Komatsu 140-3 Series Diesel Engine Shop Manual SEBM022213 – PDF DOWNLOAD

Komatsu 140-3 Series Diesel Engine Shop Manual SEBM022213 – PDF DOWNLOAD

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Komatsu 140-3 Series Diesel Engine Shop Manual SEBM022213 – PDF DOWNLOAD

Language : English
Pages : 357
Downloadable : Yes
File Type : PDF
Size: 26.1 MB

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Komatsu 140-3 Series Diesel Engine Shop Manual SEBM022213 – PDF DOWNLOAD

The Komatsu 140-3 Series Diesel Engine Shop Manual SEBM022213 is a comprehensive technical reference guide for maintaining, repairing, and overhauling the Komatsu 140-3 series diesel engine. This engine is widely used in heavy-duty applications, such as construction equipment, mining vehicles, and marine vessels. The manual is an essential resource for mechanics, technicians, and service personnel responsible for servicing and maintaining these engines.

The shop manual is organized into several sections, each of which covers a specific aspect of the engine. These sections include:

1. General Information: This section provides an overview of the engine, including specifications, operating guidelines, and maintenance intervals.
2. Inspection and Adjustment: This section provides detailed instructions for inspecting and adjusting engine components, including the fuel injection system, valves, and timing belt.
3. Engine Assembly: This section covers the removal and installation of major engine components, such as the cylinder head, crankshaft, and pistons. The manual includes detailed illustrations and specifications to help technicians perform these tasks safely and efficiently.
4. Lubrication System: This section provides information on the engine’s lubrication system, including oil pump removal and installation, oil filter replacement, and oil pressure testing.
5. Cooling System: This section provides information on the engine’s cooling system, including water pump removal and installation, radiator removal and installation, and thermostat replacement.
6. Fuel System: This section covers the engine’s fuel system, including fuel pump removal and installation, fuel injector replacement, and fuel system troubleshooting.
7. Air Intake and Exhaust System: This section provides information on the engine’s air intake and exhaust system, including air filter replacement, turbocharger removal and installation, and exhaust manifold removal and installation.
8. Electrical System: This section provides information on the engine’s electrical system, including alternator and starter motor removal and installation, as well as troubleshooting procedures for electrical faults.
9. Special Tools: This section lists the special tools required for servicing the engine, including part numbers and illustrations.

The Komatsu 140-3 Series Diesel Engine Shop Manual SEBM022213 is an essential resource for maintaining and repairing these engines. It provides a comprehensive guide to servicing the engine and includes detailed instructions, specifications, and illustrations to help technicians perform tasks accurately and safely. The manual is a valuable tool for ensuring that the Komatsu 140-3 series diesel engine continues to operate at peak performance, with maximum efficiency and reliability over its long service life.

TABLE OF CONTENTS:

Komatsu 140-3 Series Diesel Engine Shop Manual SEBM022213 – PDF DOWNLOAD

COVER…………………………………………………………………………………………………………………………… 1
CONTENTS………………………………………………………………………………………………………………………… 2
01 GENERAL………………………………………………………………………………………………………………………. 27
OUTLINE……………………………………………………………………………………………………………………… 28
SPECIFICATIONS……………………………………………………………………………………………………………….. 31
OVERALL DRAWING………………………………………………………………………………………………………………. 36
WEIGHT TABLE…………………………………………………………………………………………………………………. 43
ENGINE PERFORMANCE CURVE………………………………………………………………………………………………………. 45
11 STRUCTURE AND FUNCTION,MAINTENANCE STANDARD………………………………………………………………………………………. 55
INTAKE,EXHAUST SYSTEM…………………………………………………………………………………………………………. 56
INTAKE,EXHAUST EQUIPMENT…………………………………………………………………………………………………… 56
AIR CLEANER………………………………………………………………………………………………………………. 68
TURBOCHARGER……………………………………………………………………………………………………………… 71
AFTERCOOLER………………………………………………………………………………………………………………. 75
ENGINE………………………………………………………………………………………………………………………. 77
CYLINDER HEAD…………………………………………………………………………………………………………….. 77
CYLINDER BLOCK……………………………………………………………………………………………………………. 80
CYLINDER LINER……………………………………………………………………………………………………………. 83
MAIN MOVING PARTS…………………………………………………………………………………………………………. 84
CRANKSHAFT……………………………………………………………………………………………………………….. 86
CAMSHAFT…………………………………………………………………………………………………………………. 87
CAM FOLLOWER AND PUSH ROD………………………………………………………………………………………………….. 88
PISTON・PISTON RING・PISTON PIN………………………………………………………………………………………………. 89
CONNECTING ROD……………………………………………………………………………………………………………. 91
FLYWHEEL,FLYWHEEL HOUSING………………………………………………………………………………………………….. 92
VIBRATION DAMPER………………………………………………………………………………………………………….. 94
TIMING GEAR………………………………………………………………………………………………………………. 95
VALVE SYSTEM……………………………………………………………………………………………………………… 99
VALVE,VALVE GUIDE………………………………………………………………………………………………………….101
ROCKER ARM AND SHAFT……………………………………………………………………………………………………….103
CROSSHEAD AND GUIDE………………………………………………………………………………………………………..104
LUBRICATION SYSTEM…………………………………………………………………………………………………………….105
LUBRICATION SYSTEM DIAGRAM………………………………………………………………………………………………….105
OIL PUMP………………………………………………………………………………………………………………….106
OIL FILTER………………………………………………………………………………………………………………..109
OIL COOLER………………………………………………………………………………………………………………..110
FUEL SYSTEM…………………………………………………………………………………………………………………..112
FUEL SYSTEM DIAGRAM………………………………………………………………………………………………………..112
OUTLINE OF CRI SYSTEM………………………………………………………………………………………………………113
FUEL PIPING……………………………………………………………………………………………………………….126
FUEL COOLER……………………………………………………………………………………………………………….128
FUEL FILTER……………………………………………………………………………………………………………….129
COOLANT SYSTEM………………………………………………………………………………………………………………..130
COOLING SYSTEM DIAGRAM……………………………………………………………………………………………………..130
WATER PUMP………………………………………………………………………………………………………………..133
THERMOSTAT………………………………………………………………………………………………………………..136
CORROSION RESISTOR…………………………………………………………………………………………………………138
COOLING FAN DRIVE………………………………………………………………………………………………………….140
ACCESSORIES…………………………………………………………………………………………………………………..151
FRONT PTO…………………………………………………………………………………………………………………151
AIR COMPRESSOR…………………………………………………………………………………………………………….154
EXHAUST BRAKE……………………………………………………………………………………………………………..157
ELECTRICAL COMPONENTS………………………………………………………………………………………………………….161
ALTERNATOR………………………………………………………………………………………………………………..161
STARTING MOTOR…………………………………………………………………………………………………………….168
STARTING AID………………………………………………………………………………………………………………170
12 TESTING AND ADJUSTING…………………………………………………………………………………………………………..172
STANDARD VALUE TABLE FOR TESTING,ADJUSTING,AND TROUBLESHOOTING……………………………………………………………………..173
STANDARD VALUE TABLE FOR ELECTRICAL RELATED PARTS…………………………………………………………………………………178
TOOLS FOR TESTING,ADJUSTING,AND TROUBLESHOOTING…………………………………………………………………………………..180
MEASURING INTAKE AIR PRESSURE(BOOST PRESSURE)…………………………………………………………………………………….181
MEASURING EXHAUST TEMPERATURE…………………………………………………………………………………………………..181
ADJUSTING VALVE CLEARANCE………………………………………………………………………………………………………182
MEASURING COMPRESSION PRESSURE………………………………………………………………………………………………….183
MEASURING BLOW-BY PRESSURE……………………………………………………………………………………………………..184
MEASURING OIL PRESSURE…………………………………………………………………………………………………………185
HANDLING EQUIPMENT IN FUEL CIRCUIT………………………………………………………………………………………………185
RELEASING REMAINING PRESSURE IN FUEL SYSTEM………………………………………………………………………………………186
MEASURING FUEL PRESSURE………………………………………………………………………………………………………..186
REDUCED CYLINDER MODE OPERATION…………………………………………………………………………………………………187
BLEEDING AIR FROM FUEL SYSTEM…………………………………………………………………………………………………..188
CHECK FOR LEAKAGE IN FUEL SYSTEM………………………………………………………………………………………………..190
ADJUSTING SPEED SENSOR…………………………………………………………………………………………………………191
TESTING AND ADJUSTING ALTERNATOR BELT TENSION…………………………………………………………………………………….191
TESTING AND ADJUSTING FAN BELT TENSION…………………………………………………………………………………………..192
HANDLING CONTROLLER HIGH VOLTAGE CIRCUIT…………………………………………………………………………………………194
RUN-IN STANDARD……………………………………………………………………………………………………………….195
PERFORMANCE TEST STANDARDS……………………………………………………………………………………………………..197
TROUBLESHOOTING OF ENGINE SYSTEM(S MODE)…………………………………………………………………………………………203
POINTS TO REMEMBER WHEN TROUBLESHOOTING………………………………………………………………………………………204
METHOD OF USING TROUBLESHOOTING CHARTS……………………………………………………………………………………….205
S-1 STARTING PERFORMANCE IS POOR(STARTING ALWAYS TAKES TIME)……………………………………………………………………208
S-2 ENGINE DOES NOT START…………………………………………………………………………………………………..209
S-3 ENGINE DOES NOT PICK UP SMOOTHLY(FOLLOW-UP IS POOR)………………………………………………………………………..212
S-4 ENGINE STOPS DURING OPERATIONS…………………………………………………………………………………………..213
S-5 ENGINE DOES NOT ROTATE SMOOTHLY(HUNTING)………………………………………………………………………………….214
S-6 ENGINE LACKS OUTPUT(OR LACKS POWER)………………………………………………………………………………………215
S-7 EXHAUST SMOKE IS BLACK(INCOMPLETE COMBUSTION)……………………………………………………………………………..216
S-8 OIL CONSUMPTION IS EXCESSIVE(OR EXHAUST SMOKE IS BLUE)……………………………………………………………………..217
S-9 OIL BECOMES CONTAMINATED QUICKLY…………………………………………………………………………………………218
S-10 FUEL CONSUMPTION IS EXCESSIVE…………………………………………………………………………………………..219
S-11 OIL IS IN COOLING WATER(OR WATER SPURTS BACK,OR WATER LEVEL GOES DOWN)………………………………………………………220
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP(DROP IN OIL PRESSURE)………………………………………………………………….221
S-13 OIL LEVEL RISES(WATER,FUEL IN OIL)………………………………………………………………………………………222
S-14 WATER TEMPERATURE BECOMES TOO HIGH(OVERHEATING)…………………………………………………………………………..223
S-15 ABNORMAL NOISE IS MADE…………………………………………………………………………………………………224
S-16 VIBRATION IS EXCESSIVE…………………………………………………………………………………………………225
TROUBLESHOOTING OF ELECTRICAL SYSTEM(E MODE)……………………………………………………………………………………..226
POINTS TO REMEMBER WHEN TROUBLESHOOTING………………………………………………………………………………………228
METHOD OF USING TROUBLESHOOTING FLOWCHART…………………………………………………………………………………….229
ERROR CODE DISPLAYS AND POINTS TO REMEMBER WHEN TROUBLESHOOTING…………………………………………………………………230
ACTION TAKEN BY CONTROLLER AND CONDITION OF MACHINE WHEN ERROR CODE IS DISPLAYED………………………………………………….233
E-1 ERROR CODE [E-1b] [ABNORMALITY IN NE REVOLUTION SENSOR SYSTEM]………………………………………………………………241
E-2 ERROR CODE [E-1C] [ABNORMALITY IN G REVOLUTION SENSOR SYSTEM]……………………………………………………………….242
E-3 ERROR CODE [E-20] [ABNORMALITY IN MODEL SELECTION SYSTEM]…………………………………………………………………..243
E-4 ERROR CODE [E-22] [OVERRUN]……………………………………………………………………………………………..244
E-5 ERROR CODE [E-23] [OVERHEAT]…………………………………………………………………………………………….244
E-6 ERROR CODE [E-24] [DROP IN OIL PRESSURE]………………………………………………………………………………….245
E-7 ERROR CODE [E-30] [ABNORMALITY IN IDLING VALIDATION SIGNAL SYSTEM]…………………………………………………………..246
E-8 ERROR CODE [E-31] [ABNORMALITY IN THROTTLE SENSOR SYSTEM]…………………………………………………………………..248
E-9 ERROR CODE [E-34] [ABNORMALITY IN WATER TEMPERATURE HIGH-TEMPERATURE SENSOR SYSTEM]……………………………………………251
E-10 ERROR CODE [E-36] [ABNORMALITY IN OIL PRESSURE SWITCH SYSTEM]………………………………………………………………252
E-11 ERROR CODE [E-3C] [ABNORMALITY IN BOOST PRESSURE SENSOR SYSTEM]…………………………………………………………….254
E-12 ERROR CODE [E-3D] [ABNORMALITY IN FUEL TEMPERATURE SENSOR SYSTEM]…………………………………………………………..255
E-13 ERROR CODE [E-50] [ABNORMALITY IN PREHEATING RELAY CONNECTING POINT SYSTEM]………………………………………………….256
E-14 ERROR CODE [E-51] [ABNORMALITY IN PREHEAT RELAY COIL SYSTEM]……………………………………………………………….257
E-15 ERROR CODE [E-54] [SHORT CIRCUIT IN STARTING SWITCH C SYSTEM]………………………………………………………………258
E-16 ERROR CODE [E-56] [POWER SOURCE SYSTEM ABNORMALITY 1]……………………………………………………………………..259
E-17 ERROR CODE [E-57] [POWER SOURCE SYSTEM ABNORMALITY 2]……………………………………………………………………..261
E-18 ERROR CODE [E-5A] [ABNORMALITY IN FUEL INJECTION QUANTITY CONTROL SWITCH SIGNAL]……………………………………………..262
E-19 ERROR CODE [E-6A] [ABNORMALITY IN WATER TEMPERATURE LOW-TEMPERATURE SENSOR SYSTEM]……………………………………………263
E-20 ERROR CODE [E-70] [EXCESS CURRENT IN FUEL SUPPLY PUMP PCV1 SYSTEM]………………………………………………………….264
E-21 ERROR CODE [E-71] [EXCESS CURRENT IN FUEL SUPPLY PUMP PCV2 SYSTEM]………………………………………………………….265
E-22 ERROR CODE [E-74] [DISCONNECTION IN FUEL SUPPLY PUMP PCV1 SYSTEM]…………………………………………………………..266
E-23 ERROR CODE [E-75] [DISCONNECTION IN FUEL SUPPLY PUMP PCV2 SYSTEM]…………………………………………………………..267
E-24 ERROR CODE [E-77] [ABNORMALITY IN COMMON RAIL FUEL PRESSURE SENSOR SYSTEM]…………………………………………………..268
E-25 ERROR CODE [E-79] [COMMON RAIL FUEL HIGH PRESSURE ABNORMALITY 1];ERROR CODE [E-7A] [COMMON RAIL FUEL HIGH PRESSURE ABNORMALITY 2]….269
E-26 ERROR CODE [E-7b] [FUEL SUPPLY PUMP NON-FORCE FEED 1];ERROR CODE [E-7C] [FUEL SUPPLY PUMP NON-FORCE FEED 2]……………………..270
E-27 ERROR CODE [E-7d] [ABNORMALITY IN COMMON RAIL FUEL PRESSURE]……………………………………………………………….272
E-28 ERROR CODE [E-80] [DEFECTIVE CONTROLLER]…………………………………………………………………………………272
E-29 ERROR CODE [E-81] [DISCONNECTION IN NO.1 FUEL INJECTOR SYSTEM]……………………………………………………………..273
E-30 ERROR CODE [E-82] [DISCONNECTION IN NO.2 FUEL INJECTOR SYSTEM]……………………………………………………………..274
E-31 ERROR CODE [E-83] [DISCONNECTION IN NO.3 FUEL INJECTOR SYSTEM]……………………………………………………………..275
E-32 ERROR CODE [E-84] [DISCONNECTION IN NO.4 FUEL INJECTOR SYSTEM]……………………………………………………………..276
E-33 ERROR CODE [E-85] [DISCONNECTION IN NO.5 FUEL INJECTOR SYSTEM]……………………………………………………………..277
E-34 ERROR CODE [E-86] [DISCONNECTION IN NO.6 FUEL INJECTOR SYSTEM]……………………………………………………………..278
E-35 ERROR CODE [E-8A] [SHORT CIRCUIT IN NO.1,NO.2,NO.3 FUEL INJECTOR SYSTEM]…………………………………………………….279
E-36 ERROR CODE [E-8b] [SHORT CIRCUIT IN NO.4,NO.5,NO.6 FUEL INJECTOR SYSTEM]…………………………………………………….282
13 DISASSEMBLY AND ASSEMBLY………………………………………………………………………………………………………..285
METHOD OF USING MANUAL…………………………………………………………………………………………………………286
PRECAUTIONS WHEN CARRYING OUT OPERATION………………………………………………………………………………………….287
SPECIAL TOOL LIST……………………………………………………………………………………………………………..289
GENERAL DISASSEMBLY OF ENGINE…………………………………………………………………………………………………..290
GENERAL ASSEMBLY OF ENGINE……………………………………………………………………………………………………..306
PROCEDURE FOR REMOVING AND INSTALLING FUEL SUPPLY PUMP UNIT………………………………………………………………………..338
15 REPAIR AND REPLACEMENT OF PARTS………………………………………………………………………………………………….340
CYLINDER HEAD…………………………………………………………………………………………………………………341
GRINDING OF FITTING FACE OF CYLINDER HEAD…………………………………………………………………………………….341
REPLACING VALVE SEAT INSERT…………………………………………………………………………………………………342
PRESSURE TEST……………………………………………………………………………………………………………..347
REPLACING VALVE GUIDE………………………………………………………………………………………………………348
REPLACING CROSSHEAD GUIDE…………………………………………………………………………………………………..349
GRINDING VALVE…………………………………………………………………………………………………………….350
CYLINDER BLOCK………………………………………………………………………………………………………………..351
REPLACING CAM BUSHING………………………………………………………………………………………………………351
REPLACING CRANKSHAFT GEAR…………………………………………………………………………………………………..354
REPLACING CAM GEAR…………………………………………………………………………………………………………355
REPLACING FLYWHEEL RING GEAR………………………………………………………………………………………………..356
REPLACING CONNECTING ROD SMALL END BUSHING……………………………………………………………………………………357