Komatsu 140E-7 Series Diesel Engine Shop Manual SEN06498-09 – PDF DOWNLOAD

Komatsu 140E-7 Series Diesel Engine Shop Manual SEN06498-09 – PDF DOWNLOAD

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Komatsu 140E-7 Series Diesel Engine Shop Manual SEN06498-09 – PDF DOWNLOAD

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Komatsu 140E-7 Series Diesel Engine Shop Manual SEN06498-09 – PDF DOWNLOAD

The Komatsu 140E-7 Series Diesel Engine Shop Manual SEN06498-09 is a comprehensive guide that provides detailed information on the service, repair, and maintenance of the 140E-7 Series diesel engine. This engine is a six-cylinder, turbocharged engine that is commonly used in heavy construction equipment, such as excavators and loaders.

The manual is published by Komatsu, a leading manufacturer of heavy equipment and construction machinery. The manual is designed to be used by mechanics and technicians who are responsible for maintaining and repairing Komatsu equipment. It is an essential tool for anyone who works with Komatsu engines.

The manual is divided into several sections, each of which provides specific information on different aspects of the engine. The sections include:

1. General information: This section provides an overview of the engine, including its specifications, features, and operating principles. It also includes information on safety precautions, tools, and equipment needed for maintenance and repair.
2. Inspection and adjustment: This section provides detailed instructions on how to inspect and adjust various components of the engine, including the cylinder head, valves, fuel system, and cooling system.
3. Engine disassembly and assembly: This section provides step-by-step instructions on how to disassemble and assemble the engine. It includes detailed diagrams and illustrations to help users understand each step of the process.
4. Troubleshooting: This section provides a comprehensive list of potential problems that may arise with the engine, along with diagnostic procedures to help identify and fix these issues.
5. Maintenance: This section provides information on the regular maintenance tasks that should be performed on the engine, including oil changes, filter replacements, and other routine tasks.
6. Reassembly and testing: This section provides detailed instructions on how to reassemble the engine after repairs have been made. It also includes information on how to test the engine to ensure that it is functioning properly.
7. Service data: This section provides detailed technical data on the engine, including torque specifications, compression pressures, and other important information.

The manual is written in clear, concise language, and is filled with detailed diagrams and illustrations to help users understand each step of the process. It is an essential tool for anyone who works with Komatsu engines, and can help to ensure that the engine is maintained and repaired to the highest standards. It is important to note that the manual is designed for use by qualified mechanics and technicians, and should not be used by individuals without the appropriate training and experience.

TABLE OF CONTENTS:

Komatsu 140E-7 Series Diesel Engine Shop Manual SEN06498-09 – PDF DOWNLOAD

COVER……………………………………………………………………………………………………… 1
00 INDEX AND FOREWORD………………………………………………………………………………………. 3
INDEX…………………………………………………………………………………………………. 4
ABBREVIATION LIST………………………………………………………………………………………. 6
FOREWORD, SAFETY, BASIC INFORMATION………………………………………………………………………. 12
HOW TO READ THE ENGINE SHOP MANUAL……………………………………………………………………. 12
SAFETY NOTICE FOR OPERATION………………………………………………………………………….. 14
PRECAUTIONS TO PREVENT FIRE………………………………………………………………………….. 22
ACTIONS IF FIRE OCCURS………………………………………………………………………………. 24
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS…………………………………………………………… 25
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS………………………………………………………….. 26
PRECAUTIONS FOR DEF…………………………………………………………………………………. 27
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING……………………………………………………… 27
PRECAUTIONS FOR ADDING…………………………………………………………………………… 27
PRECAUTIONS FOR STORING………………………………………………………………………….. 27
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE……………………………………………………………. 27
THE OTHER PRECAUTIONS……………………………………………………………………………. 27
STORE AdBlue/DEF……………………………………………………………………………………. 28
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT…………………………………………………………… 29
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS…………………………………………………. 32
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT………………………………………………………….. 39
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT…………………………………………………………. 41
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT……………………………………………………….. 42
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER………………………………………………………….. 43
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER…………………………………. 43
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER…………………………………. 44
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER…………………………………. 45
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS………………………………………………. 47
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR……………………………………………….. 51
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR………………………………………… 52
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL………………………………………. 54
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH………………………………………. 55
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE………………………………….. 57
HOW TO READ ELECTRICAL WIRE CODE……………………………………………………………………… 58
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD………………………………………………………….. 62
STANDARD TIGHTENING TORQUE TABLE……………………………………………………………………… 65
CONVERSION TABLE……………………………………………………………………………………. 72
01 SPECIFICATIONS………………………………………………………………………………………….. 77
CONTENTS………………………………………………………………………………………………. 78
ABBREVIATION LIST………………………………………………………………………………………. 79
SPECIFICATIONS…………………………………………………………………………………………. 85
OUTLINE OF EXHAUST GAS REGULATION…………………………………………………………………….. 85
SYSTEM DRAWINGS OF ENGINE CONFORMED TO TIER4 REGULATION……………………………………………… 86
IMPROVED POINTS OF ENGINE CONFORMED TO TIER4 REGULATION……………………………………………… 87
LIST OF APPLICABLE MACHINES: 140E-7…………………………………………………………………… 88
SPECIFICATIONS……………………………………………………………………………………… 89
SPECIFICATIONS: SAA6D140E-7 (D155AX-8, D155AX-8E0, D155AXI-8, D155AXI-8E0)…………………………….. 89
SPECIFICATIONS: SAA6D140E-7 (HD325-8, HD325-8E0, HD405-8, HD405-8E0)………………………………….. 90
SPECIFICATIONS: SAA6D140E-7 (HM400-5, HM400-5E0)……………………………………………………. 91
SPECIFICATIONS: SAA6D140E-7 (PC650LC-11)…………………………………………………………… 92
SPECIFICATIONS: SAA6D140E-7 (WA500-8)……………………………………………………………… 93
ENGINE GENERAL VIEW…………………………………………………………………………………. 94
ENGINE GENERAL VIEW: SAA6D140E-7 (D155AX-8, D155AX-8E0, D155AXI-8, D155AXI-8E0)………………………… 94
ENGINE GENERAL VIEW: SAA6D140E-7 (HD325-8, HD325-8E0, HD405-8, HD405-8E0)……………………………… 98
ENGINE GENERAL VIEW: SAA6D140E-7 (HM400-5, HM400-5E0)………………………………………………..102
ENGINE GENERAL VIEW: SAA6D140E-7 (PC650LC-11)……………………………………………………….106
ENGINE GENERAL VIEW: SAA6D140E-7 (WA500-8)………………………………………………………….110
WEIGHT TABLE………………………………………………………………………………………..114
WEIGHT TABLE: 140E-7……………………………………………………………………………..114
ENGINE PERFORMANCE CURVE……………………………………………………………………………..116
ENGINE PERFORMANCE CURVE: SAA6D140E-7 (D155AX-8, D155AX-8E0, D155AXI-8, D155AXI-8E0)…………………….116
ENGINE PERFORMANCE CURVE: SAA6D140E-7 (HD325-8, HD325-8E0, HD405-8, HD405-8E0)………………………….117
ENGINE PERFORMANCE CURVE: SAA6D140E-7 (HM400-5, HM400-5E0)……………………………………………118
ENGINE PERFORMANCE CURVE: SAA6D140E-7 (PC650LC-11)…………………………………………………..119
ENGINE PERFORMANCE CURVE: SAA6D140E-7(WA500-8)………………………………………………………120
10 STRUCTURE AND FUNCTION……………………………………………………………………………………121
CONTENTS……………………………………………………………………………………………….122
ABBREVIATION LIST……………………………………………………………………………………….124
UREA SCR SYSTEM…………………………………………………………………………………………130
LAYOUT DRAWING OF UREA SCR SYSTEM……………………………………………………………………..130
UREA SCR SYSTEM DIAGRAM………………………………………………………………………………133
FUNCTION OF UREA SCR SYSTEM…………………………………………………………………………..134
FUNCTION OF AdBlue/DEF SUPPLY SYSTEM……………………………………………………………….134
INDUCEMENT STRATEGY………………………………………………………………………………137
COMPONENT PARTS OF UREA SCR SYSTEM…………………………………………………………………….151
AdBlue/DEF MIXING TUBE……………………………………………………………………………151
SCR ASSEMBLY…………………………………………………………………………………….152
AdBlue/DEF TANK………………………………………………………………………………….154
AdBlue/DEF PUMP………………………………………………………………………………….156
AdBlue/DEF INJECTOR………………………………………………………………………………157
AdBlue/DEF HOSE………………………………………………………………………………….158
AdBlue/DEF TANK HEATING VALVE……………………………………………………………………..159
ENGINE SYSTEM…………………………………………………………………………………………..160
LAYOUT OF ENGINE COMPONENTS…………………………………………………………………………..160
LAYOUT DRAWING OF ENGINE COMPONENTS………………………………………………………………..160
INTAKE AND EXHAUST SYSTEM PARTS……………………………………………………………………….162
LAYOUT DRAWING OF INTAKE AND EXHAUST SYSTEM…………………………………………………………162
INTAKE AND EXHAUST SYSTEM CIRCUIT DIAGRAM…………………………………………………………..163
FUNCTION OF INTAKE AND EXHAUST SYSTEM………………………………………………………………163
AIR CLEANER……………………………………………………………………………………..165
ENGINE MAIN BODY PARTS……………………………………………………………………………….166
CYLINDER HEAD……………………………………………………………………………………166
CYLINDER BLOCK…………………………………………………………………………………..168
MAIN MOVING PARTS………………………………………………………………………………..171
VIBRATION DAMPER…………………………………………………………………………………174
TIMING GEAR……………………………………………………………………………………..175
FRONT COVER……………………………………………………………………………………..176
VALVE SYSTEM…………………………………………………………………………………….177
FLYWHEEL AND FLYWHEEL HOUSING……………………………………………………………………..179
TURBOCHARGER SYSTEM………………………………………………………………………………….180
CIRCUIT DIAGRAM OF VGT SYSTEM……………………………………………………………………..180
FUNCTION OF VGT SYSTEM……………………………………………………………………………181
VGT…………………………………………………………………………………………….183
EGR SYSTEM………………………………………………………………………………………187
EGR VALVE……………………………………………………………………………………….189
EGR COOLER………………………………………………………………………………………191
MIXING CONNECTOR…………………………………………………………………………………192
KCCV SYSTEM……………………………………………………………………………………..193
KCCV VENTILATOR………………………………………………………………………………….197
KDPF……………………………………………………………………………………………199
LUBRICATION SYSTEM…………………………………………………………………………………..203
LAYOUT DRAWING OF LUBRICATION SYSTEM PARTS………………………………………………………….203
LUBRICATION SYSTEM CIRCUIT DIAGRAM…………………………………………………………………204
ENGINE OIL PUMP………………………………………………………………………………….205
ENGINE BOOST OIL PUMP…………………………………………………………………………….207
ENGINE OIL FILTER………………………………………………………………………………..209
ENGINE OIL COOLER………………………………………………………………………………..210
ENGINE OIL PAN…………………………………………………………………………………..212
FUEL SYSTEM…………………………………………………………………………………………213
LAYOUT DRAWING OF FUEL SYSTEM PARTS………………………………………………………………..213
FUEL SYSTEM CIRCUIT DIAGRAM……………………………………………………………………….215
FUNCTION OF FUEL SYSTEM…………………………………………………………………………..216
OPERATION OF FUEL SYSTEM………………………………………………………………………….216
CRI SYSTEM………………………………………………………………………………………217
SUPPLY PUMP……………………………………………………………………………………..221
COMMON RAIL……………………………………………………………………………………..224
INJECTOR………………………………………………………………………………………..227
FUEL DOSING SYSTEM……………………………………………………………………………….230
FUEL PREFILTER…………………………………………………………………………………..232
FUEL MAIN FILTER…………………………………………………………………………………233
COOLING SYSTEM………………………………………………………………………………………234
LAYOUT DRAWING OF COOLING SYSTEM PARTS……………………………………………………………..234
COOLING SYSTEM CIRCUIT DIAGRAM…………………………………………………………………….235
WATER PUMP………………………………………………………………………………………236
THERMOSTAT………………………………………………………………………………………238
ELECTRICAL SYSTEM……………………………………………………………………………………….240
COMPONENT PARTS OF ELECTRICAL SYSTEM…………………………………………………………………..240
ALTERNATOR………………………………………………………………………………………240
ALTERNATOR MOUNTING………………………………………………………………………………243
STARTING MOTOR…………………………………………………………………………………..244
ENGINE WIRING HARNESS…………………………………………………………………………….246
ENGINE CONTROLLER………………………………………………………………………………..248
FUEL FEED PUMP…………………………………………………………………………………..256
FUEL FEED PUMP SWITCH…………………………………………………………………………….257
SENSOR……………………………………………………………………………………………..258
LAYOUT DRAWING OF ENGINE SENSOR……………………………………………………………………258
STRUCTURE OF AMBIENT PRESSURE SENSOR……………………………………………………………….261
FUNCTION OF AMBIENT PRESSURE SENSOR………………………………………………………………..261
STRUCTURE OF ENGINE OIL PRESSURE SENSOR…………………………………………………………….262
FUNCTION OF ENGINE OIL PRESSURE SENSOR……………………………………………………………..262
STRUCTURE OF CHARGE PRESSURE SENSOR………………………………………………………………..263
FUNCTION OF CHARGE PRESSURE SENSOR…………………………………………………………………263
STRUCTURE OF CHARGE TEMPERATURE SENSOR……………………………………………………………..264
FUNCTION OF CHARGE TEMPERATURE SENSOR………………………………………………………………264
STRUCTURE OF COOLANT TEMPERATURE SENSOR…………………………………………………………….265
FUNCTION OF COOLANT TEMPERATURE SENSOR……………………………………………………………..265
STRUCTURE OF NE (CRANKSHAFT) SPEED SENSOR…………………………………………………………..266
FUNCTION OF NE (CRANKSHAFT) SPEED SENSOR……………………………………………………………266
STRUCTURE OF Bkup (CAMSHAFT) SPEED SENSOR…………………………………………………………..267
FUNCTION OF Bkup (CAMSHAFT) SPEED SENSOR……………………………………………………………267
STRUCTURE OF COMMON RAIL PRESSURE SENSOR……………………………………………………………268
FUNCTION OF COMMON RAIL PRESSURE SENSOR…………………………………………………………….268
STRUCTURE OF EGR VALVE LIFT SENSOR…………………………………………………………………269
FUNCTION OF EGR VALVE LIFT SENSOR………………………………………………………………….269
STRUCTURE OF VGT SPEED SENSOR……………………………………………………………………..270
FUNCTION OF VGT SPEED SENSOR………………………………………………………………………270
STRUCTURE OF VGT POSITION SENSOR…………………………………………………………………..271
FUNCTION OF VGT POSITION SENSOR……………………………………………………………………271
STRUCTURE OF MASS AIR FLOW AND TEMPERATURE SENSOR……………………………………………………272
FUNCTION OF MASS AIR FLOW AND TEMPERATURE SENSOR…………………………………………………….272
STRUCTURE OF DOSING FUEL PRESSURE SENSOR……………………………………………………………273
FUNCTION OF DOSING FUEL PRESSURE SENSOR…………………………………………………………….273
STRUCTURE OF KDPF DIFFERENTIAL PRESSURE AND OUTLET PRESSURE SENSOR…………………………………….274
FUNCTION OF KDPF DIFFERENTIAL PRESSURE AND OUTLET PRESSURE SENSOR……………………………………..274
STRUCTURE OF CRANKCASE PRESSURE SENSOR……………………………………………………………..275
FUNCTION OF CRANKCASE PRESSURE SENSOR………………………………………………………………275
STRUCTURE OF ENGINE OIL LEVEL SENSOR……………………………………………………………….276
FUNCTION OF ENGINE OIL LEVEL SENSOR………………………………………………………………..276
STRUCTURE OF AIR CLEANER CLOGGING SENSOR……………………………………………………………277
FUNCTION OF AIR CLEANER CLOGGING SENSOR…………………………………………………………….277
20 STANDARD VALUE TABLE……………………………………………………………………………………..279
CONTENTS……………………………………………………………………………………………….280
ABBREVIATION LIST……………………………………………………………………………………….281
STANDARD VALUE TABLE FOR ENGINE…………………………………………………………………………..287
STANDARD VALUE TABLE FOR ENGINE: SAA6D140E-7 (D155AX-8, D155AX-8E0, D155AXI-8, D155AXI-8E0)………………….287
STANDARD VALUE TABLE FOR ENGINE: SAA6D140E-7 (HD325-8, HD325-8E0, HD405-8, HD405-8E0)……………………….289
STANDARD VALUE TABLE FOR ENGINE: SAA6D140E-7 (HM400-5, HM400-5E0)…………………………………………291
STANDARD VALUE TABLE FOR ENGINE: SAA6D140E-7 (PC650LC-11)………………………………………………..293
STANDARD VALUE TABLE FOR ENGINE: SAA6D140E-7 (WA500-8)…………………………………………………..295
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD…………………………………………………………..297
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA6D140E-7 (D155AX-8, D155AX-8E0, D155AXI-8, D155AXI-8E0)….297
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA6D140E-7 (HD325-8, HD325-8E0, HD405-8, HD405-8E0)……….299
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA6D140E-7 (HM400-5, HM400-5E0)…………………………301
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA6D140E-7 (PC650LC-11)………………………………..303
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA6D140E-7 (WA500-8)…………………………………..305
50 DISASSEMBLY AND ASSEMBLY………………………………………………………………………………….307
CONTENTS……………………………………………………………………………………………….308
ABBREVIATION LIST……………………………………………………………………………………….309
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY…………………………………………………………….315
HOW TO READ THIS MANUAL………………………………………………………………………………315
COATING MATERIALS LIST……………………………………………………………………………….317
SPECIAL TOOLS LIST…………………………………………………………………………………..321
SKETCHES OF SPECIAL TOOLS…………………………………………………………………………….323
ENGINE SYSTEM…………………………………………………………………………………………..326
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY………………………………………………………………326
METHOD FOR DISASEMBLING ENGINE GENERALLY……………………………………………………………327
METHOD FOR ASEMBLING ENGINE GENERALLY………………………………………………………………351
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY………………………………………………………………..394
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY……………………………………………………………394
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY………………………………………………………….394
REMOVE AND INSTALL ENGINE FRONT OIL SEAL……………………………………………………………….398
METHOD FOR REMOVING ENGINE FRONT OIL SEAL…………………………………………………………..398
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL…………………………………………………………399
REMOVE AND INSTALL ENGINE REAR OIL SEAL………………………………………………………………..401
METHOD FOR REMOVING ENGINE REAR OIL SEAL……………………………………………………………401
METHOD FOR INSTALLING ENGINE REAR OIL SEAL………………………………………………………….402
60 MAINTENANCE STANDARD……………………………………………………………………………………..407
CONTENTS……………………………………………………………………………………………….408
ABBREVIATION LIST……………………………………………………………………………………….409
ENGINE SYSTEM…………………………………………………………………………………………..415
INTAKE AND EXHAUST SYSTEM PARTS……………………………………………………………………….415
MAINTENANCE STANDARD OF VGT……………………………………………………………………….415
ENGINE MAIN BODY PARTS……………………………………………………………………………….416
MAINTENANCE STANDARD OF CYLINDER HEAD………………………………………………………………416
MAINTENANCE STANDARD OF CYLINDER BLOCK……………………………………………………………..418
MAINTENANCE STANDARD OF CYLINDER LINER……………………………………………………………..420
MAINTENANCE STANDARD OF CRANKSHAFT…………………………………………………………………422
MAINTENANCE STANDARD OF CAM FOLLOWER AND PUSH ROD……………………………………………………424
MAINTENANCE STANDARD OF PISTON…………………………………………………………………….426
MAINTENANCE STANDARD OF CONROD…………………………………………………………………….428
MAINTENANCE STANDARD OF VIBRATION DAMPER……………………………………………………………430
MAINTENANCE STANDARD OF TIMING GEAR………………………………………………………………..431
MAINTENANCE STANDARD OF CAMSHAFT…………………………………………………………………..433
MAINTENANCE STANDARD OF VALVE AND VALVE GUIDE……………………………………………………….434
MAINTENANCE STANDARD OF ROCKER ARM…………………………………………………………………436
MAINTENANCE STANDARD OF CROSSHEAD AND GUIDE…………………………………………………………437
MAINTENANCE STANDARD OF FLYWHEEL…………………………………………………………………..438
LUBRICATION SYSTEM…………………………………………………………………………………..440
MAINTENANCE STANDARD OF RELIEF VALVE OF ENGINE OIL PUMP………………………………………………440
MAINTENANCE STANDARD OF RELIEF VALVE OF ENGINE BOOST OIL PUMP…………………………………………441
MAINTENANCE STANDARD OF SAFETY VALVE OF ENGINE OIL FILTER…………………………………………….442
COOLING SYSTEM………………………………………………………………………………………443
MAINTENANCE STANDARD OF OIL COOLER…………………………………………………………………443
MAINTENANCE STANDARD OF WATER PUMP…………………………………………………………………445
MAINTENANCE STANDARD OF THERMOSTAT…………………………………………………………………447
INDEX………………………………………………………………………………………………………449