brackets (2), (3), (4), (5) and (6). 1) Install joint housing (2) to bracket (1).
2) Install venturi nozzle, air heater (3) and
connector (4) to joint housing (2).
a Direct the terminal of the air heater
toward the original direction. (The
direction of the terminal depends on
the applicable machines.)
4) Tighten clamp (12) of the high-pressure

pipe.
3 Clamp bolt:
9.8 ± 1.0 Nm {1.0 ± 0.1 kgm}
5) Tighten wiring harness clamp (13) tempo-
rarily.
3) Fit the gasket and install air intake con-
nector (5) to the air intake manifold and
joint housing (2).
4) Install clamps (7), (8), (9), (10) and (11) of
wiring harness.
6) Install clamp (19) of sensor connectors

TFUEL (15), PIM (16), TIM (17) and wiring
harness (18).
3 Joint bolt:
(Head side) 5) Install high-pressure pipe bracket (6) to
9.8 – 12.7 Nm {1.0 – 1.3 kgm} the joint housing.
(Block side)
19.6 – 29.4 Nm {2.0 – 3.0 kgm}
140E-5 Series 43
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).
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 mount-
ing plates (7) and (6).
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.
3) Install fuel filter head (5). a Corrosion resistor is not set for some
4) Install fuel tubes (3) and (2). models.
3
q 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}
5) Install air bleeding tube (4).
3 Joint bolt of tube (4)
7.8 – 9.8 Nm {0.8 – 1.0 kgm}
44 140E-5 Series
42. Oil cooler assembly 3) Fit the gasket and install thermostat
Using eyebolts [1] and guide bolt [2], fit the assembly (5).
gasket, install oil cooler assembly (1) and 4) Insert bypass tube (4) in the water pump
tighten the 16 mounting bolts. assembly and install snap ring (6).
4
5) Tighten the water pump assembly mount-
Oil cooler assembly: 35 kg
ing bolts permanently.
6) Fit the gasket and install tubes (7) and (8).
7) Install alternator drive pulley (9).
43. Water pump assembly and thermostat

assembly
1) Fit the O-ring, install water pump assem- 44. Alternator assembly
bly (1) and tighten the mounting bolts tem- 1) Install the V-belts to the pulley of alternator
porarily. assembly (9) and tighten mounting bolt (4)
a The mounting bolts are also used to and clamping bolt (5) temporarily.
secure the front cover. 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).
2) Install bypass tube (4) fitted with thermo-

stat (3) and O-ring to thermostat housing
(2).
140E-5 Series 45
45. Exhaust manifold 3) Fit the gasket and install lubrication tube
1) Apply heat-resistant sealant to the mating (5) and 4 clamps (4).
portions of exhaust manifold (between 3 Tube joint bolt:
ports No. 2 and No. 3 and between ports 24.5 – 34.3 Nm {2.5 – 3.5 kgm}
No. 4 and No. 5). 4) Install wiring harness (3).
2 Mating portion:
Heat-resistant sealant (Holtz MH 705)
2) Fit the gasket and sling and install exhaust
manifold and then tighten the mounting
bolts in the following order.
a Tighten the 3 bolts of (1) – (3) tempo-
rarily first in the numerical order, and
tighten the bolts (4) – (24) temporarily
in the numerical order. Then, tighten
all the bolts again to the specified
torque in the numerical order.
2 Mounting bolt:
3 Mounting bolt: 5) Fit the gasket and install turbocharger
58.8 – 73.5 Nm {6 – 7.5 kgm} lubrication drain tube (3) and tube clamps
(4).
6) Install connector (2) and heat insulation
cover (1).

1) Fit the gasket and install tube (8).
2) Fit the gasket and install air inlet pipe and
turbocharger assembly (7).
assembly: 30 kg
3 Mounting nut:
44.1 – 49 Nm {4.5 – 5.0 kgm}
46 140E-5 Series
47. Front plate 50. Starting motor assembly

Fit the gasket to the air intake connector and 1) Fit the gasket and install starting motor
sling and install front plate (1). assembly (4) with bolts (3).
4
2) Install wiring harness (1) and alternator
Bracket: 20 kg
connector terminal R (2).
48. Bracket 51. Air cleaner bracket and wiring harness

Install brackets (1) and (2), stay (3), brackets 1) Install air cleaner bracket (2).
(4) and (5). a The type of the bracket depends on
2) Install wiring harness clamp (1).
49. Heat insulation cover

Install covers (1), (2), (3), (4) and (5).
3) After assembling, check the installing con-
dition 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 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.
140E-5 Series 47
53. Checking for fuel leakage 9) Check the fuel piping and devices for fuel
a If fuel supply pump (2), common rail (1), or leakage.
high-pressure pipe is removed and a Check mainly around the high-pres-
installed, after assembling the engine, sure circuit parts coated with the color
check for fuel leakage according to the fol- checker for fuel leakage.
lowing procedure. a If any fuel leakage is detected, repair
a If no fuel leakage is detected, check
is completed.
a 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 injec-
tor, and joints of the high-pressure piping.
2) Run the engine at speed below 1,000 rpm
and stop it after its speed is stabilized.
leakage.
4) Run the engine at low idle.
leakage.
6) Run the engine at high idle.
leakage.
8) Run the engine at high idle and load it.
a When checking while the components
to be checked are mounted on the
relieve the hydraulic pump.
48 140E-5 Series
140E-5 Series 49
SEN00158-05
© 2011 KOMATSU
All Rights Reserved
50
SEN00159-04
ENGINE 1SHOP MANUAL
140E-5 Series

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
Disassembly and assembly, Part 3 1

Removal and installation of fuel 4. Remove the clamp and EGR oil tubes (4) and
supply pump unit (with EGR) 1 (5). [*2]
Removal
5. Disconnect sensor connectors PCV1 (8) and G
1. Remove cover (1). (9).
2. Rotate the crankshaft forward and set interme- 6. Remove the clamp and fuel tubes (10) and
diate point (a) between stamped “2/5 TOP” (11) and then disconnect fuel tubes (12) and
and “3/4 TOP” on damper (2) to pointer (3). (13) and fuel hose (14). [*3]
a At this time, check that the forcing tap of
the drive gear is set to the bolt hole at the 7. Remove the clamp and oil tubes (15) and (16).
top of cover (1). [*4]
(If not, rotate the crankshaft 1 more turn.)
a At this point, the key of the shaft is turned 8. Remove the splash prevention cover, clamps
clockwise by 15° from the top. (17), (18), (19), and bracket (20), and then
remove high-pressure tube (21). [*5]
3. Remove mounting nut (6). [*1]

a Take care not to drop the nut into the gear
case.
2 140E-5 Series
9. Remove mounting bolts (23) and remove Installation

bracket (24) from supply pump assembly (22). q Carry out installation in the reverse order to
a Leave bolts (23) tightened by 2 – 3 removal.
threads to prevent the pump from falling
down. [*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 Joint bolt of fuel tube (12) (Pump side):
14.8 – 19.6 Nm {1.5 – 2.0 kgm}
Joint bolt of fuel tube (13):
(Pump side)
14.8 – 19.6 Nm {1.5 – 2.0 kgm}
(Common rail side)
17.7 – 22.6 Nm {1.8 – 2.3 kgm}
10. Set tool P to the drive gear, tighten center bolt Joint bolt of fuel tubes (10) and (11):
of P, and remove gear (25) from the shaft. (Pump side)
14.8 – 19.6 Nm {1.5 – 2.0 kgm}
11. Remove mounting bolts (23) which have been
left and remove supply pump assembly (22). [*4]
a If tool P is removed, the gear falls down. 3 Joint bolt of oil tubes (15) and (16):
Accordingly, keep it installed until the (Pump side)
pump is installed. 7.9 – 12.7 Nm {0.8 – 1.3 kgm}
(Cylinder block side)
9.8 – 12.7 Nm {1.0 – 1.3 kgm}
[*5]
1) Tighten fuel tube (21) with the hand first,
and then tighten it permanently.
3 Sleeve nut:
(Pump side)
39.2 – 49.0 Nm {4.0 – 5.0 kgm}
(Common rail side)
39.2 – 58.8 Nm {4.0 – 6.0 kgm}
2) Tighten clamps (17), (18), and (19) with
the hand first, and then tighten them per-
manently.
a Tighten clamps permanently in the
order of (17), (18) and (19).
3 Clamp mounting bolt:
9.8 ± 1 Nm {1 ± 0.1 kgm}
3) Direct the notch of the splash prevention
cover on the supply pump side toward the
block and direct that on the common rail
side down.
140E-5 Series 3
Removal and installation of fuel 4. Remove fuel filters (1) and oil filters (2). [*2]
supply pump unit (EGR-less) 1 a Single cartridge is set for some models.
Removal 5. Remove oil filler (3) and electric priming pump

1. Remove cover (1). cover (4). [*3]
a Electric priming pump is not set for some
2. Rotate the crankshaft forward and set interme- models.
diate 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.
6. Remove clamps (8) and (9) and fuel tubes (5),

(6) and (7). [*4]
3. Remove mounting nut (6). [*1]

a Take care not to drop the nut into the gear
case.
4 140E-5 Series
7. Remove sensor connectors (10), (11) and (12). 14. Remove mounting bolts (32) and remove
bracket (33) from supply pump assembly (31).
8. Remove the scatter prevention cover bracket a Leave bolts (32) tightened by 2 – 3
(13). threads to prevent the pump from falling
down.
9. Remove clamps (14), (15) and (16) and high-
pressure pipes (17) and (18). [*5]
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.
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
12. Remove fuel tubes (24), (25), (26), (27) and pump is installed.
(28). [*7]
13. Remove clamp (29) and oil tube (30). [*8]
140E-5 Series 5
Installation [*7]
q Carry out installation in the reverse order to 3
removal. q Joint bolt of tube (24):

(Both side)
[*1] 14.8 – 19.6 Nm {1.5 – 2.0 kgm}
3 Nut: 176 – 196 Nm {18 – 20 kgm} q Sleeve nut of tube (25):
43 – 47 Nm {4.4 – 4.8 kgm}
[*2] q Sleeve nut of tube (26):
a Apply engine oil thinly to the oil filter cartridge 43 – 47 Nm {4.4 – 4.8 kgm}
packing and tighten the oil filter cartridge 3/4 – q Joint bolt of tube (27):
1 more turn after the packing touches the seal- (Pump side)
ing face. 14.8 – 19.6 Nm {1.5 – 2.0 kgm}
(Common rail side)
[*3] 17.7 – 22.6 Nm {1.8 – 2.3 kgm}
3 Oil filler mounting U-clamp nut: q Joint bolt of tube (28):
10.8 – 26.5 Nm {1.1 – 2.7 kgm} (Pump side)
14.8 – 19.6 Nm {1.5 – 2.0 kgm}
[*4] (Fuel block side)
3 19.6 – 29.4 Nm {2.0 – 3.0 kgm}
q Joint bolt of tubes (5), (6):
24.5 – 34.3 Nm {2.5 – 3.5 kgm} [*8]
q Sleeve nut of tube (6): 3
43 – 47 Nm {4.4 – 4.8 kgm} q Joint bolt of tube (30):

q Joint bolt of tube (7): (Cylinder block side)
(Filter head side) 9.8 – 12.7 Nm {1.0 – 1.3 kgm}
7.8 – 9.8 Nm {0.8 – 1.0 kgm} (Pump side)
(Fuel block side) 7.9 – 12.7 Nm {0.8 – 1.3 kgm}
19.6 – 29.4 Nm {2.0 – 3.0 kgm}
[*5]
1) Tighten fuel high-pressure tubes (17), (18)
with the hand first, and then tighten them
permanently.
3 Sleeve nut:
(Pump side)
39.2 – 49.0 Nm {4.0 – 5.0 kgm}
(Common rail side)
39.2 – 58.8 Nm {4.0 – 6.0 kgm}
2) Tighten clamps (14), (15), and (16) with
the hand first, and then tighten them per-
manently.
a Tighten clamps permanently in the
order of (14), (15) and (16).
3 Clamp mounting bolt:
9.8 ± 1 Nm {1 ± 0.1 kgm}
3) Direct the notch of the splash prevention
cover on the supply pump side toward the
block and direct that on the common rail
side down.
[*6]
3 Clamps (21), (22) and (23) mounting bolt:
9.8 ± 1 Nm {1 ± 0.1 kgm}
6 140E-5 Series
Replacement of oil seal of engine q Left: Standard seal, Right: Sleeved seal
mounted on machine 1
a There are standard seal and sleeved seal.
(Refer to the "Installation")
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). Installation
3) Insert the top end of tool L into the a Check the Teflon seal (Laydown lip seal) by
drilled hole, and remove the front seal checking the wear of the shaft and replace it
by the impact of slide hammer (SH). with the "standard seal" or "sleeved seal".
(Apply the slide hammer evenly not to If the shaft is worn to the degree of luster (If
tilt the rear seal.) wear which you feel with your finger is less
(For sleeved seal) than 10 mm) and does not have any flaw, install
1) Cut and remove the sleeve (7) with a "standard seal A". In other cases, install
chisel and a hammer. "sleeved seal B".
2) Replace the tip of tool L with the a (8): Plastic inside cylinder which is also
puller type one (PT). used as installation guide.
3) Hitch the end of tool L to the metal a (6): Sleeve.
ring of rear seal (4) and pull out the a Do not remove plastic inside cylinder (8)
seal with impacts slide hammer (SH). from rear seal (4) before installing the rear
a Remove the metal powders completely. seal.
a Take care not to damage crankshaft (6). a Handle rear seal (4) and sleeve (7) as an
q Tool L each other.
140E-5 Series 7
a Clean, degrease, and dry the contact sur- 1. Procedure for installing standard seal
face against the flywheel housing. a When installing rear seal (4), do not apply
a Clean, degrease, and dry the seal lip sur- oil or grease to the shaft and seal lip.
face (periphery of the crankshaft). 1) Set large inside diameter side (b) of guide
a Check that the end corners and lip sliding (8) of rear seal (4) to the end of crankshaft
surfaces of the crankshaft are free from (6).
flaw, burr, and rust of the housing. a Take care extremely not to mistake
the direction of the plastic inside cylin-
der.

evenly.
a Hit the metal ring of rear seal with
a Do not hit it strongly.
3) After pushing in the seal, remove guide
(8).
8 140E-5 Series
4) Tighten the 4 bolts evenly to press fit rear 2) Set sleeve (7) of the rear seal to the end of
seal (4) until the end of tool N1 (for press crankshaft (6) and tighten the 4 bolts
fitting the seal) reaches the end of crank- evenly to press fit sleeve and rear seal
shaft (6). assembly (9) until the end of tool N2
a Tighten tool N1 (for press fitting the reaches the end of crankshaft (6).
seal) first until the bolt without washer a Tighten tool N2 (for press fitting the
stops and then tighten the bolt with 2 sleeved seal) until the bolt with
washers. washer stops.
not to damage the lip with the tool set
etc.

fitting the seal).
4) Tighten the 4 bolts evenly to press fit
sleeve and rear seal assembly (9) until the
2. Procedure for installing sleeved seal end of tool N3 reaches the end of crank-
a When installing the rear seal, do not apply shaft (6).
oil or grease to the shaft, inside cylinder a Tighten tool N3 (for press fitting the
surface (C) of the sleeve (7) and seal lip. seal) first until the bolt without washer
1) Set sleeve and rear seal assembly (9) to stops and then tighten the bolt with 2
tool N2 (for fitting the sleeved seal). washers.
2 Sleeve inside cylinder surface (C): a After press fitting the seal, remove the
Gasket sealant (LG-7) red sealant layer from its periphery.
of crankshaft
140E-5 Series 9
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).
Installation
a Check the seal by checking the wear of the
shaft and replace it with the "standard seal" or
"sleeved seal".
If the shaft is worn to the degree of luster (If
wear which you feel with your finger is less
Removal with tool L than 10 mm) and does not have any flaw, install
1) Drill several holes about 3 mm in diameter into "standard seal A". In other cases, install
front oil seal (1). "sleeved seal B".
2) Replace the tip of tool L with the drill type one. a (7): Plastic inside cylinder which is also used
3) Insert the top end of tool L into the drilled hole, as installation guide.
and remove the front seal by the impact of a (6): Sleeve.
slide hammer (SH). (Apply the slide hammer a Do not remove installation guide (7) from front
evenly not to tilt the front seal.) seal (3) before installing the front seal.
a Remove the metal powders completely. a Handle front seal (3) and sleeve (6) as an
a When the sleeve is attached, cut sleeve assembly and never separate them from each
(6) using a gad and hammer to remove it. other.
a Take care not to damage crankshaft (5).
Standard spare seal Sleeved seal
10 140E-5 Series
1. Procedure for installing standard seal 2) Push the metal ring of front seal (3)
a Before installing the seal, check that the evenly as if you are passing over the large
end corners and lip sliding surfaces of the inside diameter side of plastic inside cylin-
crankshaft are free from flaw, burr, and der (7).
rust of the housing. a Hit the metal ring of front seal with
a When installing the seal, do not apply oil plastic hammer evenly.
or grease to the shaft and seal lip. Wipe a Do not hit it strongly.
off the oil from the shaft. 3) After pushing in the seal, remove plastic
the replacement seal before installing the take care not to damage the seal lip.
seal.
1) Set large inside diameter side (b) of plas-
tic inside cylinder (7) to the end of crank-
shaft (5).
a Take care not to mistake the direction
of the plastic inside cylinder.
4) Using tool M1, tighten the 3 bolts evenly

to press fit seal (9) until the end of tool M1
tighten them.
shaft: 9.1 – 10.1 mm
the tool set etc.
140E-5 Series 11
SEN00159-04
© 2010KOMATSU
All Rights Reserved
12
SEN05198-00
ENGINE 1SHOP MANUAL
140E-5 Series

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 For removal, installation, disassembly and assembly of the engine, see the Shop Manual, "Disassembly
and assembly".
a If the judgment of No. 9 is NO, examine A.
2 140E-5 Series
90 Repair and replacement of parts SEN05198-00
140E-5 Series 3
Special tool table

Replacement/Rebuilding
Symbol Part No. Part name Q'ty Remarks
item
Pressure test of cylinder A 795-611-1300 Coolant tester 1 KIT
head B 79A-471-1050 Pump assembly 1
Replacement of valve 1 795-100-1522 Push tool 1
C
guide 2 795-411-1310 Push tool 1
D 795-100-4801 Seat puller 1 For valve seat insert
1 790-101-5001 Push tool KIT 1 KIT
E 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
1
795-100-3300 Gauge 1
Replacement of valve seat
795-100-3401 Tool head 1
insert
795-100-3601 Head support 1
F 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°
795-100-4211 Pilot 1 f10.000 mm
795-100-4221 Pilot 1 f10.010 mm
5
795-100-4231 Pilot 1 f10.020 mm
795-100-4241 Pilot 1 f10.030 mm
Replacement of crosshead 1 795-140-6410 Guide puller 1
G
guide 2 795-130-1310 Guide driver 1
Commercially
Repair of valve by grinding H Valve refacer 1
available
Check of main bearing
Commercially
mounting hole inside J Alignment bar 1
available
diameter
Replacement of crankshaft 1 790-101-2800 Bearing puller 1
K
gear 2 790-101-2300 Push puller 1
L 795-240-6401 Push tool 1 KIT
1 795-240-6411 Push tool 1
Replacement of connecting
2 795-240-6420 Push tool 1
rod small end bushing L
3 795-240-6431 Block 1
4 795-240-6440 Nut 1
M 795-213-1200 Push tool 1 KIT
1 795-213-1250 Bar 1
Replacement of cam 2 795-213-1210 Push tool 1
bushing M 3 795-213-1240 Collar 1
4 795-213-1230 Guide 1
5 795-103-0400 Grip 1
4 140E-5 Series
Replacement/Rebuilding
Symbol Part No. Part name Q'ty Remarks
item
N 795-931-1100 Seal puller assembly 1 For pulling out
1 795T-421-1260 Sleeve jig 1 For press fitting standard
2 01050-31640 Bolt 3 seal
3 01643-31645 Washer 3 (For wet type)
4 795T-421-1240 Sleeve jig 1

P 5 01050-31645 Bolt 3
6 01643-31645 Washer 3 For press fitting sleeved seal
7 795T-421-1231 Sleeve jig 1 (For wet type)
8 01050-31645 Bolt 3
Replacement of engine
9 01643-31645 Washer 9
rear seal
1 795T-421-1270 Sleeve jig 1
For press fitting standard
2 01050-31645 Bolt 3 seal
(For dry type)
3 01643-31645 Washer 3
4 795T-421-1240 Sleeve jig 1
Q 5 01050-31645 Bolt 3
6 01643-31645 Washer 3 For press fitting sleeved seal
7 795T-421-1250 Sleeve jig 1 (For dry type)
8 01050-31645 Bolt 3
9 01643-31645 Washer 9
140E-5 Series 5
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
P7. Sleeve jig
Q1. Sleeve jig
140E-5 Series 7
Q7. Sleeve jig
8 140E-5 Series
140E-5 Series 9
SEN05198-00
© 2009 KOMATSU
All Rights Reserved
10
SEN05199-02
ENGINE 1SHOP MANUAL
140E-5 Series

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
Part names related to cylinder head
1. Cylinder head
2. Crosshead guide
3. Valve guide
4. Valve seat insert (intake side)
5. Valve (intake valve)
6. Valve (exhaust valve)
7. Valve seat insert (exhaust side)
2 140E-5 Series
Testing and inspection of cylinder head

Unit: mm
Inspection item Criteria Remedy
• Presence of crack (External dye check)
Repair by welding
Water leakage from and crack • Presence of water leakage during air pressure test
or replace cylinder
of cylinder head (0.29 – 0.34 MPa {3.0 – 3.5 kg/cm2}, 30 sec) head
• Water pressure test (0.34 – 0.39 MPa {3.5 – 4.0 kg/cm2}, 10 min)
Tolerance Repair by grinding
Distortion of cylinder head top
or replace cylinder
and bottom 0 – 0.06 head
• Presence of dent on valve seat insert contact surface Repair valve seat
Damage of valve contact
surface of valve seat insert or • Check of valve seat insert contact surface insert contact
• Airtightness test surface or replace
looseness of valve seat insert
• Hit cylinder head lightly to check for looseness valve seat insert
a See Fig. A
Valve sinking quantity Sink (a)
Replace valve seat
(both intake and exhaust Standard value Repair limit insert
valves)
0 ± 0.1 —
a See Fig. B
Valve head thickness (c)
Valve Standard value Repair limit
Intake 2.4 1.9
Valve head thickness
Exhaust 2.15 1.6
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
Abnormality in valve • Play when new cotter pin is inserted in cotter groove
• Uneven wear or bend of valve stem
• Presence of dent at valve stem end Repair stem
Valve Standard size Standard value Repair limit
Outside diameter of valve Intake 10 9.940 – 9.955 —
Replace valve
stem
Exhaust 10 9.911 – 9.926 —
Intake 10 9.991 – 10.011 —

Inside diameter of valve guide
Replace valve
Exhaust 10 9.991 – 10.011 —
guide
a See Fig. C
Projection of valve guide Allowable range of projection (d): 22 ± 0.2
Standard size Standard value Repair limit
Outside diameter of crosshead Replace crosshead
guide 11 11.000 – 11.011 — guide
a See Fig. D Repair crosshead

Projection of crosshead guide
Allowable range of projection (e): 49 ± 0.25 guide
140E-5 Series 3
Illustrations related to testing and inspection table
Fig. A Fig. D
a: Sink e: Projection
1. Crosshead guide
Fig. B 2. Cylinder head
b: Valve seat contact surface angle

c: Valve head thickness
Fig. C
d: Projection
4 140E-5 Series
Pressure test of cylinder head Replacement of valve guide

a Pressure test tools a Valve guide replacement tools
Symbol Part No. Part name Symbol Part No. Part name
A 790-553-1601 Coolant tester 1 795-100-1522 Push tool
C
B 79A-471-1050 Pump assembly 2 795-411-1310 Push tool
q If the cylinder head parts were repaired, per- Pulling out of valve guide
form the test according to the following proce- q Using tool C1, pull out the valve guide.
dure.
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 per-

form the test with hot water at 80 – 95°C.
k Pay fully attention to handling the cylinder
head and water whose temperature are
high, and take care not to get burnt. Press fitting of valve guide
1. Machine the valve guide hole of the cylinder
head to the dimension below.
q Inside diameter: 17(+0.011/0)mm
2. Press fit the valve guide until the tool C2 end
touches the cylinder head.
3. Check that the projection of the valve guide is

within the standard value.
a Projection tolerance of valve guide:
22 ± 0.2 mm
Air pressure test

1. Connect the air compressor hose to the cylin-
der 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 leak-
age.
a If any crack is detected in the cylinder head by

the above tests, replace the cylinder head.
140E-5 Series 5
Replacement of valve seat insert

a Valve seat insert replacement tools
D 795-100-4801 Seat puller
1 790-101-5001 Push tool KIT
E 2 790-101-5081 Plate
3 790-101-5071 Plate
1 795-100-3005 Seat cutter
2 795-100-3710 Cutter
F 3 795-100-3720 Cutter
4 795-100-3730 Cutter
5 795-100-4211 Pilot
Pulling out of valve seat insert

k Keep the air pressure at 0.5 – 0.6 MPa {5 – 6
kg/cm2} during the work.
k When replacing the grinding stone, stop
the air.
k 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.
k Ensure that the grinding stone is free from
damage and install it to the grinder shaft
with no play.
k 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
6. Push in 3 claws (10) of puller head (9) of tool D When pulling out valve seat insert (a) by weld-
with the hand and put them in valve seat insert ing a bar to it
(a). 1. Weld bar (b) (Length: 0.1 – 0.5 mm shorter
than valve seat inside diameter, Diameter:
7. Tighten screw (12) to press 3 claws (10) Approx. 10 mm) to the inside of valve seat
against the inside groove of valve seat insert insert (a).
(a). a Take care that welding spatters will not
a If screw (12) is tightened too strongly, the stick to the head.
insert will be broken and become difficult
to pull out. Accordingly, stop tightening 2. After the temperature of the welded parts has
when 3 claws (10) reach the groove fully. decreased to around the ambient temperature,
insert an unnecessary valve (c) in the reverse
8. Put bridge (8) in the outside of puller head (9), direction and hit its head with a small hammer
place plates (11) and (7) on the bridge, and to pull out valve seat insert (a).
tighten nut (6) to pull out valve seat insert (a). a If a large impact is given, the welded parts
may come off. Take care.
140E-5 Series 7
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. 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
8 140E-5 Series
140E-5 Series 9
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 diame-

ter to 1.0 mm. If the hole diameter needs to be
increased more than 1.0 mm, replace the cylin-
der head.
Machining dimensions of valve seat insert and mounting hole

Intake valve side Unit: mm
Valve seat insert Valve seat insert mounting hole
Valve seat insert size
d1 c1 d2 d3 c2
55.0 +0.111 0 55.0 +0.019 0

Standard 8.8 –0.1 58.00 ± 0.2 11 –0.1
+0.086 0
55.25 +0.111 0 55.25 +0.019 0

0.25 OS 8.8 –0.1 58.25 ± 0.2 11 –0.1
+0.086 0
55.5 +0.111 0 55.5 +0.019 0

0.50 OS 8.92 –0.1 58.50 ± 0.2 11.12 –0.1
+0.086 0
55.75 +0.111 0 55.75 +0.019 0

0.75 OS +0.086 9.05 –0.1 0 58.75 ± 0.2 11.25 –0.1
56.0 +0.111 0 56.0 +0.019 0

1.00 OS 9.18 –0.1 59.00 ± 0.2 11.38 –0.1
+0.086 0
a OS: Oversize
Exhaust valve side Unit: mm

Valve seat insert Valve seat insert mounting hole
Valve seat insert size
d1 c1 d2 d3 c2
52.0 +0.080 0 52.0 +0.019 0

Standard 8.6 –0.1 55.00 ± 0.2 11 –0.1
+0.070 0
52.25 +0.080 0 52.25 +0.019 0

0.25 OS 8.6 –0.1 55.25 ± 0.2 11 –0.1
+0.070 0
52.5 +0.080 0 52.5 +0.019 0

0.50 OS 8.72 –0.1 55.50 ± 0.2 11.12 –0.1
+0.070 0
52.75 +0.080 0 52.75 +0.019 0

0.75 OS 8.85 –0.1 55.75 ± 0.2 11.25 –0.1
+0.070 0
53.0 +0.080 0 53.0 +0.019 0

1.00 OS 8.98 –0.1 56.00 ± 0.2 11.38 –0.1
+0.070 0
a OS: Oversize
10 140E-5 Series
Valve seat insert Finish machining of valve contact surface

of valve seat insert
1. Using tool F1 and attached cutters F3 and F4,
machine the valve contact surface of the valve
seat insert to the following dimensions.
a Select tool F5 which will be inserted in the
valve guide with no clearance.
Valve seat insert mounting hole
g: Cylinder head bottom
a Inside finished surface roughness: Max. 12.5S

a Mounting hole bottom surface roughness:
Max. 12.5S
EV: Exhaust valve
a Concentricity of valve guide hole and valve
IV: Intake valve
seat insert hole: Max. 0.07 mm (TIR)
h: Finish machining width
a Squareness of valve guide hole to valve seat
insert hole bottom: Max. 0.03 mm (TIR)
a TIR is an abbreviation for Total Indicator Read-
ing, which is the difference between the maxi-
mum and minimum readings in runout
measurement.
140E-5 Series 11
2. Fit the contact surface of the valve seat insert Final inspection
to the valve by using compound. q Thinly apply red lead to the valve seat insert
1) Thinly apply rough compound mixed with contact surface of a new valve and insert that
oil to the seat surface of a valve and insert valve in the valve guide.
that valve in the valve guide. q Lightly press the valve against the valve seat
2) Install the fitting rod to the valve head and insert and rotate it 10°.
lightly hit valve against the valve seat q Check the valve seat insert contact surface of
while rotating it with both hands to fit the the valve and ensure that the contact is even
valve to the valve seat. and is not broken.
3) After the valve and valve seat are fitted q Or, make marks (m) (about 20 places) on the
and their surfaces become smooth, wipe valve seat insert contact surface of a new
off the compound. valve with a pencil and insert that valve in the
4) Apply fine compound and fit the valve and valve guide.
valve seat again similarly to the above q Lightly press the valve against the valve seat
until they are fitted to each other without insert and rotate it 10°.
breakage. q Ensure that all the pencil marks (m) have been
erased evenly.
When master valve is used
EV: Exhaust valve

IV: Intake valve
j: Cylinder head bottom
k: Contact width against valve
a Concentricity of contact surfaces of valve

guide and valve seat insert:
Max. 0.07 mm (TIR)
ing, which is the difference between the maxi-
mum and minimum readings in runout
measurement.
12 140E-5 Series
Replacement of crosshead guide Press fitting of crosshead guide

q Using tool G2, insert crosshead guide (a) in
a Crosshead guide replacement tools cylinder head (b) and press fit it with a copper
Symbol Part No. Part name or plastic hammer until the projection is within
1 795-140-6410 Guide puller the tolerance.
G a Projection tolerance of crosshead guide:
2 795-130-1310 Guide driver
49 ± 0.25 mm
a Diameter of cylinder head crosshead guide
Pulling out of crosshead guide f11 –0.027
hole: –0.054 mm
q Using tool G1, pull out crosshead guide (a)
from cylinder head (b).
1. 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 13
Repair of cylinder head mounting

face by grinding 1
Grinding
1. Remove the valve seat insert.
q For the removal procedure, see "Replace-
ment of valve seat insert".
2. Remove the distortion and corrosion of the cyl-

inder 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
a Limit after grinding: 139.65 mm
a Grinding depth by 1 grinding: 0.10 – 0.15 mm
a Ground surface roughness: Max. 8S
a Flatness (Distortion): Max. 0.05 mm
a Grinding depth limit: 0.3 mm
a Difference in head height (a) for 1 unit:
Max. 0.15 mm
3. Press fit the valve seat insert of the next over-

size.
q For the press fitting procedure, see
"Replacement of valve seat insert".
Check after repair by grinding

q Measure the valve recess and projection of the
injector and ensure that they are within the
standard values and then adjust if necessary.
a Valve recess Standard: 0 ± 0.1 mm
a Projection of the injector nozzle: 2.3 – 2.9
14 140E-5 Series
Repair of valve by grinding a Apply dial gauge (1) to the facial runout mea-
suring point of seat contact surface (c) of the
a Valve grinding tool valve and rotate the valve to measure its facial
Symbol Part No. Part name runout while pressing it toward left (d).
Commercially Intake valve: Max. 0.045 mm (TIR)
H Valve refacer
available Exhaust valve: Max. 0.030 mm (TIR)
Grinding of seat contact surface of valve ing, which is the difference between the maxi-
q Using tool H, grind the seat contact surface of mum and minimum readings in runout
the valve. measurement.
a Seat contact surface angle of valve (a) e: Block

Intake valve: 30° ± 0°15'
Exhaust valve: 45° ± 0°15' a Check the contact of the seat contact surface
of the valve by either of the following methods.
Check after grinding q Thinly apply red lead to the seat contact sur-
q Measure the valve head thickness, sinking face of the ground valve and insert that valve
quantity of the valve, and contact of the seat in the valve guide.
contact surface of the valve, and ensure that q Lightly press the valve against the valve seat
they are within the standard values. insert and rotate it 10°.
a Allowable limit of valve head thickness (b) q Check the valve seat insert contact surface of
Intake valve: the valve and ensure that the contact is even
Min. 1.9 mm (Standard size: 2.4 mm) and is not broken.
Exhaust valve: q Make marks (f) (about 20 places) on the seat
Min. 1.6 mm (Standard size: 2.15 mm) contact surface of the ground valve with a pen-
a Standard of contact surface (c) of valve cil and insert that valve in the valve guide.
Intake valve: 4.32 mm q Lightly press the valve against the valve seat
Exhaust valve: 3.41 mm insert and rotate it 10°.
a Standard of valve sinking quantity: q Ensure that all the pencil marks (f) have been
0 ± 0.10 mm (Both intake and exhaust valves) erased evenly.
140E-5 Series 15
SEN05199-02
© 2010 KOMATSU
All Rights Reserved
16
SEN05200-01
ENGINE 1SHOP MANUAL
140E-5 Series

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
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
Part names related to cylinder block
1. Cylinder liner
2. Clevis seal
3. Cylinder liner O-ring
4. Cylinder block
5. Main bearing metal cap bolt
6. Main bearing metal cap (No. 1, 2, 3, 4, 5 and 6 are same)
7. Camshaft bushing
140E-5 Series 3
Testing and inspection of cylinder block

Unit: mm
Presence of crack (External dye check)
Crack
Cylinder head bolt hole etc. Replace cylinder
a See Fig. A block
Repair of contact of packing
Water leakage caused by corrosion
a See Fig. B
Standard value
Standard size Standard Replace cylinder
Clearance to cylinder liner Bore of Outside diameter clearance liner or cylinder
cylinder block of cylinder liner block
158.000 – 157.897 –
f158 158.040 157.927
0.073 – 0.143
Inside diameter
Inside diameter of camshaft Standard size Standard value Replace camshaft
bushing bushing
65 65.000 – 60.060
a See Fig. C Replace cylinder

Projection of cylinder liner liner or repair
Allowable range: 0.07 – 0.15
cylinder block
a See Fig. D
Presence of corrosion
Depth and bottom corrosion of Repair by cutting
counterbore Standard size Standard value Add shim
11 11.000 – 11.050
Tolerance Repair by cutting or
Distortion and wear of cylinder
Flatness of cylinder block top replace cylinder
head mounting face 0 – 0.09 block
a See Fig. E
Main bearing mounting hole Standard size Standard value
diameter
• Tighten main bearing metal 127 127.000 – 127.018
cap bolt to specified torque
• Measure in range of 10° on Roundness of f127 must be 0.005 from front to
General concentricity rear of cylinder block
upper and lower sides of
main bearing metal cap Concentricity of Alignment bar for roundness of 0.010 must go
Replace cylinder
adjacent holes through smoothly
block
a See Fig. F
Standard fit
Journal
Fit of main bearing metal cap (Interference)
and cylinder block
(Interference) No. 1 – 6 0.002 – 0.060
No. 7 0.002 – 0.060

a See Fig. G
Cylinder liner
Standard size Standard value
Replace cylinder
Upper section 170.2 170.10 – 170.20 liner
Inside diameter of counterbore
and outside diameter of Lower section 161.2 161.25 – 161.29
cylinder liner flange
Cylinder block
Upper section 170.2 170.200 – 170.263 Replace cylinder
block
Lower section 161.2 161.17 – 161.23
4 140E-5 Series
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 h: Fit

d: Cylinder block
e: Projection
140E-5 Series 5
Fig. G 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
–0.014
Diameter 157 –0.039
Roundness 0.005
Straightness 0.010
i: Upper section
j: Lower section 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 bear-

ing 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.
6 140E-5 Series
Part names related to crankshaft
1. Crankshaft
2. Main bearing metal (upper)
3. Main bearing metal (lower)
4. Thrust metal (All of upper x 1 and lower x 2 are the same)
140E-5 Series 7
Testing and inspection of crankshaft

Unit: mm
Crack Check for crack by magnaflux inspection Replace crankshaft
If damaged slightly,
Presence of damage in journal
• Flaw repair with oilstone
or by lapping.
• Seizure
Damage If seized, replace
• Discoloration
crankshaft
Damage of tap holes at front and rear ends Repair or replace
crankshaft
Clogging of oil hole Presence of clogged oil hole Repair
Standard value Replace thrust
End play of crankshaft metal or repair with
0.140 – 0.315 oversize parts
Size Standard size Tolerance
Standard 4.000
0.25 US 4.125 Replace thrust
Thrust metal thickness –0.07 metal or repair with
0.50 US 4.250 –0.12 oversize crankshaft
0.75 US 4.375
1.00 US 4.500
Standard 90.00
0.25 US 89.75
Outside diameter of crankpin –0.050
journal 0.50 US 89.50 –0.068 Repair with
0.75 US 89.25
undersize parts or
1.00 US 89.00 replace crankshaft
Standard
Roundness of crankpin journal
0 – 0.009
Repair with
undersize parts or
Clearance in crankpin journal 0.042 – 0.110
replace connecting
rod bearing metal
Standard 120.00
Outside diameter of crank 0.25 US 119.75
main journal 0.50 US 119.50 –0.050
–0.068 Repair with
0.75 US 119.25 undersize parts or
replace crankshaft
1.00 US 119.00
Standard
Roundness of crank main
journal 0 – 0.009
Repair with under-
Clearance in crank main
0.044 – 0.106 size parts or replace
journal main bearing metal
Standard
Bend of crankshaft Concentricity of all main journals 0 – 0.15
Replace crankshaft
(Total indicator reading)
Concentricity of adjacent journals 0 – 0.05
8 140E-5 Series
Part names related to connecting rod
1. Connecting rod bolt

2. Cap
3. Dowel pin
4. Bearing metal (lower)
5. Bearing metal (upper)
6. Rod
7. Small end bushing
140E-5 Series 9
Testing and inspection of connecting rod

Unit: mm
Crack Check for crack by dye check or magnaflux inspection
a See Fig. H Replace connecting
Parallelism and twist of small rod
and large end holes of Presence of bend (after small end bushing is installed)
Parallelism: 0.20
connecting rod
Twist: 0.30
Tolerance Replace small end
Standard size Standard clearance bushing
Clearance between Shaft Hole
Surface roughness
connecting rod small end
0 –0.049 – of inside of small
bushing and piston pin f52 0.030 – 0.055
–0.006 –0.030 end bushing
Max. 3.2S
• Large end hole diameter Standard
Tolerance
• Without bearing metal. size
• Inside surface roughness of large end hole: +0.026
95
Max. 3.2S –0.004 Replace bearing
Connecting rod large end hole
diameter • Clearance to crankshaft bearing Standard clearance metal or connecting
(with bearing metal) rod
• Wave of large end hole: Max. 0.004 (All width) 0.042 – 0.111
Even if dimensions of each part are within allowable limits, if any clear-
ance exceeds allowable clearance, replace parts (bearing metal etc.)
Standard 3.500
1.00 US 4.000 Replace bearing
Bearing metal thickness 0
0.75 US 3.875 metal
–0.010
0.50 US 3.750
0.25 US 3.625
Replace bearing
Flaw on inside of or seizure of
Presence of flaw and seizure metal and
bearing metal connecting rod
Distance between large and Replace connecting
small end hole centers 0 rod
264
–0.040
Replace connecting
rod
a See Fig. J
Streak and bruise on I-portion • Presence of lateral streak If there is bruise,
of connecting rod replace connecting
• Presence of lateral grinding mark
rod regardless of
size of bruise
Presence of fretting on mating face
• Mating face roughness: Max. 6.3S If fretting is felt with
Fretting on cap mating face nail, replace
• Back fitted area of mating face: Min. 70%
connecting rod
a There must not be non-fitted area on outside of bolt hole center.
Scuffing on cap bolt seat surface Repair with oilstone
Scuffing on bolt seat surface Scuffing on bolt seat surface Replace bolt
Scuffing on washer surface Replace washer

• Presence of deformation of dowel pin Replace connecting
Deformation of dowel pin
• Presence of deformation of dowel pin hole rod
Damage of bolt • Presence of crack and/or damage on threaded portion of bolt Replace bolt
• Presence of bend of bolt
a If all the items of this criteria (particularly the wave of the large end hole) cannot be measured after the
connecting rod is rebuilt, do not rebuild since the accuracy of the connecting rod large end hole after
rebuilding cannot be confirmed.
a When reusability is judged, if there are honing marks left on the inside of the connecting rod large end
hole, it is not required to measure the surface roughness of the inside and wave of the large end hole.
a Do not reuse the connecting rod cap mounting bolt more than 5 times.
Each time the bolt is tightened, make a punch mark on it.
10 140E-5 Series
Fig. H Replacement of flywheel ring gear

k Take care not to throw down the flywheel
and get hurt by mistake.
Removal of gear
q Make a notch at the tooth bottom of the gear
with a grinder and break the gear to remove
with a chisel.
k Take care in handling the grinder and
chisel.
Press fitting of gear

1. Check the gear mounting face. If there is a
flaw, repair with an oilstone.
a: Measured value
2. Heat the gear at the specified shrink fit temper-
Fig. J ature 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 con-
tacts the flywheel.
b: Inspection range
c: Streaks
d: Lengthwise direction
140E-5 Series 11
Replacement of crankshaft gear 4. Using the drive tool, press fit the gear with the
timing mark out until its side contacts the
a Crankshaft gear replacement tools crankshaft flange.
Symbol Part No. Part name a Press fit the gear quickly before it cools
1 790-101-2800 Bearing puller down.
K
2 790-101-2300 Push puller
Removal of gear
q Make a notch at the tooth bottom of the gear
with a grinder, assemble tools K1 and K2, and
rotate the nut to pull out the gear.
a If the gear cannot be pulled out by the above
method, make a notch at the tooth bottom of
the gear with a grinder, heat the gear with a
gas burner, and drive out the gear with a cop-
per rod etc.
a Take care not to damage the crankshaft.

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 crank-

shaft.

ature for a certain time.
a Gear shrink fit temperature: Max. 200°C
Heating time: Min. 30 min
12 140E-5 Series
Replacement of camshaft gear

k When setting the camshaft assembly on the
press stand, take care not to catch your fin-
gers 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.

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 cam-

shaft.
3. Install the thrust plate.

ature 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 cam-
shaft flange.
a Press fit the gear quickly before it cools
down.
140E-5 Series 13
Replacement of main bearing 5. While checking the inside diameter of main

metal cap bearing metal cap (1), cut little by little.
a Cut to the degree that the boring bar tool
a When replacing the main bearing metal cap, almost touches the inside of cylinder block
work on the semi-finished cap according to the (2).
following procedure and install it. a Inside diameter of main bearing metal cap
q Machining dimension
Repair parts Tolerance: f127 +0.018
0 mm
Part No. Part name q After machining, remove the main bearing
6217-21-1240 No. 1, 2, 3, 4, 5, 6 main bearing metal cap metal cap, assemble it again, and check
its inside diameter.
6217-21-1250 No. 7 main bearing metal cap
Tolerance: f127 +0.018
0 mm
(Range to upper and lower 10° from mat-
ing face of main bearing metal cap)
Inside machining of main bearing metal cap
a Finished surface roughness: Max. 10S
1. Remove the cylinder liner.
a Do not cut the inside surface of the cylin-
der block.
2. Install the replacement main bearing metal cap
to the cylinder block and tighten it to the speci-
fied 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:
Unit: Nm {kgm}
Step Target Range
1st time 98 {10} 88 – 108 {9 – 11}
2nd time 196 {20} 191 – 201 {19.5 – 20.5} Side machining of main bearing metal cap
(Machine only No. 7 main bearing metal cap)
Tightening by
3rd time 90° +30°
0 1. Insert cast iron bushing (3) and pass arbor (4)
90°
through it.
3. Set the cylinder block mounting jig on the table
of the horizontal boring machine and install the 2. Install facing tool (5) to the arbor.
cylinder block by fitting its cylinder liner mount-
ing hole to the datum line of the jig. 3. Cut main bearing metal cap (1) to the degree
that facing tool almost touches the cylinder
block surface.
4. 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.
14 140E-5 Series
4. 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
Replacement of connecting rod Press fitting of bushing

small end bushing 1. Set the connecting rod to block (3) of tool L.
a Connecting rod small end bushing replace- 2. Install the bushing to push tool (1), set push
ment tool tool (2), and fix them with nut (4).
Symbol Part No. Part name a Match the oil holes of the bushing and
L 795-240-6401 Push tool (KIT) connecting rod to each other.
3. Drive push tool (1) with the press to press fit

Pulling out of bushing
the bushing.
1. Set the connecting rod to block (3) of tool L.
a Since the bushing is semi-finished, its
inside diameter is small and the piston pin
2. Using push tool (1) and block (3), drive out the
does not go through it.
busing with the press.
After press fitting the bushing, machine its
a After removing the bushing, remove sharp
inside with a reamer or a honing machine
edges and burrs from and clean the bush-
according to the maintenance standard.
ing mounting hole.
a After machining, remove all the chips from
the oil hole and oil groove.
16 140E-5 Series
Replacement of cam bushing 3. Pulling out of No. 3, No. 4 and No. 5 bushings
1) Assemble bar (1), push tool (2), collar (3)
a Cam bushing replacement tools and guide (4).
Symbol Part No. Part name 2) While hitting bar (1), drive out the bushing
M 795-213-1200 Push tool (KIT) from the cylinder block.
a 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.
4. After removing the bushing, remove burrs and

foreign matter from and clean the bushing
mounting hole.
Installation
a Cam bushing installation drawing
2. 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
1. Press fitting of No. 3, No. 4 and No. 5 bushings 3. Press fitting of No. 1 and No. 7 bushings
1) Install bar (1), push tool (2), collar (3) and 1) Install bar (1), push tool (2) and collar (3)
guide (4) to the bushing. to the bushing.
2) Press fit the bushing until the oil holes of 2) Press fit the bushing until the oil holes of
the cylinder block and bushing are the cylinder block and bushing are
matched to each other. matched to each other.
a Ensure that the pin 2 mm in diameter goes a Ensure that the pin 2 mm in diameter goes
smoothly through the drilled hole of the smoothly through the drilled hole of the
cylinder block and oil holes (upper and cylinder block and oil holes (upper and
lower) of the bushing. lower) of the bushing.
2. Press fitting of No. 2 and No. 6 bushings 4. Measurement after bushing is press fitted
1) Install bar (1), push tool (2), collar (3) and 1) Using dial inside gauge (a), measure the
guide (4) to the bushing. inside diameter of the bushing.
2) Press fit the bushing until the oil holes of
the cylinder block and bushing are
matched to each other.
a Ensure that the pin 2 mm in diameter goes
smoothly through the drilled hole of the
cylinder block and oil holes (upper and
lower) of the bushing.
2) Measure the clearance between the bush-

ing 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 bush-
ing with a reamer, remove all the
chips from the oil hole and oil groove.
a Inside diameter of cam bushing:
f65 +0.06
0 mm
a Clearance to camshaft journal:
0.016 – 0.096 mm
18 140E-5 Series
Repair of cylinder block top by Grinding of top

grinding 1 q Measure the wear quantity and distortion of the
cylinder block top. If the measured value is
Repair by grinding larger than the allowable limit, repair the cylin-
If there is distortion or corrosion on the cylinder der block top by grinding within the allowable
block top, remove it by grinding. limit of cylinder block height (d).
a If the cylinder liner contact surface of counter-
Unit: mm
bore portion is blackened and grained (particu-
Standard Repair
larly in the forward and backward directions of dimension dimension
the cylinder block) more than a half of the con-
Flatness of cylinder block Max. 0.05 Max. 0.05
tact surface or the cylinder block top needs to top (per cylinder)
be ground, repair the counterbore portion.
a Rough criteria for repairing cylinder block top Cylinder block height (d) 430.5 ± 0.04 430.1 ± 0.04
by grinding Cylinder block top surface Max. 12.5S
q The cylinder block top is worn and corroded in roughness
the shape of the trace of the head gasket.
q Quantity (a) of the above wear is 0.15 mm or Fig. 2
more.
Fig. 1
a When repairing with grinding stone (Refer-

ence)
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
140E-5 Series 19
Repair of counterbore by grinding 1 q Machine only the hatched part of counterbore

portion depth (f).
a Counterbore grinding tool q Set the machining margin of counterbore por-
Symbol Part No. Part name tion depth (f) so that cylinder liner projection (e)
will be within the standard value.
1 79A-513-1710 Basic machine
q If counterbore portion depth (f) exceeds the
2 79A-513-1780 Guide plate standard dimension and the counterbore por-
3 79A-513-1820 Cutter plate tion needs to be ground within the allowable
4 79A-513-1860 Cutter limit, set the machining margin so that 1 shim
shown next page will be used for 1 cylinder.
5 79A-513-1940 Cutter set gauge
q Remove burrs and sharp edges from the
6 79A-513-1950 Micrometer tapered portion etc.
7 79A-513-1960 Driver plate
8 79A-513-2090 Driver shaft
9 79A-513-2110 Driver handle
10 79A-513-2120 Service package
N
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 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.
a Rough criteria for repairing counterbore portion
by grinding
q A dimension is out of the standard dimension.
q The cylinder liner contact surface of the coun-
terbore portion is blackened and grained (par-
ticularly in the forward and backward
directions) more than a half of the whole area.
q If counterbore portion depth (f) after the repair
is 11.05 – 12.525 mm, adjust cylinder liner pro-
jection (f) to 0.07 – 0.15 mm with shims.
Unit: mm
size
Counterbore portion depth (f) 11 +0.05
+0
12.525
Cylinder liner projection (e) — 0.07 – 0.15
Counterbore surface rough- Max. 12.5S

ness
Grinding shape See right figure *: See "b" and "c" in Fig. 2 of previous page for
"Detail B and c".
20 140E-5 Series
q When grinding the counterbore portion, use

tool N.
Shims for adjusting counterbore depth (reference)

Unit: mm
Part No. T t Weight Remarks
(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 Outside diameter and inside diameter of shim
140E-5 Series 21
Check and identification after

repair by grinding 1
q After repairing by grinding, check the flat por-
tions around the water and oil holes on the cyl-
inder block top for flaw.
q Remove all burrs and sharp edges.
q After grinding the top surface, check cylinder
block height (d) is 430.1 ± 0.04 mm, and use
the oversize head gasket.
Unit: mm
Head gasket Part No. Plate thickness
Standard 6210-17-1814 2.0
Oversize 6210-19-1814 2.4
a The 2 letters of "OS" are stamped on the plate

for identification.
q 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 Shim Stamp
gasket
— — Unnecessary
Spare parts used
Q — OS
— Q SH
Q Q WS
(Stamp letter size shall be 5 – 10 mm)
22 140E-5 Series
Gasket sealant application

procedure 1
q 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)
a When using shim for the deck, apply the gas-
ket 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. 4. Set the cylinder liner to the cylinder block,
At this time, apply a little amount of rubber install the used head gasket, and tighten the
lubricant (RF-1) to cylinder block contact sur- cylinder head temporarily.
face (d) of the O-ring and seal of the cylinder At this time, tighten the bolts in the following
liner. order.
a Apply the engine oil just before press fit- 3 Tightening torque:
ting the cylinder liner. 147 ± 10 Nm {15 ± 1 kgm}

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 23
5. 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 grom-
met 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.
24 140E-5 Series
Repair standard for cylinder liner

O-ring 1
After repairing the bushing at the cylinder liner O-
ring portion of the cylinder block, finish to the fol-
lowing 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 25
Replacement of engine rear seal 2. Pull slide hammer (1) of the seal puller to pull
out the seal with impacts.
a Engine rear seal replacement tools a Rear seal (c) can be pulled out easily, if it
Symbol Part No. Part name is driven in a little to separate it from the
O 795-931-1100 Seal puller assembly flywheel housing in advance.
a Do not damage the crankshaft.
a For disassembly and assembly of flywheel and a Do not use a drill since chips will enter the
flywheel housing, see "Disassembly and engine.
assembly".
Types of engine rear seal (Teflon seal)

Illustration No. 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)
a 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).
26 140E-5 Series
2. Screw drill end (6) into the metal ring of rear a Before installing the rear seal, remove all
seal (c) and pull slide hammer (1) of the seal flaws, sharp edges, burrs, rust, etc. from the
puller to pull out the seal with impacts. end corners and sliding surfaces of the crank-
a Rear seal (c) can be pulled out easily, if it shaft and from the flywheel housing.
is driven in a little to separate it from the a Do not apply oil or grease to the sliding sur-
flywheel housing in advance. faces of the crankshaft and lip (e) of the rear
a Do not damage the crankshaft. seal.
a Do not use a drill since chips will enter the Wipe off the oil from the sliding surfaces of the
engine. crankshaft thoroughly.
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).
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 2. Hold the metal ring of seal (c) with both hands
can be used. and push it in evenly.
a Push in the rear seal as if you pass over
2. In other cases than 1 above, install the sleeved large inside diameter side (f) of internal
rear seal. plastic cylinder (d).
3. Remove internal plastic cylinder (d), taking

Installation of rear seal (without sleeve) care not to damage lip (h).
a Do not remove internal plastic cylinder (d) of
the spare rear seal (which is used as an instal-
lation guide) before installing the rear seal
since it is also used to protect the seal lip.
140E-5 Series 27
4. Install sleeve jig (1) and clamp bolts (2) (Stem Installation of rear seal (with sleeve)
length: 40 mm (wet), 45 mm (dry)). a Handle the spare rear seal and sleeve (n) as
a Do not install washers to the bolts. an assembly and do not separate them.
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.
a Before installing the rear seal, remove all

flaws, sharp edges, burrs, rust, etc. from the
end corners and sliding surfaces of the crank-
shaft and from the flywheel housing.
a Do not apply oil or grease to the sliding sur-
6. Remove clamp bolts (2) (Stem length: 40 mm faces of the crankshaft and lip (e) of the rear
(wet), 45 mm (dry)), install 2 washers (3) each, seal.
and tighten bolts (2) evenly again to press fit Wipe off the oil from the sliding surfaces of the
the rear seal until end (k) of sleeve jig (1) crankshaft thoroughly.
touches end (m) of the crankshaft.
a Take care not to damage the end of lip (j) 1. Apply gasket sealant to inside wall (p) of rear
on the transmission side. seal (c) and set it to sleeve jig (4).
a After press fitting, remove the gasket seal- 2 Inside wall (p) of rear seal (c):
ant projected around the periphery. Gasket seal (LG-7)
28 140E-5 Series
2. Install sleeve jig (4), clamp bolts (5) (Stem 5. Remove clamp bolts (8) (Stem length: 45 mm),
length: 45 mm), and 1 washer (6). install 2 washers (9) each, and tighten bolts (8)
evenly again to press fit the rear seal until end
3. Evenly tighten clamp bolts (5) to press fit the (q) of sleeve jig (7) touches end (r) of the
rear seal until they stop. crankshaft.
a Be sure to press fit rear seal (c) and a After press fitting, remove the gasket seal-
sleeve (n) as an assembly. ant projected around the periphery.
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 29
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. 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.
30 140E-5 Series
Repair of crankshaft by grinding Pin journal oil hole (See figure below)
q Finish part (d) with sandpaper.
q When the crankshaft is worn, seized or dam- q Check part (e) extremely carefully since
aged slightly and needs to be repaired, grind it quenching crack tends to occur in that part.
to one of the following undersizes.
Undersizes: 0.25, 0.50, 0.75, 1.00 mm
q If the crankshaft is bent or worn unevenly, it
should not be repaired but should be replaced.
(Repairing the crankshaft requires high tech-
nologies)
q Finish fillet portion (R), shoulder portion (r) and
area (R) around the hole of the crankshaft with
extreme care.
Finish dimensions of fillet portion

(R): 5.3 +0.3
0 mm
Surface roughness: 3.2S
q Finish the main journal and pin journal accord-

q The outside surface roughness of the pin jour-
Main journal oil hole (See figure below) nal and main journal must be maximum of
q Dimension of tapered part (a) of oil hole: 0.6S.
12 mm
q Angle (b) of tapered part of oil hole: 120° Equipment necessary for grinding
q Surface roughness of oil hole top (c): q Magnaflux inspection machine
1.6S (Finished with sandpaper) q Shore hardness tester
q Dimension of parts (R) at 2 places: 1 – 2 mm q Etching kit
q Crankshaft grinding machine
q Crankshaft polishing machine
q Surface roughness gauge
q Fillet (R) gauge
140E-5 Series 31
Inspection before repair by grinding Check during and after repair by grinding
Visual check Check of fillet (R) portion

q Check for crack, damage, discoloration by sei- q Check that each fillet (R) portion is connected
zure, wear, etc. and judge if the crankshaft can to the journal shoulder smoothly.
be repaired by grinding. q Using fillet (R) gauges [1] and [2], check that
"dimension (R)" is between the minimum value
Hardness check of journal surface gauge and maximum value gauge.
Allowable range: HRC55 – 60 q (c) is the contact point of minimum value gauge.
a If the hardness is below the allowable limit, dis- q (d) are the contact points of maximum value
card the crankshaft. gauge.
Fillet (R) Min. radius: 5.3 mm
Check for twist Max. radius: 5.6 mm
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

q 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.
Magnaflux inspection
q Before using the repaired crankshaft, check it
by magnaflux inspection to ensure that it has
no crack.
q Extremely closely check journal fillet portion (a)
which is in the dangerous area of each web of
the crankshaft.
q After the magnaflux inspection, be sure to
demagnetize the crankshaft.
32 140E-5 Series
Measurement of bend (Measurement of align- Grinding of thrust surface

ment) a It is not always required to grind the thrust sur-
q Measure the bend of the ground crankshaft faces of the front and rear to the same under-
and ensure that it is within the standard value. size dimension.
q Measure the bend (alignment) at the following a If the thrust surface was repaired by grinding,
4 places. ensure that the end play of the crankshaft is
Tolerance of overall length alignment: within the allowable range.
Max. 0.15 mm (See the section of general assembly)
Tolerance of adjacent alignment: Max. 0.05 mm
Undersize dimensions of thrust surface
Tolerance of front end alignment: Max. 0.03 mm Unit: mm
Tolerance of rear end alignment: Max. 0.03 mm Rear thrust surface
Standard 0.125 OS 0.25 OS
Standard
size 52 +0.050
0 52.125 +0.050
0 52.25 +0.050
0
Standard
Repair
Front thrust surface

52.060 52.185 52.310
limit
Standard 52.125 +0.050 52.25 +0.050 52.375 +0.050
0.125 size 0 0 0
OS Repair
limit 52.185 52.310 52.435
Standard
52.25 +0.050 52.375 +0.050 52.50 +0.050
0.25 size 0 0 0
OS Repair 52.310 52.435 52.560
limit
q Squareness of thrust surface (TIR)
Permissible deviation: 0.04 mm
Grinding of main journal Grinding of pin journal

a Grind all the main journals to the same under- a Grind all the pin journals to the same under-
size. size.
a When grinding, leave the polish finishing mar- a When grinding, leave the polish finishing mar-
gin of 0.007 – 0.008 mm. gin of 0.007 – 0.008 mm.
Undersize dimensions of main journal Undersize dimensions of pin journal

Unit: mm Unit: mm
Size Standard size Tolerance Size Standard size Tolerance
Standard 120.000 Standard 90.000
0.25 US 119.750 0.25 US 89.750
–0.050 –0.050
0.50 US 119.500 0.50 US 89.500
–0.068 –0.068
0.75 US 119.250 0.75 US 89.250
1.00 US 119.000 1.00 US 89.000
Roundness, cylindricality (TIR) and surface Roundness, cylindricality (TIR) and surface
roughness of main journal roughness of pin journal
Permissible deviation: Max. 0.009 mm Permissible deviation: Max. 0.009 mm
Surface roughness: 0.6S Surface roughness: 0.6S
140E-5 Series 33
Grinding of sides of main journal and pin journal Prevention of grinding burn
q When repairing worn surfaces (c) of main jour- q Apply the flange grinding method.
nal (a) and pin journal (b), limit the grinding q Use all the width of the grinding stone.
quantity to the minimum. Avoid grinding the boss surface.
q (d) is thickness of worn surface. q Apply cooling oil sufficiently.
q Width of crankpin journal q Set the standard peripheral speed of the grind-
When only 1 side is ground ing stone to 2,000 m/min when the crankshaft
Standard: 58 +0.074
0 mm rotation speed is 50 rpm.
q Width of main journal (#7 only)
Standard: 52 +0.05
0 mm Finishing of surface
q Squareness of thrust surface (TIR) q Surface roughness standard
Permissible deviation: 0.04 mm Journal surface (c):
0.6S (finished with sandpaper)
Thrust surface and fillet portion (d): Max. 3.2S
Front seal insertion portion (e) (Range of 33
mm from end): 1 – 2.5S
q Polish finishing margin: 0.007 – 0.008 mm
Dressing of grinding stone

q 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 check-
ing with gauges.
34 140E-5 Series
Work after repair by grinding 2. Measure the outside diameter of the main jour-
q Ensure again that each dimension is as speci- nal in directions (X) and (Y) at 2 places ((1)
fied. and (2)) and that of the pin journal in directions
q Clean each part thoroughly and apply rust-pre- (X) and (Y) at 2 places ((1) and (2)) with a
ventive oil. micrometer or an air micrometer.
q When storing the crankshaft for a long period,
support it on 3 points or keep it erected with a
sling.
Balancing (Reference)
Avoid performing repair that may affect the crank-
shaft balancing.
q Allowable limit of unbalance: 110 gcm
Limits for reading balance accurately
Bend of crankshaft: 0.09 mm (TIR)
Rotation speed of crankshaft: Max. 325 rpm
q When balancing, perform the following correc-
tions.
Front key way: 30.7 gcm
q Correct the balance by drilling holes in or grind
the counterweight, if necessary.
Repair quantity limit of counterweight: 56 g
Drilling direction: Radial direction or in parallel
with each other
Number of holes: Max. 6
Hole diameter: 13 mm or 15 mm
Hole depth: Max. 40 mm
Distance between hole and side:
Min. 5 mm
Distance between holes: Min. 5 mm
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 mini-
mum and maximum values.
140E-5 Series 35
Improvement of surface 3. Check the surface roughness with the stan-

dard piece.
roughness of crankshaft journal 1 a Measure the surface roughness of the
q If the surface roughness of the journal portions journal by comparing it with the standard
of the crankshaft is out of the standard or the piece.
journal surface has a flaw, bruise or rust which Surface roughness standard (Pin journal
can be removed, improve the surface rough- and main journal)
ness. Journal surface: Max. 0.8S
Round part: Max. 3.2S
1. Cleaning and blowing air
Before starting grinding, brush the oil holes 4. If the surface roughness does not satisfy the
and blow air into them. standard, make round polishing with the sand-
paper (#500) again between both ends.
2. Improvement of surface roughness of journal a After improving the surface roughness, be
portions sure to brush the oil holes and blow air
into them.
When improving with special polishing ma- a Ensure that the there is no flaw or bruise
chine on the journal portion and the round part
q Use the special polishing machine shown of each fillet.
below. If there is any flaw or bruise, polish again
from step 1.
1. Set the rotation speed of the crank shaft to 40

– 50 rpm. If the special polishing machine is not available,
Improve the surface roughness by making use the following clamp jig for polishing to
round polishing with sandpaper (belt type) improve the surface roughness.
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 han-
dle (1) to move the sandpaper by the play.
a Move the sandpaper smoothly without
stopping at a place.
1. 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
36 140E-5 Series
2. 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.
3. Insert 2 pieces of upper and lower sandpapers

2. Cut off sandpaper (#800) (a, b) to the shapes (a) or (b) in slit (e) and fix the ends with tape
shown below. (f).
q (a) is for the pin journal and its size is as
follows; 4 Fold slit portion (d) of the sandpaper along the
L: 171 mm, W: 82 mm round part of the clamp.
q (b) is for the main journal and its size is as
follows. 5. Hold the journal with the clamp and fix the
L: 218 mm, W: 75 mm lever ends with rubber tube (g) etc.
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 37
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
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
© 2010 KOMATSU
All Rights Reserved
40

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SEN00074-16

ENGINE 140E -5 SERIES

ENGINE 1SHOP MANUAL

00 Index and foreword 1

Composition of shop manual 1

Section Title Form Number

00 Index and foreword ......................................................................................................... SEN00075-16

10 Structure, function and maintenance standard ............................................................... SEN00080-08

20 Standard value table ....................................................................................................... SEN00083-07

30 Testing and adjusting ...................................................................................................... SEN00148-05

40 Troubleshooting .............................................................................................................. SEN00150-06

50 Disassembly and assembly ............................................................................................ SEN00155-07

90 Repair and replacement of parts..................................................................................... SEN05197-02

10 Structure, function and maintenance standard

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

20 Standard value table

30 Testing and adjusting

Testing compression pressure................................................................................................. 32

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

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

50 Disassembly and assembly

90 Repair and replacement of parts

Gasket sealant application procedure ..................................................................................... 23

KOMATSU 140E-5 Series engine

Form No. SEN00076-16

ENGINE 1SHOP MANUAL

00 Index and foreword 1

Safety notice ................................................................................................................................................... 2

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

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

4. Precautions for sling work and making

How to read the shop manual 1

1. Composition of shop manual

00. Index and foreword

10. Structure, function and maintenance standard

20. Standard value table

30. Testing and adjusting

50. Disassembly and assembly

2. Revision and distribution

q Revised edition mark

Symbol Item Remarks

k Safety Special safety precautions are necessary when performing work.

Special technical precautions or other precautions for preserving stan-

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

Explanation of terms for maintenance standard 1

1. Standard size and tolerance

a The tolerance may be indicated in the text

q Usually, the size of a hole and the size of

2. Standard clearance and standard value 5. Clearance limit

4. Repair limit and allowable value or allow-

Handling of electric equipment and hydraulic component 1

Points to remember when handling electric

2. Main failures occurring in wiring harness

2) Defective crimping or soldering of connec-

4) High-pressure water entering connector

5) Oil or dirt stuck to connector

3. Removing, installing, and drying connec-

2] When removing from clips

q When removing a connector from a

3] Action to take after removing connec-

4) Drying wiring harness

5. Points to remember when troubleshooting

Points to remember when handling hydraulic equipment