Komatsu 140E-7 Series Engine Shop Manual SEN06498-11 – PDF DOWNLOAD

Komatsu 140E-7 Series Engine Shop Manual SEN06498-11 – PDF DOWNLOAD

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Komatsu 140E-7 Series Engine Shop Manual SEN06498-11 – PDF DOWNLOAD

Language : English
Pages : 454
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Komatsu 140E-7 Series Engine Shop Manual SEN06498-11 – PDF DOWNLOAD

The Komatsu 140E-7 Series Engine Shop Manual SEN06498-11 is a comprehensive technical manual that provides detailed information and instructions for the maintenance, repair, and overhaul of the Komatsu SAA6D107E-1 diesel engine. This engine is commonly used in Komatsu construction equipment, including excavators, bulldozers, and wheel loaders.

• The manual is organized into several sections, each of which covers different aspects of engine maintenance and repair. The sections include general specifications, testing and adjusting procedures, disassembly and assembly instructions, and troubleshooting guidelines.
• The general specifications section provides an overview of the engine’s technical specifications, including its dimensions, weight, power output, and torque ratings. It also includes information on the engine’s various components, such as the cylinder block, cylinder head, crankshaft, and pistons.
• The testing and adjusting procedures section of the manual provides step-by-step instructions for performing various tests and adjustments on the engine. These procedures include compression tests, fuel injection timing adjustment, and valve clearance adjustment. The manual also provides information on the tools and equipment required for performing these procedures.
• The disassembly and assembly instructions section of the manual provides detailed guidance on how to disassemble and reassemble the engine, including the removal and installation of various components such as the cylinder head, pistons, and crankshaft. This section also includes detailed diagrams and illustrations that provide a clear understanding of the engine’s internal components and how they fit together.
• The troubleshooting guidelines section of the manual provides information on how to diagnose and repair common problems that may occur with the engine. This section provides a list of potential symptoms and causes, along with step-by-step instructions for identifying and fixing the problem.
• Overall, the Komatsu 140E-7 Series Engine Shop Manual SEN06498-11 is an essential resource for technicians and mechanics working with the Komatsu SAA6D107E-1 engine. Its comprehensive coverage of maintenance, repair, and troubleshooting procedures make it an indispensable tool for ensuring the reliable and efficient operation of Komatsu equipment.

TABLE OF CONTENTS:

Komatsu 140E-7 Series Engine Shop Manual SEN06498-11 – 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, D155CX-8)…………………………….. 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, D155CX-8)………………………… 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, D155CX-8)…………………….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……………………………………………………………………………………….136
COMPONENT PARTS OF UREA SCR SYSTEM……………………………………………………………………………..150
AdBlue/DEF MIXING TUBE…………………………………………………………………………………….150
SCR ASSEMBLY……………………………………………………………………………………………..151
AdBlue/DEF TANK…………………………………………………………………………………………..153
AdBlue/DEF PUMP…………………………………………………………………………………………..155
AdBlue/DEF INJECTOR……………………………………………………………………………………….156
AdBlue/DEF HOSE…………………………………………………………………………………………..157
AdBlue/DEF TANK HEATING VALVE………………………………………………………………………………158
ENGINE SYSTEM……………………………………………………………………………………………………159
LAYOUT OF ENGINE COMPONENTS……………………………………………………………………………………159
LAYOUT DRAWING OF ENGINE COMPONENTS…………………………………………………………………………159
INTAKE AND EXHAUST SYSTEM PARTS………………………………………………………………………………..161
LAYOUT DRAWING OF INTAKE AND EXHAUST SYSTEM………………………………………………………………….161
INTAKE AND EXHAUST SYSTEM CIRCUIT DIAGRAM……………………………………………………………………162
FUNCTION OF INTAKE AND EXHAUST SYSTEM……………………………………………………………………….162
AIR CLEANER………………………………………………………………………………………………164
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………………………………………………………………………………………………..190
EGR COOLER……………………………………………………………………………………………….192
MIXING CONNECTOR………………………………………………………………………………………….193
KCCV SYSTEM………………………………………………………………………………………………194
KCCV VENTILATOR…………………………………………………………………………………………..198
KDPF…………………………………………………………………………………………………….200
LUBRICATION SYSTEM……………………………………………………………………………………………204
LAYOUT DRAWING OF LUBRICATION SYSTEM PARTS…………………………………………………………………..204
LUBRICATION SYSTEM CIRCUIT DIAGRAM………………………………………………………………………….205
ENGINE OIL PUMP…………………………………………………………………………………………..206
ENGINE BOOST OIL PUMP……………………………………………………………………………………..208
ENGINE OIL FILTER…………………………………………………………………………………………210
ENGINE OIL COOLER…………………………………………………………………………………………211
ENGINE OIL PAN……………………………………………………………………………………………213
FUEL SYSTEM………………………………………………………………………………………………….214
LAYOUT DRAWING OF FUEL SYSTEM PARTS…………………………………………………………………………214
FUEL SYSTEM CIRCUIT DIAGRAM………………………………………………………………………………..216
FUNCTION OF FUEL SYSTEM……………………………………………………………………………………217
OPERATION OF FUEL SYSTEM…………………………………………………………………………………..217
CRI SYSTEM……………………………………………………………………………………………….218
SUPPLY PUMP………………………………………………………………………………………………222
COMMON RAIL………………………………………………………………………………………………225
INJECTOR…………………………………………………………………………………………………228
FUEL DOSING SYSTEM………………………………………………………………………………………..231
FUEL PREFILTER……………………………………………………………………………………………233
FUEL MAIN FILTER………………………………………………………………………………………….234
COOLING SYSTEM……………………………………………………………………………………………….235
LAYOUT DRAWING OF COOLING SYSTEM PARTS………………………………………………………………………235
COOLING SYSTEM CIRCUIT DIAGRAM……………………………………………………………………………..236
WATER PUMP……………………………………………………………………………………………….237
THERMOSTAT……………………………………………………………………………………………….239
ELECTRICAL SYSTEM………………………………………………………………………………………………..241
COMPONENT PARTS OF ELECTRICAL SYSTEM……………………………………………………………………………241
ALTERNATOR……………………………………………………………………………………………….241
ALTERNATOR MOUNTING……………………………………………………………………………………….244
STARTING MOTOR……………………………………………………………………………………………245
ENGINE WIRING HARNESS……………………………………………………………………………………..247
ENGINE CONTROLLER…………………………………………………………………………………………249
FUEL FEED PUMP……………………………………………………………………………………………257
FUEL FEED PUMP SWITCH……………………………………………………………………………………..258
SENSOR………………………………………………………………………………………………………259
LAYOUT DRAWING OF ENGINE SENSOR…………………………………………………………………………….259
STRUCTURE OF AMBIENT PRESSURE SENSOR………………………………………………………………………..262
FUNCTION OF AMBIENT PRESSURE SENSOR…………………………………………………………………………262
STRUCTURE OF ENGINE OIL PRESSURE SENSOR……………………………………………………………………..263
FUNCTION OF ENGINE OIL PRESSURE SENSOR………………………………………………………………………263
STRUCTURE OF CHARGE PRESSURE SENSOR…………………………………………………………………………264
FUNCTION OF CHARGE PRESSURE SENSOR………………………………………………………………………….264
STRUCTURE OF CHARGE TEMPERATURE SENSOR………………………………………………………………………265
FUNCTION OF CHARGE TEMPERATURE SENSOR……………………………………………………………………….265
STRUCTURE OF COOLANT TEMPERATURE SENSOR……………………………………………………………………..266
FUNCTION OF COOLANT TEMPERATURE SENSOR………………………………………………………………………266
STRUCTURE OF NE (CRANKSHAFT) SPEED SENSOR……………………………………………………………………267
FUNCTION OF NE (CRANKSHAFT) SPEED SENSOR…………………………………………………………………….267
STRUCTURE OF Bkup (CAMSHAFT) SPEED SENSOR……………………………………………………………………268
FUNCTION OF Bkup (CAMSHAFT) SPEED SENSOR…………………………………………………………………….268
STRUCTURE OF COMMON RAIL PRESSURE SENSOR…………………………………………………………………….269
FUNCTION OF COMMON RAIL PRESSURE SENSOR……………………………………………………………………..269
STRUCTURE OF EGR VALVE LIFT SENSOR………………………………………………………………………….270
FUNCTION OF EGR VALVE LIFT SENSOR…………………………………………………………………………..270
STRUCTURE OF VGT SPEED SENSOR………………………………………………………………………………271
FUNCTION OF VGT SPEED SENSOR……………………………………………………………………………….271
STRUCTURE OF VGT POSITION SENSOR……………………………………………………………………………272
FUNCTION OF VGT POSITION SENSOR…………………………………………………………………………….272
STRUCTURE OF MASS AIR FLOW AND TEMPERATURE SENSOR…………………………………………………………….273
FUNCTION OF MASS AIR FLOW AND TEMPERATURE SENSOR……………………………………………………………..273
STRUCTURE OF DOSING FUEL PRESSURE SENSOR…………………………………………………………………….274
FUNCTION OF DOSING FUEL PRESSURE SENSOR……………………………………………………………………..274
STRUCTURE OF KDPF DIFFERENTIAL PRESSURE AND OUTLET PRESSURE SENSOR……………………………………………..275
FUNCTION OF KDPF DIFFERENTIAL PRESSURE AND OUTLET PRESSURE SENSOR………………………………………………275
STRUCTURE OF CRANKCASE PRESSURE SENSOR………………………………………………………………………276
FUNCTION OF CRANKCASE PRESSURE SENSOR……………………………………………………………………….276
STRUCTURE OF ENGINE OIL LEVEL SENSOR………………………………………………………………………..277
FUNCTION OF ENGINE OIL LEVEL SENSOR…………………………………………………………………………277
STRUCTURE OF AIR CLEANER CLOGGING SENSOR…………………………………………………………………….278
FUNCTION OF AIR CLEANER CLOGGING SENSOR……………………………………………………………………..278
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, D155CX-8)………………….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, D155CX-8)….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