Manual de Taller Komatsu Saa6d140e 5

SEN00074-16
ENGINE
140E
-5
SERIES
SEN00076-16
ENGINE
1SHOP MANUAL
140E-5 Series
00 Index and foreword
Index
Composition of shop manual .......................................................................................................................... 2
Table of contents ............................................................................................................................................. 3
140E-5 Series
SEN00076-16
Composition of shop manual
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 accordingly.
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
140E-5 Series
SEN00076-16
Table of contents

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
SEN00076-16
Fuel system .................................................................................................................................

CRI system diagram ................................................................................................................
Outline of CRI system..............................................................................................................
Fuel piping ...............................................................................................................................
Fuel cooler ...............................................................................................................................
Fuel filter ..................................................................................................................................
Priming pump...........................................................................................................................
Electric priming pump ..............................................................................................................
Engine controller cooler ...........................................................................................................
Cooling system............................................................................................................................
Cooling system diagram ..........................................................................................................
Water pump .............................................................................................................................
Thermostat...............................................................................................................................
Corrosion resistor ....................................................................................................................
Cooling fan drive......................................................................................................................
Accessories .................................................................................................................................
Front PTO ................................................................................................................................
Electrical equipment ....................................................................................................................
Alternator .................................................................................................................................
Starting motor ..........................................................................................................................
Starting aid...............................................................................................................................
Engine controller......................................................................................................................
14
14
16
38
42
43
46
47
48
49
49
54
57
58
60
63
63
65
65
76
78
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
Sketches of special tools ......................................................................................................... 28
Testing air boost pressure........................................................................................................ 29
Testing exhaust temperature ................................................................................................... 30
Adjusting valve clearance ........................................................................................................ 31
140E-5 Series
SEN00076-16
Testing compression pressure.................................................................................................

Testing blow-by pressure.........................................................................................................
Testing engine oil pressure......................................................................................................
Handling fuel system parts ......................................................................................................
Releasing residual pressure in fuel system .............................................................................
Testing fuel pressure ...............................................................................................................
Reduced cylinder mode operation...........................................................................................
No-injection cranking ...............................................................................................................
Testing fuel return rate and leakage ........................................................................................
Bleeding air from fuel circuit ....................................................................................................
Testing fuel system for leakage ...............................................................................................
Testing and adjusting alternator belt tension ...........................................................................
Testing and adjusting fan belt tension .....................................................................................
Handling controller high-voltage circuit....................................................................................
32
34
35
36
36
37
38
38
39
42
44
45
46
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
SEN00076-16
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
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
140E-5 Series
SEN00076-16
E-69 Code [(143)/B@BAZG] Eng. Oil Press Low Torque Derate............................................ 48

E-70 Code [(146)/B@BCNS] Eng. Overheat........................................................................... 48
E-71 Code [(415)/B@BAZG] Eng. Oil Press. Low Speed Derate............................................ 49
50 Disassembly and assembly
General information on disassembly and assembly
SEN00156-05
General information on disassembly and assembly....................................................................
2
How to read this manual..........................................................................................................
2
Coating materials list ...............................................................................................................
4
Special tools list .......................................................................................................................
7
Sketches of special tools .........................................................................................................
8
Disassembly and assembly, Part 1 (with EGR)
SEN00157-05
Disassembly and assembly, Part 1 (with EGR)...........................................................................
2
General disassembly of engine ...............................................................................................
2
General assembly of engine.................................................................................................... 20
Disassembly and assembly, Part 2 (EGR-less)
SEN00158-05
Disassembly and assembly, Part 2 (EGR-less)...........................................................................
2
General disassembly of engine ...............................................................................................
2
General assembly of engine.................................................................................................... 18
Disassembly and assembly, Part 3
SEN00159-04
Disassembly and assembly, Part 3 .............................................................................................
2
Removal and installation of fuel supply pump unit (with EGR) ................................................
2
Removal and installation of fuel supply pump unit (EGR-less)................................................
4
Replacement of oil seal of engine mounted on machine.........................................................
7
90 Repair and replacement of parts
Information related to repair and replacement
SEN05198-00
Flowchart .................................................................................................................................
2
Special tool table .....................................................................................................................
4
Special tool sketch...................................................................................................................
6
Cylinder head
SEN05199-02
Part names related to cylinder head........................................................................................
2
Testing and inspection of cylinder head...................................................................................
3
Pressure test of cylinder head .................................................................................................
5
Replacement of valve guide ....................................................................................................
5
Replacement of valve seat insert ............................................................................................
6
Replacement of crosshead guide ............................................................................................ 13
Repair of cylinder head mounting face by grinding ................................................................. 14
Repair of valve by grinding ...................................................................................................... 15
Cylinder block
SEN05200-01
Part names related to cylinder block .......................................................................................
3
Testing and inspection of cylinder block ..................................................................................
4
Method of checking main bearing metal inside diameter with alignment bar ..........................
6
Part names related to crankshaft.............................................................................................
7
Testing and inspection of crankshaft .......................................................................................
8
Part names related to connecting rod......................................................................................
9
Testing and inspection of connecting rod ................................................................................ 10
Replacement of flywheel ring gear .......................................................................................... 11
Replacement of crankshaft gear.............................................................................................. 12
Replacement of camshaft gear................................................................................................ 13
Replacement of main bearing metal cap ................................................................................. 14
Replacement of connecting rod small end bushing................................................................. 16
Replacement of cam bushing .................................................................................................. 17
Repair of cylinder block top by grinding................................................................................... 19
Repair of counterbore by grinding ........................................................................................... 20
Check and identification after repair by grinding...................................................................... 22
140E-5 Series
SEN00076-16
Gasket sealant application procedure .....................................................................................

Repair standard for cylinder liner O-ring ..................................................................................
Replacement of engine rear seal.............................................................................................
Replacement of wear sleeve (when sleeve is installed) ..........................................................
Repair of crankshaft by grinding ..............................................................................................
Improvement of surface roughness of crankshaft journal........................................................
23
25
26
30
31
36
140E-5 Series
140E-5 Series
SEN00076-16
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
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
SEN00077-07
Safety notice
(Rev. 2008/08)
1
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 situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with
the situation.
1.
General precautions
k Mistakes in operation are extremely
dangerous. Read the Operation and
Maintenance Manual carefully before
operating the machine. In addition,
read this manual and understand its
contents before starting the work.
1) Before carrying out any greasing or
repairs, read all the safety labels stuck to
the machine. For the locations of the
safety labels and detailed explanation of
precautions, see the Operation and Maintenance Manual.
2) Decide a place in the repair workshop to
keep tools and removed parts. Always
keep the tools and parts in their correct
places. Always keep the work area clean
and make sure that there is no dirt, water,
or oil on the floor. Smoke only in the areas
provided for smoking. Never smoke while
working.
3) When carrying out any operation, always
wear safety shoes and helmet. Do not
wear loose work clothes, or clothes with
buttons missing.
q
Always wear safety glasses when hitting parts with a hammer.
q
Always wear safety glasses when
grinding parts with a grinder, etc.
4) When carrying out any operation with 2 or
more workers, always agree on the operating procedure before starting. Always
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, forklift, service car, etc.
7)
8)
9)
If welding repairs are needed, always

have a trained and experienced welder
carry out the work. When carrying out
w elding work, alw ays wear welding
gloves, apron, shielding goggles, cap and
other clothes suited for welding work.
Before starting work, warm up your body
thoroughly to start work under good condition.
Avoid continuing work for long hours and
take rests at proper intervals to keep your
body in good condition. Take rests in
specified safe places.
Safety points
1 Good arrangement
2 Correct work clothes
3 Following work standard
4 Making and checking signs
5
Prohibition of operation and handling by

unlicensed workers
6 Safety check before starting work

7
Wearing protective goggles

(for cleaning or grinding work)
Wearing shielding goggles and protectors

(for welding work)
9 Good physical condition and preparation

10
Precautions against work which you are

not used to or you are used to too much
140E-5 Series
2.
3.
SEN00077-07
Preparations for work

1) Before adding oil or making any repairs,
park the machine on a hard and level
ground, and apply the parking brake and
block the wheels or tracks to prevent the
machine from moving.
2) Before starting work, lower the work
equipment (blade, ripper, bucket, etc.) to
the ground. If this is not possible, insert
the lock pin or use blocks to prevent the
work equipment from falling. In addition,
be sure to lock all the control levers and
hang warning signs on them.
3) When disassembling or assembling, support the machine with blocks, jacks, or
stands before starting work.
4) Remove all mud and oil from the steps or
other places used to get on and off the
machine. Always use the handrails, ladders or steps when getting on or off the
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
machine. If it is impossible to use the
handrails, ladders or steps, use a stand to
provide safe footing.
6)
Precautions during work

1) Before disconnecting or removing components of the oil, water, or air circuits, first
release the pressure completely from the
circuit. When removing the oil filler cap, a
drain plug, or an oil pressure pickup plug,
loosen it slowly to prevent the oil from
spurting out.
2) The coolant and oil in the circuits are hot
when the engine is stopped, so be careful
not to get scalded. Wait for the oil and
coolant to cool before carrying out any
work on the oil or water circuits.
3) Before starting work, stop the engine.
When working on or around a rotating
part, in particular, stop the engine. When
checking the machine without stopping
the engine (measuring oil pressure,
revolving speed, temperature, etc.), take
extreme care not to get rolled or caught in
rotating parts or moving parts.
4) Before starting work, remove the leads
from the battery. Always remove the lead
from the negative () terminal first.
5) When raising a heavy component (heavier
than 25 kg), use a hoist or crane. Before
starting work, check that the slings (wire
ropes, chains, and hooks) are free from
damage. Always use slings which have
ample capacity and install them to proper
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.
11)
140E-5 Series
7)
8)
9)
10)
12)
13)
14)
15)
16)
When removing a cover which is under

internal pressure or under pressure from a
spring, always leave 2 bolts in diagonal
positions. Loosen those bolts gradually
and alternately to release the pressure,
and then remove the cover.
When removing components, be careful
not to break or damage the electrical wiring. Damaged wiring may cause electrical
fires.
When removing piping, stop the fuel or oil
from spilling out. If any fuel or oil drips
onto the floor, wipe it up immediately. Fuel
or oil on the floor can cause you to slip
and can even start fires.
As a general rule, do not use gasoline to
wash parts. Do not use it to clean electrical parts, in particular.
Be sure to assemble all parts again in their
original places. Replace any damaged
parts and parts which must not be reused
with new parts. When installing hoses and
wires, be sure that they will not be damaged by contact with other parts when the
machine is operated.
When installing high pressure hoses,
make sure that they are not twisted. Damaged tubes are dangerous, so be
extremely careful when installing tubes for
high pressure circuits. In addition, check
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
installed.
When assembling or installing parts,
always tighten them to the specified
torques. When installing protective parts
such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are
installed correctly.
When aligning 2 holes, never insert your
fingers or hand. Be careful not to get your
fingers caught in a hole.
When measuring hydraulic pressure,
check that the measuring tools are correctly assembled.
Take care when removing or installing the
tracks of track-type machines. When
removing the track, the track separates
suddenly, so never let anyone stand at
either end of the track.
If the engine is operated for a long time in
a place which is not ventilated well, you
may suffer from gas poisoning. Accordingly, open the windows and doors to ventilate well.
SEN00077-07
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.
3) Keep putting on gloves during sling work.
(Put on leather gloves, if available.)
4) Measure the weight of the load by the eye
and check its center of gravity.
5) Use proper sling according to the weight
of the load and method of slinging. If too
thick wire ropes are used to sling a light
load, the load may slip and fall.
6) Do not sling a load with 1 wire rope alone.
If it is slung so, it may rotate and may slip
out of the rope. Install 2 or more wire
ropes symmetrically.
k Slinging with 1 rope may cause
turning of the load during hoisting,
untwisting of the rope, or slipping
of the rope from its original winding 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 forming 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 allowable 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
sling a load vertically, up to 19.6 kN {2,000
kg} of total weight can be suspended.
This weight is reduced to 9.8 kN {1,000
kg} when the 2 ropes make a hanging
angle of 120. If the 2 ropes sling a 19.6
kN {2,000 kg} load at a lifting angle of
150, each of them is subjected to a force
as large as 39.2 kN {4,000 kg}.
8)
When installing wire ropes to an angular

load, apply pads to protect the wire ropes.
If the load is slippery, apply proper material to prevent the wire rope from slipping.
9) Use the specified eyebolts and fix wire
ropes, chains, etc. to them with shackles,
etc.
10) Apply wire ropes to the middle portion of
the hook.
q
Slinging near the tip of the hook may
cause the rope to slip off the hook
during hoisting. The hook has the
maximum strength at the middle portion.
11) Do not use twisted or kinked wire ropes.

12) When lifting up a load, observe the following.
q
Wind in the crane slowly until wire
ropes are stretched. When settling
the wire ropes with the hand, do not
grasp them but press them from
above. If you grasp them, your fingers
may be caught.
q
After the wire ropes are stretched,
stop the crane and check the condition of the slung load, wire ropes, and
pads.
140E-5 Series
If the load is unstable or the wire rope

or chains are twisted, lower the load
and lift it up again.
q
Do not lift up the load slantingly.
13) When lifting down a load, observe the following.
q
When lifting down a load, stop it temporarily at 30 cm above the floor, and
then lower it slowly.
q
Check that the load is stable, and
then remove the sling.
q
Remove kinks and dirt from the wire
ropes and chains used for the sling
work, and put them in the specified
place.
SEN00077-07
13) If the hoist stops because of a power failure, turn the power switch OFF. When
turning on a switch which was turned OFF
by the electric shock prevention earth
leakage breaker, check that the devices
related to that switch are not in operation
state.
14) If you find an obstacle around the hoist,
stop the operation.
15) After finishing the work, stop the hoist at
the specified position and raise the hook
to at least 2 m above the floor. Do not
leave the sling installed to the hook.
5.
6.
Precautions for using mobile crane

a Read the Operation and Maintenance
Manual of the crane carefully in advance
and operate the crane safely.
Precautions for using overhead hoist crane
k When raising a heavy part (heavier
than 25 kg), use a hoist, etc. In Disassembly and assembly, the weight of a
part heavier than 25 kg is indicated
after the mark of 4.
1) Before starting work, inspect the wire
ropes, brake, clutch, controller, rails, over
wind stop device, electric shock prevention earth leakage breaker, crane collision
prevention device, and power application
warning lamp, and check safety.
2) Observe the signs for sling work.
3) Operate the hoist at a safe place.
4) Check the direction indicator plates (east,
west, south, and north) and the directions
of the control buttons without fail.
5) Do not sling a load slantingly. Do not move
the crane while the slung load is swinging.
6) Do not raise or lower a load while the
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 immediately in an emergency.
140E-5 Series
7.
Selecting wire ropes

1) Select adequate ropes depending on the
weight of parts to be hoisted, referring to
the table below.
Wire ropes
(Standard Z twist ropes without galvanizing)
(JIS G3525, No. 6, Type 6X37-A)
Nominal
Allowable load
diameter of rope
mm
kN
ton
10
8.8
0.9
12
12.7
1.3
14
17.3
1.7
16
22.6
2.3
18
28.6
2.9
20
35.3
3.6
25
55.3
5.6
30
79.6
8.1
40
141.6
14.4
50
221.6
22.6
60
318.3
32.4
The allowable load is one-sixth of the

breaking strength of the rope used
(Safety coefficient: 6).
SEN00077-07
8.
Precautions for disconnecting and connecting hoses and tubes in air conditioner
circuit
1) Disconnection
k For the environment, the air conditioner 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 disconnecting the refrigerant gas circuit and then reuse it.
a Ask professional traders for collecting
and filling operation of refrigerant
(R134a).
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 recovering or adding the refrigerant.
Refrigerant gas must be recovered
and added by a qualified person.
2)

a
Example of O-ring (Fitted to every joint of

hoses and tubes)
For tightening torque, see the precautions for

installation in each section of "Disassembly
and assembly".
Connection
1] When installing the air conditioner circuit 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 damaged or deteriorated.
4] When connecting the refrigerant piping, apply compressor oil for refrigerant (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.
140E-5 Series
How to read the shop manual

q
q
q
1.
SEN00077-07
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.
Materials and specifications are subject to change without notice.
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.
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 disassembly 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
SEN00077-07
3.
4.
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 )
Revisions
Revised brochures are shown in the shop manual composition table.
Symbols
Important safety and quality portions are marked with the following symbols so that the shop manual will
be used practically.
Symbol
Item
Safety
Caution
Special technical precautions or other precautions for preserving standards are necessary when performing work.
Weight
Weight of parts of component or parts. Caution necessary when

selecting hoisting wire, or when working posture is important, etc.
Tightening
torque
Coat
Oil, coolant
Drain
Remarks
Special safety precautions are necessary when performing work.
Places that require special attention for tightening torque during

assembly.
Places to be coated with adhesives, etc. during assembly.
Places where oil, etc. must be added, and capacity.
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, conventionally used Gravitational System of units is indicated in parentheses { }.
140E-5 Series
SEN00077-07
Explanation of terms for maintenance standard
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 temporary standard size is set and an allowable difference from that size is indicated.
q
The above size set temporarily is called
the standard size and the range of difference 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
120
Tolerance
0.022
0.126
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)
Usually, the size of a hole and the size of

the shaft to be fitted to that hole are indicated by the same standard size and different tolerances of the hole and shaft.
The tightness of fit is decided by the tolerance.
Indication of size of rotating shaft and hole
and relationship drawing of them
Example:
Standard size
60
140E-5 Series
Tolerance
Shaft
Hole
0.030
+0.046
0.076
+0
SEN00077-07
2.
Standard clearance and standard value

q
The clearance made when new parts are
assembled is called the standard clearance, which is indicated by the range
from the minimum clearance to the maximum clearance.
q
When some parts are repaired, the clearance is generally adjusted to the standard
clearance.
q
A value of performance and function of
new products or equivalent is called the
standard value, which is indicated by a
range or a target value.
q
When some parts are repaired, the value
of performance/function is set to the standard value.
3.
Standard interference
q
When the diameter of a hole of a part
shown in the given standard size and tolerance 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 allowable 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 product 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 various tests or experiences in most cases,
however, it must be judged after considering the operating condition and customer's
requirement.
10
5.
Clearance limit
Parts can be used until the clearance
between them is increased to a certain
limit. The limit at which those parts cannot
be used is called the clearance limit.
q
If the clearance between the parts
exceeds the clearance limit, they must be
replaced or repaired.
q
6.
Interference limit
The allowable maximum interference
between the hole of a part and the shaft of
another part to be assembled is called the
interference limit.
q
The interference limit shows the repair
limit of the part of smaller tolerance.
q
If the interference between the parts
exceeds the interference limit, they must
be replaced or repaired.
q
140E-5 Series
Handling of electric equipment and hydraulic component
SEN00077-07
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, connectors used for connecting and disconnecting
one wire from another wire, and protectors or
tubes used for protecting the wiring.
Compared with other electrical components fitted 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 (defective contact between male and female)
Problems with defective contact are likely
to occur because the male connector is
not properly inserted into the female connector, or because one or both of the connectors is deformed or the position is not
correctly aligned, or because there is corrosion or oxidization of the contact surfaces. The corroded or oxidized contact
surfaces may become shiny again (and
contact may become normal) by connecting and disconnecting the connector about
10 times.
2)
Defective crimping or soldering of connectors

The pins of the male and female connectors are in contact at the crimped terminal
or soldered portion, but if there is excessive force brought to bear on the wiring,
the plating at the joint will peel and cause
improper connection or breakage.
140E-5 Series
11
SEN00077-07
12
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 soldering may be damaged, or the wiring
may be broken.
4)
High-pressure water entering connector

The connector is designed to make it difficult for water to enter (drip-proof structure), 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-circuited 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 surface 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 compressed 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 compressed air, the contacts will become
even dirtier, so remove the oil and
water from the compressed air completely before cleaning with compressed air.
140E-5 Series
3.
SEN00077-07
Removing, installing, and drying connectors and wiring harnesses

1) Disconnecting connectors
1] Hold the connectors when disconnecting.
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 connectors apart.
a Never pull with one hand.
2]
q
When removing from clips

Both of the connector and clip have
stoppers, which are engaged with
each other when the connector is
installed.
When removing a connector from a

clip, pull the connector in a parallel
direction to the clip for removing stoppers.
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 connectors

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 disassembled for a long time, it is particularly easy for improper contact to
occur, so always cover the connector.
140E-5 Series
13
SEN00077-07
2)
14
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 damage to the connector pins.
Check that there is no damage or
breakage to the outside of the connector.
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 breakage, 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 stopper clicks into position.
3] Correct any protrusion of the boot and
any misalignment of the wiring harness.
For connectors fitted with boots, correct any protrusion of the boot. In
addition, if the wiring harness is misaligned, or the clamp is out of position, adjust it to its correct position.
a If the connector cannot be corrected 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.
140E-5 Series
3)
Heavy duty wire connector (DT 8-pole, 12pole)

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) horizontally 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
SEN00077-07
Disconnection
Connection (Example of
incomplete setting of (a))
15
SEN00077-07
4)
16
Drying wiring harness

If there is any oil or dirt on the wiring harness, 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 follows.
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 compressed 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 connector.
After drying, leave the wiring harness
disconnected and carry out a continuity test to check for any short circuits
between pins caused by water.
a After completely drying the conn e c t o r, b l o w i t w i t h c o n ta c t
restorer and reassemble.
140E-5 Series
4.
Handling controller
1) The controller contains a microcomputer
and electronic control circuits. These control 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 controller.
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 connectors 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 disconnecting 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 connectors before going on to the next step.
a If the power is turned ON with the
connectors still disconnected, unnecessary abnormality displays will be
generated.
4) When carrying out troubleshooting of circuits (measuring the voltage, resistance,
continuity, or current), move the related
wiring and connectors several times and
check that there is no change in the reading of the tester.
a If there is any change, there is probably defective contact in that circuit.
140E-5 Series
SEN00077-07
17
SEN00077-07
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 performance 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 cleaning 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 equipment, 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 circuit. The oil cleaning equipment is used to
remove the ultra fine (about 3 m) particles that
the filter built in the hydraulic equipment cannot remove, so it is an extremely effective
device.
140E-5 Series
SEN00077-07
19
SEN00077-07
Handling of connectors newly used for engines

a
1.
Mainly, following engines are object for following connectors.

q
95E-5
q
107E-1
q
114E-3
q
125E-5
q
140E-5
q
170E-5
q
12V140E-3
Slide lock type
(FRAMATOME-3, FRAMATOME-2)
q
95 170, 12V140 engines
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)
2.
Pull lock type (PACKARD-2)

95 170, 12V140 engines
q
Various temperature sensors
Example)
Intake air temperature sensor in
intake manifold: TIM
Fuel temperature sensor: TFUEL
Oil temperature sensor: TOIL
Coolant temperature sensor: TWTR,
etc.
Disconnect the connector by pulling lock
(B) (on the wiring harness side) of connector (2) outward.
Disconnect connector (1) according to the following procedure.

1) Slide lock (L1) to the right.
2) While pressing lock (L2), pull out connector (1) toward you.
a Even if lock (L2) is pressed, connector (1) cannot be pulled out toward
you, if part A does not float. In this
case, float part A with a small screwdriver while press lock (L2), and then
pull out connector (1) toward you.
20
140E-5 Series
3.
SEN00077-07
Push lock type

q
95, 107, 114 engines
Example)
Fuel pressure sensor in common rail
(BOSCH-03)
Disconnect connector (3) according to the following procedure.
1) While pressing lock (C), pull out connector
(3) in the direction of the arrow.
q
114 engine
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.
107 engine
2)
If the lock is on the underside, use

flat-head screwdriver [1] since you
cannot insert your fingers.
While pressing up lock (C) of the connector with flat-head screwdriver [1], pull out
connector (3) in the direction of the arrow.
140E-5 Series
21
SEN00077-07
4)
95, 125 170, 12V140 engines

While pressing lock (E) of the connector,
pull out connector (5) in the direction of
the arrow.
Example)
Fuel pressure sensor in common rail:
PFUEL etc. (AMP-3)
4.
Turn-housing type (Round green connector)

140 engine
Example)
Intake air pressure sensor in intake manifold (CANNON-04): PIM etc.
1)
Disconnect connector (6) according to the

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 harness side.
2)
Connect the connector according to the

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)
Injection pressure control valve of fuel
supply pump: PCV (SUMITOMO-2)
Example)
Speed sensor of fuel supply pump:
G (SUMITOMO-3)
a Pull the connector straight up.
22
140E-5 Series
SEN00077-07
How to read electric wire code

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 symbols. 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 nominal 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 indicated.)
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)
Type
Low-voltage
wire for
automobile
Thin-cover
low-voltage
wire for
automobile
Symbol
AV
AVS
Heat-resistant low-voltAEX
age wire for
automobile
140E-5 Series
Material
Conductor
Insulator
Conductor
Annealed copper for electric appliance

Soft polyvinyl chloride
Insulator
Soft polyvinyl chloride
Conductor

Heat-resistant crosslinked
polyethylene
Insulator
Using
temperature
range (C)
Example of use
General wiring
(Nominal No. 5 and above)
30 to +60
General wiring
(Nominal No. 3 and below)
General wiring in extremely
50 to +110 cold district, wiring at high-temperature place
23
SEN00077-07
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
CovAV
Standard
4.6
er D
AEX
Standard
2.0
2.2
2.7
3.0
3.1
3.8
4.6
Nominal No.
Number of
strands/Diameter of strand
Conductor
Sectional
area (mm2)
d (approx.)
AVS
Standard
CovAV
Standard
er D
AEX
Standard
15
20
30
40
50
60
85
100
50/0.45
84/0.45
41/0.80
70/0.80
85/0.80
7.95
13.36
20.61
35.19
42.73
54.29
63.84
84.96
109.1
3.7
5.5
5.3
4.8
7.0
7.0
6.0
8.2
8.2
8.0
10.8
10.8
8.6
11.4
11.4
9.8
13.0
13.0
10.4
13.6
13.6
12.0
16.0
16.0
13.6
17.6
17.6
108/0.80 127/0.80 169/0.80 217/0.80
f of nominal No. denotes flexible.
24
140E-5 Series
3.
SEN00077-07
Color codes table
(Table 3)
Color Code
B
Br
BrB
BrR
BrW
BrY
Ch
Dg
G
GB
GL
Gr
GR
GW
GY
L
LB
Lg
LgB
LgR
Color of wire
Color Code
LgW
LgY
LR
LW
LY
O
P
R
RB
RG
RL
RW
RY
Sb
Y
YB
YG
YL
YR
YW
Black
Brown
Brown & Black
Brown & Red
Brown & White
Brown & Yellow
Charcoal
Dark green
Green
Green & Black
Green & Blue
Gray
Green & Red
Green & White
Green & Yellow
Blue
Blue & Black
Light green
Light green & Black
Light green & Red
Color of wire
Light green & White
Light green & Yellow
Blue & Red
Blue & White
Blue & Yellow
Orange
Pink
Red
Red & Black
Red & Green
Red & Blue
Red & White
Red & Yellow
Sky Blue
Yellow
Yellow & Black
Yellow &Green
Yellow & Blue
Yellow & Red
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
Charge
Ground
Start
Light
Instrument
Signal
Type of
circuit
Others
140E-5 Series
AVS or AV
R
B
R
RW
Y
G
L
Br
Lg
O
Gr
P
Sb
Dg
Ch
AEX
R
B
R
D
Y
G
L
WG
RB
YR
GW
LW
BrW
LgR
RY
YB
GR
LR
BrR
LgY
RG
YG
GY
LY
BrY
LgB
RL
YL
GB
LB
BrB
LgW
YW
GL
Gr
Br
25
SEN00077-07
Precautions when carrying out operation
[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.
q
q
q
q
q
q
q
q
q
q
Precautions when carrying out removal work

If the coolant contains antifreeze, dispose of it correctly.
After disconnecting hoses or tubes, cover them or fit plugs to prevent dirt or dust from entering.
When draining oil, prepare a container of adequate size to catch the oil.
Confirm the match marks showing the installation position, and make match marks in the necessary
places before removal to prevent any mistake when assembling.
To prevent any excessive force from being applied to the wiring, always hold the connectors when disconnecting the connectors. Do not pull the wires.
Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.
Check the number and thickness of the shims, and keep in a safe place.
When raising components, be sure to use lifting equipment of ample strength.
When using forcing screws to remove any components, tighten the forcing screws uniformly in turn.
Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from
entering after removal.
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
number
02
03
04
05
06
10
12
2)
26
Sleeve nut (elbow end)
07376-70210
07376-70315
07376-70422
07376-70522
07376-70628
07376-71034
07376-71234
02789-20210
02789-20315
02789-20422
02789-20522
02789-20628
07221-21034
07221-21234
Split flange type hoses and tubes

Nominal
number
04
05
3)
Plug (nut end)
Flange (hose end)
Sleeve head (tube end)
Split flange
07379-00400
07379-00500
07378-10400
07378-10500
07371-30400
07371-30500
If the part is not under hydraulic pressure, the following corks can be used.
Nominal
number
Part Number
06
08
10
12
14
16
18
20
22
24
07049-00608
07049-00811
07049-01012
07049-01215
07049-01418
07049-01620
07049-01822
07049-02025
07049-02228
07049-02430
Dimensions
D
d
L
6
5
8
8
6.5
11
10
8.5
12
12
10
15
14
11.5
18
16
13.5
20
18
15
22
20
17
25
22
18.5
28
24
20
30
27
07049-02734
27
22.5
34
140E-5 Series
2.
q
q
q
q
q
q
q
q
q
q
q
q
q
a
3.
SEN00077-07
Precautions when carrying out installation work

Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any.
Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
Bend the cotter pins and lock plates securely.
When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion with 2 3 drops of adhesive.
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.
Clean all parts, and correct any damage, dents, burrs, or rust.
Coat rotating parts and sliding parts with engine oil.
When press fitting parts, coat the surface with anti-friction compound (LM-P).
After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
securely.
When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align
the direction of the hook.
When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
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.
When using the machine for the first time after repair or long storage, follow the same procedure.
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 specified 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
SEN00077-07
4)
5)
28
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.
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.
140E-5 Series
SEN00077-07
Method of disassembling and connecting push-pull type coupler

k
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.
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
SEN00077-07
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 hexagonal 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 disconnect it. (Fig. 8)
2.
Connection
q
Hold the tightening portion and push body
contacts contact surface (a) of the hexagonal portion at the male end. (Fig. 9)
30
140E-5 Series
SEN00077-07
Type 3
1.
Disconnection
1) Hold the tightening portion and push body
contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 10)
2) While holding the condition of Step 1),
push cover (10) straight until it contacts
contact surface (b) of the hexagonal portion at the male end. (Fig. 11)
3) While holding the condition of Steps 1)
and 2), pull out whole body (9) to disconnect 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 hexagonal portion at the male end. (Fig. 13)
140E-5 Series
31
SEN00077-07
Standard tightening torque table

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

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

mm
6
8
10
12
a Fig. A
Width across flats

mm
10
13
17
19
22
24
27
30
32
36
41
46
50
55
60
Width across flats

mm
10
12
14
17
Tightening torque
Nm
kgm
5.9 9.8
0.6 1.0
13.7 23.5
1.4 2.4
34.3 46.1
3.5 4.7
74.5 90.2
7.6 9.2
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
10
12
16
3.
Width across flats

mm
14
17
22
Tightening torque
Nm
59 74
98 123
235 285
kgm
6.0 7.5
10.0 12.5
23.5 29.5
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
mm
14
20
24
33
42
Nominal No.
02
03,04
05,06
10,12
14
4.
SEN00077-07
Width across flats

mm
Tightening torque Nm {kgm}

Range
Target
35 63 { 3.5 6.5}
44 { 4.5}
84 132 { 8.5 13.5}
103 {10.5}
Varies depending
on type of connec- 128 186 {13.0 19.0}
157 {16.0}
tor.
363 480 {37.0 49.0}
422 {43.0}
746 1,010 {76.0 103}
883 {90.0}
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
No.
08
10
12
14
16
18
20
24
30
33
36
42
52
Thread diameter
mm
8
10
12
14
16
18
20
24
30
33
36
42
52
140E-5 Series
Width across flats

mm
14
17
19
22
24
27
30
32
32
36

Range
Target
5.88 8.82 {0.6 0.9}
7.35 {0.75}
9.81 12.74 {1.0 1.3}
11.27 {1.15}
14.7 19.6 {1.5 2.0}
17.64 {1.8}
19.6 24.5 {2.0 2.5}
22.54 {2.3}
24.5 34.3 {2.5 3.5}
29.4 {3.0}
34.3 44.1 {3.5 4.5}
39.2 {4.0}
44.1 53.9 {4.5 5.5}
49.0 {5.0}
58.8 78.4 {6.0 8.0}
68.6 {7.0}
93.1 122.5 { 9.5 12.5}
107.8 {11.0}
107.8 147.0 {11.0 15.0}
127.4 {13.0}
127.4 176.4 {13.0 18.0}
151.9 {15.5}
181.3 240.1 {18.5 24.5}
210.7 {21.5}
274.4 367.5 {28.0 37.5}
323.4 {33.0}
33
SEN00077-07
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.
Nominal
No. of
hose
Width
across
flats
02
19
03
04
05
06
(10)
(12)
(14)
6.
22
24
27
32
36
41
46
55
Range
34 54 { 3.5 5.5}
34 63 { 3.5 6.5}
54 93 { 5.5 9.5}
59 98 { 6.0 10.0}
84 132 { 8.5 13.5}
128 186 {13.0 19.0}
177 245 {18.0 25.0}
177 245 {18.0 25.0}
197 294 {20.0 30.0}
246 343 {25.0 35.0}
Target
44 { 4.5}
74 { 7.5}
78 { 8.0}
103 {10.5}
157 {16.0}
216 {22.0}
216 {22.0}
245 {25.0}
294 {30.0}
Taper seal
Thread size
(mm)
14
18
22
24
30
33
36
42
Face seal
Nominal No.
Thread
Number of
diameter (mm)
threads, type of
(Reference)
thread
9/16-18UN
14.3
11/16-16UN
17.5
13/16-16UN
20.6
1-14UNS
25.4
1-3/16-12UN
30.2
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
diameter
of pipe
(mm)
Width
across
flats
(mm)
8
10
12
15 (16)
22 (20)
19
22
24 (27)
30 (32)
36

Range
Target
14 16 {1.4 1.6}
24 27 {2.4 2.7}
43 47 {4.4 4.8}
60 68 {6.1 6.8}
90 95 {9.2 9.7}
15 {1.5}
25.5 {2.6}
45 {4.6}
64 {6.5}
92.5 {9.4}
Face seal
Thread diameter
Nominal No.
(mm)
Number of threads,
(Reference)
type of thread
9/16-18UN
14.3
11/16-16UN
17.5
13/16-16UN
20.6
1-14UN
25.4
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
Bolts and nuts
Thread size
mm
6
8
10
12
14
34
Nm
10 2
24 4
43 6
77 12
kgm
1.02 0.20
2.45 0.41
4.38 0.61
7.85 1.22
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
mm
6
8
10
12
14
9.
SEN00077-07
Tightening torque
Nm
82
10 2
12 2
24 4
36 5
kgm
0.81 0.20
1.02 0.20
1.22 0.20
2.45 0.41
3.67 0.51
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.
Material
Thread size (inch)
1/16
1/8
1/4
3/8
1/2
3/4
140E-5 Series
Tightening torque
In cast iron or steel
In aluminum
Nm
kgm
Nm
kgm
15 2
1.53 0.20
51
0.51 0.10
20 2
2.04 0.20
15 2
1.53 0.20
25 3
2.55 0.31
20 2
2.04 0.20
35 4
3.57 0.41
25 3
2.55 0.31
55 6
5.61 0.61
35 4
3.57 0.41
75 8
7.65 0.82
45 5
4.59 0.51
35
SEN00077-07
Conversion table
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 horizontal 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
(A)
36
(B)
0
10
20
30
40
0
0
0.394
0.787
1.181
1.575
1
0.039
0.433
0.827
1.220
1.614
2
0.079
0.472
0.866
1.260
1.654
3
0.118
0.512
0.906
1.299
1.693
4
0.157
0.551
0.945
1.339
1.732
50
60
70
80
90
1.969
2.362
2.756
3.150
3.543
2.008
2.402
2.795
3.189
3.583
2.047
2.441
2.835
3.228
3.622
2.087
2.480
2.874
3.268
3.661
2.126
2.520
2.913
3.307
3.701
5
0.197
0.591
0.984
1.378
1.772
(C)
2.165
2.559
2.953
3.346
3.740
6
0.236
0.630
1.024
1.417
1.811
7
0.276
0.669
1.063
1.457
1.850
2.205
2.598
2.992
3.386
3.780
2.244
2.638
3.032
3.425
3.819
1 mm = 0.03937 in
8
9
0.315
0.354
0.709
0.748
1.102
1.142
1.496
1.536
1.890
1.929
2.283
2.677
3.071
3.465
3.858
2.323
2.717
3.110
3.504
3.898
140E-5 Series
SEN00077-07
Millimeters to inches
0
10
20
30
40
0
0
0.394
0.787
1.181
1.575
1
0.039
0.433
0.827
1.220
1.614
2
0.079
0.472
0.866
1.260
1.654
3
0.118
0.512
0.906
1.299
1.693
4
0.157
0.551
0.945
1.339
1.732
5
0.197
0.591
0.984
1.378
1.772
6
0.236
0.630
1.024
1.417
1.811
1 mm = 0.03937 in
7
8
9
0.276
0.315
0.354
0.669
0.709
0.748
1.063
1.102
1.142
1.457
1.496
1.536
1.850
1.890
1.929
50
60
70
80
90
1.969
2.362
2.756
3.150
3.543
2.008
2.402
2.795
3.189
3.583
2.047
2.441
2.835
3.228
3.622
2.087
2.480
2.874
3.268
3.661
2.126
2.520
2.913
3.307
3.701
2.165
2.559
2.953
3.346
3.740
2.205
2.598
2.992
3.386
3.780
2.244
2.638
3.032
3.425
3.819
1 kg = 2.2046 lb
6
7
8
9
13.23
15.43 17.64
19.84
35.27
37.48 39.68
41.89
57.32
59.53 61.73
63.93
79.37
81.57 83.78
85.98
101.41 103.62 105.82 108.03
2.283
2.677
3.071
3.465
3.858
2.323
2.717
3.110
3.504
3.898
Kilogram to pound
0
10
20
30
40
0
0
22.05
44.09
66.14
88.18
1
2.20
24.25
46.30
68.34
90.39
2
4.41
26.46
48.50
70.55
92.59
3
6.61
28.66
50.71
72.75
94.80
4
8.82
30.86
51.91
74.96
97.00
5
11.02
33.07
55.12
77.16
99.21
50
60
70
80
90
110.23
132.28
154.32
176.37
198.42
112.44
134.48
156.53
178.57
200.62
114.64
136.69
158.73
180.78
202.83
116.85
138.89
160.94
182.98
205.03
119.05
141.10
163.14
185.19
207.24
121.25
143.30
165.35
187.39
209.44
123.46
145.51
167.55
189.60
211.64
125.66
147.71
169.76
191.80
213.85
127.87
149.91
171.96
194.01
216.05
130.07
152.12
174.17
196.21
218.26
Liters to U.S. Gallons
0
10
20
30
40
0
1
2
0
0.264 0.528
2.642
2.906 3.170
5.283
5.548 5.812
7.925
8.189 8.454
10.567 10.831 11.095
3
0.793
3.434
6.076
8.718
11.359
4
1.057
3.698
6.340
8.982
11.624
1 l = 0.2642 U.S.Gal
5
6
7
8
9
1.321
1.585
1.849
2.113
2.378
3.963
4.227
4.491 4.755
5.019
6.604
6.869
7.133 7.397
7.661
9.246
9.510
9.774 10.039 10.303
11.888 12.152 12.416 12.680 12.944
50
60
70
80
90
13.209
15.850
18.492
21.134
23.775
14.001
16.643
19.285
21.926
24.568
14.265
16.907
19.549
22.190
24.832
14.529
17.171
19.813
22.455
25.096
140E-5 Series
13.473
16.115
18.756
21.398
24.040
13.737
16.379
19.020
21.662
24.304
14.795
17.435
20.077
22.719
25.361
15.058
17.700
20.341
22.983
25.625
15.322
17.964
20.605
23.247
25.889
15.586
18.228
20.870
23.511
26.153
37
SEN00077-07
Liters to U.K. Gallons
0
10
20
30
40
0
0
2.200
4.399
6.599
8.799
1
0.220
2.420
4.619
6.819
9.019
2
0.440
2.640
4.839
7.039
9.239
3
0.660
2.860
5.059
7.259
9.459
4
0.880
3.080
5.279
7.479
9.679
5
1.100
3.300
5.499
7.699
9.899
50
60
70
80
90
10.998
13.198
15.398
17.598
19.797
11.281
13.418
15.618
17.818
20.017
11.438
13.638
15.838
18.037
20.237
11.658
13.858
16.058
18.257
20.457
11.878
14.078
16.278
18.477
20.677
12.098
14.298
16.498
18.697
20.897
1 l = 0.21997 U.K.Gal
6
7
8
9
1.320
1.540 1.760
1.980
3.520
3.740 3.950
4.179
5.719
5.939 6.159
6.379
7.919
8.139 8.359
8.579
10.119 10.339 10.559 10.778
12.318
14.518
16.718
18.917
21.117
12.528
14.738
16.938
19.137
21.337
12.758
14.958
17.158
19.357
21.557
12.978
15.178
17.378
19.577
21.777
kgm to ft.lb
0
10
20
30
40
0
0
72.3
144.7
217.0
289.3
1
7.2
79.6
151.9
224.2
296.6
2
14.5
86.8
159.1
231.5
303.8
3
21.7
94.0
166.4
238.7
311.0
4
28.9
101.3
173.6
245.9
318.3
5
36.2
108.5
180.8
253.2
325.5
6
43.4
115.7
188.1
260.4
332.7
1 kgm = 7.233 ft.lb

7
8
9
50.6
57.9
65.1
123.0 130.2
137.4
195.3 202.5
209.8
267.6 274.9
282.1
340.0 347.2
354.4
50
60
70
80
90
361.7
434.0
506.3
578.6
651.0
368.9
441.2
513.5
585.9
658.2
376.1
448.5
520.8
593.1
665.4
383.4
455.7
528.0
600.3
672.7
390.6
462.9
535.2
607.6
679.9
397.8
470.2
542.5
614.8
687.1
405.1
477.4
549.7
622.0
694.4
412.3
484.6
556.9
629.3
701.6
419.5
491.8
564.2
636.5
708.8
426.8
499.1
571.4
643.7
716.1
100
110
120
130
140
723.3
730.5 737.8
745.0
752.2 759.5
766.7
773.9 781.2
788.4
795.6
802.9 810.1
817.3
824.6 831.8
839.0
846.3 853.5
860.7
868.0
875.2 882.4
889.7
896.9 904.1
911.4
918.6 925.8
933.1
940.3
947.5 954.8
962.0
969.2 976.5
983.7
990.9 998.2 1005.4
1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150
160
170
180
190
1084.9
1157.3
1129.6
1301.9
1374.3
38
1092.2
1164.5
1236.8
1309.2
1381.5
1099.4
1171.7
1244.1
1316.4
1388.7
1106.6
1179.0
1251.3
1323.6
1396.0
1113.9
1186.2
1258.5
1330.9
1403.2
1121.1
1193.4
1265.8
1338.1
1410.4
1128.3
1200.7
1273.0
1345.3
1417.7
1135.6
1207.9
1280.1
1352.6
1424.9
1142.8
1215.1
1287.5
1359.8
1432.1
1150.0
1222.4
1294.7
1367.0
1439.4
140E-5 Series
SEN00077-07
kg/cm2 to lb/in2
0
10
20
30
40
0
0
142.2
284.5
426.7
568.9
1
14.2
156.5
298.7
440.9
583.2
2
28.4
170.7
312.9
455.1
597.4
3
42.7
184.9
327.1
469.4
611.6
4
56.9
199.1
341.4
483.6
625.8
5
71.1
213.4
355.6
497.8
640.1
6
85.3
227.6
369.8
512.0
654.3
1 kg/cm2 = 14.2233 lb/in2

7
8
9
99.6
113.8
128.0
241.8
256.0
270.2
384.0
398.3
412.5
526.3
540.5
554.7
668.5
682.7
696.9
50
60
70
80
90
711.2
853.4
995.6
1,138
1,280
725.4
867.6
1,010
1,152
1,294
739.6
881.8
1,024
1,166
1,309
753.8
896.1
1,038
1,181
1,323
768.1
910.3
1,053
1,195
1,337
782.3
924.5
1,067
1,209
1,351
796.5
938.7
1,081
1,223
1,365
810.7
953.0
1,095
1,237
1,380
825.0
967.2
1,109
1,252
1,394
839.2
981.4
1,124
1,266
1,408
100
110
120
130
140
1,422
1,565
1,707
1,849
1,991
1,437
1,579
1,721
1,863
2,005
1,451
1,593
1,735
1,877
2,020
1,465
1,607
1,749
1,892
2,034
1,479
1,621
1,764
1,906
2,048
1,493
1,636
1,778
1,920
2,062
1,508
1,650
1,792
1,934
2,077
1,522
1,664
1,806
1,949
2,091
1,536
1,678
1,821
1,963
2,105
1,550
1,693
1,835
1,977
2,119
150
160
170
180
190
2,134
2,276
2,418
2,560
2,702
2,148
2,290
2,432
2,574
2,717
2,162
2,304
2,446
2,589
2,731
2,176
2,318
2,460
2,603
2,745
2,190
2,333
2,475
2,617
2,759
2,205
2,347
2,489
2,631
2,773
2,219
2,361
2,503
2,646
2,788
2,233
2,375
2,518
2,660
2,802
2,247
2,389
2,532
2,674
2,816
2,262
2,404
2,546
2,688
2,830
200
210
220
230
240
2,845
2,987
3,129
3,271
3,414
2,859
3,001
3,143
3,286
3,428
2,873
3,015
3,158
3,300
3,442
2,887
3,030
3,172
3,314
3,456
2,901
3,044
3,186
3,328
3,470
2,916
3,058
3,200
3,343
3,485
2,930
3,072
3,214
3,357
3,499
2,944
3,086
3,229
3,371
3,513
2,958
3,101
3,243
3,385
3,527
2,973
3,115
3,257
3,399
3,542
140E-5 Series
39
SEN00077-07
Temperature
Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centigrade 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 Fahrenheit 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 Centigrade values, and read the corresponding Fahrenheit temperature on the right.
1C = 33.8F
F
40.4
37.2
34.4
31.7
28.9
40
35
30
25
20
40.0
31.0
22.0
13.0
4.0
11.7
11.1
10.6
10.0
9.4
11
12
13
14
15
51.8
53.6
55.4
57.2
59.0
7.8
8.3
8.9
9.4
10.0
46
47
48
49
50
114.8
116.6
118.4
120.2
122.0
27.2
27.8
28.3
28.9
29.4
81
82
83
84
85
177.8
179.6
181.4
183.2
185.0
28.3
27.8
27.2
26.7
26.1
19
18
17
16
15
2.2
0.4
1.4
3.2
5.0
8.9
8.3
7.8
7.2
6.7
16
17
18
19
20
60.8
62.6
64.4
66.2
68.0
10.6
11.1
11.7
12.2
12.8
51
52
53
54
55
123.8
125.6
127.4
129.2
131.0
30.0
30.6
31.1
31.7
32.2
86
87
88
89
90
186.8
188.6
190.4
192.2
194.0
25.6
25.0
24.4
23.9
23.3
14
13
12
11
10
6.8
8.6
10.4
12.2
14.0
6.1
5.6
5.0
4.4
3.9
21
22
23
24
25
69.8
71.6
73.4
75.2
77.0
13.3
13.9
14.4
15.0
15.6
56
57
58
59
60
132.8
134.6
136.4
138.2
140.0
32.8
33.3
33.9
34.4
35.0
91
92
93
94
95
195.8
197.6
199.4
201.2
203.0
22.8
22.2
21.7
21.1
20.6
9
8
7
6
5
15.8
17.6
19.4
21.2
23.0
3.3
2.8
2.2
1.7
1.1
26
27
28
29
30
78.8
80.6
82.4
84.2
86.0
16.1
16.7
17.2
17.8
18.3
61
62
63
64
65
141.8
143.6
145.4
147.2
149.0
35.6
36.1
36.7
37.2
37.8
96
97
98
99
100
204.8
206.6
208.4
210.2
212.0
20.0
19.4
18.9
18.3
17.8
4
3
2
1
0
24.8
26.6
28.4
30.2
32.0
0.6
0
0.6
1.1
1.7
31
32
33
34
35
87.8
89.6
91.4
93.2
95.0
18.9
19.4
20.0
20.6
21.1
66
67
68
69
70
150.8
152.6
154.4
156.2
158.0
40.6
43.3
46.1
48.9
51.7
105
110
115
120
125
221.0
230.0
239.0
248.0
257.0
17.2
16.7
16.1
15.6
15.0
1
2
3
4
5
33.8
35.6
37.4
39.2
41.0
2.2
2.8
3.3
3.9
4.4
36
37
38
39
40
96.8
98.6
100.4
102.2
104.0
21.7
22.2
22.8
23.3
23.9
71
72
73
74
75
159.8
161.6
163.4
165.2
167.0
54.4
57.2
60.0
62.7
65.6
130
135
140
145
150
266.0
275.0
284.0
293.0
302.0
14.4
13.9
13.3
12.8
12.2
6
7
8
9
10
42.8
44.6
46.4
48.2
50.0
5.0
5.6
6.1
6.7
7.2
41
42
43
44
45
105.8
107.6
109.4
111.2
113.0
24.4
25.0
25.6
26.1
26.7
76
77
78
79
80
168.8
170.6
172.4
174.2
176.0
68.3
71.1
73.9
76.7
79.4
155
160
165
170
175
311.0
320.0
329.0
338.0
347.0
40
140E-5 Series
140E-5 Series
SEN00077-07
41
SEN00077-07

2009 KOMATSU
All Rights Reserved
42
SEN00079-07
ENGINE
1SHOP MANUAL
140E-5 Series
01 Specification
Specification and technical data

Outline............................................................................................................................................................. 2
Specifications .................................................................................................................................................. 6
General view ................................................................................................................................................. 24
Weight table .................................................................................................................................................. 61
Engine performance curves .......................................................................................................................... 65
140E-5 Series
SEN00079-07
01 Specification
Outline
1. Applicable machine
Engine
SAA6D140E-5
Engine serial No.
Machine models
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
PC800-8, PC800SE-8, PC800LC-8
PC850-8, PC850SE-8
PC800-8R, PC800SE-8R, PC800LC-8R
PC850-8R, PC850SE-8R
PC800-8R1, PC800SE-8R1, PC800LC-8R1
PC850-8R1, PC850SE-8R1
PC800-8E0, PC800SE-8E0, PC800LC-8E0
PC850-8E0, PC850SE-8E0
D155AX-6, D155A-6
D275AX-5E0, D275A-5R
WA500-6, WA500-6R
HD325-7, HD405-7, HD325-7R, HD405-7R
HM350-2, HM350-2R
HM400-2, HM400-2R
HM400-3M0, HM400-3R
SDG400S-6B1 (HOKUETSU INDUSTRIES)
Hydraulic excavator
Hydraulic excavator
Hydraulic excavator
Hydraulic excavator
Hydraulic excavator
Hydraulic excavator
Hydraulic excavator
Hydraulic excavator
Hydraulic excavator
Hydraulic excavator
Hydraulic excavator
Hydraulic excavator
Hydraulic excavator
Bulldozer
Bulldozer
Wheel loader
Dump truck
Articulated dump truck
Generator
140E-5 Series
01 Specification
SEN00079-07
2. Outline of engine
(With EGR)
q
The 140E-5 engine is a high-performance and

high-efficiency engine, which passed strict
emission regulations (USA: EPA Regulations
for 2006, EU: Regulations for 2006, Japan:
Construction machinery regulations for 2006)
and attained low fuel consumption, low noise,
better exhaust gas color, and high acceleration
performance. Accordingly, this newly developed engine is suitable as a power source of
construction machinery and industrial machinery used for various purposes.
The 140E-5 engine is the successor to the

140E-3 engine. While it is an in-line 6-cylinder,
water-cooled, common rail direct injection, 4stroke diesel engine similar to 140E-3, it is
equipped with the cooled EGR system which is
a new technology.
1)
2)
3)
The main components of the cooled EGR system are the EGR cooler of corrugated tube
type made of newly developed special stainless steel and the EGR valve driven hydraulically and controlled electronically which
KOMATSU developed by itself. The cooled
EGR system secures the optimum EGR rate
from the low-speed range to the high-speed
range to attain both clean exhaust gas and low
fuel consumption with the bypass assist circuit
consisting of the venturi system and bypass
valve which has the same function and structure as those of the EGR valve.
The special EGR oil pump is employed to generate high oil pressure (1.47 MPa {15 kg/cm2})
as the drive power source of the EGR valve
driven hydraulically and controlled electronically. The engine oil pump has sufficient delivery for the EGR valve and increased output of
the engine. As a result, the reliability and durability of the engine are improved.
While the 140E-3 engine has only 1 combination filter of high performance and high efficiency, the 140E-5 engine has 2 of the same
filter to meet the requirements of the EGR system and high-dispersion oil and improve the
ability to capture the soot in the oil. In addition,
the recommended sub-materials for operation
(oil and fuel) are changed to improve the reliability and durability of the engine.
140E-5 Series
4)
To secure the high output of the engine, the

twin cooling nozzle to cool the piston employed
for 140E-3 and after models is improved to
increase the durability of the piston and lower
the back side temperature of the piston. As a
result, the lubricating oil on the piston is not
exposed to high temperature, thus it is not
deteriorated. Since the high-pressure fuel
injection system controlled electronically is
employed, less soot is produced and the draining interval of the oil is lengthened. (While the
capacity of the oil pan is not changed, the oil
replacement interval of 500 hours is secured.)
5)
The common rail high-pressure fuel injection

system controlled electronically is employed
for all of 140E-3 and after models. This system
can inject the fuel at high pressure of 120 MPa
{1,200 kg/cm2} from the low-speed range to the
high-speed range. In addition, this system can
control the form of injection most properly by
electronic control according to the speed and
load. The injection system of 140E-5 is further
improved to employ multiple injections and
increase the injection pressure up to 160 MPa
{1,600 kg/cm2}. As a result, exhaust gas of the
cleanest level in the world, good exhaust gas
color, low fuel consumption, and low noise are
realized simultaneously.
6)
As the injection pressure of the common rail

injection system employed for the 140E-3
engine and after models is increased (from
120 to 160 MPa {from 1,200 to 1,600 kg/cm2}),
the pressure resistance of the common rail,
injector, and supply pump is improved for
higher reliability.
7)
The main fuel filter of high efficiency and the

pre-fuel filter are installed as standard so that
the low grade fuel in the market (equivalent to
Class NAS13) can be used. In addition, the
delivery of the priming pump used to replace
the filters is increased for higher serviceability.
8)
The high-quality piston made of cast iron which

has been employed for the 140E-2 engine and
after models is employed. This piston has a
less coefficient of thermal expansion, a reentrant combustion chamber, and a shaker cooling gallery. As a result, clean exhaust gas,
good exhaust gas color, and low fuel consumption are attained simultaneously, and high
durability and reliability are also obtained.
SEN00079-07
9)
01 Specification
By using the above-mentioned high-pressure

fuel injection system controlled electronically,
the multiple injection and injection characteristics are set most properly to improve the startability 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 turbocharger manufactured by KOMATSU which
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 highspeed 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.
140E-5 Series
01 Specification
SEN00079-07
(EGR-less)
q
The 140E-5 engine is a high-performance and

high-efficiency engine, which attained low fuel
consumption and low noise. Accordingly, this
newly developed engine is suitable as a power
source of construction machinery and industrial machinery used for various purposes.
4)
As the injection pressure of the common rail

injection system employed for the 140E-3
engine and after models is increased, the pressure resistance of the common rail, injector,
and supply pump is improved for higher reliability.
The 140E-5 engine is the successor to the

140E-3 engine. While it is an in-line 6-cylinder,
water-cooled, 4-stroke diesel engine, it is
equipped with the common rail direct injection
system.
5)
The main fuel filter of high efficiency and the

pre-fuel filter are installed as standard so that
the low grade fuel in the market can be used.
In addition, the delivery of the priming pump
used to replace the filters is increased for
higher serviceability.
1)
While the 140E-3 engine has only 1 combination filter of high performance and high efficiency, the 140E-5 engine has 2 of the same
filter to meet the requirements of the high-dispersion oil and improve the ability to capture
the soot in the oil. In addition, the recommended sub-materials for operation (oil and
fuel) are changed to improve the reliability and
durability of the engine.
6)
The high-quality piston made of cast iron which

after models is employed. This piston has a
less coefficient of thermal expansion, a reentrant combustion chamber, and a shaker cooling gallery. As a result, clean exhaust gas,
good exhaust gas color, and low fuel consumption are attained simultaneously, and high
durability and reliability are also obtained.
7)
By using the above-mentioned high-pressure

fuel injection system controlled electronically,
the multiple injection and injection characteristics are set most properly to improve the startability and reduce the white exhaust smoke
when the temperature is low.
8)
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.
9)
The improved type of the KTR110 turbocharger manufactured by KOMATSU which

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 highspeed range. As a result, the engine has high
performance and consumes less fuel and
attains high reliability.
2)
3)
To secure the high output of the engine, the

twin cooling nozzle to cool the piston employed
for 140E-3 and after models is improved to
increase the durability of the piston and lower
the back side temperature of the piston. As a
result, the lubricating oil on the piston is not
exposed to high temperature, thus it is not
deteriorated. Since the high-pressure fuel
injection system controlled electronically is
employed, less soot is produced and the draining interval of the oil is lengthened. (While the
capacity of the oil pan is not changed, the oil
replacement interval of 500 hours is secured.)
The common rail high-pressure fuel injection
system controlled electronically is employed
for all of 140E-3 and after models. This system
can inject the fuel at high pressure of 120 MPa
{1,200 kg/cm2} from the low-speed range to the
high-speed range. In addition, this system can
control the form of injection most properly by
electronic control according to the speed and
load. The injection system of 140E-5 is further
improved to employ multiple injections and
increase the injection pressure. As a result,
exhaust gas of the cleanest level in the world,
good exhaust gas color, low fuel consumption,
and low noise are realized simultaneously.
140E-5 Series
SEN00079-07
01 Specification
Specifications
1
Engine name
SAA6D140E-5
Machine models
PC600-8, PC600LC-8
PC600-8E0, PC600LC-8E0
PC700-8E0, PC700LC-8E0
Number of cylinders Bore Stroke

Total displacement
Firing order
mm
Overall length
mm
1,494
Overall width
mm
1,151
Overall height (excluding exhaust pipe)
mm
1,467
Overall height (including exhaust pipe)
mm
1,863
Rated horsepower
kW{HP}/
min-1{rpm}
323 {433.3}/1,800 {1,800}

(Gross)
Max. torque
Nm{kgm}/
min-1{rpm}
1,944 {198.4}/1,400 {1,400}

(Gross)
Max. speed with no load

(High idle speed)
min-1{rpm}
1,950 50 {1,950 50}
Min. speed with no load

(Low idle speed)
min-1{rpm}
800 25 {800 25}
g/kWh
{g/HPh}
209 {156}
Dry weight
kg
1,845
Fuel supply pump

Governor
DENSO ECD-U2
Electronic control type
Quantity of lubricating oil (refill capacity)
48 (40)
Quantity of coolant
24
Alternator
Starting motor
Battery
24V, 60A, 90A

24V, 11kW
12V, 170Ah 2
Turbocharger
Air compressor
Others
KOMATSU KTR110L
With air-cooled aftercooler

With cooled EGR
Performance
Dimensions
6 140 165
15.2 {15,230}
153624
Fuel consumption ratio at rated point
l{cc}
140E-5 Series
01 Specification
SEN00079-07
1
Engine name
SAA6D140E-5
Machine models
PC600-8R, PC600LC-8R
PC600-8R1, PC600LC-8R1
PC700-8R, PC700LC-8R, PC700LC-8R1

Total displacement
Firing order
mm
Overall length
mm
1,482
Overall width
mm
1,191
mm
1,467
mm
1,863
Rated horsepower
kW{HP}/
min-1{rpm}
323 {433.3}/1,800 {1,800}

(Gross)
Max. torque
Nm{kgm}/
min-1{rpm}
1,944 {198.4}/1,400 {1,400}

(Gross)

(High idle speed)
min-1{rpm}
1,950 50 {1,950 50}

(Low idle speed)
min-1{rpm}
800 25 {800 25}
g/kWh
{g/HPh}
205 {153}
Dry weight
kg
1,770
Fuel supply pump

Governor
DENSO ECD-U2
48 (40)
Quantity of coolant
24
Alternator
Starting motor
Battery
24V, 60A, 90A

24V, 11kW
12V, 170Ah 2
Turbocharger
Air compressor
Others
KOMATSU KTR110L
Performance
Dimensions
6 140 165
15.2 {15,230}
153624
140E-5 Series
l{cc}
SEN00079-07
01 Specification
1
Engine name
SAA6D140E-5
Machine models
PC800-8, PC800SE-8, PC800LC-8,

PC850-8, PC850SE-8
PC800-8E0, PC800SE-8E0, PC800LC-8E0,
PC850-8E0, PC850SE-8E0
6 140 165
15.2 {15,230}
153624
Overall length
mm
1,762
Overall width
mm
1,176
mm
1,686
mm
1,902
Rated horsepower
kW{HP}/
min-1{rpm}
370 {496.4}/1,800 {1,800}

(Gross)
Max. torque
Nm{kgm}/
min-1{rpm}
2,195 {223.8}/1,350 {1,350}

(Gross)

(High idle speed)
min-1{rpm}
1,980 50 {1,980 50}

(Low idle speed)
min-1{rpm}
825 25 {825 25}
g/kWh
{g/HPh}
204 {152}
Dry weight
kg
1,920
Fuel supply pump

Governor
DENSO ECD-U2
58 (53)
Quantity of coolant
25 (In only engine)
Alternator
Starting motor
Battery
24V, 60A, 90A

24V, 11kW
12V, 170Ah 2
Turbocharger
Air compressor
Others
KOMATSU KTR110L

With cooled EGR
Performance
Dimensions

Total displacement
Firing order
mm
l{cc}
140E-5 Series
01 Specification
SEN00079-07
1
Engine name
SAA6D140E-5
Machine models
PC800-8R, PC800SE-8R, PC800LC-8R,

PC800-8R1, PC800SE-8R1, PC800LC-8R1
PC850-8R1, PC850SE-8R1
6 140 165
15.2 {15,230}
153624
Overall length
mm
1,718
Overall width
mm
1,176
mm
1,686
mm
1,902
Rated horsepower
kW{HP}/
min-1{rpm}
370 {496.4}/1,800 {1,800}

(Gross)
Max. torque
Nm{kgm}/
min-1{rpm}
2,195 {223.8}/1,350 {1,350}

(Gross)

(High idle speed)
min-1{rpm}
1,980 50 {1,980 50}

(Low idle speed)
min-1{rpm}
825 25 {825 25}
g/kWh
{g/HPh}
204 {152}
Dry weight
kg
1,850
Fuel supply pump

Governor
DENSO ECD-U2
58 (53)
Quantity of coolant
25 (In only engine)
Alternator
Starting motor
Battery
24V, 60A, 90A

24V, 11kW
12V, 170Ah 2
Turbocharger
Air compressor
Others
KOMATSU KTR110L
Performance
Dimensions

Total displacement
Firing order
140E-5 Series
mm
l{cc}
SEN00079-07
01 Specification
1
Engine name
SAA6D140E-5
Machine models
D155AX-6
6 140 165
15.2 {15,230}
153624
Overall length
mm
1,477
Overall width
mm
1,109
mm
1,157
mm
1,950
Rated horsepower
kW{HP}/
min-1{rpm}
268 {359.9}/1,900 {1,900}

(Gross)
Max. torque
Nm{kgm}/
min-1{rpm}
1,834 {187}/1,300 {1,300}

(Gross)

(High idle speed)
min-1{rpm}
2,100 (0/50) {2,100 (0/50)}

(Low idle speed)
min-1{rpm}
740 (+40/0) {740 (+40/0)}
g/kWh
{g/HPh}
215 {160}
Dry weight
kg
1,800
Fuel supply pump

Governor
DENSO ECD-U2
45 (37)
Quantity of coolant
25 (In only engine)
Alternator
Starting motor
Battery
24V, 60A, 75A, 90A

24V, 11kW
12V, 170Ah 2
Turbocharger
Air compressor
Others
KOMATSU KTR110L

With cooled EGR
Performance
Dimensions

Total displacement
Firing order
10
mm
l{cc}
140E-5 Series
01 Specification
SEN00079-07
1
Engine name
SAA6D140E-5
Machine models
D155A-6
6 140 165
15.2 {15,230}
153624
Overall length
mm
1,461
Overall width
mm
1,109
mm
1,157
mm
1,950
Rated horsepower
kW{HP}/
min-1{rpm}
268 {359.9}/1,900 {1,900}

(Gross)
Max. torque
Nm{kgm}/
min-1{rpm}
1,834 {187}/1,300 {1,300}

(Gross)

(High idle speed)
min-1{rpm}
2,100 (0/50) {2,100 (0/50)}

(Low idle speed)
min-1{rpm}
740 (+40/0) {740 (+40/0)}
g/kWh
{g/HPh}
215 {160}
Dry weight
kg
1,725
Fuel supply pump

Governor
DENSO ECD-U2
45 (37)
Quantity of coolant
25 (In only engine)
Alternator
Starting motor
Battery
24V, 60A, 75A, 90A

24V, 11kW
12V, 170Ah 2
Turbocharger
Air compressor
Others
KOMATSU KTR110L
Performance
Dimensions

Total displacement
Firing order
140E-5 Series
mm
l{cc}
11
SEN00079-07
01 Specification
1
Engine name
SAA6D140E-5
Machine models
D275AX-5E0
6 140 165
15.2 {15,230}
153624
Overall length
mm
1,477
Overall width
mm
966
mm
2,020
mm
Rated horsepower
kW{HP}/
min-1{rpm}
337 {451.6}/2,000 {2,000}

(Gross)
Max. torque
Nm{kgm}/
min-1{rpm}
2,030 {207}/1,400 {1,400}

(Gross)

(High idle speed)
min-1{rpm}
2,200 50 {2,200 50}

(Low idle speed)
min-1{rpm}
700 50 {700 50}
g/kWh
{g/HPh}
218 {162.3}
Dry weight
kg
1,869
Fuel supply pump

Governor
DENSO ECD-U2
58 (50)
Quantity of coolant
25 (In only engine)
Alternator
Starting motor
Battery
24V, 75A, 90A

24V, 11kW
12V, 170Ah 2
Turbocharger
Air compressor
Others
KOMATSU KTR110L

With cooled EGR
Performance
Dimensions

Total displacement
Firing order
12
mm
l{cc}
140E-5 Series
01 Specification
SEN00079-07
1
Engine name
SAA6D140E-5
Machine models
D275A-5R
6 140 165
15.2 {15,230}
153624
Overall length
mm
1,461
Overall width
mm
966
mm
2,020
mm
Rated horsepower
kW{HP}/
min-1{rpm}
337 {451.6}/2,000 {2,000}

(Gross)
Max. torque
Nm{kgm}/
min-1{rpm}
2,030 {207}/1,400 {1,400}

(Gross)

(High idle speed)
min-1{rpm}
2,200 50 {2,200 50}

(Low idle speed)
min-1{rpm}
700 50 {700 50}
g/kWh
{g/HPh}
215 {160}
Dry weight
kg
1,800
Fuel supply pump

Governor
DENSO ECD-U2
58 (50)
Quantity of coolant
25 (In only engine)
Alternator
Starting motor
Battery
24V, 75A, 90A

24V, 11kW
12V, 170Ah 2
Turbocharger
Air compressor
Others
KOMATSU KTR110L
Performance
Dimensions

Total displacement
Firing order
140E-5 Series
mm
l{cc}
13
SEN00079-07
01 Specification
1
Engine name
SAA6D140E-5
Machine models
WA500-6
6 140 165
15.2 {15,230}
153624
Overall length
mm
1,477
Overall width
mm
1,094
mm
1,435
mm
1,727
Rated horsepower
kW{HP}/
min-1{rpm}
266 {356.9}/1,900 {1,900}

(Gross)
Max. torque
Nm{kgm}/
min-1{rpm}
1,803 {184}/1,250 {1,250}

(Gross)

(High idle speed)
min-1{rpm}
2,150 50 {2,150 50}

(Low idle speed)
min-1{rpm}
700 25 {700 25}
g/kWh
{g/HPh}
216.2 {161.3}
Dry weight
kg
1,750
Fuel supply pump

Governor
DENSO ECD-U2
45 (37)
Quantity of coolant
25
Alternator
Starting motor
Battery
24V, 75A, 90A

24V, 11kW
12V, 170Ah 2
Turbocharger
Air compressor
Others
KOMATSU KTR110L

With cooled EGR
Performance
Dimensions

Total displacement
Firing order
14
mm
l{cc}
140E-5 Series
01 Specification
SEN00079-07
1
Engine name
SAA6D140E-5
Machine models
WA500-6R
6 140 165
15.2 {15,230}
153624
Overall length
mm
1,461
Overall width
mm
1,094
mm
1,435
mm
1,727
Rated horsepower
kW{HP}/
min-1{rpm}
266 {356.9}/1,900 {1,900}

(Gross)
Max. torque
Nm{kgm}/
min-1{rpm}
1,803 {184}/1,250 {1,250}

(Gross)

(High idle speed)
min-1{rpm}
2,150 50 {2,150 50}

(Low idle speed)
min-1{rpm}
700 25 {700 25}
g/kWh
{g/HPh}
211.4 {157.7}
Dry weight
kg
1,680
Fuel supply pump

Governor
DENSO ECD-U2
45 (37)
Quantity of coolant
25
Alternator
Starting motor
Battery
24V, 75A, 90A

24V, 11kW
12V, 170Ah 2
Turbocharger
Air compressor
Others
KOMATSU KTR110L
Performance
Dimensions

Total displacement
Firing order
140E-5 Series
mm
l{cc}
15
SEN00079-07
01 Specification
1
Engine name
SAA6D140E-5
Machine models
HD325-7, HD405-7
6 140 165
15.2 {15,230}
153624
Overall length
mm
1,775
Overall width
mm
1,009
mm
1,604
mm
Rated horsepower
kW{HP}/
min-1{rpm}
386 {517.7}/2,000 {2,000}

(Gross)
Max. torque
Nm{kgm}/
min-1{rpm}
2,170 {221.3}/1,400 {1,400}

(Gross)

(High idle speed)
min-1{rpm}
2,300 25 {2,300 25}

(Low idle speed)
min-1{rpm}
725 25 {725 25}
g/kWh
{g/HPh}
212 {158}
Dry weight
kg
1,810
Fuel supply pump

Governor
DENSO ECD-U2
58 (50)
Quantity of coolant
25 (In only engine)
Alternator
Starting motor
Battery
24V, 60A, 75A

24V, 11kW
12V, 170Ah 2
Turbocharger
Air compressor
Others
KOMATSU KTR110L

With cooled EGR
Performance
Dimensions

Total displacement
Firing order
16
mm
l{cc}
140E-5 Series
01 Specification
SEN00079-07
1
Engine name
SAA6D140E-5
Machine models
HD325-7R, HD405-7R
6 140 165
15.2 {15,230}
153624
Overall length
mm
1,775
Overall width
mm
1,009
mm
1,604
mm
Rated horsepower
kW{HP}/
min-1{rpm}
386 {517.7}/2,000 {2,000}

(Gross)
Max. torque
Nm{kgm}/
min-1{rpm}
2,170 {221.3}/1,400 {1,400}

(Gross)

(High idle speed)
min-1{rpm}
2,300 25 {2,300 25}

(Low idle speed)
min-1{rpm}
725 25 {725 25}
g/kWh
{g/HPh}
207 {154}
Dry weight
kg
1,740
Fuel supply pump

Governor
DENSO ECD-U2
58 (50)
Quantity of coolant
25 (In only engine)
Alternator
Starting motor
Battery
24V, 60A, 75A

24V, 11kW
12V, 170Ah 2
Turbocharger
Air compressor
Others
KOMATSU KTR110L
Performance
Dimensions

Total displacement
Firing order
140E-5 Series
mm
l{cc}
17
SEN00079-07
01 Specification
1
Engine name
SAA6D140E-5
Machine models
HM350-2
6 140 165
15.2 {15,230}
153624
Overall length
mm
1,724
Overall width
mm
1,250
mm
1,496
mm
Rated horsepower
kW{HP}/
min-1{rpm}
304 {407.2}/2,000 {2,000}

(Gross)
Max. torque
Nm{kgm}/
min-1{rpm}
1,991 {203}/1,400 {1,400}

(Gross)

(High idle speed)
min-1{rpm}
2,200 (+50/0) {2,200 (+50/0)}

(Low idle speed)
min-1{rpm}
725 25 {725 25}
g/kWh
{g/HPh}
223 {166}
Dry weight
kg
1,820
Fuel supply pump

Governor
DENSO ECD-U2
58 (50)
Quantity of coolant
25 (In only engine)
Alternator
Starting motor
Battery
24V, 60A, 75A

24V, 11kW
12V 170Ah 2
Turbocharger
Air compressor
Others
KOMATSU KTR110L

With cooled EGR
Performance
Dimensions

Total displacement
Firing order
18
mm
l{cc}
140E-5 Series
01 Specification
SEN00079-07
1
Engine name
SAA6D140E-5
Machine models
HM350-2R
6 140 165
15.2 {15,230}
153624
Overall length
mm
1,724
Overall width
mm
1,250
mm
1,496
mm
Rated horsepower
kW{HP}/
min-1{rpm}
304 {407.2}/2,000 {2,000}

(Gross)
Max. torque
Nm{kgm}/
min-1{rpm}
1,991 {203}/1,400 {1,400}

(Gross)

(High idle speed)
min-1{rpm}
2,200 (+50/0) {2,200 (+50/0)}

(Low idle speed)
min-1{rpm}
725 25 {725 25}
g/kWh
{g/HPh}
222 {165}
Dry weight
kg
1,750
Fuel supply pump

Governor
DENSO ECD-U2
58 (50)
Quantity of coolant
25 (In only engine)
Alternator
Starting motor
Battery
24V, 60A, 75A

24V, 11kW
12V 170Ah 2
Turbocharger
Air compressor
Others
KOMATSU KTR110L
Performance
Dimensions

Total displacement
Firing order
140E-5 Series
mm
l{cc}
19
SEN00079-07
01 Specification
1
Engine name
SAA6D140E-5
Machine models
HM400-2, HM400-3M0
6-140 165
15.2 {15,230}
153624
Overall length
mm
1,724
Overall width
mm
1,250
mm
1,496
mm
Rated horsepower
kW{HP}/
min-1{rpm}
338 {452.6}/2,000 {2,000}

(Gross)
Max. torque
Nm{kgm}/
min-1{rpm}
2,089 {213}/1,400 {1,400}

(Gross)

(High idle speed)
min-1{rpm}
2,200 (+50/0) {2,200 (+50/0)}

(Low idle speed)
min-1{rpm}
725 25 {725 25}
g/kWh
{g/HPh}
213 {159}
Dry weight
kg
1,820
Fuel supply pump

Governor
DENSO ECD-U2
58 (50)
Quantity of coolant
25 (In only engine)
Alternator
Starting motor
Battery
24V, 60A, 75A

24V, 11kW
12V, 170Ah 2
Turbocharger
Air compressor
Others
KOMATSU KTR110L

With cooled EGR
Performance
Dimensions

Total displacement
Firing order
20
mm
l{cc}
140E-5 Series
01 Specification
SEN00079-07
1
Engine name
SAA6D140E-5
Machine models
HM400-2R, HM400-3R
6-140 165
15.2 {15,230}
153624
Overall length
mm
1,724
Overall width
mm
1,250
mm
1,496
mm
Rated horsepower
kW{HP}/
min-1{rpm}
338 {452.6}/2,000 {2,000}

(Gross)
Max. torque
Nm{kgm}/
min-1{rpm}
2,089 {213}/1,400 {1,400}

(Gross)

(High idle speed)
min-1{rpm}
2,200 (+50/0) {2,200 (+50/0)}

(Low idle speed)
min-1{rpm}
725 25 {725 25}
g/kWh
{g/HPh}
218 {162}
Dry weight
kg
1,750
Fuel supply pump

Governor
DENSO ECD-U2
58 (50)
Quantity of coolant
25 (In only engine)
Alternator
Starting motor
Battery
24V, 60A, 75A

24V, 11kW
12V, 170Ah 2
Turbocharger
Air compressor
Others
KOMATSU KTR110L
Performance
Dimensions

Total displacement
Firing order
140E-5 Series
mm
l{cc}
21
SEN00079-07
01 Specification
1
Engine name
SAA6D140E-5
Machine models
SDG400S-6B1
(HOKUETSU INDUSTRIES GENERATOR)
6 140 165
15.2 {15,230}
153624
Overall length
mm
1,785
Overall width
mm
1,242
mm
1,523
mm
Rated horsepower
kW{HP}/
min-1{rpm}
357 {478}/1,800 {1,800}

(Net)
Max. torque
Nm{kgm}/
min-1{rpm}

(High idle speed)
min-1{rpm}

(Low idle speed)
min-1{rpm}
g/kWh
{g/HPh}
222 {163}
Dry weight
kg
1,950
Fuel supply pump

Governor
DENSO ECD-U2
82 (73)
Quantity of coolant (with radiator)
53
Alternator
Starting motor
Battery
24V, 35A
24V, 7.5kW
Turbocharger
Air compressor
Others
KOMATSU KTR110L

With cooled EGR
Performance
Dimensions

Total displacement
Firing order
22
mm
l{cc}
140E-5 Series
01 Specification
140E-5 Series
SEN00079-07
23
SEN00079-07
General view
01 Specification
SAA6D140E-5 (Left side view of engine)

Machine model: PC600-8, PC600LC-8
The shape is subject to machine models.
1.
2.
Center of crankshaft
Rear face of flywheel housing
24
140E-5 Series
01 Specification
SEN00079-07
SAA6D140E-5 (Front view of engine)

Machine model: PC600-8, PC600LC-8
1.
2.
Center of cylinder liner
140E-5 Series
25
SEN00079-07
01 Specification

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

Corrosion resistor-less, Single cartridge and Manual priming pump are set for some models. (See the
PC700-8R, PC700LC-8R.)
1.
2.
26
140E-5 Series
01 Specification
SEN00079-07

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

Corrosion resistor-less, Single cartridge and Manual priming pump are set for some models. (See the
PC700-8R, PC700LC-8R.)
1.
2.
140E-5 Series
27
SEN00079-07
01 Specification

Machine model: PC600-8E0, PC600LC-8E0, PC700-8E0, PC700LC-8E0
1.
2.
28
140E-5 Series
01 Specification
SEN00079-07

Machine model: PC600-8E0, PC600LC-8E0, PC700-8E0, PC700LC-8E0
1.
2.
140E-5 Series
29
SEN00079-07
01 Specification

Machine model: PC600-8R1, PC600LC-8R1,
PC700-8R, PC700LC-8R, PC700LC-8R1
1.
2.
30
140E-5 Series
01 Specification
SEN00079-07

Machine model: PC600-8R1, PC600LC-8R1,
PC700-8R, PC700LC-8R, PC700LC-8R1
1.
2.
140E-5 Series
31
SEN00079-07
01 Specification

Machine model: PC800-8, PC800SE-8, PC800LC-8, PC850-8, PC850SE-8
PC800-8E0, PC800SE-8E0, PC800LC-8E0, PC850-8E0, PC850SE-8E0
1.
2.
32
140E-5 Series
01 Specification
SEN00079-07

Machine model: PC800-8, PC800SE-8, PC800LC-8, PC850-8, PC850SE-8
1.
2.
140E-5 Series
33
SEN00079-07
01 Specification

Machine model: PC800-8R, PC800SE-8R, PC800LC-8R, PC850-8R, PC850SE-8R
1.
2.
34
140E-5 Series
01 Specification
SEN00079-07

Machine model: PC800-8R, PC800SE-8R, PC800LC-8R, PC850-8R, PC850SE-8R
1.
2.
140E-5 Series
35
SEN00079-07
01 Specification

Machine model: PC800-8R1, PC800SE-8R1, PC800LC-8R1, PC850-8R1,
PC850SE-8R1
1.
2.
36
140E-5 Series
01 Specification
SEN00079-07

Machine model: PC800-8R1, PC800SE-8R1, PC800LC-8R1, PC850-8R1,
PC850SE-8R1
1.
2.
140E-5 Series
37
SEN00079-07
01 Specification

Machine model: D275AX-5E0
1.
2.
38
140E-5 Series
01 Specification
SEN00079-07

Machine model: D275AX-5E0
1.
2.
140E-5 Series
39
SEN00079-07
01 Specification

Machine model: D275A-5R
1.
2.
40
140E-5 Series
01 Specification
SEN00079-07

Machine model: D275A-5R
1.
2.
140E-5 Series
41
SEN00079-07
01 Specification

Machine model: WA500-6
1.
2.
42
140E-5 Series
01 Specification
SEN00079-07

Machine model: WA500-6
1.
2.
140E-5 Series
43
SEN00079-07
01 Specification

Machine model: WA500-6R
1.
2.
44
140E-5 Series
01 Specification
SEN00079-07

Machine model: WA500-6R
1.
2.
140E-5 Series
45
SEN00079-07
01 Specification

Machine model: HD325-7, HD405-7
1.
2.
46
140E-5 Series
01 Specification
SEN00079-07

Machine model: HD325-7, HD405-7
1.
2.
140E-5 Series
47
SEN00079-07
01 Specification

Machine model: HD325-7R, HD405-7R
1.
2.
48
140E-5 Series
01 Specification
SEN00079-07

Machine model: HD325-7R, HD405-7R
1.
2.
140E-5 Series
49
SEN00079-07
01 Specification

Machine model: HM350-2, HM400-2
1.
2.
50
140E-5 Series
01 Specification
SEN00079-07

Machine model: HM350-2, HM400-2
1.
2.
140E-5 Series
51
SEN00079-07
01 Specification

Machine model: HM350-2R, HM400-2R
1.
2.
52
140E-5 Series
01 Specification
SEN00079-07

Machine model: HM350-2R, HM400-2R
1.
2.
140E-5 Series
53
SEN00079-07
01 Specification

Machine model: HM400-3M0
1.
2.
54
140E-5 Series
01 Specification
SEN00079-07

Machine model: HM400-3M0
1.
2.
140E-5 Series
55
SEN00079-07
01 Specification

Machine model: HM400-3R
1.
2.
56
140E-5 Series
01 Specification
SEN00079-07

Machine model: HM400-3R
1.
2.
140E-5 Series
57
SEN00079-07
01 Specification

Machine model: SDG400S-6B1 (HOKUETSU INDUSTRIES GENERATOR)
1.
2.
58
140E-5 Series
01 Specification
SEN00079-07

Machine model: SDG400S-6B1 (HOKUETSU INDUSTRIES GENERATOR)
1.
2.
140E-5 Series
59
SEN00079-07
01 Specification
Dimensions table
1
Unit: mm
Engine
Machine model
Dimension of each part

C
1,494 1,863
441
227
143
920
1,155 1,151
PC600-8E0, PC600LC-8E0
1,412 1,867
PC700-8E0, PC700LC-8E0
444
227
143
920
1,155 1,061
PC600-8R1, PC600LC-8R1,
1,482 1,863
PC700LC-8R1
411
227
143
920
1,155 1,151
PC800-8, PC800LC-8,
PC800SE-8,
PC850-8, PC850SE-8,
PC800-8E0,
PC800LC-8E0,
PC800SE-8E0,
PC850-8E0,
1,350 1,902
PC850SE-8E0,
PC800-8R, PC800LC-8R,
PC800SE-8R,
SAA6D140E-5 PC800-8R1, PC800LC-8R1,
PC800SE-8R1,
PC850-8R1, PC850SE-8R1
594
196
196
PC600-8, PC600LC-8
1,000 1,185 1,176
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,
HD325-7R, HD405-7R
1,775 1,604
542
80
80
875
HM350-2, HM350-2R,
HM400-2, HM400-2R
1,724 1,496
542
147
147
815
945
1,250
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
1,785 1,523
403
213
213
877
956
1,242
1,005 1,025
a These dimensions are given for reference when the engine is set on a test bench.
60
140E-5 Series
01 Specification
SEN00079-07
Weight table
(With EGR)
No.
Unit: kg
Item
Main parts
SAA6D140E-5
Turbocharger
KOMATSU KTR110L
24 (Air-cooled) /
28 (Water-cooled)
Cylinder head assembly
Cylinder head, valve,

valve spring
23 6
Cylinder block assembly
Cylinder block, bearing, cap,

cylinder liner
Front cover
60
Oil pan
Flywheel assembly
480
Flywheel ring gear
PC800-8, PC800SE-8, PC800LC-8

PC850-8, PC850SE-8
PC800-8E0, PC800SE-8E0,
PC800LC-8E0
PC850-8E0, PC850SE-8E0
36
PC600-8, PC600LC-8
PC600-8E0, PC600LC-8E0
PC700-8E0, PC700LC-8E0
D155AX-6
WA500-6
30
D275AX-5E0
HD325-7, HD405-7
HM350-2, HM400-2
HM400-3M0
28
SDG400S-6B1 (HOKUETSU
INDUSTRIES GENERATOR)
62
PC600-8, PC600LC-8
PC800-8, PC800SE-8, PC800LC-8
PC850-8, PC850SE-8
PC800-8E0, PC800SE-8E0,
PC800LC-8E0
PC850-8E0, PC850SE-8E0
D155AX-6
D275AX-5E0
WA500-6
60
HD325-7, HD405-7
HM350-2, HM400-2
HM400-3M0
47
123
65
7
Flywheel housing assembly
Crankshaft assembly
Crankshaft, crank gear
136
Camshaft assembly
Camshaft, cam gear, thrust

plate
20
10
Piston and connecting rod

assembly
Piston, piston ring, piston

pin, connecting rod
11
Oil pump
12
Fuel supply pump
13
13
Water pump
18
140E-5 Series
63
11 6
61
SEN00079-07
01 Specification
Unit: kg
No.
14
Item
Alternator
Main parts
SAA6D140E-5
24V, 35A
24V, 50A
11
24V, 60A
11
24V, 75A
12.5
24V, 90A
19
24V, 7.5kW
15.5
24V, 11kW
18
15
Starting motor
16
EGR oil pump
17
EGR valve
10
18
Bypass valve
10
19
EGR cooler
10
62
140E-5 Series
01 Specification
SEN00079-07
(EGR-less)
No.
Unit: kg
Item
Main parts
SAA6D140E-5
Turbocharger
KOMATSU KTR110L
24 (Air-cooled) /
28 (Water-cooled)
Cylinder head assembly
Cylinder head, valve,

valve spring
23 6
Cylinder block assembly
Cylinder block, bearing, cap,

cylinder liner
Front cover
60
Oil pan
Flywheel assembly
480
Flywheel ring gear
PC800-8R, PC800SE-8R,
PC800LC-8R
PC800-8R1, PC800SE-8R1
PC800LC-8R1
PC850-8R1, PC850SE-8R1
36
PC600-8R1, PC600LC-8R1
PC700LC-8R1
D155A-6
WA500-6R
30
D275A-5R
HD325-7R, HD405-7R
HM350-2R, HM400-2R
HM400-3R
28
PC600-8R1, PC600LC-8R1
PC700LC-8R1
PC800-8R, PC800SE-8R,
PC800LC-8R
PC800-8R1, PC800SE-8R1
PC800LC-8R1
PC850-8R1, PC850SE-8R1
D155A-6
D275A-5R
WA500-6R
60
HD325-7R, HD405-7R
HM350-2R, HM400-2R
HM400-3R
47
Flywheel housing assembly
Crankshaft assembly
Crankshaft, crank gear
136
Camshaft assembly
Camshaft, cam gear,

thrust plate
20
10
Piston and connecting rod

assembly
Piston, piston ring, piston pin,

connecting rod
11
Oil pump
12
Fuel supply pump
13
13
Water pump
18
140E-5 Series
65
11 6
63
SEN00079-07
01 Specification
Unit: kg
No.
14
15
64
Item
Alternator
Starting motor
Main parts
SAA6D140E-5
24V, 35A
24V, 50A
11
24V, 60A
11
24V, 75A
12.5
24V, 90A
19
24V, 11kW
18
140E-5 Series
01 Specification
SEN00079-07
Engine performance curves

Engine
SAA6D140E-5
140E-5 Series
Engine serial No.
1
Machine model
Page
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
66
PC800-8, PC800LC-8,
PC800SE-8, PC800SE-8R
PC850-8, PC850-8R
PC800-8E0, PC800SE-8E0,
PC800LC-8E0,
PC850-8E0, PC850SE-8E0
PC800-8R1, PC800SE-8R1
PC800LC-8R1
PC850-8R1, PC850SE-8R1
67
D155AX-6, D155A-6
68
D275AX-5E0, D275A-5R
69
WA500-6, WA500-6R
70
HD325-7, HD325-7R
HD405-7, HD405-7R
71
HM350-2, HM350-2R
72
HM400-2, HM400-2R
HM400-3M0, HM400-3R
73
65
SEN00079-07
01 Specification
SAA6D140E-5
(Machine model: PC600-8, PC600LC-8, PC600-8R, PC600LC-8R, PC6008E0, 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
01 Specification
SEN00079-07
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, PC8008R1, PC800SE-8R1, PC800LC-8R1, PC850-8R1, PC850SE-8R1)
140E-5 Series
67
SEN00079-07
01 Specification
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
01 Specification
SEN00079-07
SAA6D140E-5 (Machine model: D275AX-5E0, D275A-5R)

140E-5 Series
69
SEN00079-07
01 Specification
SAA6D140E-5 (Machine model: WA500-6, WA500-6R)

70
140E-5 Series
01 Specification
SEN00079-07
SAA6D140E-5 (Machine model: HD325-7, HD405-7, HD325-7R, HD405-7R)

140E-5 Series
71
SEN00079-07
01 Specification
SAA6D140E-5 (Machine model: HM350-2, HM350-2R)

72
140E-5 Series
01 Specification
SEN00079-07
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
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
SEN00081-08
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
140E-5 Series
Air intake and exhaust unit
SEN00081-08
The above illustration shows the engine for PC600-8.
A:
Air intake unit (Between air-cooled aftercooler and air intake manifold)
1.
2.
3.
Electrical intake air heater (ribbon heater)

Diffuser
Air intake manifold
140E-5 Series
SEN00081-08
SAA6D140E-5 (Right side view of engine)
A:
B:
C:
To EGR cooler
To turbocharger
From bypass valve
1.
2.
3.
Exhaust manifold (rear)

Exhaust manifold (center)
Exhaust manifold (front)
140E-5 Series
Air cleaner
SEN00081-08
ERB type
[Air cleaner of automatic exhaust gas discharge type (radial seal type)]
A:
B:
C:
Air inlet
To turbocharger (intake air)
To muffler (dust)
1.
2.
3.
4.
Pre-cleaner
Air cleaner casing
Outer element
Inner element
Engine
Machine
model
Type
D155AX-6,
D155A-6,
Komaclone, multi-cyclone
SAA6D140E-5
D275AX-5E0
(ERB type)
D275A-5R
140E-5 Series
Method of discharging
dust from pre-cleaner
Number of elements
Automatic discharge
(Exhaust ejector)
Inner cylinder: 1,
Outer cylinder: 1
SEN00081-08
FRG type
[Air cleaner of cyclone pack type with evacuator valve (radial seal type)]
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Inlet
Outlet
Guide vane
Primary element
Safety element
Evacuator valve
Dust pan
Guide plate (sleeve)
Body
Element
140E-5 Series
Engine
Machine model
SEN00081-08
Type
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
FRG
SAA6D140E-5
(radial seal type)
PC800-8E0, PC800LC-8E0,
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
q
The size of the body is reduced from the conventional type without changing the diameter
of the element.
q
Since the inlet is set in the tangential direction,
air is given sufficient centrifugal force by the
simple spiral guide vane, not by the guide
plate.
140E-5 Series
Evacuator valve
Number of
elements
Automatic
discharge
Inner cylinder: 1,
Outer cylinder: 1
Operation
q
Air containing dust is sucked in vertically
through inlet (1) and the dust is separated by
the centrifugal effect of guide vane (3).
q
More than 99.9% of the dust is removed by primary element (4) and clean air is sucked in the
engine through safety element (5) and outlet
(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 discharged out automatically.
SEN00081-08
Turbocharger
(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)
140E-5 Series
A:
B:
C:
D:
E:
F:
Intake air inlet

Intake air outlet
Exhaust gas inlet
Exhaust gas outlet
Oil inlet
Oil outlet
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Blower housing
V-band
Diffuser plate
Center housing
Shroud
Turbine housing
Blower impeller
Seal ring
Bearing metal
Journal bearing
Seal ring
Turbine impeller
SEN00081-08
Specifications
Model: KOMATSU KTR110L (air-cooled)
Overall length: 308 mm
Overall width: 305 mm
Overall height: 287 mm
Weight: 24 kg
140E-5 Series
SEN00081-08
(EGR-less)
Air-cooled type
Model: KTR110L
PC600-8R, PC600-8R1, PC600LC-8R, PC600LC-8R1, PC700-8R, PC700LC-8R, PC700LC-8R1, HD3257R, HD405-7R, WA500-6R, HM350-2R, HM400-2R, HM400-3R
10
140E-5 Series
A:
B:
C:
D:
E:
F:
Intake air inlet

Intake air outlet
Exhaust gas inlet
Exhaust gas outlet
Oil inlet
Oil outlet
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Blower housing
V-band
Diffuser plate
Center housing
Shroud
Turbine housing
Blower impeller
Seal ring
Bearing metal
Journal bearing
Seal ring
Turbine impeller
SEN00081-08
Specifications
Model: KOMATSU KTR110L (air-cooled)
Weight: 24 kg
140E-5 Series
11
SEN00081-08
(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:
B:
C:
D:
E:
F:
G:
SEN00081-08
Intake air inlet

Intake air outlet
Exhaust gas inlet
Exhaust gas outlet
Oil inlet
Oil outlet
Coolant
1.
2.
3.
4.
Blower housing
V-band
Diffuser plate
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
12. Turbine impeller
Specifications
Model: KOMATSU KTR110L (water-cooled)
Weight: 28 kg
140E-5 Series
13
SEN00081-08
(EGR-less)
Water-cooled type
Model: KTR110L
PC800-8R, PC800LC-8R, PC800SE-8R, PC850-8R, PC850SE-8R, PC800-8R1, PC800LC-8R1, PC800SE8R1, PC850-8R1, PC850SE-8R1, D155A-6, D275A-5R
14
140E-5 Series
A:
B:
C:
D:
E:
F:
G:
SEN00081-08
Intake air inlet

Intake air outlet
Exhaust gas inlet
Exhaust gas outlet
Oil inlet
Oil outlet
Coolant
1.
2.
3.
4.
Blower housing
V-band
Diffuser plate
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
12. Turbine impeller
Specifications
Model: KOMATSU KTR110L (water-cooled)
Weight: 28 kg
140E-5 Series
15
SEN00081-08
Model: KTR110L
16
The above illustration shows the air-cooled turbocharger.
140E-5 Series
SEN00081-08
Unit: mm
No.
Check item
End play (play in axial direction)
Radial play (play in radial direction)
Clearance between blower housing and

impeller
140E-5 Series
Criteria
Remedy
Standard
Repair limit
0.08 to 0.13
0.18
0.43 to 0.68
0.84
Clearance limit (min.): 0.14
Replace thrust
parts
Replace bearing
parts
Replace bearing
parts
17
SEN00081-08
Turbocharger mounting
a
a

A:
B:
Intake air inlet

Intake air (between turbocharger and air-cooled aftercooler)
1.
2.
Muffler
Turbocharger
18
140E-5 Series
Aftercooler
SEN00081-08
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.
2.
3.
4.
Tank
Side support
Tube
Fin
140E-5 Series
19
SEN00081-08
Muffler
For PC600-8, PC600-8R, PC600LC-8, PC600LC-8R, PC600-8E0, PC600-8R1, PC600LC-8E0, PC600LC8R1, PC700-8E0, PC700-8R,PC700LC-8E0, PC700LC-8R, PC700LC-8R1
A:
B:
C:
20
Exhaust gas inlet (from turbocharger)

Exhaust gas outlet
Water drain
140E-5 Series
SEN00081-08
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
A:
B:
C:

Exhaust gas outlet
Water drain
140E-5 Series
21
SEN00081-08
For PC800-8E0, PC800SE-8E0, PC800LC-8E0, PC850-8E0, PC850SE-8E0

PC800-8R1, PC800SE-8R1, PC800LC-8R1, PC850-8R1, PC850SE-8R1
A:
B:
C:
22

Exhaust gas outlet
Water drain
140E-5 Series
SEN00081-08
For D155AX-6, D155A-6
A:
B:
C:
D:

Exhaust gas outlet
Water drain
From air cleaner (dust)
140E-5 Series
23
SEN00081-08
For D275AX-5E0, D275A-5R
A:
B:
C:
D:
24

Exhaust gas outlet
Water drain
From air cleaner (dust)
140E-5 Series
EGR system
No.
SEN00081-08
Component part
Function
EGR valve
1 (driven hydraulically)
Controls the gas flow from the exhaust system to the air intake system.
Since the exhaust pressure (PEX) is higher than the boost pressure (PIN), the
exhaust gas flows to the air intake valve.
2 Bypass valve
Opens the bypass valve when the boost pressure (PIN) is higher than the
exhaust pressure (PEX).
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.
5 Each sensor
Controls the EGR according to the operating condition.

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 troubleshooted, a serious trouble is prevented.
140E-5 Series
25
SEN00081-08
26
The above illustration shows the engine for D155AX-6.
140E-5 Series
1.
2.
3.
4.
5.
6.
7.
8.
9.
SEN00081-08
EGR valve
Bypass valve
EGR cooler
Venturi system
EGR valve position sensor
Bypass valve position sensor
Bypass piping
EGR piping
EGR oil pump
Operation
q
The engine controller outputs signals for opening 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 manifold 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 pressure 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
SEN00081-08
EGR valve and bypass valve
A:
B:
C:
D:
Oil inlet
Oil outlet
EGR gas passage (EGR valve)
Boost air passage (bypass valve)
Function
q
The EGR valve controls the EGR gas.
q
This valve is driven hydraulically and its opening ratio is controlled electronically.
Operation
q
The oil pressure (engine oil) of 1.47 MPa {15
kg/cm2} supplied to oil inlet (A) is reduced by
oil pressure control valve (2).
q
Hydraulic piston (5) generates pressing force
from the reduced oil pressure.
q
The control oil pressure can be changed with
the drive current of solenoid (3).
28
1.
2.
3.
4.
5.
6.
7.
Stick prevention device

Oil pressure control valve
Solenoid
Position sensor
Hydraulic piston
Spring
Valve
Valve (7) is closed by spring (6) but pushed

open by hydraulic piston (5) to an opening ratio
in proportion to the control oil pressure.
The valve opening ratio is sensed with position
sensor (4) installed to hydraulic piston (5) and
set to the specified opening ratio by controlling
the solenoid current.
The bypass valve assists the EGR gas by
increasing the exhaust pressure.
The structure and operation of the EGR
bypass valve are the same as those of the
EGR valve.
q
q
140E-5 Series
SEN00081-08
EGR cooler
A:
B:
C:
EGR gas inlet

EGR gas outlet
Coolant inlet
1.
Heat exchange tube (corrugated tube)
D:
E:
Coolant outlet
Air bleeder
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 efficiency.
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 corrosionresistant stainless steel and corrugated to
increase the cooling efficiency.
140E-5 Series
29
SEN00081-08
Venturi system
A:
B:
Air inlet
EGR gas inlet
1.
2.
3.
Venturi nozzle
Throat
Diffuser
Structure
q
The EGR gas and intake air mix together in the
venturi system.
q
The venturi system consists of throat (2), venturi nozzle (1), and diffuser (3).
Operation
q
The boost pressure increased by the turbocharger 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
SEN00081-08
31
SEN00081-08
Cylinder head
32
140E-5 Series
A:
B:
C:
D:
Intake air
Exhaust gas
To fuel tank
To radiator
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Rocker cover bolt

Cylinder head bolt
Air bleeding pipe from coolant
Fuel spill pipe
Rocker cover
Cylinder head
Injector connector
Injector assembly
Injector holder mounting bolt
Injector holder retainer
SEN00081-08
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
O-ring seal
Injector
q
Installation: Dry type (without sleeve)
140E-5 Series
33
SEN00081-08
Tighten the cylinder head mounting bolts in the order of (1) to (7).
Unit: mm
No.
Check item
Strain of cylinder head mounting face
Projection of nozzle
Tightening torque for cylinder

head mounting bolt (Apply
molybdenum disulfide or
engine oil to threaded part)
Criteria
Remedy
Tolerance
Repair limit
0 to 0.06
0.09
Engine
Standard
SAA6D140E-5
2.3 to 2.9
Bolt No.
(1) to (6)
Target(Nm{kgm})
1st stage
137 to 157{14 to 16} Tighten in order

shown above. If
289{29.5}
284 to 294{29 to 30}
there are 5 punch
Retighten 90 deg.
90(+30/0) deg.
marks, replace bolt.
2nd stage
3rd stage
Range(Nm{kgm})
147{15}
68.6{7}
58.8 to 73.5{6 to 7.5}
Target(Nm{kgm})
Range(Nm{kgm})
Tightening torque for injector

holder mounting bolt
66.7{6.8}
58.8 to 73.5{6 to 7.5}
Tightening torque for fuel injection pipe
37.3{3.8}
34.3 to 40.2{3.5 to 4.1}
Tightening torque for head

cover mounting bolt
32.4{3.3}
29.4 to 34.3{3.0 to 3.5}
34
Replace nozzle or
gasket
Procedure
(7)
Correct by grinding
or replace
Retighten
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.
140E-5 Series
140E-5 Series
SEN00081-08
35
SEN00081-08
Cylinder block
36
140E-5 Series
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
SEN00081-08
Front cover
Cylinder block
Cylinder liner
Clevis seal
Liner O-ring (water)
Liner O-ring (oil)
Thrust bearing metal
Main bearing metal
Main bearing metal cap
Main bearing metal cap bolt
Front oil seal
Piston cooling nozzle (front side)
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
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
Upper: Clevis seal
q
Middle: O-ring (ethylene-propylene rubber)
q
Lower: O-ring (silicone rubber)
q
140E-5 Series
37
SEN00081-08
Unit: mm
No.
1
Check item
Remedy
Tolerance
Repair limit
0 to 0.09
0.135
Standard dimension
Tolerance
127
+0.018
0.006
3.5
0.010
0.010
Strain of cylinder head mounting face

Diameter of main bearing metal
mounting hole
Criteria
Thickness of main bearing

metal
Roundness of mounting hole
Repair limit: 0.005

Standard dimension
Tolerance
Repair limit
120
+0.038
0.006
120.15
Diameter of cam bushing

mounting hole
69
+0.030
+0.030
Inside diameter of cam bushing
65
+0.040
+0.040
65.15
Level difference between

underside faces of cylinder
block and front cover
Tightening torque for main cap

mounting bolt (Apply engine oil
to threads)
Inside diameter of main bearing

metal
8
a
38
Tightening torque for crank pulley mounting bolt
Repair limit: 0.14
Correct by grinding
or replace
Replace main bearing metal cap
Replace bearing
metal
Replace bearing
metal
Correct or replace
block
Replace cam bushing
Reassemble
Procedure
Target(Nm{kgm})
Range(Nm{kgm})
1st stage
118{12}
108 to 127{11 to 13}
2nd stage
235{24}
230 to 240{23.5 to 24.5}
3rd stage
Retighten 90 deg.
90(+30/0) deg.
275{28}
245 to 309{25 to 31.5}
Retighten
Do not use a main cap mounting bolt more than 5 times.

140E-5 Series
Cylinder liner
SEN00081-08
Unit: mm
No.
1
Check item
Criteria
Projection of cylinder liner
Standard dimension
Tolerance
Repair limit
140
+0.020
+0.020
140.12
140
+0.040
+0.021
140.14
Roundness of inside of cylinder

liner
Repair limit: 0.02
Cylindricality of inside of cylinder

liner
Repair limit: 0.02
Outside diameter of cylinder liner
4
Interference of cylinder liner and
block

(at O-ring)
Clearance between cylinder liner
and block (at O-ring)
140E-5 Series
Replace cylinder liner
Standard dimension
Tolerance
170.2
0.10
0.10
Clearance between cylinder liner

and block
Replace cylinder liner or

cylinder block
Permissible range: 0.07 to 0.15

Rank
Inside diameter of cylinder liner
Remedy
Standard clearance: 0 to 0.163

Standard dimension
Tolerance
161.2
+0.090
+0.050
Interference limit
0.02 to 0.12
Min. 0.02
Standard size
Tolerance
158
0.073
0.103
Standard clearance: 0.024 to 0.089

block
Replace or correct cylinder liner or block

block
39
SEN00081-08
Main moving parts
1.
2.
3.
4.
5.
6.
7.
8.
Piston (FCD piston)

Piston pin
Connecting rod bushing
Top ring
Second ring
Oil ring
Connecting rod
Connecting rod cap
40
9.
10.
11.
12.
13.
14.
15.
16.
Connecting rod cap bolt

Connecting rod bearing metal
Crank gear (number of teeth: 36)
Key (crank gear)
Crankshaft
Vibration damper
Pin (flange)
Flange
140E-5 Series
Specifications
Crankshaft:
Piston:
SEN00081-08
Closed die forging

Journal, fillet
Induction hardening
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):
140E-5 Series
M-shaped
steel,
with
expander, nitrided surface
coil
41
SEN00081-08
Crankshaft
Unit: mm
No.
1
Check item
Criteria
End play
Standard value
Repair limit
0.140 to 0.315
0.50
Standard dimension
Outside diameter of main journal
0.25 US
119.75
0.50 US
119.50
0.75 US
119.25
119.13
1.00 US
119.00
118.88
Clearance of crank pin journal
42
Bend of crankshaft
119.88
119.63
0.050
0.068
119.38
Standard
Repair limit
0 to 0.009
0.020
Standard clearance
Allowable clearance
0.044 to 0.106
0.27
Tolerance
STD
90
89.88
89.75
89.63
0.50 US
89.50
0.75 US
89.25
0.050
0.068
89.38
89.13
89.00
Standard
Use undersize journal or

replace
Replace main bearing

metal
Repair limit
0.25 US
1.00 US
Roundness
Repair limit
120
Standard dimension
Outside diameter of crank pin

journal
Tolerance
Replace thrust bearing

metal or use oversize
metal
STD
Roundness
Clearance of main journal
Remedy
Use undersize journal or

replace
88.88
Repair limit
0 to 0.009
0.020
Standard clearance
Allowable clearance
0.042 to 0.110
0.24
Standard clearance
Repair limit
Coaxiallity of all main journals:

Max. 0.150
0.20
Coaxiallity of adjacent journals:

Max. 0.050
0.10
Replace connecting rod

bearing metal
Use undersize crankshaft

or replace
US: Undersize
140E-5 Series
Camshaft
SEN00081-08
Unit: mm
No.
1
Check item
Criteria
Standard
Repair limit
0.1 to 0.25
0.36
Standard dimension
Tolerance
65
0.016
0.036
Standard clearance
Allowable clearance
0.016 to 0.096
0.15
End play
Outside diameter of camshaft

journal
2
Clearance of camshaft journal
3
4
Bend of camshaft
Height of cam
140E-5 Series
Remedy
Replace thrust plate
Replace camshaft
Replace cam bushing
Repair limit: 0.03 (Overall swing of indicator)

Cam
Standard dimension
Tolerance
Repair limit
Intake
55.48
0.1
55.08
Exhaust
55.75
0.1
55.35
Replace camshaft
43
SEN00081-08
Cam follower and push rod
Unit: mm
No.
Check item
Repair limit
22
0.021
0.034
21.92
Diameter of cam follower shaft

hole
22
+0.021
+0.021
22.07
Outside diameter of cam roller
31.7
+0.05
+0.02
31.50
Inside diameter of cam roller
12.7
+0.038
+0.013
12.78
12.63
0.006
Remedy
Tolerance
Diameter of cam follower shaft
Criteria
Standard dimension
Diameter of cam roller pin
12.56
Standard dimension
Tolerance
12.7
0.20
0.20
0.20
0.20
Diameter of push rod ball end
Diameter of push rod socket

end
13.4
Bend of push rod
Repair limit: 0.3 (Overall swing of indicator)
44
Replace
140E-5 Series
140E-5 Series
SEN00081-08
45
SEN00081-08
Piston, piston ring and piston pin
46
140E-5 Series
SEN00081-08
Unit: mm
No.
Check item
Criteria
Rank Standard dimension
Outside diameter of piston
Thickness of piston ring
Width of piston ring groove
2 to 4
Clearance between piston ring
and piston ring groove
Closed gap of piston ring
Outside diameter of piston pin
Diameter of piston pin hole

Clearance between piston pin
and piston
a
a
Remedy
Tolerance
Repair limit
140
0.120
0.135
139.830
140
0.105
0.120
139.845
No.
Measuring point
Standard dimension
Tolerance
No. 1 ring
2.9
0.015
0.035
No. 2 ring
2.41
0.010
0.035
Oil ring
0.010
0.030
No. 1 ring
Judge using groove wear gauge (*1)
No. 2 ring
Judge using groove wear gauge (*2)
Oil ring
No.
Measuring point
No. 1 ring
No. 2 ring
Oil ring
0.035 to 0.060
0.14
No. 1 ring
0.42 to 0.57
(Tension 16.5 to 23.5N
{1.68 to 2.40kg})
2.0
No. 2 ring
(Identification: 2RN
white mark)
1.15 to 1.30
{1.65 to 2.47kg})
1.8
Oil ring
0.30 to 0.50
{8.61 to 11.39kg})
1.0
Replace piston
Replace piston ring
Replace piston
+0.040
+0.025
Standard clearance Allowable clearance

Judge using groove wear gauge
Standard dimension
Tolerance
52
0.006
0.006
52
+0.045
+0.035
Standard clearance
Allowable clearance
0.035 to 0.051
0.10
Replace piston or
piston ring
Replace piston ring

or cylinder liner
Replace piston pin
Replace piston
Replace piston or
piston pin
*1: Part No. (groove wear gauge) 795-901-1150

*2: Part No. (groove wear gauge) 795-901-1130
140E-5 Series
47
SEN00081-08
Connecting rod
Unit: mm
No.
Check item
Inside diameter of connecting
rod small end bushing
(Ream after press fitting)
Criteria
Remedy
Standard dimension
Tolerance
Repair limit
52
+0.049
+0.030
52.09
Clearance between connecting rod small end bushing and

piston pin
Standard clearance
Allowable clearance
0.030 to 0.055
0.11
Diameter of connecting rod

small end bushing mounting
hole
Standard dimension
Tolerance
57.4
+0.030
+0.030
Inside diameter of connecting

rod large end bearing metal
48
Replace bushing
(Spare is half
worked)
Replace bushing or
piston pin
Replace connecting
rod
Standard dimension
Tolerance
Repair limit
90
+0.042
0.008
90.15
Diameter of connecting rod

large end bearing metal
mounting hole
(Before measuring, tighten
connecting rod cap mounting
bolt to specified torque)
95
+0.026
0.004
Replace connecting
rod
Thickness of connecting rod

bearing metal
2.5
+0.002
0.008
Replace bearing
metal
Parallelism and twist of connecting rod
Tightening torque for connecting rod cap mounting bolt

(Apply engine oil to bolt
threads and nut seat)
Weight of connecting rod
Item
Standard
Repair limit
Parallelism a
0.20
0.25
Twist b
0.30
0.35
Dimension c
264
Procedure
Target(Nm{kgm})
Range(Nm{kgm})
1st stage
127.5{13}
117.7 to 132.4
{12.5 to 13.5}
2nd stage
Retighten 90 deg.
90(+30/0) deg.
Replace bearing
metal
Replace connecting
rod
Retighten
Permissible range: Dispersion of weight of connecting rods in one engine

Replace
must not exceed 154 g.
Do not use a connecting rod cap mounting bolt more than 5 times.
140E-5 Series
Flywheel and flywheel housing
1.
2.
3.
4.
5.
6.
Rear seal
Ring gear
Flywheel
Engine speed sensor (for monitor)
Flywheel housing
Engine speed sensor
(NE sensor for engine control)
140E-5 Series
SEN00081-08
49
SEN00081-08
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:
B:
Tightening order of flywheel mounting bolts

Tightening order of flywheel housing mounting
bolts
50
140E-5 Series
SEN00081-08
Unit: mm
No.
Check item
Criteria
Facial runout of flywheel housing
Repair limit: 0.20
Radial runout of flywheel housing
Repair limit: 0.20
Facial runout of flywheel
Repair limit: 0.20
Radial runout of flywheel
Repair limit: 0.13

Target(Nm{kgm})
Range(Nm{kgm})
Tightening torque for flywheel

Procedure
housing mounting bolt
1st stage
(Apply engine oil to bolt threads
2nd stage
and seat surface)
191{19.5}
147 to 235{15 to 24}
275{28.0}
245 to 309{25 to 31.5}
Tightening torque for flywheel

Procedure
mounting bolt
1st stage
(Apply engine oil to bolt threads
2nd stage
and seat surface)
Target(Nm{kgm})
Range(Nm{kgm})
118{12}
113 to 123{11.5 to 12.5}
Retighten 90 deg.
90(+30/0) deg.
Remedy
Reassemble
Tighten in order
shown in above figure
Tighten and
retighten in order
shown in above figure
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
SEN00081-08
Vibration damper
1.
2.
3.
4.
5.
6.
Adapter
Pin (between adapter and crankshaft pulley)
Vibration damper
Bolt (between adapter and vibration damper)
Bolt (between crankshaft and adapter)
Pin (between adapter and vibration damper)
52
140E-5 Series
140E-5 Series
SEN00081-08
53
SEN00081-08
Timing gear
(With EGR)
54
140E-5 Series
A:
B:
C:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
SEN00081-08
Timing mark
[Between crank gear and main idler gear (large)]
Timing mark
[Between main idler gear (small) and fuel supply pump drive gear]
Timing mark
[Between main idler gear (small) and cam gear]
Water pump drive gear (Number of teeth: 23)
Sub idler gear (Number of teeth: 42)
Main idler gear (large) (Number of teeth: 60)
Main idler gear (small) (Number of teeth: 40)
Cam gear (Number of teeth: 48)
Air compressor pulley drive gear (Number of teeth: 14)
Fuel supply pump drive gear (Number of teeth: 48)
EGR oil pump drive gear (Number of teeth: 22)
Crank gear (Number of teeth: 36)
Oil pump drive gear (Number of teeth: 20)
Unit: mm
No.
11
Check item
Clearance between main idler

gear bushing and shaft
12
Clearance between sub idler

13
End play of main idler gear
14
End play of sub idler gear
Criteria
Standard
dimension
Position
Backlash of each gear
140E-5 Series
Tolerance
Remedy
Standard
clearance
Allowable
clearance
+0.034
+0.009
0.025 to 0.063
0.20
+0.055
+0.055
0.016 to 0.084
0.20
Shaft
Hole
56
0.016
0.029
56
0.016
0.029
Standard
Repair limit
0.06 to 0.24
0.4
0.11 to 0.23
0.4
Measuring point
Standard
15
Crank gear and main idler gear (large) 0.028 to 0.312
16
Main idler gear (small) and fuel supply

0.016 to 0.278
pump gear
17
Main idler gear (small) and cam gear
0.016 to 0.278
18
Main idler gear (large) and sub idler

gear
0.028 to 0.313
19
Sub idler gear and oil pump drive gear 0.080 to 0.417
20
Sub idler gear and water pump drive

gear
0.095 to 0.346
21
Cam gear and air conditioner drive

gear
0.118 to 0.369
22
Fuel supply pump gear and EGR oil

pump drive gear
0.118 to 0.369
Replace bushing
Replace thrust
bearing
Repair limit
Replace
0.6
55
SEN00081-08
(EGR-less)
56
140E-5 Series
A:
B:
C:
1.
2.
3.
4.
5.
6.
7.
8.
9.
SEN00081-08
Timing mark
[Between crank gear and main idler gear (large)]
Timing mark
[Between main idler gear (small) and fuel supply pump drive gear]
Timing mark
[Between main idler gear (small) and cam gear]
Water pump drive gear (Number of teeth: 23)
Sub idler gear (Number of teeth: 42)
Main idler gear (large) (Number of teeth: 60)
Main idler gear (small) (Number of teeth: 40)
Air compressor pulley drive gear (Number of teeth: 14)
Fuel supply pump drive gear (Number of teeth: 48)
Crank gear (Number of teeth: 36)
Oil pump drive gear (Number of teeth: 20)
Unit: mm
No.
10
Check item
Clearance between main idler

11
Clearance between sub idler

12
End play of main idler gear
13
End play of sub idler gear
Criteria
Standard
dimension
Position
Backlash of each gear
140E-5 Series
Tolerance
Remedy
Standard
clearance
Allowable
clearance
+0.034
+0.009
0.025 to 0.063
0.20
+0.055
+0.055
0.016 to 0.084
0.20
Shaft
Hole
56
0.016
0.029
56
0.016
0.029
Standard
Repair limit
0.06 to 0.24
0.4
0.11 to 0.23
0.4
Measuring point
Standard
14
Crank gear and main idler gear (large) 0.141 to 0.425
15
Main idler gear (small) and fuel supply

0.129 to 0.391
pump gear
16
Main idler gear (small) and cam gear
0.129 to 0.391
17
Main idler gear (large) and sub idler

gear
0.141 to 0.425
18
Sub idler gear and oil pump drive gear 0.080 to 0.417
19
Sub idler gear and water pump drive

gear
0.095 to 0.346
20
Cam gear and air conditioner drive

gear
0.118 to 0.369
Replace bushing
Replace thrust
bearing
Repair limit
Replace
0.6
57
SEN00081-08
Valve system
58
140E-5 Series
A:
Lubricating oil inlet
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.

Thrust plate
Camshaft
Cam roller
Cam roller pin
Cam follower shaft
Cam follower
Push rod
Rocker arm shaft
Locknut
Rocker arm adjustment screw
Rocker arm
Crosshead adjustment screw
Locknut
Crosshead
Valve retainer
Outer valve spring
Inner valve spring
Air intake valve
Valve guide
Spring seat
Exhaust valve
SEN00081-08
Valve timing
Specifications
Camshaft: Drawn steel bar (turning)
Journal and cam sections:
Induction hardening
140E-5 Series
59
SEN00081-08
Valve and valve guide
60
140E-5 Series
SEN00081-08
Unit: mm
No.
1
Check item
Sinking distance of valve
Criteria
Valve
Standard dimension
Tolerance
Repair limit
Intake
0.10
0.70
Exhaust
0.10
Valve
Remedy
Thickness of valve lip
0.70
Standard dimension
Repair limit
Intake
2.4
1.9
Exhaust
2.15
1.75
Valve
Standard dimension
Tolerance
Intake
30 deg.
15 min.
Exhaust
45 deg.
15 min.
Intake
10
0.045
0.060
Exhaust
10
0.074
0.089
Before head is press

fitted
10
+0.019
+0.001
Standard dimension
Tolerance
Valve seat angle
Diameter of valve stem
After head is press fitted
Clearance between valve guide

and stem
Bend of valve stem
+0.008
0.009
(Press fitted part)
Inside diameter of valve guide

10
+0.011
0.009
(Other than press
fitted part)
Valve
Standard clearance
Allowable clearance
Intake
0.036 to 0.068
0.22
Exhaust
0.065 to 0.097
0.24
Repair limit: 0.02 (Overall swing of indicator in 100)
Driving height of valve guide
Standard
Tolerance
22.0
0.2
Spring
Standard dimension
Repair limit
Outer
81.7
Inner
72.0
Spring Installed length
Standard installed
load(N{kg})
Allowable installed
load(N{kg})
377.3
{38.5}
192.1
{19.6}
Free length of valve spring
6
Installed load of valve spring
Perpendicularity of valve spring
140E-5 Series
Outer
51.0
424.321.6
{43.32.2}
Inner
46.0
215.610.8
{22.01.1}
Replace valve or valve

seat
Replace valve
Correct or replace valve

or valve seat
Replace valve
Replace valve guide
Replace valve or valve

guide
Replace valve
Correct
Replace valve spring
Repair limit: 2 deg. (both sides)
61
SEN00081-08
Rocker arm and shaft
Unit: mm
No.
Check item
Diameter of rocker arm shaft
62
Valve clearance (when cold)
Tightening torque for locknut of

rocker arm adjustment screw
Remedy
Tolerance
32.0
0.0065
32.0
+0.087
+0.035
Standard clearance
Allowable clearance
0.0285 to 0.0935
0.13
Inside diameter of rocker arm

bushing
Clearance between rocker arm
shaft and rocker arm
Criteria
Standard dimension
Valve
Standard
Tolerance
Intake
0.35
0.02
Exhaust
0.57
0.02
Target(Nm{kgm})
Range(Nm{kgm})
58.8{6}
52.9 to 64.7{5.4 to 6.6}
Replace rocker arm shaft

Replace rocker arm
Replace rocker arm shaft
or rocker arm
Adjust
Tighten
140E-5 Series
Crosshead and guide
SEN00081-08
Unit: mm
No.
1
Check item
Depth of crosshead stem
receiver
Inside diameter of crosshead
Criteria
Remedy
Standard dimension
Tolerance
Repair limit
6.2
+0.3
+0.3
6.61
11.04
0.02
11.17
Outside diameter of crosshead

guide
11
+0.011
+0.011
10.95
Projection of crosshead guide
49.0
0.25
140E-5 Series
Replace
Correct
63
SEN00081-08

2012 KOMATSU
All Rights Reserved
64
SEN00082-06
ENGINE
1SHOP MANUAL
140E-5 Series
10 Structure, function and

maintenance standard

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
SEN00082-06
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
140E-5 Series
140E-5 Series
SEN00082-06
SEN00082-06
Lubrication system
Lubrication system diagram
(With EGR)
The layout of the oil filter, shapes of the oil pan and piping, etc. are subject to machine models.
140E-5 Series
SEN00082-06
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
SEN00082-06
(EGR-less)
The layout of the oil filter, shapes of the oil pan and piping, etc. are subject to machine models.
140E-5 Series
SEN00082-06
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
19. Main gallery
140E-5 Series
SEN00082-06
Oil pump
A: From oil pan

B: To oil cooler
C: Rotation direction
D: Pump mounting face
Specifications
Oil pump
Type: Gear pump
Revolving speed: Engine speed 1.8
1. Pump cover
2. Drive gear
3. Pump body
4. Pump drive gear (Number of teeth: 20)
5. Driven gear
6. Main relief valve
7. Main valve spring
8. Sub relief valve
9. Sub valve spring
Main relief valve

Cracking pressure:
600 50 kPa {6.0 0.5 kg/cm2}

Sub relief valve
Cracking pressure:
1,000 50 kPa {10.0 0.5 kg/cm2}
140E-5 Series
SEN00082-06
EGR oil pump
A: From main gallery

B: To EGR valve and bypass valve
1. Pump cover
2. Drive gear
3. Pump body
4. Driven gear
5. Pump drive gear (Number of teeth: 22)
6. Main relief valve
7. Main valve spring
8. Sub-relief valve
9. Sub-valve spring
140E-5 Series
Specifications
Oil pump
Type: Gear pump
Revolving speed: Engine speed 1.09
Main relief valve
Cracking pressure:
1,430 100 kPa {14.6 1.0 kg/cm2}
Sub-relief valve
Cracking pressure:
1,800 150 kPa {18.4 1.5 kg/cm2}
SEN00082-06
Oil filter
Except SDG400S-6B1 (HOKUETSU INDUSTRIES GENERATOR)
A: Oil inlet
B: Oil outlet
1. Safety valve
2. Filter head
3. Cartridge
10
Specifications
Oil filter
Filtration area: 0.44 m2 (full flow)
Safety valve
Cracking pressure: 343 19.6 kPa {3.5 0.2 kg/cm2}
140E-5 Series
SEN00082-06
For SDG400S-6B1 (HOKUETSU INDUSTRIES GENERATOR)
A: Oil inlet
B: Oil outlet
1. Safety valve
2. Filter head
3. Cartridge
4. Clogging switch
Specifications
Oil filter
Filtration area: 0.44 m2 (full flow)
Safety valve
Cracking pressure: 343 19.6 kPa {3.5 0.2 kg/cm2}
Clogging switch
q
Operating differential pressure:
+0.4
2
147 +39
+0 kPa {1.5 +0 kg/cm }
q
Contact type: NO (Normal Open)
140E-5 Series
11
SEN00082-06
Oil cooler
12
140E-5 Series
SEN00082-06
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 1.5C
Full opening temperature: 100C
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
No.
Check item
Criteria
Remedy
Lift of thermostat at full opening Min. 8 mm (Before checking, leave valve in oil of 100C for 4 to 5 minutes)
Opening/Closing of thermostat
140E-5 Series
Check that valve closes fully when its temperature is lowered from 100C Replace
for full opening to 85C. (Before checking valve, leave it in oil for 4 to 5
minutes)
13
SEN00082-06
Fuel system
CRI system diagram
(With EGR)
CRI is an abbreviation for common rail injection.
1. NE speed sensor
2. Engine controller
3. Injector
4. Fuel cooler
5. Fuel tank
6. Pre-fuel filter
7. Main fuel filter
8. Overflow valve
9. Fuel supply pump
9A. PCV
9B. High-pressure pump
14
9C. Priming pump (sub)

9D. Feed pump
9E. Relief valve
9F. Bkup speed sensor (G sensor)
10. Common rail
11. High-pressure injection pipe
12. Flow damper
13. Pressure limiter
14. Priming pump (main)
15. Engine controller cooler
140E-5 Series
SEN00082-06
(EGR-less)
CRI is an abbreviation for common rail injection.
1. NE speed sensor
3. Injector
4. Fuel cooler
5. Fuel tank
6. Pre-fuel filter
7. Main fuel filter (double cartridges)
a Single cartridge is set for some models.
8. Overflow valve
9. Fuel supply pump
9A. PCV
9B. High-pressure pump
140E-5 Series
9C. Priming pump

9D. Feed pump
9E. Relief valve
9F. Bkup speed sensor (G sensor)
10. Common rail
11. High-pressure injection pipe
12. Flow damper
13. Pressure limiter
14. Electric priming pump
a Manual priming pump is set for some models.
15
SEN00082-06
Outline of CRI system

Outline
q
The CRI system checks the condition of the
engine (engine speed, accelerator angle, coolant 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 function which stops the engine when a certain
parts fail and a backup function which continues 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})
1
1. Fuel system
Configuration
The CRI system is divided by the function into
the fuel system and control system.
16
The fuel system distributes the high-pressure

fuel supplied by the fuel supply pump to the
cylinders through the common rail.
The solenoid valve in the injector opens and
closes the nozzle needle valve to start and finish injection.
140E-5 Series
SEN00082-06
2. Control system
Parts marked with * (2 places) are installed to only the engines with EGR.
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 quantity of fuel in proper timing.
The control system is roughly divided by the
electric parts into the sensors, computer, and
actuators.
140E-5 Series
17
SEN00082-06
Structure and operation of CRI system
18
The CRI system consists of the fuel supply

pump, common rail, injector, engine controller
to control them, and sensors.
The fuel supply pump generates fuel pressure
in the common rail. The fuel pressure is controlled by the fuel discharge rate of the supply
pump.
The discharge rate is controlled by turning on
and off the PCV (pressure control valve) of the
fuel supply pump according to the electric signals from the engine controller.
The common rail receives the pressurized fuel
from the fuel supply pump and distributes it to
the cylinders.
The fuel pressure is sensed by the common
rail fuel pressure sensor installed to the common rail.
A feedback control is applied so that the actual
fuel pressure will match to the command pressure set according to the engine speed and the
load on the engine.
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.
The injector controls the fuel injection rate and
fuel injection timing by turning on and off the
TWV (2-way solenoid valve).
If the TWV is turned on (energized), the fuel

circuit is so changed that the high-pressure
fuel in the control chamber will flow through the
orifice. As a result, the needle valve is raised
to start fuel injection by the nozzle cracking
pressure of the high-pressure fuel on the nozzle side.
If the TWV is turned off (de-energized), the fuel
circuit is so changed that the high-pressure
fuel will be applied to the control chamber
through the orifice. As a result, the needle
valve lowers and finishes fuel injection.
Accordingly, the fuel injection timing and fuel
injection rate are controlled respectively by the
timing to turn on the TWV and the length of the
turn-on time of the TWV.
140E-5 Series
SEN00082-06
Structure and operation of component parts
1. Fuel supply pump
1. 3-head cam
2. Overflow valve
3. Drive gear
4. No. 1 high-pressure pump
5. PCV (pressure control valve)
6. No. 2 high-pressure pump

7. Priming pump
8. Feed pump
9. Gear for Bkup speed sensor (G sensor)
Outline
q
The fuel supply pump consists of priming
pump (7), feed pump (8), and high-pressure
pumps (4) and (6).
q
The function of the fuel supply pump is to generate common rail fuel pressure by controlling
the fuel delivery.
Structure
High-pressure pumps (4) and (6) have the
pressure feed systems similar to those of the
conventional in-line fuel injection pump and the
PCVs (pressure control valves) for each cylinder to control the fuel delivery.
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.
q
140E-5 Series
q
q
Since the number of the times of feeding fuel

to the common rail is the same as the number
of the times of fuel injection, the common rail
fuel pressure is smooth and stable.
The fuel fed by high-pressure pumps (4) and
(6) to the common rail is divided as follows.
No. 1 high-pressure pump (on the drive gear
side) (4) compensates for drop in the common
rail fuel pressure caused by fuel injection into
the No. 1, 3, and 5 cylinders.
No. 2 high-pressure pump (on the feed pump
side) (6) compensates for drop in the common
rail fuel pressure caused by fuel injection into
the No. 2, 4, and 6 cylinders.
19
SEN00082-06
Operation
20
(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.
(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.
(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.
(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 deenergized, it opens and the low-pressure
fuel is sucked in the plunger chamber, or
the state of (A) starts again.
140E-5 Series
1) PCV (pressure control valve)

q
The PCV adjusts the fuel delivery from the fuel
supply pump to adjust the common rail fuel
pressure. The delivery from the fuel supply
pump to the common rail is decided by the timing of energizing the PCV.
140E-5 Series
SEN00082-06
2) Feed pump
q
The feed pump built in the fuel supply pump
assembly draws the fuel from the fuel tank and
sends it through the fuel filter to the high-pressure pump chamber.
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.
21
SEN00082-06
2. Common rail
Structure
q
Common rail (4) distributes the high-pressure
fuel from the high-pressure pump to the injectors of the cylinders.
q
Common rail (4) is equipped with common rail
fuel pressure sensor (2), flow dampers (1), and
pressure limiter (3).
q
The fuel injection pipes are connected to flow
dampers (1) to send the high-pressure fuel to
the injectors.
q
The piping of the pressure limiter (3) is
returned to the fuel tank.
When fuel is stopped

q
If the fuel flows out abnormally because of a
burst of the piping, etc., piston (2) moves to the
right stroke end.
q
The tip of piston (2) contacts seat (b) to stop
the fuel.
q
Once the fuel is stopped, piston (2) does not
return to the initial position until the engine is
stopped.
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
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.
q
22
140E-5 Series
2) Pressure limiter
q
If abnormally high pressure is generated, the
pressure limiter opens to release that pressure.
q
If the common rail fuel pressure reaches about
200 MPa {2,040 kg/cm2}, the pressure limiter
operates (opens).
q
If the common rail fuel pressure lowers to 30
MPa {310 kg/cm2}, the pressure limiter resets
itself (closes) to maintain the pressure.
q
Under the normal condition, the pressure limiter does not reset itself (close) until the engine
is stopped.
SEN00082-06
3) Common rail fuel pressure sensor

q
The common rail fuel pressure sensor is
installed to the common rail to sense the fuel
pressure.
q
This sensor is a semiconductor pressure sensor, which utilizes the phenomenon that the
electric resistance of silicon changes according
to pressure applied to it.
1. Ball
2. Housing
3. Spring
4. Guide
5. Body
140E-5 Series
23
SEN00082-06
3. Injector
Outline
q
The function of the injector is to inject the highpressure fuel from the common rail into each
combustion chamber of the engine in the optimum 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 nozzle and controls the fuel injection rate.
q
The hydraulic piston transmits the force generated by the pressure in the control chamber to
the needle valve of the nozzle.
q
The nozzle sprays the fuel.
24
140E-5 Series
SEN00082-06
Structure
1. Inlet connector
2. Terminal
3. Upper body
4. Solenoid
5. Valve body
6. Orifice (out)
q
7. Orifice (in)
8. Pressure control chamber
9. Control piston
10. Spring
11. Pressure pin
12. Nozzle assembly
The injector consists of the nozzle section, orifice to control the fuel injection rate, hydraulic
piston section, and 2-way solenoid valve section.
140E-5 Series
25
SEN00082-06
A: No fuel injection
B: Start of fuel injection
C: Finish of fuel injection

D: From common rail
1. Nozzle
2. Control piston
3. Orifice (in)
4. Orifice (out)
5. Valve body
6. Solenoid
7. Spring
8. Pressure control chamber
Operation
1) No fuel injection (A)
q
While solenoid (6) is not energized, valve body
(5) is pressed down by spring (7).
q
Since the high-pressure fuel is applied from
the common rail to pressure control chamber
(8), nozzle (1) is closed and the fuel is not
injected.
3) Finish of fuel injection (C)

q
If solenoid (6) is de-energized, valve body (5)
is lowered by spring (7) and the fuel passage is
closed.
q
At this time, the high-pressure fuel in the common rail is applied to pressure control chamber
(8) suddenly and nozzle (1) is closed quickly,
fuel injection is finished sharply.
2) Start of fuel injection (B)

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 injection rate is increased to the maximum.
q
26
140E-5 Series
SEN00082-06
Electric circuit diagram
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
SEN00082-06
28
140E-5 Series
SEN00082-06
Various controls
Parts marked with * (3 places) are installed to only the engines with EGR.
The CRI system controls the fuel injection rate

and fuel injection timing more properly than the
mechanical governor or timer of the conventional fuel injection pump.
For the control of the system, calculations necessary to the engine controller are performed
fr om th e si gn als se nt fr om the s en so rs
installed to the engine and machine.
The energizing timing and energizing period of
the injector are so controlled that the optimum
quantity of fuel will be injected in the optimum
timing.
2. Fuel injection timing control function

q
3. Fuel injection pressure control function (Common rail fuel pressure control
function)
q
1. Fuel injection rate control function

q
The fuel injection rate control function is

employed instead of the function of the conventional governor. It controls the fuel injection
according to the signals of engine speed and
accelerator angle so that the fuel injection rate
will be most proper.
140E-5 Series
The fuel injection timing control function is

employed instead of the function of the conventional timer. It controls the fuel injection
timing most properly from the engine speed
and fuel injection rate.
The fuel injection pressure control function

(common rail fuel pressure control function) is
a function of measuring the fuel pressure with
the common rail fuel pressure sensor and
feeding it back to the engine controller to control the delivery of the fuel supply pump.
This function performs pressure feedback control so that the fuel injection pressure will be
the same as the optimum value (command
value) set according to the engine speed and
fuel injection rate.
29
SEN00082-06
4. Various sensors and relays
a
a
a
30
Nos. 1 to 13 in the above illustration correspond to title Nos. 1) to 13).

The above illustration shows the engine for HD325-7.
Parts *1, *3 and *4 are installed to only the engines with EGR.
140E-5 Series
140E-5 Series
SEN00082-06
31
SEN00082-06
1) EGR inlet pressure sensor (with EGR)

q
This sensor is used to sense the EGR pressure.
2) Fuel temperature sensor

q
32
The fuel temperature sensor senses the fuel

temperature and sends it to the engine controller. The sensor unit is a thermistor the resistance of which changes according to the
temperature.
The engine controller applies voltage to the
thermistor and senses the temperature by the
voltage divided by the resistance in the computer and the resistance of the thermistor.
The following graph shows the output characteristics of the EGR inlet pressure sensor.
140E-5 Series
SEN00082-06
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

q
The following graph shows the output characteristics of the position sensor.
140E-5 Series
33
SEN00082-06
5) Engine controller
7) Atmospheric pressure sensor

This sensor is used to correct altitude.
(with EGR)
6) NE speed sensor (crank angle sensor)

q
q
If the signal hole made on the flywheel passes

the sensor, the magnetic line of force changes.
If the magnetic line of force changes, the output 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}
q
34
The following graph shows the output characteristics of the atmospheric pressure sensor.
140E-5 Series
SEN00082-06
(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.
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.
In addition to the above teeth, one more tooth
is installed. Accordingly, 7 pulses are generated every 2 revolutions of the engine.
The standard pulse of the No. 1 cylinder is recognized 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}
q
The following graph shows the output characteristics of the atmospheric pressure sensor.
8) Common rail pressure sensor

9) Oil pressure sensor
140E-5 Series
35
SEN00082-06
11) Charge pressure sensor
(EGR-less)
This sensor is used to sense the charge pressure (boost pressure).

(with EGR)
1. Sensor
2. O-ring
q
The following graph shows the output characteristics 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
q
36
The following graph shows the output characteristics of the charge pressure sensor.
140E-5 Series
12) Charge temperature sensor

q
The charge temperature sensor senses the

intake air temperature (boost temperature) and
sends it to the engine controller.
The sensor unit is a thermistor the resistance
of which changes according to the temperature. The engine controller applies voltage to
the thermistor and senses the temperature by
the voltage divided by the resistance in the
computer and the resistance of the thermistor.
140E-5 Series
SEN00082-06
13) Coolant temperature sensor

q
The coolant temperature sensor senses the

coolant temperature and sends it to the engine
controller.
The sensor unit is a thermistor the resistance
of which changes according to the temperature. The engine controller applies voltage to
the thermistor and senses the temperature by
the voltage divided by the resistance in the
computer and the resistance of the thermistor.
37
SEN00082-06
Fuel piping
(with EGR)
a
a

Specifications
Fuel supply pump
Manufacturer: DENSO CORPORATION
Model: DENSO ECD-U2
Lubrication method:
Forced lubrication with engine oil
38
A: Fuel inlet
B: To engine controller cooler
C: To main fuel filter
D: From main fuel filter
E: To injector
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)
140E-5 Series
a
a
SEN00082-06

1. Fuel injection pipe (No. 1 cylinder)

7. Common rail
8. Fuel return pipe
9. Priming pump (sub)
10. Feed pump
140E-5 Series
11. Oil inlet pipe (for pump lubricating oil)

13. Drive gear (Number of teeth: 48)
14. Overflow valve
15. PCV
16. Priming pump (main)
17. Pre-fuel filter
18. Main fuel filter
39
SEN00082-06
(EGR-less)
a
a
The above illustration shows the engine for D275A-5R.

Specifications
Fuel supply pump
Manufacturer: DENSO CORPORATION
Model: DENSO ECD-U2
Lubrication method:
Forced lubrication with engine oil
40
A: Fuel inlet
B: To engine controller cooler
C: To main fuel filter
D: From main fuel filter
E: To injector
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)
140E-5 Series
a
a
SEN00082-06
The above illustration shows the engine for D275A-5R.


7. Common rail
8. Fuel return pipe
9. Priming pump
10. Feed pump
140E-5 Series
11. Oil inlet pipe (for pump lubricating oil)

13. Drive gear (Number of teeth: 48)
14. Overflow valve
15. PCV
a Manual priming pump is set for some models.
(See the "with EGR".)
17. Pre-fuel filter
18. Main fuel filter (double cartridges)
19. Air bleeding valve for electric priming pump
41
SEN00082-06
Fuel cooler
(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
SEN00082-06
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
SEN00082-06
(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
SEN00082-06
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
SEN00082-06
Priming pump
(with EGR)
1. Spring
2. Cover
3. Shaft
4. Bushing
5. Diaphragm
6. Diaphragm cover
7. Body
8. Check valve
46
9. Valve stopper
10. Packing
11. Check valve body
12. Lever pin
13. E-ring
14. Washer
15. Bolt
16. Lever
140E-5 Series
Electric priming pump
SEN00082-06
(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
SEN00082-06
Engine controller cooler
A: Fuel IN (from feed pump of fuel supply pump)

B: Fuel OUT (main fuel filter)
Outline
q
The fuel is circulated as refrigerant through
engine controller cooler (2) to prevent engine
controller (1) from overheating.
48
140E-5 Series
SEN00082-06
Cooling system
Cooling system diagram
SAA6D140E-5 (For construction machinery)

1. Hydraulic cooling fan (With EGR)
(PC600-8, PC600LC-8, PC600-8E0, PC600LC-8E0, PC700-8E0, PC700LC-8E0, PC8008, PC800SE-8, PC850-8, PC850SE-8, PC800LC-8, PC800-8E0, PC800SE-8E0, PC8508E0, PC850SE-8E0, PC800LC-8E0, D155AX-6, D275AX-5E0, WA500-6, HM400-3M0)
A: Oil inlet
B: Oil outlet
C: Exhaust gas inlet
D: Exhaust gas outlet
1. Radiator
2. Thermostat
3. Oil cooler
4. Water pump
5. EGR cooler
140E-5 Series
6. Corrosion resistor
a Corrosion resistor is not set for some models.
7. Hydraulic cooling fan
8. Hydraulic fan motor
49
SEN00082-06
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
6. Hydraulic cooling fan
7. Hydraulic fan motor
50
140E-5 Series
SEN00082-06
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
C: Exhaust gas inlet
D: Exhaust gas outlet
1. Radiator
2. Thermostat
3. Oil cooler
4. Water pump
5. EGR cooler
7. Engine-driven cooling fan
140E-5 Series
51
SEN00082-06
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
SEN00082-06
53
SEN00082-06
Water pump
SAA6D140E-5
54
140E-5 Series
SEN00082-06
A: From radiator
B: To oil cooler
D: Pump mounting face
1. Alternator drive pulley
2. Oil seal
3. Ball bearing
4. Pump shaft
5. Water pump drive gear (Number of teeth: 23)
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
No.
10
Check item
Interference between impeller and
shaft
Criteria
Standard
dimension
Remedy
Tolerance
Shaft
Hole
16
0.082
0.095
0.120
0.150
0.025 to 0.068
11
Interference between drive gear and

shaft
28
+0.015
+0.002
0.023
0.055
0.025 to 0.070 Replace
12
Interference between flange and shaft
25
+0.015
+0.002
0.023
0.053
0.025 to 0.068
13
14
Clearance between impeller and body

Wear of water seal ring
140E-5 Series
Standard clearance: 0.6 to 0.9 (including end play)

Limits of size: 1.5
55
SEN00082-06
Water pump mounting
SAA6D140E-5
a
a

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
SEN00082-06
Thermostat
A: To radiator inlet
B: From radiator outlet
1. Thermostat housing
2. Thermostat
Specifications
Opening temperature: 76.5 2C
Full opening temperature: 90C
Lift at full opening: Min. 9 mm
Unit: mm
No.
Check item
Lift of thermostat at full opening
Criteria
Min. 9 mm (Before checking, leave valve in water of 90C for 4 to 5 minutes)
Check that valve closes fully when its temperature is lowered from 90C
Opening/Closing of thermostat
140E-5 Series
Remedy
Replace
for full opening to 76.5C. (Before checking valve, leave it in water for 4 to
5 minutes)
57
SEN00082-06
Corrosion resistor
a
a

Corrosion resistor is not set for some models.
A: Coolant inlet
B: Coolant outlet
1. Head
2. Cartridge
3. Element
4. Inhibitor (solid anti-corrosion agent)
5. Spring
6. Stop valve
58
Specifications
Filtration area
Quantity of anti-corrosion
agent
0.13m2
0.19m2
0.37m2
400g
600g
1,000g
140E-5 Series
SEN00082-06
Corrosion resistor mounting
a
a

Corrosion resistor is not set for some models.
1. Tube (return from corrosion resistor)

2. Corrosion resistor head
3. Corrosion resistor cartridge
4. Tube (to corrosion resistor)
140E-5 Series
59
SEN00082-06
Cooling fan drive
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
2. Tension pulley
3. Adjustment bolt
4. Fan belt
5. Fan pulley
Outside diameter of pulley

Unit: mm
Engine
SAA6D140E-5
60
Machine model
Crankshaft pulley
Tension pulley
Fan pulley
HD325-7, HD405-7,
HD325-7R, HD405-7R
166
120
322
HM350-2, HM350-2R
166
120
262
HM400-2, HM400-2R
166
120
262
SDG400S-6B1
203
120
277
140E-5 Series
SEN00082-06
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
SEN00082-06
Fan mounting case

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

2. Ball bearing
3. Shaft
4. Case
62
140E-5 Series
SEN00082-06
Accessories
Front PTO
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
SEN00082-06
Front PTO mounting
1. Front PTO (for driving air conditioner compressor)

2. O-ring
64
140E-5 Series
SEN00082-06
Electrical equipment
Alternator
1. Alternator with built-in regulator (open type, 35 A)
1. Alternator
2. Alternator pulley
3. Terminal B
4. Terminal E
5. Terminal R
140E-5 Series
6. Internal electric circuit diagram

6A. Field coil
6B. Regulator
65
SEN00082-06
1. Alternator
3. Terminal B
4. Terminal E
5. Terminal R
66

6A. Field coil
6B. Initial excitation resistor
6C. Regulator
140E-5 Series
SEN00082-06
1. Alternator
3. Terminal B
4. Terminal E
5. Terminal R
140E-5 Series

6A. Stator
6B. Regulator
67
SEN00082-06
1. Alternator
3. Terminal B
4. Terminal E
5. Terminal R
68

6A. Field coil
6C. Regulator
140E-5 Series
Engine
Machine model
Type
Specification
Open type (brushless)

manufactured by NIKKO DENKI
24V, 60A
PC800-8, PC800LC-8, PC800-8R,

PC800LC-8R, PC800SE-8,
PC800SE-8R
PC850-8, PC850-8R, PC850SE-8,
PC850SE-8R
PC800-8E0, PC800SE-8E0,
PC850-8E0, PC850SE-8E0,
PC800LC-8E0
PC800-8R1, PC800SE-8R1
PC850-8R1, PC850SE-8R1
PC800LC-8R1
24V, 60A
D155AX-6, D155A-6

24V, 60A
HD325-7, HD325-7R
HD405-7, HD405-7R

24V, 60A
HM350-2, HM350-2R
HM400-2, HM400-2R
HM400-3M0, HM400-3R

24V, 60A
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
SAA6D140E-5
SEN00082-06
140E-5 Series
Outside diameter
Weight (kg)
of pulley (mm)
69
SEN00082-06
1. Alternator
3. Terminal B
4. Terminal E
5. Terminal R
Engine
SAA6D140E-5
70
Machine model

6A. Stator
6B. Regulator
Type
Specification
D155AX-6, D155A-6
(If equipped)
Open type (brushless) manufactured

by SAWAFUJI DENKI
24V, 75A
D275AX-5E0,
D275A-5R

by SAWAFUJI DENKI
24V, 75A
WA500-6, WA500-6R

by SAWAFUJI DENKI
24V, 75A
HD325-7, HD325-7R
HD405-7, HD405-7R
(If equipped)

by SAWAFUJI DENKI
24V, 75A
HM350-2, HM350-2R
HM400-2, HM400-2R
HM400-3M0, HM400-3R by SAWAFUJI DENKI
(If equipped)
24V, 75A
Outside diameter of
pulley (mm)
Weight (kg)
140E-5 Series
140E-5 Series
SEN00082-06
71
SEN00082-06
1. Alternator
3. Terminal B
4. Terminal E
5. Terminal R
72

6A. Field coil
6C. Regulator
140E-5 Series
Engine
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
(If equipped)
PC800-8, PC800LC-8, PC800-8R,
PC800LC-8R, PC800SE-8,
PC800SE-8R
PC850-8, PC850-8R
PC800-8E0, PC800SE-8E0,
PC850-8E0, PC850SE-8E0,
PC800LC-8E0
PC800-8R1, PC800SE-8R1
PC850-8R1, PC850SE-8R1
PC800LC-8R1
(If equipped)
D155AX-6, D155A-6
(If equipped)
D275AX-5E0, D275A-5R
(If equipped)
WA500-6, WA500-6R
(If equipped)
140E-5 Series
SEN00082-06
Type
Specification

24V, 90A

24V, 90A

Outside diameter
Weight (kg)
of pulley (mm)
24V, 90A
24V, 90A
24V, 90A
73
SEN00082-06
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
SEN00082-06
75
SEN00082-06
Starting motor
For 7.5kW (for SDG400S-6B1 (HOKUETSU INDUSTRIES GENERATOR))
E: To chassis ground
R: To alternator terminal R
S: To starting switch terminal C
5. Terminal C
6. Safety relay
7. External connection diagram
(2-pole connector type)
7A. Safety relay section
7B. Starting motor section
8. Jump start prohibition label
9. Jump start prevention cover
1. Pinion gear
2. Starting motor assembly
3. Magnetic switch
4. Terminal B
Engine
Machine model
SDG400S-6B1
(HOKUETSU
SAA6D140E-5
INDUSTRIES
GENERATOR)
76
Type
Specification
Number of
pinion teeth
Weight (kg)
Type of
connector
Water-resistant, oil-resistant
type manufactured by
NIKKO DENKI
24V, 7.5kW
12
15.5
DT
140E-5 Series
SEN00082-06
For 11kW (except SDG400S-6B1 (HOKUETSU INDUSTRIES GENERATOR))
E: To chassis ground
R: To alternator terminal R
S: To starting switch terminal C
5. Terminal C
6. Safety relay
7. External connection diagram
(2-pole connector type)
7A. Safety relay section
7B. Starting motor section
8. Jump start prohibition label
9. Jump start prevention cover
1. Pinion gear
3. Magnetic switch
4. Terminal B
Engine
SAA6D140E-5
Machine model
All machines
140E-5 Series
Type
Specification
Number of
pinion teeth
Weight (kg)
Type of
connector
Water-resistant, oil-resistant
type manufactured by
NIKKO DENKI
24V, 11kW
12
18
DT
77
SEN00082-06
Starting aid
Electric heater
For SAA6D140E-5
1. Body
2. Heater coil
3. Terminal
4. Connection diagram
78
Specifications
Type of heater: Electrical intake air heater
q
Rated voltage: 22 V (DC)
q
Load current: 175 A
140E-5 Series
Engine controller
SEN00082-06
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
Engine controller CM850 developed by the
cooperation between KOMATSU and CUMMINS is employed.
140E-5 Series
79
SEN00082-06

2012 KOMATSU
All Rights Reserved
80
SEN00147-07
ENGINE
1SHOP MANUAL
140E-5 Series
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
SEN00147-07
Air intake and exhaust system
Performance Category
Standard service value table for testing, adjusting, and troubleshooting
Body
Lubrication system
Cooling system
SAA6D140E-5
Machine models
D155AX-6
Unit
Standard value for

new machine
Repair limit
rpm
2,100(0/50)
2,100(0/50)
rpm
740(+40/0)
740(+40/0)
Necessary speed for

starting
At 0C (without starting aid)
rpm
Min. 110
At 20C (with starting aid)
rpm
Min. 85
Air intake resistance
Whole speed range
kPa
{mmH2O}
Max. 3.73
{Max. 380}
7.47
{762}
Air boost pressure
At rated horsepower
kPa
{mmHg}
Min. 117
{Min. 880}
100
{750}
Exhaust pressure
At rated horsepower
kPa
{mmHg}
Min. 127
{Min. 950}
108
{810}
Exhaust temperature
Whole speed range (20C)
660
700
% (Bosch
index)
Max. 25
(Max. 2.5)
35
(3.5)
At rated horsepower
Bosch
index
Max. 1.5
2.5
At high idle
Bosch
index
Max. 1.0
2.0
Intake valve
mm
0.35
Exhaust valve
mm
0.57
At low idle
MPa
{kg/cm2}
Min. 1.18
{Min. 12}
Min. 1.18
{Min. 12}
At high idle
MPa
{kg/cm2}
Min. 1.43
{Min. 14.6}
Min. 1.43
{Min. 14.6}
Compression pressure
Engine oil temperature: 40 to 60C

Engine speed: 200 to 250 rpm
MPa
{kg/cm2}
Min. 4.1
{Min. 42}
2.8
{29}
Blow-by pressure
At rated horsepower
Engine coolant temperature: Min. 70C
kPa
{mmH2O}
Max. 2.94
{Max. 300}
3.92
{400}
Min. 0.34
{Min. 3.5}
0.21
{2.1}
Oil pressure
At rated horsepower
MPa
Engine oil temperature: SAE0W30EOS
2
}
{kg/cm
SAE5W40EOS
Min. 80C
SAE10W30DH
At low idle
SAE15W40DH
MPa
Engine oil temperature: SAE30DH
{kg/cm2}
Min. 80C
Min. 0.10
{Min. 1.0}
0.08
{0.8}
Item
Speed
Measurement conditions
At sudden acceleration (Low High)

Exhaust gas color
Valve clearance
EGR valve and bypass

valve drive oil pressure
Engine
Oil temperature
Whole speed range
90 to 110
120
Oil consumption
Ratio to fuel consumption at continuous

rated horsepower
Max. 0.15
0.3
Function of radiator
pressure valve
Cracking pressure
(Differential pressure)
kPa
{kg/cm2}
Fan speed
At rated speed
rpm
Hydraulically driven on machine side
Fan belt tension
Deflection under finger pressure of 98 N

{10 kg}
mm
Alternator belt tension

{10 kg}
mm
13 to 16
13 to 16
140E-5 Series
Body
Lubrication system
Engine
SAA6D140E-5
Machine models
D155A-6
Unit
Standard value for

new machine
Repair limit
rpm
2,100(0/50)
2,100(0/50)
rpm
740(+40/0)
740(+40/0)
Necessary speed for

starting
rpm
Min. 110
rpm
Min. 85
Whole speed range
kPa
{mmH2O}
Max. 3.73
{Max. 380}
7.47
{762}
Air boost pressure
At rated horsepower
kPa
{mmHg}
Min. 85
{Min. 640}
72
{540}
Exhaust pressure
At rated horsepower
kPa
{mmHg}
Min. 92
{Min. 690}
77
{580}
Exhaust temperature
670
720
% (Bosch
index)
Max. 30
(Max. 3.0)
40
(4.0)
At rated horsepower
Bosch
index
Max. 1.5
2.5
At high idle
Bosch
index
Max. 1.0
2.0
Item
Speed

Exhaust gas color
Valve clearance
Cooling system
SEN00147-07
Intake valve
mm
0.35
Exhaust valve
mm
0.57

MPa
{kg/cm2}
Min. 4.1
{Min. 42}
2.8
{29}
Blow-by pressure
At rated horsepower
kPa
{mmH2O}
Max. 2.94
{Max. 300}
3.92
{400}
Min. 0.34
{Min. 3.5}
0.21
{2.1}
Oil pressure
At rated horsepower
MPa
{kg/cm2}
SAE5W40EOS
Min. 80C
SAE10W30DH
At low idle
SAE15W40DH
MPa
{kg/cm2}
Min. 80C
Min. 0.10
{Min. 1.0}
0.08
{0.8}
Oil temperature
Whole speed range
90 to 110
120
Oil consumption

rated horsepower
Max. 0.15
0.3
pressure valve
Cracking pressure
kPa
{kg/cm2}
Fan speed
At rated speed
rpm
Fan belt tension

{10 kg}
mm

{10 kg}
mm
140E-5 Series
13 to 16
13 to 16
SEN00147-07
Body
Lubrication system
Cooling system
Engine
SAA6D140E-5
Machine models
D275AX-5E0
Unit
Standard value for

new machine
Repair limit
rpm
2,200 50
2,200 50
rpm
700 50
700 50
Necessary speed for

starting
rpm
Min. 110
rpm
Min. 85
Whole speed range
kPa
{mmH2O}
Max. 3.73
{Max. 380}
7.47
{762}
Air boost pressure
At rated horsepower
kPa
{mmHg}
Min. 169
{Min. 1,270}
144
{1,080}
Exhaust pressure
At rated horsepower
kPa
{mmHg}
Min. 169
{Min. 1,270}
144
{1,080}
Exhaust temperature
Item
Speed
Max. 620
670
% (Bosch
index)
Max. 25
(Max. 2.5)
35
(3.5)
At rated horsepower
Bosch
index
Max. 1.5
2.5
At high idle
Bosch
index
Max. 1.0
2.0
Intake valve
mm
0.35

Exhaust gas color
Valve clearance
mm
0.57
At low idle
MPa
{kg/cm2}
Min. 1.18
{Min. 12}
Min. 1.18
{Min. 12}
At high idle
MPa
{kg/cm2}
Min. 1.43
{Min. 14.6}
Min. 1.43
{Min. 14.6}

MPa
{kg/cm2}
Min. 4.1
{Min. 42}
2.8
{29}
Blow-by pressure
At rated horsepower
kPa
{mmH2O}
Max. 2.94
{Max. 300}
3.92
{400}
Min. 0.34
{Min. 3.5}
0.21
{2.1}
Oil pressure
At rated horsepower
SAE0W30EOS
MPa
Engine oil temperature:
{kg/cm2}
SAE5W40EOS
Min. 80C
SAE10W30DH
At low idle
SAE15W40DH
MPa
SAE30DH
{kg/cm2}
Min. 80C
Min. 0.10
{Min. 1.0}
0.08
{0.8}

Exhaust valve
Oil temperature
Whole speed range
90 to 110
120
Oil consumption

rated horsepower
Max. 0.15
0.3
pressure valve
Cracking pressure
kPa
{kg/cm2}
Fan speed
At rated speed
rpm
Fan belt tension

{10 kg}
mm

{10 kg}
mm
13 to 16
13 to 16
140E-5 Series
Body
Lubrication system
Engine
SAA6D140E-5
Machine models
D275A-5R
Unit
Standard value for

new machine
Repair limit
rpm
2,200 50
2,200 50
rpm
700 50
700 50
Necessary speed for

starting
rpm
Min. 110
rpm
Min. 85
Whole speed range
kPa
{mmH2O}
Max. 3.73
{Max. 380}
7.47
{762}
Air boost pressure
At rated horsepower
kPa
{mmHg}
Min. 116
{Min. 870}
99
{740}
Exhaust pressure
At rated horsepower
kPa
{mmHg}
Min. 116
{Min. 870}
99
{740}
Exhaust temperature
Max. 670
720
% (Bosch
index)
Max. 40
(Max. 4.0)
50
(5.0)
At rated horsepower
Bosch
index
Max. 1.5
2.5
At high idle
Bosch
index
Max. 1.0
2.0
Intake valve
mm
0.35
Exhaust valve
mm
0.57
Item
Speed

Exhaust gas color
Valve clearance
Cooling system
SEN00147-07

MPa
{kg/cm2}
Min. 4.1
{Min. 42}
2.8
{29}
Blow-by pressure
At rated horsepower
kPa
{mmH2O}
Max. 2.94
{Max. 300}
3.92
{400}
Min. 0.34
{Min. 3.5}
0.21
{2.1}
Oil pressure
At rated horsepower
SAE0W30EOS
MPa
{kg/cm2}
SAE5W40EOS
Min. 80C
SAE10W30DH
At low idle
SAE15W40DH
MPa
SAE30DH
{kg/cm2}
Min. 80C
Min. 0.10
{Min. 1.0}
0.08
{0.8}
Oil temperature
Whole speed range
90 to 110
120
Oil consumption

rated horsepower
Max. 0.15
0.3
pressure valve
Cracking pressure
kPa
{kg/cm2}
Fan speed
At rated speed
rpm
Fan belt tension

{10 kg}
mm

{10 kg}
mm
140E-5 Series
13 to 16
13 to 16
SEN00147-07
Item
Speed
Necessary speed for
starting
Body
Lubrication system
Cooling system
Engine
SAA6D140E-5
Machine models
PC600-8, PC600LC-8
PC600-8E0, PC600LC-8E0
PC700-8E0, PC700LC-8E0
Unit
Standard value for

new machine
Repair limit
rpm
1,950 50
1,950 50
rpm
800 25
800 25
rpm
Min. 110
rpm
Min. 85
Max. 3.73
{Max. 380}
7.47
{762}
Whole speed range
kPa
{mmH2O}
Air boost pressure
At rated horsepower
kPa
{mmHg}
Min. 147
{Min. 1,100}
125
{940}
Exhaust pressure
At rated horsepower
kPa
{mmHg}
Min. 145
{Min. 1,090}
128
{930}
Exhaust temperature
Max. 650
700
% (Bosch
index)
Max. 25
(Max. 2.5)
35
(3.5)
At rated horsepower
Bosch
index
Max. 1.5
2.5
At high idle
Bosch
index
Max. 1.0
2.0
Intake valve
mm
0.35
Exhaust valve
mm
0.57
At low idle
MPa
{kg/cm2}
Min. 1.18
{Min. 12}
Min. 1.18
{Min. 12}
At high idle
MPa
{kg/cm2}
Min. 1.43
{Min. 14.6}
Min. 1.43
{Min. 14.6}

MPa
{kg/cm2}
Min. 4.1
{Min. 42}
2.8
{29}
Blow-by pressure
At rated horsepower
kPa
{mmH2O}
Max. 2.94
{Max. 300}
3.92
{400}
Min. 0.34
{Min. 3.5}
0.21
{2.1}
Oil pressure
At rated horsepower
SAE0W30EOS
MPa
{kg/cm2}
SAE5W40EOS
Min. 80C
SAE10W30DH
At low idle
SAE15W40DH
MPa
{kg/cm2}
SAE30DH
Min. 80C
Min. 0.10
{Min. 1.0}
0.08
{0.8}

Exhaust gas color
Valve clearance

Oil temperature
Whole speed range
90 to 110
120
Oil consumption

rated horsepower
Max. 0.15
0.3
pressure valve
Cracking pressure
kPa
{kg/cm2}
Fan speed
At rated speed
rpm
Fan belt tension

{10 kg}
mm

{10 kg}
mm
13 to 16
13 to 16
140E-5 Series
Body
Lubrication system
Engine
SAA6D140E-5
Machine models
PC600-8R, PC600LC-8R,
PC600-8R1, PC600LC-8R1,
PC700-8R, PC700LC-8R,
PC700LC-8R1
Unit
Standard value for

new machine
Repair limit
rpm
1,950 50
1,950 50
rpm
800 25
800 25
Necessary speed for

starting
rpm
Min. 110
rpm
Min. 85
Whole speed range
kPa
{mmH2O}
Max. 3.73
{Max. 380}
7.47
{762}
Air boost pressure
At rated horsepower
kPa
{mmHg}
Min. 120
{Min. 900}
102
{760}
Exhaust pressure
At rated horsepower
kPa
{mmHg}
Min. 116
{Min. 870}
99
{740}
Exhaust temperature
Max. 700
750
% (Bosch
index)
Max. 30
(Max. 3.0)
40
(4.0)
At rated horsepower
Bosch
index
Max. 1.5
2.5
At high idle
Bosch
index
Max. 1.0
2.0
Item
Speed

Exhaust gas color
Valve clearance
Cooling system
SEN00147-07
Intake valve
mm
0.35
Exhaust valve
mm
0.57

MPa
{kg/cm2}
Min. 4.1
{Min. 42}
2.8
{29}
Blow-by pressure
At rated horsepower
kPa
{mmH2O}
Max. 2.94
{Max. 300}
3.92
{400}
Min. 0.34
{Min. 3.5}
0.21
{2.1}
Oil pressure
At rated horsepower
SAE0W30EOS
MPa
{kg/cm2}
SAE5W40EOS
Min. 80C
SAE10W30DH
At low idle
SAE15W40DH
MPa
SAE30DH
{kg/cm2}
Min. 80C
Min. 0.10
{Min. 1.0}
0.08
{0.8}
Oil temperature
Whole speed range
90 to 110
120
Oil consumption

rated horsepower
Max. 0.15
0.3
pressure valve
Cracking pressure
kPa
{kg/cm2}
Fan speed
At rated speed
rpm
Fan belt tension

{10 kg}
mm

{10 kg}
mm
140E-5 Series
13 to 16
13 to 16
SEN00147-07
Body
Lubrication system
Cooling system
Engine
SAA6D140E-5
Machine models
PC800-8, PC800SE-8, PC800LC-8

PC850-8, PC850SE-8
PC800-8E0, PC800SE-8E0,
PC800LC-8E0
PC850-8E0, PC850SE-8E0
Unit
Standard value for

new machine
Repair limit
rpm
1,980 50
1,980 50
rpm
825 25
825 25
Necessary speed for

starting
rpm
Min. 110
rpm
Min. 85
Whole speed range
kPa
{mmH2O}
Max. 3.73
{Max. 380}
7.47
{762}
Air boost pressure
At rated horsepower
kPa
{mmHg}
Min. 184
{Min. 1,380}
157
{1,180}
Exhaust pressure
At rated horsepower
kPa
{mmHg}
Min. 172
{Min. 1,290}
147
{1,100}
Exhaust temperature
Max. 650
700
% (Bosch
index)
Max. 25
(Max. 2.5)
35
(3.5)
At rated horsepower
Bosch
index
Max. 1.5
2.5
At high idle
Bosch
index
Max. 1.0
2.0
Intake valve
mm
0.35
Exhaust valve
mm
0.57
At low idle
MPa
{kg/cm2}
Min. 1.18
{Min. 12}
Min. 1.18
{Min. 12}
At high idle
MPa
{kg/cm2}
Min. 1.43
{Min. 14.6}
Min. 1.43
{Min. 14.6}

MPa
{kg/cm2}
Min. 4.1
{Min. 42}
2.8
{29}
Blow-by pressure
At rated horsepower
kPa
Engine coolant temperature: Min. 70C {mmH2O}
Max. 2.94
{Max. 300}
3.92
{400}
Min. 0.34
{Min. 3.5}
0.21
{2.1}
Oil pressure
At rated horsepower
SAE0W30EOS
MPa
SAE5W40EOS {kg/cm2}
Min. 80C
SAE10W30DH
At low idle
SAE15W40DH
MPa
2
}
{kg/cm
SAE30DH
Min. 80C
Min. 0.10
{Min. 1.0}
0.08
{0.8}
Item
Speed

Exhaust gas color
Valve clearance

Oil temperature
Whole speed range
90 to 110
120
Oil consumption

rated horsepower
Max. 0.15
Max. 0.3
pressure valve
Cracking pressure
kPa
{kg/cm2}
Fan speed
At rated speed
rpm
Fan belt tension

{10 kg}
mm

{10 kg}
mm
13 to 16
13 to 6
140E-5 Series
Body
Lubrication system
Engine
SAA6D140E-5
Machine models
PC800-8R, PC800SE-8R,
PC800LC-8R
PC800-8R1, PC800SE-8R1,
PC800LC-8R1, PC850-8R1,
PC850SE-8R1
Unit
Standard value for

new machine
Repair limit
rpm
1,980 50
1,980 50
rpm
825 25
825 25
Necessary speed for

starting
rpm
Min. 110
rpm
Min. 85
Whole speed range
kPa
{mmH2O}
Max. 3.73
{Max. 380}
7.47
{762}
Air boost pressure
At rated horsepower
kPa
{mmHg}
Min. 128
{Min. 960}
108
{810}
Exhaust pressure
At rated horsepower
kPa
{mmHg}
Min. 113
{Min. 850}
96
{720}
Exhaust temperature
Max. 700
750
% (Bosch
index)
Max. 30
(Max. 3.0)
40
(4.0)
At rated horsepower
Bosch
index
Max. 1.5
2.5
At high idle
Bosch
index
Max. 1.0
2.0
Item
Speed

Exhaust gas color
Valve clearance
Cooling system
SEN00147-07
Intake valve
mm
0.35
Exhaust valve
mm
0.57
MPa
{kg/cm2}
Min. 4.1
{Min. 42}
2.8
{29}
Max. 2.94
{Max. 300}
3.92
{400}
Min. 0.34
{Min. 3.5}
0.21
{2.1}
Min. 0.10
{Min. 1.0}
0.08
{0.8}

Blow-by pressure
At rated horsepower
kPa
Oil pressure
At rated horsepower
SAE0W30EOS
MPa
SAE5W40EOS {kg/cm2}
Min. 80C
SAE10W30DH
At low idle
SAE15W40DH
MPa
{kg/cm2}
SAE30DH
Min. 80C
Oil temperature
Whole speed range
90 to 110
120
Oil consumption

rated horsepower
Max. 0.15
Max. 0.3
pressure valve
Cracking pressure
kPa
{kg/cm2}
Fan speed
At rated speed
rpm
Fan belt tension

{10 kg}
mm

{10 kg}
mm
140E-5 Series
13 to 16
13 to 6
SEN00147-07
Body
Lubrication system
Cooling system
Engine
SAA6D140E-5
Machine models
WA500-6
Unit
Standard value for

new machine
Repair limit
rpm
2,150 50
2,150 50
rpm
700 25
700 25
Necessary speed for

starting
rpm
Min. 110
rpm
Min. 85
Whole speed range
kPa
{mmH2O}
Max. 3.73
{Max. 380}
7.47
{762}
Air boost pressure
At rated horsepower
kPa
{mmHg}
Min. 116
{Min. 870}
89
{670}
Exhaust pressure
At rated horsepower
kPa
{mmHg}
Min. 121
{Min. 910}
91
{680}
Exhaust temperature
Max. 650
700
% (Bosch
index)
Max. 25
(Max. 2.5)
35
(3.5)
At rated horsepower
Bosch
index
Max. 1.5
2.5
At high idle
Bosch
index
Max. 1.0
2.0
Intake valve
mm
0.35
Exhaust valve
mm
0.57
At low idle
MPa
{kg/cm2}
Min. 1.18
{Min. 12}
Min. 1.18
{Min. 12}
At high idle
MPa
{kg/cm2}
Min. 1.43
{Min. 14.6}
Min. 1.43
{Min. 14.6}

MPa
{kg/cm2}
Min. 4.1
{Min. 42}
2.8
{29}
Blow-by pressure
At rated horsepower
kPa
Max. 2.94
{Max. 300}
3.92
{400}
Min. 0.34
{Min. 3.5}
0.21
{2.1}
Oil pressure
At rated horsepower
MPa
{kg/cm2}
SAE5W40EOS
Min. 80C
SAE10W30DH
At low idle
SAE15W40DH
MPa
{kg/cm2}
Min. 80C
Min. 0.10
{Min. 1.0}
0.08
{0.8}
Item
Speed

Exhaust gas color
Valve clearance

10
Oil temperature
Whole speed range
90 to 110
120
Oil consumption

rated horsepower
Max. 0.15
0.3
pressure valve
Cracking pressure
kPa
{kg/cm2}
Fan speed
At rated speed
rpm
Fan belt tension

{10 kg}
mm

{10 kg}
mm
13 to 16
13 to 16
140E-5 Series
Item
Speed
Necessary speed for
starting
Body
Lubrication system
Engine
SAA6D140E-5
Machine models
WA500-6R
Unit
Standard value for

new machine
Repair limit
rpm
2,150 50
2,150 50
rpm
700 25
700 25
rpm
Min. 110
rpm
Min. 85
Air intake
resistance
Whole speed range
kPa
{mmH2O}
Max. 3.73
{Max. 380}
7.47
{762}
Air boost
pressure
At rated horsepower
kPa
{mmHg}
Min. 89
{Min. 670}
76
{570}
Exhaust
pressure
At rated horsepower
kPa
{mmHg}
Min. 101
{Min. 760}
85
{640}
Exhaust
temperature
Max. 670
720
% (Bosch
index)
Max. 40
(Max. 4.0)
50
(5.0)
At rated horsepower
Bosch
index
Max. 1.5
2.5
At high idle
Bosch
index
Max. 1.0
2.0
Intake valve
mm
0.35
Exhaust valve
mm
0.57

Exhaust gas color
Valve clearance
Cooling system
SEN00147-07

MPa
{kg/cm2}
Min. 4.1
{Min. 42}
2.8
{29}
Blow-by
pressure
At rated horsepower
kPa
{mmH2O}
Max. 2.94
{Max. 300}
3.92
{400}
Min. 0.34
{Min. 3.5}
0.21
{2.1}
Oil pressure
At rated horsepower
MPa
2
}
{kg/cm
SAE5W40EOS
Min. 80C
SAE10W30DH
At low idle
SAE15W40DH
MPa
{kg/cm2}
Min. 80C
Min. 0.10
{Min. 1.0}
0.08
{0.8}
Oil temperature
Whole speed range
90 to 110
120
Oil consumption

rated horsepower
Max. 0.15
0.3
Function of
radiator
pressure valve
Cracking pressure
kPa
{kg/cm2}
Fan speed
At rated speed
rpm
Fan belt tension

{10 kg}
mm

{10 kg}
mm
140E-5 Series
13 to 16
13 to 16
11
SEN00147-07
Item
Speed
Necessary speed for
starting
Body
Lubrication system
Cooling system
Engine
SAA6D140E-5
Machine models
HD325-7
HD405-7
Unit
Standard value for

new machine
Repair limit
rpm
2,300 25
2,300 25
rpm
725 25
725 25
rpm
Min. 110
rpm
Min. 85
Max. 3.73
{Max. 380}
7.47
{762}
Whole speed range
kPa
{mmH2O}
Air boost pressure
At rated horsepower
kPa
{mmHg}
Min. 183
{Min. 1,370}
156
{1,170}
Exhaust pressure
At rated horsepower
kPa
{mmHg}
Min. 163
{Min. 1,220}
139
{1,040}
Exhaust temperature
Max. 650
700
% (Bosch
index)
Max. 25
(Max. 2.5)
35
(3.5)
At rated horsepower
Bosch
index
Max. 1.5
2.5
At high idle
Bosch
index
Max. 1.0
2.0
Intake valve
mm
0.35
Exhaust valve
mm
0.57
At low idle
MPa
{kg/cm2}
Min. 1.18
{Min. 12}
Min. 1.18
{Min. 12}
At high idle
MPa
{kg/cm2}
Min. 1.43
{Min. 14.6}
Min. 1.43
{Min. 14.6}

MPa
{kg/cm2}
Min. 4.1
{Min. 42}
2.8
{29}
Blow-by pressure
At rated horsepower
kPa
Max. 2.94
{Max. 300}
3.92
{400}
Min. 0.34
{Min. 3.5}
0.21
{2.1}
Oil pressure
At rated horsepower
SAE0W30EOS
MPa
SAE5W40EOS {kg/cm2}
Min. 80C
SAE10W30DH
At low idle
SAE15W40DH
MPa
{kg/cm2}
SAE30DH
Min. 80C
Min. 0.10
{Min. 1.0}
0.08
{0.8}

Exhaust gas color
Valve clearance

12
Oil temperature
Whole speed range
90 to 110
120
Oil consumption

rated horsepower
Max. 0.15
0.3
pressure valve
Cracking pressure
kPa
{kg/cm2}
Fan speed
At rated speed
rpm
1,020 30
1,020 30
Fan belt tension

{10 kg}
mm
13 to 15
(when new)
17 to 19
(when retightened)

{10 kg}
mm
13 to 16
13 to 16
140E-5 Series
Item
Speed
Necessary speed for
starting
Body
Lubrication system
Engine
SAA6D140E-5
Machine models
HD325-7R
HD405-7R
Unit
Standard value for

new machine
Repair limit
rpm
2,300 25
2,300 25
rpm
725 25
725 25
rpm
Min. 110
rpm
Min. 85
Max. 3.73
{Max. 380}
7.47
{762}
Whole speed range
kPa
{mmH2O}
Air boost pressure
At rated horsepower
kPa
{mmHg}
Min. 135
{Min. 1,010}
115
{860}
Exhaust pressure
At rated horsepower
kPa
{mmHg}
Min. 121
{Min. 910}
103
{770}
Exhaust temperature
Max. 680
730
% (Bosch
index)
Max. 40
(Max. 4.0)
50
(5.0)
At rated horsepower
Bosch
index
Max. 1.5
2.5
At high idle
Bosch
index
Max. 1.0
2.0
Intake valve
mm
0.35
Exhaust valve
mm
0.57

Exhaust gas color
Valve clearance
Cooling system
SEN00147-07

MPa
{kg/cm2}
Min. 4.1
{Min. 42}
2.8
{29}
Blow-by pressure
At rated horsepower
kPa
{mmH2O}
Max. 2.94
{Max. 300}
3.92
{400}
Min. 0.34
{Min. 3.5}
0.21
{2.1}
Oil pressure
At rated horsepower
SAE0W30EOS
MPa
SAE5W40EOS {kg/cm2}
Min. 80C
SAE10W30DH
At low idle
SAE15W40DH
MPa
2
}
{kg/cm
SAE30DH
Min. 80C
Min. 0.10
{Min. 1.0}
0.08
{0.8}
Oil temperature
Whole speed range
90 to 110
120
Oil consumption

rated horsepower
Max. 0.15
0.3
pressure valve
Cracking pressure
kPa
{kg/cm2}
Fan speed
At rated speed
rpm
1,020 30
1,020 30
Fan belt tension

{10 kg}
mm
13 to 15
(when new)
17 to 19
(when retightened)

{10 kg}
mm
13 to 16
13 to 16
140E-5 Series
13
SEN00147-07
Body
Lubrication system
Cooling system
Engine
SAA6D140E-5
Machine models
HM350-2
Unit
Standard value for

new machine
Repair limit
rpm
2,200(+50/0)
2,200(+50/0)
rpm
725 25
725 25
Necessary speed for

starting
rpm
Min. 110
rpm
Min. 85
Whole speed range
kPa
{mmH2O}
Max. 3.73
{Max. 380}
7.47
{762}
Air boost pressure
At rated horsepower
kPa
{mmHg}
Min. 145
{Min. 1,090}
124
{930}
Exhaust pressure
At rated horsepower
kPa
{mmHg}
Min. 148
{Min. 1,110}
127
{950}
Exhaust temperature
Max. 620
670
% (Bosch
index)
Max. 25
(Max. 2.5)
35
(3.5)
At rated horsepower
Bosch
index
Max. 1.5
2.5
At high idle
Bosch
index
Max. 1.0
2.0
Intake valve
mm
0.35
Exhaust valve
mm
0.57
At low idle
MPa
{kg/cm2}
Min. 1.18
{Min. 12}
Min. 1.18
{Min. 12}
At high idle
MPa
{kg/cm2}
Min. 1.43
{Min. 14.6}
Min. 1.43
{Min. 14.6}

MPa
{kg/cm2}
Min. 4.1
{Min. 42}
2.8
{29}
Blow-by pressure
At rated horsepower
kPa
Max. 2.94
{Max. 300}
3.92
{400}
Min. 0.34
{Min. 3.5}
0.21
{2.1}
Oil pressure
At rated horsepower
SAE0W30EOS
MPa
SAE5W40EOS {kg/cm2}
Min. 80C
SAE10W30DH
At low idle
SAE15W40DH
MPa
{kg/cm2}
SAE30DH
Min. 80C
Min. 0.10
{Min. 1.0}
0.08
{0.8}
Item
Speed

Exhaust gas color
Valve clearance

14
Oil temperature
Whole speed range
90 to 110
120
Oil consumption

rated horsepower
Max. 0.15
0.3
pressure valve
Cracking pressure
kPa
{kg/cm2}
Fan speed
At rated speed
rpm
1,256 38
1,256 38
Fan belt tension

{10 kg}
mm
13 to 15
(when new)
17 to 19
(when retightened)

{10 kg}
mm
13 to 16
13 to 16
140E-5 Series
Body
Lubrication system
Engine
SAA6D140E-5
Machine models
HM350-2R
Unit
Standard value for

new machine
Repair limit
rpm
2,200(+50/0)
2,200(+50/0)
rpm
725 25
725 25
Necessary speed for

starting
rpm
Min. 110
rpm
Min. 85
Whole speed range
kPa
{mmH2O}
Max. 3.73
{Max. 380}
7.47
{762}
Air boost pressure
At rated horsepower
kPa
{mmHg}
Min. 98
{Min. 730}
83
{620}
Exhaust pressure
At rated horsepower
kPa
{mmHg}
Min. 104
{Min. 780}
88
{660}
Exhaust temperature
Max. 670
720
% (Bosch
index)
Max. 40
(Max. 4.0)
50
(5.0)
At rated horsepower
Bosch
index
Max. 1.5
2.5
At high idle
Bosch
index
Max. 1.0
2.0
Intake valve
mm
0.35
Exhaust valve
mm
0.57
Item
Speed

Exhaust gas color
Valve clearance
Cooling system
SEN00147-07

MPa
{kg/cm2}
Min. 4.1
{Min. 42}
2.8
{29}
Blow-by pressure
At rated horsepower
kPa
{mmH2O}
Max. 2.94
{Max. 300}
3.92
{400}
Min. 0.34
{Min. 3.5}
0.21
{2.1}
Oil pressure
At rated horsepower
SAE0W30EOS
MPa
{kg/cm2}
SAE5W40EOS
Min. 80C
SAE10W30DH
At low idle
SAE15W40DH
MPa
{kg/cm2}
SAE30DH
Min. 80C
Min. 0.10
{Min. 1.0}
0.08
{0.8}
Oil temperature
Whole speed range
90 to 110
120
Oil consumption

rated horsepower
Max. 0.15
0.3
pressure valve
Cracking pressure
kPa
{kg/cm2}
Fan speed
At rated speed
rpm
1,256 38
1,256 38
Fan belt tension

{10 kg}
mm
13 to 15
(when new)
17 to 19
(when retightened)

{10 kg}
mm
13 to 16
13 to 16
140E-5 Series
15
SEN00147-07
Body
Lubrication system
Cooling system
Engine
SAA6D140E-5
Machine models
HM400-2, HM400-3M0
Unit
Standard value for

new machine
Repair limit
rpm
2,200(+50/0)
2,200(+50/0)
rpm
725 25
725 25
Necessary speed for

starting
rpm
Min. 110
rpm
Min. 85
kPa
{mmH2O}
Max. 3.73
{Max. 380}
7.47
{762}
Air boost pressure
At rated horsepower
kPa
{mmHg}
Min. 160
{Min. 1,200}
136
{1,020}
Exhaust pressure
At rated horsepower
kPa
{mmHg}
Min. 163
{Min. 1,220}
139
{1,040}
Exhaust temperature
Max. 650
700
% (Bosch
index)
Max. 25
(Max. 2.5)
35
(3.5)
At rated horsepower
Bosch
index
Max. 1.5
2.5
At high idle
Bosch
index
Max. 1.0
2.0
Intake valve
mm
0.35
Exhaust valve
mm
0.57
At low idle
MPa
{kg/cm2}
Min. 1.18
{Min. 12}
Min. 1.18
{Min. 12}
At high idle
MPa
{kg/cm2}
Min. 1.43
{Min. 14.6}
Min. 1.43
{Min. 14.6}

MPa
{kg/cm2}
Min. 4.1
{Min. 42}
2.8
{29}
Blow-by pressure
At rated horsepower
kPa
Max. 2.94
{Max. 300}
3.92
{400}
Min. 0.34
{Min. 3.5}
0.21
{2.1}
Oil pressure
At rated horsepower
SAE0W30EOS
MPa
SAE5W40EOS {kg/cm2}
Min. 80C
SAE10W30DH
At low idle
MPa
SAE15W40DH
{kg/cm2}
SAE30DH
Min. 80C
Min. 0.10
{Min. 1.0}
0.08
{0.8}
Item
Speed

Exhaust gas color
Valve clearance

16
Oil temperature
Whole speed range
90 to 110
120
Oil consumption

rated horsepower
Max. 0.15
0.3
pressure valve
Cracking pressure
kPa
{kg/cm2}
Fan speed
At rated speed
rpm
Fan belt tension

{10 kg}
mm

{10 kg}
mm
13 to 16
13 to 16
140E-5 Series
Body
Lubrication system
Engine
SAA6D140E-5
Machine models
HM400-2R, HM400-3R
Unit
Standard value for

new machine
Repair limit
rpm
2,200(+50/0)
2,200(+50/0)
rpm
725 25
725 25
Necessary speed for

starting
rpm
Min. 110
rpm
Min. 85
kPa
{mmH2O}
Max. 3.73
{Max. 380}
7.47
{762}
Air boost pressure
At rated horsepower
kPa
{mmHg}
Min. 111
{Min. 830}
94
{700}
Exhaust pressure
At rated horsepower
kPa
{mmHg}
Min. 115
{Min. 860}
98
{730}
Exhaust temperature
Max. 670
720
% (Bosch
index)
Max. 40
(Max. 4.0)
50
(5.0)
At rated horsepower
Bosch
index
Max. 1.5
2.5
At high idle
Bosch
index
Max. 1.0
2.0
Intake valve
mm
0.35
Exhaust valve
mm
0.57
Item
Speed

Exhaust gas color
Valve clearance
Cooling system
SEN00147-07

MPa
{kg/cm2}
Min. 4.1
{Min. 42}
2.8
{29}
Blow-by pressure
At rated horsepower
kPa
{mmH2O}
Max. 2.94
{Max. 300}
3.92
{400}
Min. 0.34
{Min. 3.5}
0.21
{2.1}
Oil pressure
At rated horsepower
SAE0W30EOS
MPa
SAE5W40EOS {kg/cm2}
Min. 80C
SAE10W30DH
At low idle
MPa
SAE15W40DH
{kg/cm2}
SAE30DH
Min. 80C
Min. 0.10
{Min. 1.0}
0.08
{0.8}
Oil temperature
Whole speed range
90 to 110
120
Oil consumption

rated horsepower
Max. 0.15
0.3
pressure valve
Cracking pressure
kPa
{kg/cm2}
Fan speed
At rated speed
rpm
Fan belt tension

{10 kg}
mm

{10 kg}
mm
140E-5 Series
13 to 16
13 to 16
17
SEN00147-07
Engine
SAA6D140E-5
SDG400S-6B1
Machine models
Item
Speed
Body
Lubrication system
Cooling system
Unit
Standard value for

new machine
Repair limit
rpm
1,890 50
1,890 50
rpm
875 25
875 25
Necessary speed for

starting
rpm
Min. 110
rpm
Min. 85
Whole speed range
kPa
{mmH2O}
Max. 3.73
{Max. 380}
7.47
{762}
Air boost pressure
At rated horsepower
kPa
{mmHg}
Min. 207
{Min. 1,550}
171
{1,280}
Exhaust pressure
At rated horsepower
kPa
{mmHg}
Min. 185
{Min. 1,390}
153
{1,150}
Exhaust temperature
Max. 670
700
% (Bosch
index)
()
()
At rated horsepower
Bosch
index
Max. 1.5
2.5
At high idle
Bosch
index
Max. 1.0
2.0
Intake valve
mm
0.35
Exhaust valve
mm
0.57
At low idle
MPa
{kg/cm2}
Min. 1.18
{Min. 12}
Min. 1.18
{Min. 12}
At high idle
MPa
{kg/cm2}
Min. 1.43
{Min. 14.6}
Min. 1.43
{Min. 14.6}

MPa
{kg/cm2}
Min. 4.1
{Min. 42}
2.8
{29}
Blow-by pressure
At rated horsepower
kPa
{mmH2O}
Max. 2.94
{Max. 300}
3.92
{400}
Min. 0.34
{Min. 3.5}
0.21
{2.1}
Oil pressure
At rated horsepower
MPa
2
}
{kg/cm
SAE5W40EOS
Min. 80C
SAE10W30DH
At low idle
SAE15W40DH
MPa
{kg/cm2}
Min. 80C
Min. 0.10
{Min. 1.0}
0.08
{0.8}

Exhaust gas color
Valve clearance

18
Oil temperature
Whole speed range
90 to 110
120
Oil consumption

rated horsepower
Max. 0.15
0.3
pressure valve
Cracking pressure
kPa
{kg/cm2}
Fan speed
At rated speed
rpm
1,329 40
1,329 40
Fan belt tension

{10 kg}
mm
13 to 15
(When new)
17 to 19

{10 kg}
mm
13 to 16
13 to 16
140E-5 Series
SEN00147-07
Running-in standard and performance test standard
Running-in standard
Engine
SAA6D140E-5
Machine models
D155AX-6
Procedure
Item
Running time
min.
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
a
This table shows the values when the fan is not installed.
The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Performance test standard

Engine
SAA6D140E-5
Machine models
D155AX-6
Test item
Rated horsepower
Max. torque
High idle speed
Low idle speed
Specification value
(Gross value)
Speed
rpm
1,900
1,300
2,100(0/50)
740(+40/0)
Dynamometer load
N
{kg}
1,823 to 1,940
{186 to 198}
2,460 to 2,607
{251 to 266}
Output (Gross value)
kW
{HP}
260 to 277
{349 to 371}
Torque (Gross value)
Nm
{kgm}
1,758 to 1,868
{179.4 to 190.6}
Fuel consumption
sec/300cc
Min. 16.0
Coolant temperature
70 to 90
70 to 90
70 to 90
70 to 90
Lubricating oil
temperature
90 to 110
90 to 110
90 to 110
80 to 110
Lubricating oil
pressure
kPa
{kg/cm2}
340 to 490
{3.5 to 5.0}
340 to 490
{3.5 to 5.0}
340 to 490
{3.5 to 5.0}
Min. 120
{Min. 1.2}
Exhaust temperature
Max. 650
Max. 650
a
a
a
a
a
a
268 kW/1,900 rpm 1,834 Nm/1,300 rpm

2,100(0/50) rpm
{359.9 HP/1,900 rpm} {187 kgm/1,300 rpm}
740(+40/0) rpm
This table shows the standard values obtained by using the JIS correction coefficients.
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.
This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
Use ASTM No.1 or No. 2 diesel fuel as fuel.
Use SAE15W-40 as lubricating oil.
140E-5 Series
19
SEN00147-07
Running-in standard
Engine
SAA6D140E-5
Machine models
D155A-6
Procedure
Item
Running time
min.
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
a

Engine
SAA6D140E-5
Machine models
D155A-6
Test item
Rated horsepower
Max. torque
High idle speed
Specification value
(Gross value)
Speed
rpm
1,900
1,300
2,100(0/50)
740(+40/0)
Dynamometer load
N
{kg}
1,823 to 1,940
{186 to 198}
2,482 to 2,635
{253 to 269}
kW
{HP}
260 to 277
{349 to 371}
Nm
{kgm}
1,778 to 1,888
{181.4 to 192.6}
Fuel consumption
sec/300cc
Min. 16.0
Coolant temperature
70 to 90
70 to 90
70 to 90
70 to 90
Lubricating oil
temperature
90 to 110
90 to 110
90 to 110
80 to 110
Lubricating oil
pressure
kPa
{kg/cm2}
340 to 490
{3.5 to 5.0}
340 to 490
{3.5 to 5.0}
340 to 490
{3.5 to 5.0}
Min. 120
{Min. 1.2}
Exhaust temperature
Max. 670
Max. 670
a
a
a
a
a
a
20
268 kW/1,900 rpm 1,834 Nm/1,300 rpm

2,100(0/50) rpm
{359.9 HP/1,900 rpm} {187 kgm/1,300 rpm}
Low idle speed

740(+40/0) rpm
140E-5 Series
SEN00147-07
Running-in standard
Engine
SAA6D140E-5
Machine models
D275AX-5E0
Procedure
Item
Running time
min.
Speed
rpm
740
1,260
1,580
1,820
2,000
Dynamometer load
N{kg}
0{0}
891{91}
1,420{145}
1,850{189}
2,244{229}
Output
kW{HP}
0{0}
84{113}
168{226}
253{339}
337{452}
a
a

Engine
SAA6D140E-5
Machine models
D275AX-5E0
Test item
Rated horsepower
Max. torque
Low idle speed
2,200 50 rpm
700 50 rpm
Specification value
(Gross value)
Speed
rpm
2,000
1,400
2,200 50
700 50
Dynamometer load
N
{kg}
2,177 to 2,314
{222.0 to 236.0}
2,753 to 2,917
{280.7 to 297.5}
Output
(Gross value)
kW
{HP}
327 to 347
{438 to 465}
Nm
{kgm}
1,970 to 2,087
{201 to 213}
Fuel consumption
sec/300cc
Min. 12.8
Coolant temperature
70 to 90
70 to 90
70 to 90
70 to 90
Lubricating oil
temperature
90 to 110
90 to 110
90 to 110
90 to 110
Lubricating oil
pressure
kPa
{kg/cm2}
340 to 490
{3.5 to 5.0}
340 to 490
{3.5 to 5.0}
340 to 490
{3.5 to 5.0}
Min. 120
{Min. 1.2}
Exhaust temperature
Max. 650
Max. 650
a
a
a
a
a
a
337 kW/2,000 rpm 2,030 Nm/1,400 rpm

{451.6 HP/2,000 rpm} {207 kgm/1,400 rpm}
High idle speed
140E-5 Series
21
SEN00147-07
Running-in standard
Engine
SAA6D140E-5
Machine models
D275A-5R
Procedure
Item
Running time
min.
Speed
rpm
740
1,260
1,580
1,820
2,000
Dynamometer load
N{kg}
0{0}
891{91}
1,420{145}
1,850{189}
2,244{229}
Output
kW{HP}
0{0}
84{113}
168{226}
253{339}
337{452}
a
a

Engine
SAA6D140E-5
Machine models
D275A-5R
Test item
Rated horsepower
Max. torque
Low idle speed
2,200 50 rpm
700 50 rpm
Specification value
(Gross value)
Speed
rpm
2,000
1,400
2,200 50
700 50
Dynamometer load
N
{kg}
2,177 to 2,314
{222.0 to 236.0}
2,753 to 2,917
{280.7 to 297.5}
Output
(Gross value)
kW
{HP}
327 to 347
{438 to 465}
Nm
{kgm}
1,970 to 2,087
{201 to 213}
Fuel consumption
sec/300cc
Min. 12.8
Coolant temperature
70 to 90
70 to 90
70 to 90
70 to 90
Lubricating oil
temperature
90 to 110
90 to 110
90 to 110
90 to 110
Lubricating oil
pressure
kPa
{kg/cm2}
340 to 490
{3.5 to 5.0}
340 to 490
{3.5 to 5.0}
340 to 490
{3.5 to 5.0}
Min. 120
{Min. 1.2}
Exhaust temperature
Max. 670
Max. 670
a
a
a
a
a
a
22
337 kW/2,000 rpm 2,030 Nm/1,400 rpm

{451.6 HP/2,000 rpm} {207 kgm/1,400 rpm}
High idle speed
140E-5 Series
SEN00147-07
Running-in standard
Engine
SAA6D140E-5
Machine models
PC600-8, PC600LC-8, PC600-8E0, PC600LC-8E0

PC700-8E0, PC700LC-8E0
Procedure
Item
Running time
min.
Speed
rpm
800
1,134
1,422
1,638
1,800
Dynamometer load
N{kg}
0{0}
948{97}
1,513{154}
1,970{201}
2,390{244}
Output
kW{HP}
0{0}
81{108}
161{217}
242{324}
323{433}
a
a

Engine
SAA6D140E-5
Machine models
PC600-8, PC600LC-8, PC600-8E0, PC600LC-8E0

PC700-8E0, PC700LC-8E0
Test item
Rated horsepower
Max. torque
High idle speed
Low idle speed
Specification value
(Gross value)
323 kW/1,800 rpm

{433.3 HP/
1,800 rpm}
1,944Nm/1,400rpm
{198.4 kgm/
1,400 rpm}
1,950 50 rpm
800 25 rpm
Speed
rpm
1,800
1,400
1,950 50
800 25
Dynamometer load
N
{kg}
2,323 to 2,470
{237 to 252}
2,626 to 2,793
{268 to 285}
kW
{HP}
313 to 333
{420 to 447}
Nm
{kgm}
1,882 to 1,999
{192 to 204}
Fuel consumption
sec/300cc
Min. 13.8
Coolant temperature
70 to 90
70 to 90
70 to 90
70 to 90
Lubricating oil
temperature
90 to 110
90 to 110
90 to 110
80 to 110
Lubricating oil
pressure
kPa
{kg/cm2}
340 to 490
{3.5 to 5.0}
340 to 490
{3.5 to 5.0}
340 to 490
{3.5 to 5.0}
Min. 120
{Min. 1.2}
Exhaust temperature
Max. 650
Max. 650
a
a
a
a
a
a
140E-5 Series
23
SEN00147-07
Running-in standard
Engine
SAA6D140E-5
Machine models
PC600-8R, PC600LC-8R,
PC600-8R1, PC600LC-8R1,
PC700-8R, PC700LC-8R, PC700LC-8R1
Procedure
Item
Running time
min.
Speed
rpm
800
1,134
1,422
1,638
1,800
Dynamometer load
N{kg}
0{0}
948{97}
1,513{154}
1,970{201}
2,390{244}
Output
kW{HP}
0{0}
81{108}
161{217}
242{324}
323{433}
a
a

Engine
SAA6D140E-5
Machine models
PC600-8R, PC600LC-8R,
PC600-8R1, PC600LC-8R1,
PC700-8R, PC700LC-8R, PC700LC-8R1
Test item
Rated horsepower
Max. torque
High idle speed
Low idle speed
Specification value
(Gross value)
323 kW/1,800 rpm

{433.3 HP/
1,800 rpm}
1,944Nm/1,400rpm
{198.4 kgm/
1,400 rpm}
1,950 50 rpm
800 25 rpm
Speed
rpm
1,800
1,400
1,950 50
800 25
Dynamometer load
N
{kg}
2,323 to 2,470
{237 to 252}
2,626 to 2,793
{268 to 285}
kW
{HP}
313 to 333
{420 to 447}
Nm
{kgm}
1,882 to 1,999
{192 to 204}
Fuel consumption
sec/300cc
Min. 13.8
Coolant temperature
70 to 90
70 to 90
70 to 90
70 to 90
Lubricating oil
temperature
90 to 110
90 to 110
90 to 110
80 to 110
Lubricating oil
pressure
kPa
{kg/cm2}
340 to 490
{3.5 to 5.0}
340 to 490
{3.5 to 5.0}
340 to 490
{3.5 to 5.0}
Min. 120
{Min. 1.2}
Exhaust temperature
Max. 700
Max. 700
a
a
a
a
a
a
24
140E-5 Series
SEN00147-07
Running-in standard
Engine
SAA6D140E-5
Machine models
PC800-8, PC800SE-8, PC800LC-8, PC850-8, PC850SE-8

Procedure
Item
Running time
min.
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}
a
a

Engine
SAA6D140E-5
Machine models
PC800-8, PC800SE-8, PC800LC-8, PC850-8, PC850SE-8

Test item
Rated horsepower
Max. torque
High idle speed
Low idle speed
Specification value
(Gross value)
370 kW/1,800 rpm

{496.4 HP/
1,800 rpm}
2,195 Nm/1,350 rpm

{223.8 kgm/
1,350 rpm}
1,980 50 rpm
825 25 rpm
Speed
rpm
1,800
1,350
1,980 50
825 25
Dynamometer load
N
{kg}
2,550 to 2,690
{260 to 274}
2,930 to 3,100
{299 to 316}
kW
{HP}
359 to 381
{481 to 512}
Nm
{kgm}
2,126 to 2,264
{217 to 231}
Fuel consumption
sec/300cc
Min. 12.3
Coolant temperature
70 to 90
70 to 90
70 to 90
70 to 90
Lubricating oil
temperature
90 to 110
90 to 110
90 to 110
80 to 110
Lubricating oil
pressure
kPa
{kg/cm2}
340 to 490
{3.5 to 5.0}
340 to 490
{3.5 to 5.0}
340 to 490
{3.5 to 5.0}
Min. 120
{Min. 1.2}
Exhaust temperature
Max. 650
Max. 650
a
a
a
a
a
a
140E-5 Series
25
SEN00147-07
Running-in standard
Engine
SAA6D140E-5
Machine models
PC800-8R, PC800SE-8R, PC800LC-8R, PC850-8R, PC850SE-8R

Procedure
Item
Running time
min.
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}
a
a

Engine
SAA6D140E-5
Machine models
PC800-8R, PC800SE-8R, PC800LC-8R, PC850-8R, PC850SE-8R

Test item
Rated horsepower
Max. torque
High idle speed
Low idle speed
Specification value
(Gross value)
370 kW/1,800 rpm

{496.4 HP/
1,800 rpm}
2,195 Nm/1,350 rpm

{223.8 kgm/
1,350 rpm}
1,980 50 rpm
825 25 rpm
Speed
rpm
1,800
1,350
1,980 50
825 25
Dynamometer load
N
{kg}
2,550 to 2,690
{260 to 274}
2,969 to 3,162
{303 to 323}
kW
{HP}
359 to 381
{481 to 512}
Nm
{kgm}
2,126 to 2,264
{217 to 231}
Fuel consumption
sec/300cc
Min. 12.3
Coolant temperature
70 to 90
70 to 90
70 to 90
70 to 90
Lubricating oil
temperature
90 to 110
90 to 110
90 to 110
80 to 110
Lubricating oil
pressure
kPa
{kg/cm2}
340 to 490
{3.5 to 5.0}
340 to 490
{3.5 to 5.0}
340 to 490
{3.5 to 5.0}
Min. 120
{Min. 1.2}
Exhaust temperature
Max. 700
Max. 700
a
a
a
a
a
a
26
140E-5 Series
SEN00147-07
Running-in standard
Engine
SAA6D140E-5
Machine models
WA500-6
Procedure
Item
Running time
min.
Speed
rpm
675
1,197
1,501
1,729
1,900
Dynamometer load
N{kg}
0{0}
712{73}
1,136{116}
1,479{151}
1,795{183}
Output
kW{HP}
0{0}
64{86}
128{172}
192{257}
266{357}
a
a

Engine
SAA6D140E-5
Machine models
WA500-6
Test item
Rated horsepower
Max. torque
Low idle speed
2,150 50 rpm
700 25 rpm
Specification value
(Gross value)
Speed
rpm
1,900
1,250
2,150 50
700 25
Dynamometer load
N
{kg}
1,744 to 1,852
{178 to 189}
2,440 to 2,597
{249 to 265}
kW
{HP}
248 to 263
{333 to 353}
Nm
{kgm}
1,744 to 1,862
{178 to 190}
Fuel consumption
sec/300cc
Min. 16.8
Coolant temperature
70 to 90
70 to 90
70 to 90
70 to 90
Lubricating oil
temperature
90 to 110
90 to 110
90 to 110
80 to 110
Lubricating oil
pressure
kPa
{kg/cm2}
340 to 490
{3.5 to 5.0}
340 to 490
{3.5 to 5.0}
340 to 490
{3.5 to 5.0}
Min. 120
{Min. 1.2}
Exhaust temperature
Max. 650
Max. 650
a
a
a
a
a
a
266 kW/1,900 rpm 1,803 Nm/1,250 rpm

{357 HP/1,900 rpm} {184 kgm/1,250 rpm}
High idle speed
140E-5 Series
27
SEN00147-07
Running-in standard
Engine
SAA6D140E-5
Machine models
WA500-6R
Procedure
Item
Running time
min.
Speed
rpm
675
1,197
1,501
1,729
1,900
Dynamometer load
N{kg}
0{0}
712{73}
1,136{116}
1,479{151}
1,795{183}
Output
kW{HP}
0{0}
64{86}
128{172}
192{257}
266{357}
a
a

Engine
SAA6D140E-5
Machine models
WA500-6R
Test item
Rated horsepower
Max. torque
Low idle speed
2,150 50 rpm
700 25 rpm
Specification value
(Gross value)
Speed
rpm
1,900
1,250
2,150 50
700 25
Dynamometer load
N
{kg}
1,814 to 1,922
{185 to 196}
2,440 to 2,597
{249 to 265}
kW
{HP}
258 to 274
{346 to 368}
Nm
{kgm}
1,744 to 1,862
{178 to 190}
Fuel consumption
sec/300cc
Min. 16.8
Coolant temperature
70 to 90
70 to 90
70 to 90
70 to 90
Lubricating oil
temperature
90 to 110
90 to 110
90 to 110
80 to 110
Lubricating oil
pressure
kPa
{kg/cm2}
340 to 490
{3.5 to 5.0}
340 to 490
{3.5 to 5.0}
340 to 490
{3.5 to 5.0}
Min. 120
{Min. 1.2}
Exhaust temperature
Max. 670
Max. 670
a
a
a
a
a
a
28
266 kW/1,900 rpm 1,803 Nm/1,250 rpm

{357 HP/1,900 rpm} {184 kgm/1,250 rpm}
High idle speed
140E-5 Series
SEN00147-07
Running-in standard
Engine
SAA6D140E-5
Machine models
HD325-7
HD405-7
Procedure
Item
Running time
min.
Speed
rpm
725
1,260
1,580
1,820
2,000
Dynamometer load
N{kg}
0{0}
1,021{104}
1,628{166}
2,120{216}
2,573{263}
Output
kW{HP}
0{0}
97{129}
193{259}
290{388}
386{518}
a
a

Engine
SAA6D140E-5
Machine models
HD325-7
HD405-7
Test item
Rated horsepower
Max. torque
High idle speed
Low idle speed
2,300 25 rpm
725 25 rpm
Specification value
(Gross value)
Speed
rpm
2,000
1,400
2,300 25
725 25
Dynamometer load
N
{kg}
2,499 to 2,646
{255 to 270}
2,930 to 3,120
{299 to 318}
kW
{HP}
374 to 398
{502 to 533}
Nm
{kgm}
2,100 to 2,230
{214 to 228}
Fuel consumption
sec/300cc
Min. 11.4
Coolant temperature
70 to 90
70 to 90
70 to 90
70 to 90
Lubricating oil
temperature
90 to 110
90 to 110
90 to 110
80 to 110
Lubricating oil
pressure
kPa
{kg/cm2}
340 to 490
{3.5 to 5.0}
340 to 490
{3.5 to 5.0}
340 to 490
{3.5 to 5.0}
Min. 120
{Min. 1.2}
Exhaust temperature
Max. 650
Max. 650
a
a
a
a
a
386 kW/2,000 rpm

2,170 Nm/1,400 rpm
{517.7 HP/2,000 rpm} {221.3 kgm/1,400 rpm}
140E-5 Series
29
SEN00147-07
Running-in standard
Engine
SAA6D140E-5
Machine models
HD325-7R
HD405-7R
Procedure
Item
Running time
min.
Speed
rpm
725
1,260
1,580
1,820
2,000
Dynamometer load
N{kg}
0{0}
1,021{104}
1,628{166}
2,120{216}
2,573{263}
Output
kW{HP}
0{0}
97{129}
193{259}
290{388}
386{518}
a
a

Engine
SAA6D140E-5
Machine models
HD325-7R
HD405-7R
Test item
Rated horsepower
Max. torque
High idle speed
Low idle speed
2,300 25 rpm
725 25 rpm
Specification value
(Gross value)
Speed
rpm
2,000
1,400
2,300 25
725 25
Dynamometer load
N
{kg}
2,499 to 2,646
{255 to 270}
2,930 to 3,120
{299 to 318}
kW
{HP}
374 to 398
{502 to 533}
Nm
{kgm}
2,100 to 2,230
{214 to 228}
Fuel consumption
sec/300cc
Min. 11.4
Coolant temperature
70 to 90
70 to 90
70 to 90
70 to 90
Lubricating oil
temperature
90 to 110
90 to 110
90 to 110
80 to 110
Lubricating oil
pressure
kPa
{kg/cm2}
340 to 490
{3.5 to 5.0}
340 to 490
{3.5 to 5.0}
340 to 490
{3.5 to 5.0}
Min. 120
{Min. 1.2}
Exhaust temperature
Max. 680
Max. 680
a
a
a
a
a
a
30
386 kW/2,000 rpm 2,170 Nm/1,400 rpm

{517.7 HP/2,000 rpm} {221.3 kgm/1,400 rpm}
140E-5 Series
SEN00147-07
Running-in standard
Engine
SAA6D140E-5
Machine models
HM350-2
Procedure
Item
Running time
min.
Speed
rpm
725
1,260
1,580
1,820
2,000
Dynamometer load
N{kg}
0{0}
803{82}
1,281{131}
1,668{170}
2,024{207}
Output
kW{HP}
0{0}
76{102}
152{204}
228{306}
304{407}
a
a

Engine
SAA6D140E-5
Machine models
HM350-2
Test item
Rated horsepower
Max. torque
High idle speed
Specification value
(Gross value)
Speed
rpm
2,000
1,400
2,200(+50/0)
725 25
Dynamometer load
N
{kg}
1,960 to 2,087
{200 to 213}
2,695 to 2,862
{275 to 292}
kW
{HP}
295 to 315
{395 to 419}
Nm
{kgm}
1,931 to 2,048
{197 to 209}
Fuel consumption
sec/300cc
Min. 13.8
Coolant temperature
70 to 90
70 to 90
70 to 90
70 to 90
Lubricating oil temperature
90 to 110
90 to 110
90 to 110
80 to 110
Lubricating oil pressure
kPa
{kg/cm2}
340 to 490
{3.5 to 5.0}
340 to 490
{3.5 to 5.0}
340 to 490
{3.5 to 5.0}
Min. 120
{Min. 1.2}
Exhaust temperature
Max. 650
Max. 650
a
a
a
a
a
a
304 kW/2,000 rpm 1,990 Nm/1,400 rpm

2,200(+50/0) rpm
{407.2 HP/2,000 rpm} {203 kgm/1,400 rpm}
Low idle speed

725 25 rpm
140E-5 Series
31
SEN00147-07
Running-in standard
Engine
SAA6D140E-5
Machine models
HM350-2R
Procedure
Item
Running time
min.
Speed
rpm
725
1,260
1,580
1,820
2,000
Dynamometer load
N{kg}
0{0}
803{82}
1,281{131}
1,668{170}
2,024{207}
Output
kW{HP}
0{0}
76{102}
152{204}
228{306}
304{407}
a
a

Engine
SAA6D140E-5
Machine models
HM350-2R
Test item
Rated horsepower
Max. torque
High idle speed
Specification value
(Gross value)
Speed
rpm
2,000
1,400
2,200(+50/0)
725 25
Dynamometer load
N
{kg}
1,960 to 2,087
{200 to 213}
2,695 to 2,862
{275 to 292}
kW
{HP}
295 to 315
{395 to 419}
Nm
{kgm}
1,931 to 2,048
{197 to 209}
Fuel consumption
sec/300cc
Min. 13.8
Coolant temperature
70 to 90
70 to 90
70 to 90
70 to 90
Lubricating oil temperature
90 to 110
90 to 110
90 to 110
80 to 110
Lubricating oil pressure
kPa
{kg/cm2}
340 to 490
{3.5 to 5.0}
340 to 490
{3.5 to 5.0}
340 to 490
{3.5 to 5.0}
Min. 120
{Min. 1.2}
Exhaust temperature
Max. 670
Max. 670
a
a
a
a
a
a
32
304 kW/2,000 rpm 1,991 Nm/1,400 rpm

2,200(+50/0) rpm
{407.2 HP/2,000 rpm} {203 kgm/1,400 rpm}
Low idle speed

725 25 rpm
140E-5 Series
SEN00147-07
Running-in standard
Engine
SAA6D140E-5
Machine models
HM400-2, HM400-3M0
Procedure
Item
Running time
min.
Speed
rpm
725
1,260
1,580
1,820
2,000
Dynamometer load
N{kg}
0{0}
893{91}
1,423{145}
1,854{189}
2,249{230}
Output
kW{HP}
0{0}
84{113}
169{227}
253{339}
338{453}
a
a

Engine
SAA6D140E-5
Machine models
HM400-2, HM400-3M0
Test item
Rated horsepower
Max. torque
High idle speed
Specification value
(Gross value)
Speed
rpm
2,000
1,400
2,200(+50/0)
725 25
Dynamometer load
N
{kg}
2,185 to 2,313
{223 to 236}
2,832 to 2,999
{289 to 306}
kW
{HP}
327 to 348
{439 to 466}
Nm
{kgm}
2,029 to 2,146
{207 to 219}
Fuel consumption
sec/300cc
Min. 13.0
Coolant temperature
70 to 90
70 to 90
70 to 90
70 to 90
Lubricating oil
temperature
90 to 110
90 to 110
90 to 110
80 to 110
Lubricating oil
pressure
kPa
{kg/cm2}
340 to 490
{3.5 to 5.0}
340 to 490
{3.5 to 5.0}
340 to 490
{3.5 to 5.0}
Min. 120
{Min. 1.2}
Exhaust temperature
Max. 650
Max. 650
a
a
a
a
a
a
338 kW/2,000 rpm 2,090 Nm/1,400 rpm

2,200(+50/0) rpm
{452.6 HP/2,000 rpm} {213 kgm/1,400 rpm}
Low idle speed

725 25 rpm
140E-5 Series
33
SEN00147-07
Running-in standard
Engine
SAA6D140E-5
Machine models
HM400-2R, HM400-3R
Procedure
Item
Running time
min.
Speed
rpm
725
1,260
1,580
1,820
2,000
Dynamometer load
N{kg}
0{0}
893{91}
1,423{145}
1,854{189}
2,249{230}
Output
kW{HP}
0{0}
84{113}
169{227}
253{339}
338{453}
a
a

Engine
SAA6D140E-5
Machine models
HM400-2R, HM400-3R
Test item
Rated horsepower
Max. torque
High idle speed
Specification value
(Gross value)
Speed
rpm
2,000
1,400
2,200(+50/0)
725 25
Dynamometer load
N
{kg}
2,185 to 2,313
{223 to 236}
2,832 to 2,999
{289 to 306}
kW
{HP}
327 to 348
{439 to 466}
Nm
{kgm}
2,029 to 2,146
{207 to 219}
Fuel consumption
sec/300cc
Min. 13.0
Coolant temperature
70 to 90
70 to 90
70 to 90
70 to 90
Lubricating oil
temperature
90 to 110
90 to 110
90 to 110
80 to 110
Lubricating oil
pressure
kPa
{kg/cm2}
340 to 490
{3.5 to 5.0}
340 to 490
{3.5 to 5.0}
340 to 490
{3.5 to 5.0}
Min. 120
{Min. 1.2}
Exhaust temperature
Max. 670
Max. 670
a
a
a
a
a
a
34
338 kW/2,000 rpm 2,090 Nm/1,400 rpm

2,200(+50/0) rpm
{452.6 HP/2,000 rpm} {213 kgm/1,400 rpm}
Low idle speed

725 25 rpm
140E-5 Series
SEN00147-07
Running-in standard
Engine
SAA6D140E-5
Machine models

Procedure
Item
Running time
min.
Speed
rpm
875
1,134
1,422
1,638
1,800
Dynamometer load
N{kg}
0{0}
1,087{111}
1,733{177}
2,253{230}
2,751{281}
Output
kW{HP}
0{0}
92{123}
185{248}
277{371}
371{498}
a
a

Engine
SAA6D140E-5
Machine models
Test item
Rated horsepower
Max. torque
High idle speed
Low idle speed
Specification value
(Gross value)
371 kW/1,800 rpm

{498 HP/1,800 rpm}
1,890 50 rpm
875 25 rpm
Speed
rpm
1,800
1,890 50
875 25
Dynamometer load
N
{kg}
2,695 to 2,813
{275 to 287}
kW
{HP}
360 to 382
{483 to 512}
Nm
{kgm}
Fuel consumption
sec/300cc
Min. 10.8
Coolant temperature
70 to 90
70 to 90
70 to 90
Lubricating oil
temperature
90 to 110
90 to 110
80 to 110
Lubricating oil
pressure
kPa
{kg/cm2}
340 to 490
{3.5 to 5.0}
{}
340 to 490
{3.5 to 5.0}
Min. 120
{Min. 1.2}
Exhaust temperature
Max. 670
a
a
a
a
a
a
140E-5 Series
35
SEN00147-07

2012 KOMATSU
All Rights Reserved
36
SEN00149-05
ENGINE
1SHOP MANUAL
140E-5 Series
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
SEN00149-05
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
140E-5 Series
SEN00149-05
Testing and adjusting (with EGR)

Testing and adjusting tools list
Testing and
adjusting item
Symbol
Part No.
Part name
Q'ty
Remarks
799-201-2202 Boost gauge kit
101 200 kPa {760 1,500 mmHg}
799-401-2220 Hose
I-coupler type (if necessary)
Testing air boost

pressure
Testing exhaust
temperature
799-101-1502 Digital thermometer
99.9 1,299C
Adjusting valve
clearance
Commercially
Clearance gauge
available
Intake: 0.35 mm
Exhaust: 0.57 mm
1 795-502-1590 Compression gauge
0 7 MPa {0 70 kg/cm2}
Testing compression
pressure
795-471-1330 Adapter
6261-71-6150 Gasket
799-201-1504 Blow-by checker
0 5 kPa {0 500 mmH2O}
799-101-5002 Hydraulic tester
Pressure gauge:
2.5, 6, 40, 60 MPa
{25, 60, 400, 600 kg/cm2}
790-261-1204 Digital hydraulic tester
Pressure gauge: 60 MPa {600 kg/cm2}
2 799-401-2320 Hydraulic tester
Pressure gauge:
2.5, 6, 40, 60 MPa
{25, 60, 400, 600 kg/cm2}
795-471-1450 Adapter
8 1.25 mm o R1/8
07005-00812 Gasket
1 6151-51-8490 Spacer
Inside diameter: 14 mm
2 6206-71-1770 Joint
Inside diameter of joint: 10 mm
Commercially
Hose
available
5mm 2 3 m
H 4
Commercially
Hose
available
15mm 2 3 m
Commercially
Measuring cylinder
available
Commercially
Stopwatch
available
Testing blow-by
pressure
Testing engine oil pressure
Testing EGR valve and
bypass valve drive oil
pressure
2
E
1
Testing fuel pressure
2 799-401-2320 Gauge
3
Testing fuel return rate

and leakage
140E-5 Series
For 140E-5
SEN00149-05
Testing and
adjusting item
Troubleshooting for
controllers, sensors,
and actuators
Symbol
Part No.
Part name
Q'ty
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
795-799-5530 T-adapter
For coolant temperature sensor

For fuel temperature sensor
799-601-9020 T-adapter
For EGR valve solenoid

For bypass valve solenoid
799-601-9030 T-adapter
For EGR valve stroke sensor

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)
799-601-4210 T-adapter
799-601-4220 T-adapter
799-601-9320 T-box
799-601-9310 Plate
799-601-4350 T-box
For 60-pole type
Checking coolant temperature and oil temperature
Checking voltage and

resistance
Commercially
Tester
available
Removal and installation of engine coolant

temperature sensor
Commercially
Socket
available
For 24-pole type
99.9 1,299C
21 mm deep socket
(MITOLOY 4ML 21 or equivalent)
Applicable engine serial No.:
530056-534132
19 mm deep socket
534133 and up
795T-981-1010 Socket
Remarks
140E-5 Series
Sketches of special tools
SEN00149-05
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
Socket
140E-5 Series
SEN00149-05
Testing air boost pressure

a
Testing tools for air boost pressure
Symbol
A
k
a
1.
Part No.
Part name
799-201-2202
Boost gauge kit
799-401-2220
Hose
Be careful not to touch any hot part when

removing or installing the testing tools.
The test point is subject to machine models.
Remove air boost pressure pickup plug (1)
from the bottom of the air intake connector.
4.
2.
Install nipple [1] of boost gauge kit A and connect it to gauge [2].
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.
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 installing.
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
iron.
aluminum.
140E-5 Series
SEN00149-05
Testing exhaust temperature

a
Testing tool for exhaust temperature
Symbol
Part No.
799-101-1502
a
1.
Part name
Digital thermometer
Remove and install the testing tools after

the exhaust manifold temperature has lowered.
Remove exhaust temperature pickup plug (1)
from the bottom of the exhaust manifold.
a You may measure at either front or rear
plug.
2.
Install sensor [1] of digital thermometer B and

connect it to thermometer [2].
3.
Run the engine and test the exhaust temperature in the whole speed range.
machine.
140E-5 Series
4.

q
Clean the thread of the removed plug and
apply seizure prevention compound to the
plug before installing.
2 Plug: Seizure prevention compound (LC-G)
(NEVER-SEEZ (NEVER-SEEZ COMPOUND CO, LTD) or equivalent).
3 Plug: 2.9 5.9 Nm {0.3 0.6 kgm}
SEN00149-05
Adjusting valve clearance

a
Part No.
Commercially
available
2.
3.
While fixing adjustment screw (3), loosen locknut (4).

a After setting the No. 1 cylinder to the compression top dead center, adjust the valve
clearance of the No. 1 cylinder.
4.
Insert clearance gauge C in the clearance

between rocker arm (5) and crosshead (6) and
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 locknut (4).

3 Locknut: 45.1 51.0 Nm {4.6 5.2 kgm}
a After tightening the locknut, check the
valve clearance again.
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}
Adjusting tool for valve clearance
Symbol
1.
Part name
Clearance gauge
Remove 6 cylinder head covers (1).
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 compression 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.
140E-5 Series
SEN00149-05
Testing compression pressure

a
Testing tools for compression pressure
Symbol
1
D
1.
Part No.
Part name
795-502-1590
Compression gauge
795-471-1330
Adapter
6261-71-6150
Gasket
When measuring the compression pressure, take care not to burn yourself on the
exhaust manifold, muffler, etc. or get
caught in a rotating part.
Measure the compression pressure after the
engine is warmed up (Engine oil temperature:
40 60C).
4.
Install adapter D2 to the mounting hole on the

injector and the compression gauge D1.
a Fit the gasket to the adapter end without
fail.
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.
6.
Connect the INSITE (bench test tool) to the

engine and set the engine in the no-injection
cranking mode.
a When inspecting with the engine mounted
on the machine, set the engine in the noinjection cranking mode by operating the
monitor panel.
k If the engine is not set in the no-injection cranking mode, it will start and will
be dangerous. Accordingly, be sure to
set the engine in this mode.
Remove cylinder head cover (1) of the cylinder

to be tested for compression pressure.
2.
Bring the cylinder to be tested to the compression 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 wiring 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
(Loosen the 2 terminal nuts alternately).
a Pass a wire, etc. under the fuel path projected sideways and pull up the injector
(Do not pry the injector top up).
140E-5 Series
SEN00149-05
7.
Rotate the engine with the starting motor and

measure the compression pressure.
a Read the pressure gauge pointer when it
is stabilized.
8.

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) temporarily.
2 Spherical part of washer: Engine oil
3) Tighten sleeve nut (15) of the fuel highpressure 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}
Install the injector wiring harness according 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
Adjust the valve clearance. For details, see

Adjusting valve clearance.
10
Rocker arm assembly mounting bolt:

93 103 Nm {9.5 10.5 kgm}
Cylinder head cover mounting bolt:

29.4 34.3 Nm {3.0 3.5 kgm}
140E-5 Series
SEN00149-05
Testing blow-by pressure

a
Testing tool for blow-by pressure
Symbol
Part No.
799-201-1504
Part name
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].
3.

blow-by pressure.
machine.
4.

140E-5 Series
11
SEN00149-05

a
Testing tools for engine oil pressure
Symbol
F
1
2
Part No.
Part name
799-101-5002
Hydraulic tester
790-261-1204
Digital hydraulic tester
799-401-2320
Hydraulic tester
1.
Remove oil pressure pickup plug (1) from the

cylinder block.
4.
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

q
sealant (LG-5)
3 Plug:
16.7 37.2 Nm {1.7 3.8 kgm}
140E-5 Series
SEN00149-05
Testing EGR valve and bypass

a
Connect hydraulic tester [2] (Component part

of tool F1) to the nipple.
4.
Start the engine and measure the oil pressure

at low idle and high idle.
5.
After finishing measurement, remove the measuring instruments and return the removed
parts.
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 sealant (LG-5)
3 Plug: 9.8 19.6 Nm {1.0 2.0 kgm}
Testing instrument for EGR valve and bypass

Symbol
F
3.
Part No.
Part name
799-101-5002
Hydraulic tester
790-261-1204
The measuring point may be different from the

following explanation, depending on each
applicable machine.
1.

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.
140E-5 Series
13
SEN00149-05
Handling fuel system parts

a
14
Precautions for testing and maintaining fuel

system
The common rail fuel injection system (CRI)
consists of more precise parts than the conventional fuel injection pump and nozzle. If foreign matter enters this system, it can cause a
trouble.
When testing and maintaining the fuel system,
take care more than the past. If dust, etc.
sticks to any part, wash that part thoroughly
with clean fuel.
Precautions for replacing fuel filter cartridge
Be sure to use the Komatsu genuine fuel filter
cartridge.
Since the common rail fuel injection system
(CRI) consists of more precise parts than the
conventional fuel injection pump and nozzle, it
employs a high-efficiency special filter to prevent foreign matter from entering it. If a filter
other than the genuine one is used, the fuel
system may have a trouble. Accordingly,
never use such a filter.
Releasing residual pressure in

fuel system
a
Pressure is generated in the low-pressure circuit and high-pressure circuit of the fuel system while the engine is running.
Low-pressure circuit:
Feed pump Fuel filter Supply pump
High-pressure circuit:
Supply pump Common rail Injector
The pressure in both low-pressure circuit and
high-pressure circuit lowers to a safety level
automatically 30 seconds after the engine is
stopped.
Before the fuel circuit is tested and its parts are
removed, the residual pressure in the fuel circuit must be released completely. Accordingly,
observe the following.
Before testing the fuel system or removing
its parts, wait at least 30 seconds after stopping the engine until the residual pressure
in the fuel circuit is released. (Do not start
the work just after stopping the engine
since there is residual pressure.)
140E-5 Series
SEN00149-05

a
1
2
3
a
k
1.
3.
Testing tools for fuel pressure
Symbol
Part No.
Part name
799-101-5002
Hydraulic tester
790-261-1204
799-401-2320
Gauge
795-471-1450
Adapter
07005-00812
Gasket
Engine speed
Fuel pressure
High idle
0.15 0.3 MPa

{1.5 3 kg/cm2}
Check the fuel pressure in only the low-pressure circuit from the feed pump via the fuel filter to the supply pump.
Since the pressure in the high-pressure circuit from the supply pump through the
common rail to the injector is very high, it
cannot be measured.
Remove fuel pressure pickup plug (1) from the
fuel filter head.
4.
2.
Run the engine at high idle and measure the

fuel pressure.
a If the fuel pressure is in the following
range, it is normal.

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

tester G1, and nipple [2] and connect them to
gauge G2.
140E-5 Series
15
SEN00149-05
Reduced cylinder mode

operation
No-injection cranking
a
1.
2.
3.
16
Reduced cylinder mode operation means to

run the engine with the fuel injectors of 1 or
more cylinders disabled electrically to reduce
the number of effective cylinders. The purposes and effects of this operation are as follows.
This operation is used to find out a cylinder
which does not output power normally (or,
combustion in it is abnormal).
When a cylinder is selected for the reduced
cylinder mode operation, if the engine speed
and output do not change from the normal
operation (all-cylinder operation), that cylinder
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
controls the injector of each cylinder electronically, the operator can perform the reduced cylinder mode operation easily with switches to
find out a defective cylinder.
a Perform the reduced cylinder mode operation 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).
No-injection cranking means to crank the

engine with the starting motor while all the
injections are stopped electrically. The purpose and effect of this operation are as follows.
Before the engine is started after it or the
machine has been stored for a long period, the
no-injection cranking is performed to lubricate
the engine parts and protect them from seizure.
Perform the no-injection operation 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).
140E-5 Series
SEN00149-05
Testing fuel return rate and leakage
Type of engine having intake manifold equipped with return block
If the engine has the intake manifold equipped

with the return block on it to return the fuel
spilling from the injector to the fuel tank, test
the fuel return rate and fuel leakage according
to the following procedure (The figure shows
the engine for D155AX-6).
Testing tools for fuel return rate and leakage
Symbol
Part No.
Part name
6151-51-8490
Spacer
6206-71-1770
Joint
Commercially available Hose
Commercially available Measuring cylinder
Commercially available Stopwatch
1.
Preparation work
1) Remove tube (3) between common rail (1)
and supply pump (2).
2) Insert spacer H1 on supply pump (2) side
and tighten the removed joint bolt again.
a Connect the return pipe to the fuel
tank again, too.
a Be sure to fit the gaskets to both ends
of the spacer.
Prepare a receiving pan of about 20 l to

receive the fuel flowing out during the test.
140E-5 Series
17
SEN00149-05
3)
4)
2.
18
Insert joint H2 on common rail (1) side and

tighten the removed joint bolt again.
of the joint.
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.
a The above is the preparation work for
testing the leakage from the pressure
limiter.
Testing leakage from pressure limiter

1) Lay test hose H3 so that it will not slacken
and put its end in the receiving pan.
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.
a You may test for 20 seconds and
judge by multiplying the result by 3.
5)
3.
If the leakage from the pressure limiter is in the following range, it is normal.
Engine speed
Leakage
(cc/min)
At rated output
Max. 10
After finishing testing, stop the engine.
Testing return rate from injector

a Keep the hose on the pressure limiter side
connected and keep its end in the receiving 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.
3)
Connect INSITE (bench test tool) to the

engine speed.
q
140E-5 Series
4)
5)
6)
4.
SEN00149-05
Run the engine at the rated output.

After the engine speed is stabilized, test
the return rate in 1 minute with measuring
cylinder H5.
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 injector is in the following range, it is normal.
Rated output
speed (rpm)
Limit of return rate

(spill) (cc/min)
1,600
960
1,700
1,020
1,800
1,080
1,900
1,140
2,000
1,200
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
SEN00149-05
Bleeding air from fuel circuit
a
a
1.
20
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.
The locations of the fuel circuit parts are subject to machine models (The figure shows the
engine for D155AX-6).
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).
a After filling the fuel pre-filter with fuel,
remove the cap from part (a).
a If clean fuel is not available, do not
remove the fuel pre-filter but fill it with the
fuel by operating priming pump (4).
a Do not add fuel to fuel main filter (2) from
outside.
2.
Install fuel pre-filter (1) to the filter head.

a Apply engine oil thinly over the packing on
the fuel pre-filter side.
a After the packing of the fuel pre-filter
touches the sealing face of the filter head,
tighten the fuel pre-filter 3/4 turns.
140E-5 Series
SEN00149-05
6.
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
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.
21
SEN00149-05
Testing fuel system for leakage 1

k
9.
Very high pressure is generated in the highpressure circuit of the fuel system. If fuel
leaks while the engine is running, it is dangerous since it can catch fire.
After testing the fuel system or removing
its parts, test it for fuel leakage according
to the following procedure.
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 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.
3.
Inspect the fuel piping and devices for fuel

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.
5.

leakage.
for fuel leakage.
6.
Run the engine at high idle.
7.

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

leakage.
for fuel leakage.
a If no fuel leakage is detected, inspection is
completed.
140E-5 Series
SEN00149-05
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 alternator (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
SEN00149-05
Testing and adjusting fan belt tension
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.
Before disconnecting or connecting the connector 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
SEN00149-05
25
SEN00149-05
Testing and adjusting (EGR-less)
Testing and adjusting tools list
Testing and
adjusting item
Symbol
799-401-2220 Hose
I-coupler type (if necessary)
99.9 1,299C
Commercially
Clearance gauge
available
Intake: 0.35 mm
Exhaust: 0.57 mm
1 795-502-1590 Compression gauge
0 7 MPa {0 70 kg/cm2}
Adjusting valve
clearance
795-471-1330 Adapter
6261-71-6150 Gasket
799-201-1504 Blow-by checker
0 5 kPa {0 500 mmH2O}
Pressure gauge:
2.5, 6, 40, 60 MPa
{25, 60, 400, 600 kg/cm2}
2 799-401-2320 Hydraulic tester
Pressure gauge:
2.5, 6, 40, 60 MPa
{25, 60, 400, 600 kg/cm2}
795-471-1450 Adapter
8 1.25 mm o R1/8
07005-00812 Gasket
1 6151-51-8490 Spacer
Inside diameter: 14 mm
2 6206-71-1770 Joint
Inside diameter of joint: 10 mm
Commercially
Hose
available
5mm 2 3 m
H 4
Commercially
Hose
available
15mm 2 3 m
Commercially
Measuring cylinder
available
Commercially
Stopwatch
available
Testing blow-by
pressure
2
E
1
G
2 799-401-2320 Gauge
3
Testing fuel return rate

and leakage
26
Remarks
101 200 kPa {760 1,500 mmHg}
Testing exhaust
temperature
Q'ty
1
Part name
799-201-2202 Boost gauge kit
Testing air boost

pressure
Testing compression
pressure
Part No.
For 140E-5
140E-5 Series
Testing and
adjusting item
Troubleshooting for
controllers, sensors,
and actuators
Symbol
SEN00149-05
Part No.
Part name
Q'ty
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
795-799-5530 T-adapter
799-601-9430 T-adapter
For supply pump PCV
799-601-9020 T-adapter
For injector
799-601-4260 T-adapter
799-601-4210 T-adapter
799-601-4220 T-adapter
799-601-9320 T-box
799-601-9310 Plate
799-601-4350 T-box
For 60-pole type
Checking coolant temperature and oil temperature
Checking voltage and

resistance
Commercially
Tester
available
Removal and installation of engine coolant

temperature sensor
Commercially
Socket
available
For coolant temperature sensor

For fuel temperature sensor
For 24-pole type
99.9 1,299C
21 mm deep socket
530056-534132
19 mm deep socket
534133 and up
795T-981-1010 Socket
140E-5 Series
Remarks
27
SEN00149-05
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
Socket
28
140E-5 Series
SEN00149-05
Testing air boost pressure

a
Testing tools for air boost pressure
Symbol
A
k
a
1.
Part No.
Part name
799-201-2202
Boost gauge kit
799-401-2220
Hose
Be careful not to touch any hot part when

removing or installing the testing tools.
Remove air boost pressure pickup plug (1)
from the bottom of the air intake connector.
4.
2.
Install nipple [1] of boost gauge kit A and connect it to gauge [2].
3.

air boost pressure.
machine.
140E-5 Series

q
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)
iron.
aluminum.
29
SEN00149-05
Testing exhaust temperature

a
Testing tool for exhaust temperature
Symbol
Part No.
799-101-1502
Part name
Digital thermometer
Remove and install the testing tools after

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

from the bottom of the exhaust manifold.
3.
Install sensor [1] of digital thermometer B and

connect it to thermometer [2].
4.
Run the engine and test the exhaust temperature in the whole speed range.
machine.
30
5.

q
Clean the thread of the removed plug and
apply seizure prevention compound to the
plug before installing.
2 Plug: Seizure prevention compound (LC-G)
(NEVER-SEEZ (NEVER-SEEZ COMPOUND CO, LTD) or equivalent).
3 Plug: 2.9 5.9 Nm {0.3 0.6 kgm}
140E-5 Series
SEN00149-05

a
Part No.
Commercially
available
2.
3.
While fixing adjustment screw (3), loosen locknut (4).

a After setting the No. 1 cylinder to the compression top dead center, adjust the valve
clearance of the No. 1 cylinder.
4.
Insert clearance gauge C in the clearance

between rocker arm (5) and crosshead (6) and
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 locknut (4).

3 Locknut: 45.1 51.0 Nm {4.6 5.2 kgm}
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}
Adjusting tool for valve clearance
Symbol
1.
Part name
Clearance gauge
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 compression 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.
140E-5 Series
31
SEN00149-05
Testing compression pressure

a
Testing tools for compression pressure
Symbol
1
D
1.
Part No.
Part name
795-502-1590
Compression gauge
795-471-1330
Adapter
6261-71-6150
Gasket
When measuring the compression pressure, take care not to burn yourself on the
exhaust manifold, muffler, etc. or get
caught in a rotating part.
Measure the compression pressure after the
engine is warmed up (Engine oil temperature:
40 60C).
Install adapter D2 to the mounting hole on the

injector and the compression gauge D1.
a Fit the gasket to the adapter end without
fail.
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}
6.
Connect the INSITE (bench test tool) to the

engine and set the engine in the no-injection
cranking mode.
a When inspecting with the engine mounted
on the machine, set the engine in the noinjection cranking mode by operating the
monitor panel.
k If the engine is not set in the no-injection cranking mode, it will start and will
be dangerous. Accordingly, be sure to
set the engine in this mode.
Remove cylinder head cover (1) of the cylinder

to be tested for compression pressure.
2.
Bring the cylinder to be tested to the compression 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 wiring 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
(Loosen the 2 terminal nuts alternately).
a Pass a wire, etc. under the fuel path projected sideways and pull up the injector
(Do not pry the injector top up).
32
4.
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.
8.

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) temporarily.
2 Spherical part of washer: Engine oil
3) Tighten sleeve nut (15) of the fuel highpressure 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}
SEN00149-05
Install the injector wiring harness according 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}
Adjust the valve clearance. For details, see

Adjusting valve clearance.
Cylinder head cover mounting bolt:

29.4 34.3 Nm {3.0 3.5 kgm}
140E-5 Series
33
SEN00149-05
Testing blow-by pressure

a
Testing tool for blow-by pressure
Symbol
Part No.
799-201-1504
Part name
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].
3.

blow-by pressure.
machine.
4.

34
140E-5 Series
SEN00149-05

a
Testing tools for engine oil pressure
Symbol
F
1
2
Part No.
Part name
799-101-5002
Hydraulic tester
790-261-1204
799-401-2320
Hydraulic tester
1.

cylinder block.
4.
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

q
sealant (LG-5)
3 Plug:
16.7 37.2 Nm {1.7 3.8 kgm}
35
SEN00149-05
Handling fuel system parts

a
36
Precautions for testing and maintaining fuel

system
The common rail fuel injection system (CRI)
consists of more precise parts than the conventional fuel injection pump and nozzle. If foreign matter enters this system, it can cause a
trouble.
When testing and maintaining the fuel system,
take care more than the past. If dust, etc.
sticks to any part, wash that part thoroughly
with clean fuel.
Precautions for replacing fuel filter cartridge
Be sure to use the Komatsu genuine fuel filter
cartridge.
(CRI) consists of more precise parts than the
conventional fuel injection pump and nozzle, it
employs a high-efficiency special filter to prevent foreign matter from entering it. If a filter
other than the genuine one is used, the fuel
system may have a trouble. Accordingly,
never use such a filter.
Releasing residual pressure in

fuel system
a
Pressure is generated in the low-pressure circuit and high-pressure circuit of the fuel system while the engine is running.
Low-pressure circuit:
Feed pump Fuel filter Supply pump
High-pressure circuit:
Supply pump Common rail Injector
The pressure in both low-pressure circuit and
high-pressure circuit lowers to a safety level
automatically 30 seconds after the engine is
stopped.
Before the fuel circuit is tested and its parts are
removed, the residual pressure in the fuel circuit must be released completely. Accordingly,
observe the following.
Before testing the fuel system or removing
its parts, wait at least 30 seconds after stopping the engine until the residual pressure
in the fuel circuit is released. (Do not start
the work just after stopping the engine
since there is residual pressure.)
140E-5 Series
SEN00149-05

a
1
2
3
a
k
1.
3.
Testing tools for fuel pressure
Symbol
Part No.
Part name
799-101-5002
Hydraulic tester
790-261-1204
799-401-2320
Gauge
795-471-1450
Adapter
07005-00812
Gasket
Engine speed
Fuel pressure
High idle
0.15 0.3 MPa

{1.5 3 kg/cm2}
Check the fuel pressure in only the low-pressure circuit from the feed pump via the fuel filter to the supply pump.
Since the pressure in the high-pressure circuit from the supply pump through the
common rail to the injector is very high, it
cannot be measured.
Remove fuel pressure pickup plug (1) from the
fuel filter head.
4.
2.
Run the engine at high idle and measure the

fuel pressure.
a If the fuel pressure is in the following
range, it is normal.

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

G1, and connect them to gauge G2.
140E-5 Series
37
SEN00149-05
Reduced cylinder mode operation1
No-injection cranking
1.
2.
3.
38
Reduced cylinder mode operation means to

run the engine with the fuel injectors of 1 or
more cylinders disabled electrically to reduce
the number of effective cylinders. The purposes and effects of this operation are as follows.
This operation is used to find out a cylinder
which does not output power normally (or,
combustion in it is abnormal).
When a cylinder is selected for the reduced
cylinder mode operation, if the engine speed
and output do not change from the normal
operation (all-cylinder operation), that cylinder
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
controls the injector of each cylinder electronically, the operator can perform the reduced cylinder mode operation easily with switches to
find out a defective cylinder.
a Perform the reduced cylinder mode operation 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).
No-injection cranking means to crank the

engine with the starting motor while all the
injections are stopped electrically. The purpose and effect of this operation are as follows.
Before the engine is started after it or the
machine has been stored for a long period, the
no-injection cranking is performed to lubricate
the engine parts and protect them from seizure.
Perform the no-injection operation 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).
140E-5 Series
SEN00149-05
Testing fuel return rate and leakage
Type of engine having intake manifold equipped with return block
If the engine has the intake manifold equipped

with the return block on it to return the fuel
spilling from the injector to the fuel tank, test
the fuel return rate and fuel leakage according
to the following procedure (The figure shows
the engine for WA500-6R).
Testing tools for fuel return rate and leakage
Symbol
1
2
H
Part No.
Part name
6151-51-8490
Spacer
6206-71-1770
Joint
Commercially available Measuring cylinder
Commercially available Stopwatch
1.
Preparation work
1) Remove tube (3) between common rail (1)
and supply pump (2).
2) Insert spacer H1 on supply pump (2) side
and tighten the removed joint bolt again.
a Connect the return pipe to the fuel
tank again, too.
of the spacer.
Prepare a receiving pan of about 20 l to

receive the fuel flowing out during the test.
140E-5 Series
39
SEN00149-05
3)
4)
2.
40
Insert joint H2 on common rail (1) side and

tighten the removed joint bolt again.
of the joint.
Connect test hose H3 to the end of joint
H2.
from coming off.
a The above is the preparation work for
testing the leakage from the pressure
limiter.
Testing leakage from pressure limiter

2) Connect INSITE (bench test tool) to the
engine speed.
q
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.
5)
3.
If the leakage from the pressure limiter is in the following range, it is normal.
Engine speed
Leakage
(cc/min)
At rated output
Max. 10
Testing return rate from injector

a Keep the hose on the pressure limiter side
connected and keep its end in the receiving 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.
3)
Connect INSITE (bench test tool) to the

engine speed.
q
140E-5 Series
4)
5)
6)
4.
SEN00149-05
Run the engine at the rated output.

After the engine speed is stabilized, test
the return rate in 1 minute with measuring
cylinder H5.
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 injector is in the following range, it is normal.
Rated output
speed (rpm)
Limit of return rate

(spill) (cc/min)
1,600
960
1,700
1,020
1,800
1,080
1,900
1,140
2,000
1,200
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
SEN00149-05
Bleeding air from fuel circuit
4.
Reference: The electric priming pump switch is

installed to the chassis.
a
a
Turn ON switch (3) of electric priming pump

(2) installed to the chassis.
a The electric priming pump operates and
lamp (4) blinks.
Manual priming pump is set for some models.

(See the "with EGR".)
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
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

is open.
3.
Turn lever (1) of the air bleeding piping to the

parallel position with the piping to open the circuit valve.
a
a
k
The electric priming pump has a timer in it

to start and stop itself automatically (See
the following figure).
The electric priming pump stops while the
lamp is blinking. This phenomenon is not
abnormal, however.
If the switch is turned to the OFF position
while the lamp is blinking, the lamp goes
off and the electric priming pump stops.
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.
42
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.
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 circuit valve.
SEN00149-05
9.
Start the engine with the starting motor.

a Do not operate the starting motor continuously 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 bleeding 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 operating, crank the engine.
q
If the engine does not start, repeat the
above operation.
a Do not operate the starting motor continuously 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
SEN00149-05
Testing fuel system for leakage 1

k
9.
Very high pressure is generated in the highpressure circuit of the fuel system. If fuel
leaks while the engine is running, it is dangerous since it can catch fire.
After testing the fuel system or removing
its parts, test it for fuel leakage according
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 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.
3.

leakage.
for fuel leakage.
4.
5.

leakage.
for fuel leakage.
6.
7.

leakage.
for fuel leakage.
8.

a When testing the engine mounted on the
relieve the oil from the hydraulic pump.
44

leakage.
for fuel leakage.
a If no fuel leakage is detected, inspection is
completed.
140E-5 Series
SEN00149-05
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 alternator (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
SEN00149-05
Testing and adjusting fan belt tension
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
SEN00149-05
Handling controller high-voltage

circuit
1
1.
Before disconnecting or connecting the connector 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
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
SEN00151-04
40 Troubleshooting
Points to remember when troubleshooting

k
k
k
k
k
k
When troubleshooting a machine, stop it in a level ground, and check that the lock pin, chocks,
and parking brake are securely fitted.
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.
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.
Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
When disconnecting wiring, always disconnect the negative (-) terminal of the battery first.
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 connect 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 questions to form some idea of possible causes of the failure that would produce the reported symptoms.
1.
2.
3.
When carrying out troubleshooting, do not

hurry to disassemble the components.
If components are disassembled immediately
after any failure occurs:
q
Parts that have no connection with the failure or other unnecessary parts will be disassembled.
q
It will become impossible to find the cause
of the failure.
It will also cause a waste of manhours, parts,
or oil or grease, and at the same time, will also
lose the confidence of the user or operator.
For this reason, when carrying out troubleshooting, it is necessary to carry out thorough prior
investigation and to carry out troubleshooting in
accordance with the fixed procedure.
Points to ask user or operator
1) Have any other problems occurred apart
from the problem that has been reported?
2) Was there anything strange about the
machine before the failure occurred?
3) Did the failure occur suddenly, or were
there problems with the machine condition
before this?
4) Under what conditions did the failure
occur?
5) Had any repairs been carried out before
the failure? When were these repairs carried out?
6) Has the same kind of failure occurred
before?
Check before troubleshooting
1) Check for symptoms of any abnormality in
the machine and engine.
2) Be sure to check the CHECKS BEFORE
STARTING items.
3)
4)
5)
Check other inspection items, if necessary.

Some other maintenance items can be
checked externally, so check any item that
is considered to be necessary.
Check the controller for display of an error.
4.
Confirming failure
Confirm the extent of the failure yourself, and
judge whether to handle it as a real failure or
as a problem with the method of operation, etc.
a When operating the machine or engine to
reenact the troubleshooting symptoms, do
not carry out any investigation or measurement that may make the problem
worse.
5.
Troubleshooting
Use the results of the investigation and inspection in Items 2 4 to narrow down the causes
of failure, then use the troubleshooting matrix
to locate the position of the failure exactly.
a The basic procedure for troubleshooting is
as follows.
1) Start from the simple points.
2) Start from the most likely points.
3) Investigate other related parts or information.
6.
Measures to remove root cause of failure

Even if the failure is repaired, if the root cause
of the failure is not repaired, the same failure
will occur again. To prevent this, always investigate why the problem occurred. Then,
remove the root cause.
140E-5 Series
40 Troubleshooting
SEN00151-04
Method of displaying trouble diagnosis lamps (Method of displaying

error code)
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
Item
Normal display mode

Error code display mode
(While starting switch is ON or engine is running) (While starting switch is ON and engine is stopped)
When normal
Diagnosis lamp
indication selector
switch
R
Y
When error occurs

OFF
Lamp off
Either lamp lights up
When error occurs

ON
Error code is indicated by number of flashes.
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
SEN00151-04
40 Troubleshooting
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)
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 diagnosis lamp indication selector switch ON while the engine is running.
q
140E-5 Series
40 Troubleshooting
SEN00151-04
Error codes and failure codes list
For construction equipment

INSITE error code
Machine failure
code
Failure phenomenon
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
263
CA263
Fuel Temp. Sensor High Error
265
CA265
Fuel Temp. Sensor Low Error
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
323
CA323
324
CA324
325
CA325
331
CA331
332
CA332
342
CA342
Engine Controller Data Matching Error
351
CA351
INJ. Drive Circuit Error
352
CA352
386
CA386
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
Reference document No.
Troubleshooting of
electrical system
(E-mode), Part 1
SEN00153-02
SEN00151-04
40 Troubleshooting
INSITE error code
Machine failure
code
449
CA449
Rail Press. High Error 2
451
CA451
Rail Press. Sensor High Error
452
CA452
Rail Press. Sensor Low Error
553
CA553
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
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
1631
CA1631
Bypass Valve Lift Sensor High Error
1632
CA1632
Bypass Valve Lift Sensor Low Error
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
Failure phenomenon
2249
CA2249
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
Troubleshooting of
electrical system
(E-mode), Part 2
SEN00154-02
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.
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.
140E-5 Series
40 Troubleshooting
SEN00151-04
For generator
Machine failure
code
Failure phenomenon
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
CA221
Ambient Air Press. Sensor High Error
CA222
Ambient Air Press. Sensor Low Error
CA227
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
CA323
CA324
CA325
140E-5 Series
Troubleshooting of
electrical system
(E-mode), Part 1
SEN00153-02
SEN00151-04
40 Troubleshooting
Machine failure
code
Failure phenomenon
CA331
CA332
CA342
Engine Controller Data Matching Error
CA351
INJ. Drive Circuit Error
CA352
CA386
CA441
Supply Voltage Low Error
CA442
Supply Voltage High Error
CA449
CA451
Rail Press. Sensor High Error
CA452
Rail Press. Sensor Low Error
CA553
CA559
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
CA1625
CA1633
KOMNET Error
CA2185
Throttle Sens. Sup. Volt. High Error
CA2186
Throttle Sens. Sup. Volt. Low Error
CA2249
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
Troubleshooting of
electrical system
(E-mode), Part 1
SEN00153-02
Troubleshooting of
electrical system
(E-mode), Part 2
SEN00154-02
140E-5 Series
40 Troubleshooting
140E-5 Series
SEN00151-04
SEN00151-04
40 Troubleshooting
Information in troubleshooting table

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 INSITE
Display on
applicable machine
Contents of trouble
Contents of trouble detected by engine controller
Action of controller
Action taken by engine controller to protect system or devices when engine controller
detects trouble
Trouble
Trouble in engine
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
Possible causes and

standard value in
normal state
10
<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) circuit.
Short circuit
Independent wiring harnesses are in contact with each
other abnormally.
Possible causes of trouble

(Given numbers are reference numbers, which do not <Precautions for troubleshooting>
indicate priority)
1) Method of indicating connector No. and handling of Tadapter
Insert or connect T-adapter as explained below for troubleshooting, unless otherwise specified.
3
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 otherwise specified.
4
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.
140E-5 Series
40 Troubleshooting
SEN00151-04
Related circuit diagram
This drawing is a part of the electric circuit diagram related to troubleshooting.

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
SEN00151-04
Connection table for connector pin numbers

a
12
40 Troubleshooting
(Rev. 2009.04)
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.
140E-5 Series
40 Troubleshooting
140E-5 Series
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14
40 Troubleshooting
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40 Troubleshooting
T- branch box and T- branch adapter table

a
(Rev. 2009.03)
1
q q
Out of kit
799-601-4201
799-601-4101
799-601-9300
799-601-9200
799-601-9100
799-601-9000
799-601-8000
799-601-7500
799-601-7400
799-601-7100
799-601-7000
799-601-2800
Identification
symbol
799-601-2700
Part name
T-adapter kit
799-601-2500
Part No.
Number of pins
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.
799-601-2600 T-box (for ECONO)
21
799-601-3100 T-box (for MS)
37
799-601-3200 T-box (for MS)
37
q
q
799-601-3380 Plate for MS (14-pin)

799-601-3410 Adapter for BENDIX (MS)
24
MS-24P
24
MS-24P
17
MS-17P
17
MS-17P
MS-5P
10
MS-10P
MS-5P
17
MS-17P
19
MS-19P
14
MS-14P
q
q
799-601-3470 Case
799-601-2710 Adapter for MIC
MIC-5P
q q
13
MIC-13P
q q
17
MIC-17P
q q q
21
MIC-21P
q q q
MIC-9P
799-601-2750 Adapter for ECONO
ECONO2P
q q
ECONO3P
q q
ECONO4P
q q
ECONO8P
q q
12 ECONO12P q q
799-601-2810 Adapter for DLI
DLI-8P
q q
12
DLI-12P
q q
16
DLI-16P
q q
799-601-2840 Extension cable (ECONO type)
12 ECONO12P q q
q
q q
q q
q q q
799-601-2850 Case
799-601-4350 T-box (for DRC 60, ECONO)
60
799-601-4360 Case
799-601-7010 Adapter for X (T-adapter)
799-601-7020 Adapter for X
X2P
q q q
X3P
q q q
X4P
q q q
799-601-7050 Adapter for SWP
SW6P
q q q
SW8P
q q q
12
SW12P
14
SW14P
16
SW16P
799-601-7080 Adapter for M (T-adapter)
799-601-7090 Adapter for M
48
q
q
M2P
q q q
M3P
q q q
140E-5 Series
40 Troubleshooting
SEN00151-04
799-601-7150 Adapter for S (White)
10
S10P
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
Out of kit
799-601-4201
q q q
799-601-4101
S8P
799-601-9300
799-601-9200
799-601-7140 Adapter for S
799-601-9100
M8P
799-601-9000
799-601-8000
q
799-601-7500
q q q
799-601-7400
q q q
M6P
799-601-7100
M4P
799-601-7000
799-601-2800
Part name
799-601-2700
Identification
symbol
Part No.
799-601-2500
Number of pins
T-adapter kit
q
q
16
S16PW
12
S12PW
799-601-7180 Adapter for AMP040
A8P
12
A12P
16
A16P
q q q
20
A20P
q q q
799-601-7230 Short connector for X
q q q
q q
799-601-7240 Case
799-601-7270 Case
799-601-7510 Adapter for 070
10
07-10
799-601-7520 Adapter for 070
12
07-12
799-601-7530 Adapter for 070
14
07-14
799-601-7540 Adapter for 070
18
07-18
799-601-7550 Adapter for 070
20
07-20
799-601-7360 Adapter for relay
REL-5P
799-601-7370 Adapter for relay
REL-6P
799-601-7380 Adapter for JFC
799-601-9010 Adapter for DTM
DTM2
799-601-9020 Adapter for DT
DT2
DT3
DT4
DT6
799-601-9060 Adapter for DT (Gray)
DT8GR
799-601-9070 Adapter for DT (Black)
DT8B
799-601-9080 Adapter for DT (Green)
DT8G
799-601-9090 Adapter for DT (Brown)
DT8BR
799-601-9110 Adapter for DT (Gray)
12
DT12GR
799-601-9120 Adapter for DT (Black)
12
DT12B
799-601-9130 Adapter for DT (Green)
12
DT12G
799-601-9140 Adapter for DT (Brown)
12
DT12BR
799-601-9210 Adapter for HD30-18
D18-8
q q
799-601-9220 Adapter for HD30-18
14
D18-14
q q
799-601-9230 Adapter for HD30-18
20
D18-20
q q
799-601-9240 Adapter for HD30-18
21
D18-21
q q
799-601-9250 Adapter for HD30-24
D24-9
q q
799-601-9260 Adapter for HD30-24
16
D24-16
q q
799-601-9270 Adapter for HD30-24
21
D24-21
q q
799-601-9280 Adapter for HD30-24
23
D24-23
q q
799-601-9290 Adapter for HD30-24
31
D24-31
q q
799-601-9310 Plate for HD30 (24-pin)

799-601-9320 T-box (for ECONO)
140E-5 Series
24
q q
q q
q q
q q
49
Out of kit
799-601-4201
799-601-4101
799-601-9300
799-601-9200
799-601-9100
799-601-9000
799-601-8000
799-601-7500
799-601-7400
799-601-7100
799-601-7000
799-601-2800
Identification
symbol
799-601-2700
Part name
T-adapter kit
799-601-2500
Part No.
40 Troubleshooting
Number of pins
SEN00151-04
799-601-9330 Case
799-601-9340 Case
799-601-9350 Adapter for DRC
40
DRC-40
799-601-9360 Adapter for DRC
24
DRC-24
799-601-9410* Socket for engine (CRI-T2)
Adapter for engine (CRI-T2)

799-601-9420 Adapter for engine (CRI-T3) PFUEL
Oil pressure sensor
A3
q q
q q
1,2,3
795-799-5520* Socket for engine (HPI-T2)
Socket for engine (HPI-T2)

Temperature sensor
q q
q q
795-799-5460 Cable for engine (HPI-T2)
799-601-9430*
795-799-5540*
Socket for engine (CRI-T2)

Socket for engine (CRI-T3) PCV
Socket for engine (HPI-T2)

Socket for engine (CRI-T3) TIM
799-601-4110 Adapter for engine (140-T3) PIM
ITT3N
q q
799-601-4130 Adapter for engine (CRI-T3) NE, CAM
FCIN
q q
FCIG
q q
799-601-4150 Adapter for engine (CRI-T3) POIL
FCIB
q q

799-601-4160
Oil pressure switch
4160
q q
799-601-4180 Adapter for engine (CRI-T3) PEVA
4180
q q

799-601-4190*
Commonrail pressure
1,2,3L
q q
1,2,3,4C
q q
799-601-4240* Socket for engine (CRI-T3) PAMB
1,2,3A
q q
799-601-4250* Socket for engine (CRI-T3) PIM
1,2,3B
q q
799-601-4330* Socket for engine (CRI-T3) G
1,2,3,G
q q

799-601-4340*
Pump actuator
2,PA
q q
1,2,3,4T
799-601-4260 Adapter for controller (ENG)
DTP4
799-601-4140
799-601-4230*
799-601-4380*

Atomosphere pressure

Air intake pressure/temperature
Socket for engine (CRI-T3)(95)

Air intake pressure/temperature
q
q q
50
DRC50
60
DRC60
799-601-4390* Socket for controller (95 ENG)
60
799-601-4280* Box for controller (PUMP)
121
799-601-9720 Adapter for controller (HST)
16
HST16A
16
HST16B
26
HST26A
2,
3,
4,
799-601-9890
Multi-adapter for
DT2 4 and DTM2
* Shows not T-adapter but socket.
50
140E-5 Series
40 Troubleshooting
140E-5 Series
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SEN00151-04

2009 KOMATSU
All Rights Reserved
52
SEN00152-03
ENGINE
1SHOP MANUAL
140E-5 Series
40 Troubleshooting
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
SEN00152-03
40 Troubleshooting
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
140E-5 Series
40 Troubleshooting
140E-5 Series
SEN00152-03
SEN00152-03
40 Troubleshooting
Troubleshooting of mechanical system (S-mode)
Method of using troubleshooting charts
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.)
140E-5 Series
40 Troubleshooting
140E-5 Series
SEN00152-03
SEN00152-03
40 Troubleshooting
<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].
140E-5 Series
40 Troubleshooting
SEN00152-03
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
SEN00152-03
40 Troubleshooting
S-1 Starting performance is poor
General causes why starting performance is poor
Causes
Clogged air cleaner element

Cracked EGR cooler (Coolant in exhaust pipe)
["with EGR" only]
Defective contact of valve, vale seat
Worn piston ring, cylinder
Clogged air breather hole of fuel tank cap
Leaking or clogged fuel piping, entry of air
Clogged fuel filter, element
Clogged feed pump gauze filter
Stuck, seized supply pump plunger
Defective injector
Defective intake air heater system
Defective alternator (regulator section)
Defective alternator (generator section)
Defective, deteriorated battery
Defective electrical system
Coolant in exhaust pipe ("with EGR" only)
Troubleshooting
Check items
Questions
a The common rail fuel injection system (CRI) controls the fuel
injection timing electrically. Accordingly, even if the starting
operation is carried out, the engine may not start until the crankshaft revolves 2 turns at maximum. This phenomenon does not
indicate a trouble, however.
Confirm recent repair history
Degree of use of
Operated for long period
machine
Became worse gradually
Starting performance
Engine starts easily when warm
Non-specified fuel is being used
Replacement of filters has not been carried out according to Operation and Maintenance Manual
Engine oil must be added more frequently
When engine is preheated or when temperature is low, preheating monitor does
not indicate normally (if monitor is installed)
During operation, charge level monitor indicates abnormal charge (if monitor is
installed)
Dust indicator is red (if indicator is installed)
Air breather hole of fuel tank cap is clogged
Fuel is leaking from fuel piping
When priming pump is operated, it makes no reaction or it is heavy
Starting motor cranks engine slowly
If air bleeding plug of fuel filter is removed, fuel does not
While engine is
flow out
cranked with starting
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
Engine does not pick up smoothly and combustion is irregular
There is hunting from engine (rotation is irregular)
Blow-by gas is excessive
Inspect air cleaner directly
When EGR cooler outlet gas piping is removed, coolant containing antifreeze
flows out (*1) ["with EGR" only]
When compression pressure is measured, it is found to be low
When air is bled from fuel system, air comes out
Inspect fuel filter, element directly
Inspect feed pump gauze filter directly
Carry out troubleshooting according to No-pressure feed by supply pump (*2) in
E-mode
When a cylinder is cut out for reduced cylinder mode operation, engine speed
does not change
When starting switch is turned to HEAT, intake air heater mount does not become
warm
Is voltage 20 30 V between alternator terminal B and terminal E with Yes
engine at low idle?
No
When specific gravity of electrolyte and voltage of battery are measured, they are
low
Remedy
E E
Q Q ww
EE
QQ
QQQQ
wwQQ
w
w
ww
w
w
Q
w
Q
wQQ
ww
w
QQ
w
w
w
QwQQ
q
q
qq
q
q
q
q
q
q
q
Correct
Replace
Clean
Correct
Clean
Clean
Replace
Replace
Replace
Replace
Replace
Replace
Improper selection of fuel
Replace
Insufficient intake of air
Clean
Insufficient supply of fuel
140E-5 Series
40 Troubleshooting
SEN00152-03
*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, however, it is not a problem.
*2: Code [559/CA559] and code [2249/CA2249] in E-mode
140E-5 Series
SEN00152-03
40 Troubleshooting
S-2 Engine does not start
a) Engine does not turn
Defective starting circuit wiring
Defective starting motor (motor section)
Defective starting motor (safety relay section)
Problem in drive devices on applicable machine side

Carry out troubleshooting for devices on applicable machine
Defective starting switch
Defective battery relay
Water hammer caused by coolant which entered cylinder
Defective connection of battery terminal
Internal parts of engine seized

See S-4 Engine stops during operations.
Defective or deteriorated battery
General causes why engine does not turn
Broken flywheel ring gear
Cracked EGR cooler (Coolant in exhaust pipe)

["with EGR" only]
Causes
E EE
Condition of horn when Horn does not sound

starting switch is turned
Horn volume is low
ON
Battery electrolyte is low
w
Q
Q
w
When starting switch is turned ON, there is no operating sound from battery relay
Check items
When starting switch is turned to START, starting pinion does not move out
Speed of rotation is low
w
w
w
Q w
Soon disengages again
Makes rattling noise and does not turn
q
q
Inspect flywheel ring gear directly
Troubleshooting
Makes grating noise
When EGR cooler outlet gas piping is removed, coolant containing antifreeze flows out (*1).
["with EGR" only]
When specific gravity of electrolyte and voltage of battery are measured, they are low
There is not voltage (20 30 V) between battery relay terminal B and
terminal E
Turn starting switch
OFF, connect cord, and
carry out troubleshooting at ON
Battery terminal is loose
When starting switch is

turned to START, starting pinion moves out,
but
When terminal B and terminal C of starting switch are connected,

engine starts
When terminal B and terminal C at safety relay outlet are connected,

engine starts
Even if terminal B and terminal C at safety relay outlet are connected,

engine does not start
10
Replace
Replace
Replace
Correct
Replace
Replace
Replace
Remedy
Carry out troubleshooting on applicable machine side
Degree of use of
machine
Replace
Questions
140E-5 Series
40 Troubleshooting
SEN00152-03

140E-5 Series
11
SEN00152-03
40 Troubleshooting
b) Engine turns but no exhaust smoke comes out
Supply of fuel is extremely small
Use of improper fuel

Insufficient fuel in tank
Improper selection of fuel (particularly in winter)
Defective fuel injector
Fuel is not being supplied

Clogged fuel filter element
Seized, abnormally worn feed pump
General causes why engine turns but no exhaust smoke comes out
Broken supply pump shaft, key

Defective supply pump PCV
Wrong connection of supply pump PCV
Defective operation of overflow valve (Does not close)
Defective operation of flow damper
Causes
EEE
wQwww
Exhaust smoke suddenly stopped coming out (when starting again)

QQQ
QQ

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 [with EGR

only]
wQQ
When fuel filter is removed, there is not fuel in it

Check items
When fuel tank is inspected, it is found to be empty
If air bleeding plug of fuel filter is removed, fuel does not flow
While engine is
cranked with start- out
ing motor
wQ
wwww
qq
Inspect fuel filter directly

Troubleshooting
ww
EE
Inspect feed pump directly

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

12
140E-5 Series
40 Troubleshooting
SEN00152-03
c) Exhaust smoke comes out but engine does not start (fuel is being injected)

Worn dynamic valve system (Valve, rocker lever, etc.)
Worn piston ring, cylinder liner
Leaking or clogged fuel system, entry of air
Clogged fuel filter, strainer
Clogged injector, defective spray
Defective, deteriorated battery
Defective coolant temperature sensor, wiring harness
Defective intake air heater system
Causes
General causes why exhaust smoke comes out but engine does not start
Lack of rotating force due to defective electrical system
Questions
Degree of use of machine Operated for long period
EE E
w
QQ
Suddenly failed to start

Replacement of filters has not been carried out according to Operation and Maintenance
Manual
ww
w

When engine is preheated or when temperature is low, preheating monitor does not indicate
normally (if monitor is installed)
w
w
ww
When fuel filter is removed, there is not fuel in it
w
wQQ

w
w
When engine is cranked, abnormal sound is generated around cylinder head

While engine is cranked
with starting motor,
ww
w
When exhaust manifold is touched immediately after starting engine, temperature of some
cylinders is low
w
q
Inspect dynamic valve system directly

Troubleshooting
If air bleeding plug of fuel filter is removed, fuel does not flow out
Inspect fuel filter, strainer directly

Carry out troubleshooting according to No-pressure feed by supply pump (*1) in E-mode
q
q
When injector unit is tested, spray condition is bad

When specific gravity of electrolyte and voltage of battery are measured, they are low
Coolant temperature gauge does not indicate normally (if coolant temperature gauge is
installed)
When starting switch is turned to HEAT, intake air heater mount does not become warm
Remedy
q
q
q
Clean
Replace
Replace
Replace
Clean
Correct
Clean
Clean
Replace
Clean
Replace
Replace
Replace
Check items
Starting motor cranks engine slowly
140E-5 Series
13
SEN00152-03
40 Troubleshooting
S-3 Engine does not pick up smoothly
Clogged injector, defective spray
Defective operation of flow damper

(Large leakage from injector)
Defective EGR valve or bypass valve

["with EGR" only]
Defective contact of valve and valve seat

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

q
q
q
Defective condition of fuel spray
q
q
Controller is controlling in derate mode
(limiting injection rate (output) because of an error in
electrical system)
q
EGR valve is stuck open ["with EGR" only]
(There is much EGR gas and intake of air is insufficient)
Engine pick-up suddenly became worse
E E
Q Q
Q
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
w w

w Q Q
Check items
When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low
Color of exhaust gas
Blue under light load

w
Black
When engine is cranked, interference sound is generated around turbocharger

High idle speed under no load is normal, but speed suddenly drops when load is
applied
w w
Q w
w w

q

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

Carry out troubleshooting according to No-pressure feed by supply pump (*2)
in E-mode
Replace
Adjust
Replace
Replace
Clean
Correct
Clean
Clean
Replace
Replace
Remedy
Clean
does not change
q
Replace
Degree of use of machine
Replace
Questions
*1: Code [1228/CA1228] and code [1625/CA1625] or code [1628/CA1628] and code [1629/CA1629] in Emode
14
140E-5 Series
40 Troubleshooting
SEN00152-03
S-4 Engine stops during operations
1
Broken dynamic valve system (valve, rocker arm, etc.)
Broken, seized piston, connecting rod
Broken, seized crankshaft bearing
Broken, seized gear train
Leaking, clogged fuel piping
Broken, seized feed pump
Broken supply pump shaft, key
Broken auxiliary equipment (pump, compressor, etc.)
Defective engine controller power supply wiring
Defective starting switch wiring
Problem in drive devices on applicable machine side
Causes
General causes why engine stops during operations

q
Seized parts inside engine
q
q
There is overheating
q
Problem in drive devices on applicable machine
side
o Requires troubleshooting on applicable
machine side.

E E
Questions
Abnormal noise was heard and engine

stopped suddenly
Condition when engine
stopped
w w w w
w Q
Engine overheated and stopped
Q
w
Q Q
Q Q
There was hunting and engine stopped
w Q
Q Q Q
Q Q
Q Q Q
Replacement of filters has not been carried out according to Operation

and Maintenance Manual
w w
Fuel level monitor indicates low level (if monitor is installed)
w Q Q
w w

w w w
Metal particles are found when oil is drained
w w
Does not turn at all

When engine is cranked
by hand
Engine stopped slowly
Check items
Q w Q w
Turns in opposite direction
Moves by amount of gear backlash
w
w
Supply pump shaft does not turn
Engine turns, but stops when load is applied to machine

q
Inspect piston, connecting rod directly
Inspect gear train directly
Inspect feed pump directly

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

Remedy
Replace
Replace
Replace
Replace
Add
Clean
Correct
Clean
Clean
Replace
Replace
Replace
Replace
Correct
Correct
Troubleshooting
Carry out troubleshooting

on applicable machine side
Inspect crankshaft bearing directly

140E-5 Series
15
SEN00152-03
40 Troubleshooting
S-5 Engine does not rotate smoothly
Defective Bkup speed sensor, wiring harness
Defective Ne speed sensor, wiring harness
Clogged injector, defective spray (dirt in injector)
Defective operation of flow damper (Large leakage from injector)
Defective operation of bypass valve ["with EGR" only]
Low setting of low idle speed
Defective operation of EGR valve ["with EGR" only]
Causes
General causes why engine does not rotate smoothly

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

Occurs at a certain speed range
Q Q Q
Occurs at low idle
E E
Q Q
Q Q Q Q Q Q Q
Q Q
Occurs even when speed is raised
Q Q
Occurs on slopes
Q Q
w w
w
Check items
Q Q

w Q Q
Troubleshooting
Carry out troubleshooting according to Abnormality in EGR valve servo (*1) in E-mode
["with EGR" only]
Carry out troubleshooting according to Abnormality in bypass valve servo (*2) in Emode ["with EGR" only]
q
q

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

E-mode
Carry out troubleshooting according to Abnormality in engine Bkup speed sensor (*4)
in E-mode
*1:
*2:
*3:
*4:
16
Code
Code
Code
Code
Correct
Replace
Replace
Replace
Replace
Correct
Clean
Add
Replace
Replace
Correct
Remedy
q
Correct
Questions
Degree of use of machine
[1228/CA1228] and code [1625/CA1625] in E-mode

[1628/CA1628] and code [1629/CA1629] in E-mode
[689/CA689] in E-mode
[778/CA778] in E-mode
140E-5 Series
40 Troubleshooting
SEN00152-03
S-6 Engine lacks output (or lacks power)
General causes why engine lacks output
Defective drive of injector (signal, solenoid)
Q Q Q
Q
Defective fuel temperature sensor, wiring harness
Clogged injector, defective spray (dirt in injector)
Leaking, clogged fuel piping
Controller is controlling in derate mode (limiting injection rate (output) because of an error in electrical system)
See S-14 Coolant temperature becomes too high (Overheating)
Air leakage from air intake piping
Defective spray condition of fuel
Defective charge (boost) pressure sensor, wiring harness
Defective installation of charge (boost) pressure sensor (air leakage)
Causes
Power was lost
E E
Q Q
Q Q
Suddenly
Gradually

w
Q Q Q
Output becomes insufficient after short stop of operation
Check items
When exhaust manifold is touched immediately after starting engine, temperature of

some cylinders is low
w
w
High idle speed is too low

High idle speed under no load is normal, but speed suddenly drops when load is
applied
w w Q
w
Q Q
Q Q Q Q

Inspect air intake piping directly
q
q q q
When boost pressure is measured, it is found to be low
q
q

Troubleshooting

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

Carry out troubleshooting according to Abnormality in charge pressure sensor (*2) in
E-mode
Carry out troubleshooting according to Abnormality in fuel temperature sensor (*3) in
E-mode
140E-5 Series
Correct
Replace
Replace
Replace
Clean
Replace
Correct
Clean
Replace
Adjust
Replace
Replace
Correct
Remedy
Clean

Replace
w w w
Black
Replace
Questions
Degree of use of
machine
17
SEN00152-03
40 Troubleshooting
S-7 Exhaust smoke is black (incomplete combustion)
Improper fuel injection pressure
Improper injection timing
Clogged fuel spill piping (on cylinder head side)
Abnormally worn injector
Clogged, seized injector
Crushed, clogged muffler
Leakage of air between turbocharger and cylinder head
EGR gas piping is clogged ["with EGR" only]
Defective EGR valve or bypass valve ["with EGR" only]
Causes
General causes why exhaust smoke is black

q
q
Excessive injection of fuel
q
Defective condition of fuel injection
q
q
o See S-14 Coolant temperature becomes too high
(Overheating)
q
Controller is controlling in derate mode (limiting
injection rate (output) because of an error in electrical 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)

Suddenly became black

Gradually became black
color
w Q Q
Q Q
Q Q
w
Q Q

w

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

some cylinders is low
Q w
w

Torque converter stall speed or pump relief speed is high (Fuel is injected excessively)
Q Q
Exhaust noise is abnormal
Q Q
Q Q Q
Q w
w
w
If spill hose from injector is disconnected, abnormally much fuel spills

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

Carry out troubleshooting according to No-pressure feed by supply pump (*3) in Emode
When a cylinder is cut out for reduced cylinder mode operation, engine speed does
not change
q
q
q
Inspect fuel spill piping (on cylinder head side) directly

Carry out troubleshooting according to Abnormality in coolant temperature sensor
(*4) in E-mode
18
Adjust
Adjust
Correct
Replace
Replace
Replace
Replace
Replace
Adjust
Correct
Replace
Replace
Replace
Clean
Replace
Remedy
q
Replace
Questions
Degree of use of
machine
140E-5 Series
40 Troubleshooting
SEN00152-03
*1: Code [1228/CA1228] and code [1625/CA1625] or code [1628/CA1628] and code [1629/CA1629] in Emode
*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
SEN00152-03
40 Troubleshooting
S-8 Oil consumption is excessive (or exhaust smoke is blue)

General causes why oil consumption is excessive
Long-time operation of engine at low idle or high idle (Do not run engine
at idle for more than 20 minutes continuously)
External leakage of oil
Wear of parts in lubrication system
Dust sucked in from intake system

Worn, damaged valve (stem, guide, seal)
Worn seal at turbocharger end
Turbocharger
Worn seal at blower end
Oil leakage from EGR valve stem ["with EGR" only]
Clogged breather, breather hose
Broken piston ring
Worn, damaged rear oil seal
Broken oil cooler
Oil leakage from oil cooler
Oil leakage from oil filter
Oil leakage from oil piping
Oil leakage from oil drain plug
Oil leakage from oil pan, cylinder head, etc.
Causes
Abnormal consumption of oil
Questions

Degree of use of
machine
Oil consumption suddenly increased
EEEE
E
w

Oil becomes contaminated quickly
Q
Q
w
Q Q w
w w w w w
Outside of engine is dirty with oil
There are loose piping clamps in intake system
w
Q w
Inside of turbocharger exhaust outlet pipe is dirty with oil
There is oil in coolant
Oil level in clutch chamber or damper chamber is high
Exhaust smoke is blue under light load

Amount of blow-by
gas
Excessive
Troubleshooting
Q
w
None
When intake manifold is removed, dust is found inside

When intake manifold is removed, inside is found to be dirty abnormally
Excessive play of turbocharger shaft
When EGR valve is removed, exhaust port is found to be dirty with oil
["with EGR" only]
Check breather and breather hose directly
q
q
q q
q
q
q q
q
Inspect rear oil seal directly
q q
Pressure-tightness test of oil cooler shows there is leakage
q q q
There is external leakage of oil from engine

Remedy
20
w w
w w
Correct
Replace
Replace
Replace
Replace
Clean
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Check items
Inside of turbocharger intake outlet pipe is dirty with oil
140E-5 Series
40 Troubleshooting
SEN00152-03
S-9 Oil becomes contaminated quickly
General causes why oil becomes contaminated quickly
Defective turbocharger turbine side seal

Worn EGR valve guide ["with EGR" only]
Worn valve, valve guide
Clogged breather, breather hose
Clogged oil cooler
Clogged oil filter
Defective oil filter safety valve
Clogged turbocharger lubrication drain tube
Exhaust smoke is bad
Causes
Entry of exhaust gas into oil due to internal wear

Clogging of lubrication passage
Use of improper oil

Degree of use of
machine
EEEE
Q

Even when engine oil temperature rises, oil filter clogging monitor indicates clogging (if monitor is installed)
Metal particles are found when oil is drained
w
w Q
Q Q
w
Inside of exhaust pipe is dirty with oil

color
Amount of blow-by gas
Black
Excessive
None
Excessive play of turbocharger shaft

When EGR valve is removed, exhaust port is found to be dirty with oil
["with EGR" only]
q
q
q q
q
Inspect breather and breather hose directly
Inspect oil cooler directly
Inspect oil filter directly
Spring of oil filter safety valve is hitched or broken
Inspect turbocharger lubrication drain tube directly

Remedy
140E-5 Series
Q w
Replace
Replace
Replace
Replace
Clean
Replace
Replace
Replace
Clean
Troubleshooting
Check items
Engine oil temperature rises quickly
See S-7
Questions
Operation under excessive load
21
SEN00152-03
40 Troubleshooting
S-10 Fuel consumption is excessive
General causes why fuel consumption is excessive
Fuel leakage inside head cover

Fuel leakage from fuel filter, piping, etc.
Defective feed pump oil seal
Defective supply pump plunger
Defective common rail pressure
Defective spray by injector
Defective operation of injector
Improper fuel injection timing
Causes
Leakage of fuel
Defective condition of fuel injection (fuel pressure, injection timing)
Questions
Excessive injection of fuel

Degree of use of
machine
More than for other machines of same model
Condition of fuel
Gradually increased
consumption
Suddenly increased
EE
E
Q
Q
Q Q
w
There is external leakage of fuel from engine
Engine oil level rises and oil smells of diesel fuel

w
When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low
Low idle speed is high
w
w
Q
Q
Torque converter stall speed or pump relief speed is high

Exhaust smoke
color
Q Q
Black
White
Remove and inspect head cover directly
Inspect feed pump oil seal directly

Carry out troubleshooting according to No-pressure feed by supply pump (*2)
in E-mode
does not change
If spill hose from injector is disconnected, much fuel spills
Carry out troubleshooting according to Abnormality in coolant temperature
sensor (*2) in E-mode
Confirm with INSITE or with monitoring function on applicable machine side
Remedy
Q Q
q
q
q
q
q
q
Correct
Correct
Replace
Replace
Correct
Replace
Replace
Correct
Correct
Check items
Combustion is irregular
Troubleshooting
Q Q Q
Q

22
140E-5 Series
40 Troubleshooting
SEN00152-03
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)1
Causes
Internal leakage in lubrication system
Broken oil cooler core, O-ring
Insufficient protrusion of cylinder liner
Damaged cylinder liner O-ring, holes caused by pitting
Internal cracks in cylinder block
Broken cylinder head, head gasket
Internal leakage in cooling system
Broken hydraulic oil cooler or power train oil cooler on applicable machine side
General causes why oil is in coolant

Oil level
Q Q
Q
Q Q
Gradually increased
Hard water is being used as coolant
There are excessive air bubbles in radiator, coolant spurts back
Q
w
w
Hydraulic oil or power train oil on applicable machine side is milky
When hydraulic oil or power train oil is drained, water is found
w
q
Pressure-tightness test of cylinder head shows there is leakage
q q
Inspect cylinder block, liner directly
Inspect cylinder liner directly
140E-5 Series
Replace
Replace
Replace
Remedy
Replace
Carry out troubleshooting on

applicable machine side
Check items
Oil level has risen and oil is milky
Troubleshooting
E
Q Q
Suddenly increased
Replace
Questions
23
SEN00152-03
40 Troubleshooting
S-12 Oil pressure drops
General causes why oil pressure drops

Leakage, clogging, wear in lubrication system
Defective oil pressure control
Selection of oil by the temperature etc. specified in the Operation and Maintenance Manual is not observed.

Degree of use of
E
E
E
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
Oil is milky or smells of diesel oil
w
Metal particles are found when oil pan is drained
w
w
Remedy
q q
q
See S-13
Metal particles are found in oil filter

q
Inspect oil pan strainer, pipe directly
Oil pump rotation is heavy, there is play in oil pump
Valve and spring of oil pump relief valve are fatigued, damaged
Inspect oil filter directly
Relief valve of EGR oil pump is damaged, oil leaks from it ["with EGR" only]
Inspect EGR hydraulic piping directly ["with EGR" only]
Carry out troubleshooting according to Abnormality in oil pressure sensor
(*1) in E-mode
If oil level sensor is replaced, oil pressure monitor indicates normally
q
q
q
q
q
q
Clean
Clean
Replace
Adjust
Replace
Correct
Replace
Replace
Replace
Replace
Metal particles are found when oil filter is drained
Replace
Add
Troubleshooting
Check items
Questions
Deterioration of oil due to overheating
Worn journal of bearing

Lack of oil in oil pan
Coolant, fuel in oil
Clogged strainer in oil pan
Clogged, broken pipe in oil pan
Defective oil pump
Defective oil pump relief valve
Clogged oil filter
Leaking, crushed, clogged hydraulic piping
Defective EGR oil pump ["with EGR" only]
Leaking EGR hydraulic piping ["with EGR" only]
Defective oil pressure sensor, wiring harness
Defective oil level sensor, wiring harness
Causes
24
140E-5 Series
40 Troubleshooting
SEN00152-03
S-13 Oil level rises (Entry of coolant/fuel)
General causes why oil level rises
Cracked EGR cooler (Entry of coolant) ["with EGR" only]

Fuel leakage inside head cover
Cracks inside cylinder block
Damaged cylinder liner O-ring, holes caused by pitting
Worn, damaged rear oil seal
Broken oil cooler core, O-ring
Clogged water pump drain hole (breather hole), defective seal
Defects in supply pump
Defective seal of auxiliary equipment (pump, compressor)
Causes
Coolant in oil (milky)

Fuel in oil (smells diluted diesel fuel)

Degree of use of
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
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]
q
Remove and inspect head cover directly
q
Inspect cylinder block, liner directly
q q
Inspect rear oil seal directly
q
q
Remove and inspect water pump directly
q
Remove and inspect supply pump directly
q
Inspect seal of auxiliary equipment directly
q
Remedy
140E-5 Series
Replace
Replace
Correct
Replace
Replace
Correct
Replace
Replace
Replace
Replace
Troubleshooting
Check items
Questions
a If oil is in coolant, carry out troubleshooting for S-11 Oil is in coolant
25
SEN00152-03
40 Troubleshooting

26
140E-5 Series
40 Troubleshooting
SEN00152-03
S-14 Coolant temperature becomes too high (overheating)

General causes why coolant temperature becomes too high
1
Rise in power train oil temperature on applicable machine side
Defective coolant temperature gauge
Slipping fan belt, worn fan pulley
Defective radiator cap (pressure valve)
Clogged radiator core
Clogged, crushed radiator fins
Defective operation of thermostat
Broken water pump
Rise in oil temperature in power train

Carry out troubleshooting for machine
Lack of coolant
Problem in coolant circulation system
Clogged, broken oil cooler
Drop in heat dissipation efficiency
Damaged cylinder liner O-ring, hole caused by pitting
Lack of cooling air (deformation, damage of fan)
External leakage of coolant from EGR cooler ["with EGR" only]
Causes
Degree of use of
machine
Condition of
overheating
E E E
Sudden overheated
E E
Q w
Coolant temperature Rises quickly

gauge (if installed)
Does not go down from red range
Radiator coolant level monitor indicates drop of coolant level (if monitor is installed) Q
w
w
w Q
Engine oil level has risen, oil is milky
Fan belt tension is low

When fan pulley is turned, it has play
w
w
Milky oil is floating on coolant

w
There are excessive air bubbles in radiator, coolant spurts back

Check items
Q
Q w w
Always tends to overheat
When light bulb is held behind radiator core, no light passes through
Radiator shroud, inside of underguard on applicable machine side are clogged with
dirt or mud
Coolant is leaking because of cracks in hose or loose clamps
Coolant flows out from radiator overflow hose
Fan belt whines under sudden acceleration

Power train oil temperature enters red range faster than engine coolant temperature
(if oil temperature gauge and coolant temperature gauge are installed)
w
q
Inspect EGR cooler for coolant leakage ["with EGR" only]
Inspect cylinder liner directly
q
q
Temperature difference between upper and lower tanks of radiator is large

When operation of thermostat is carried out, it does not open at cracking temperature
q
q
Temperature difference between upper and lower tanks of radiator is slight
Inspect radiator core directly
When operation of radiator cap is carried out, its cracking pressure is low
Inspect fan belt, pulley directly
140E-5 Series
Replace
Replace
Correct
Correct
Replace
Replace
Add
Replace
Replace
Replace
Remedy
Replace
When coolant temperature is measured, it is fount to be normal
Replace
Troubleshooting
Inspect oil cooler directly
Carry out troubleshooting on applicable machine
Questions
27
SEN00152-03
40 Troubleshooting
S-15 Abnormal noise is made
General causes why abnormal noise is made
Improper fuel injection timing

(abnormality in coolant temperature sensor)
Dirt caught in injector
Clogged, seized injector
Deformed cooling fan, loose fan belt, interference of fan

belt
Removed, seized gear train bushing
Improper gear train backlash
Excessive wear of piston ring, cylinder liner
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 seconds. This does not indicate abnormality, however.
a The engine is operated in the low-temperature mode while it is not

warmed up sufficiently. Accordingly, the engine sound becomes a
little larger. This does not indicate abnormality, however.
Defective inside of muffler (dividing board out of position)
a Judge if the noise is an internal noise or an external noise before

starting troubleshooting.
Broken dynamic valve system (valve, rocker lever)
Air sucked in from intake system
Cracked, leaking EGR gas piping ["with EGR" only]
Abnormal combustion
Interference of turbocharger, seized turbocharger
Abnormality due to defective parts
Leakage of air between turbocharger and cylinder head
Causes
Degree of use of
machine
Condition of
abnormal noise
Gradually occurred
Q Q Q
Sudden occurred
Q
Q
w
w


When engine is cranked, abnormal sound is generated around EGR gas piping
["with EGR" only]
w
w

Check items
Air leaks between turbocharger and cylinder head
w
w
When engine is cranked, beat noise is generated around muffler

When exhaust manifold is touched immediately after starting engine, temperature
of some cylinders is low
Color of exhaust
gas
w Q
w
Q w
Black
Abnormal noise is loud when engine is accelerated
w
Q
When turbocharger is rotated by hand, it is fount to be heavy
Inspect EGR gas piping directly ["with EGR" only]

Troubleshooting
When muffler is removed, abnormal noise disappears
q q
Inspect fan and fan belt directly

does not change
q q
q
Abnormal noise is heard only when engine is started
28
Replace
Replace
Correct
Replace
Replace
Replace
Adjust
Replace
Replace
Replace
Replace
Remedy
Replace
Confirm with INSITE or with monitoring function on applicable machine side
Correct
Questions
140E-5 Series
40 Troubleshooting
SEN00152-03
S-16 Vibration is excessive
General causes why vibration is excessive
Stuck dynamic valve system (valve, rocker lever)

Worn main bearing, connecting rod bearing
Improper gear train backlash
Worn camshaft bushing
Loose engine mounting bolts, broken cushions
Misalignment between engine and devices on applicable machine side
Worn front support spigot joint portion
Broken output shaft, parts in damper on applicable machine side
Causes
Defective parts (abnormal wear, breakage)

Misalignment between engine and chassis
Abnormal combustion

Degree of use of
machine
Suddenly increased
Condition of
vibration
Gradually increased
Metal particles are found when oil pan is drained
Oil pressure is low at low idle
Vibration occurs at mid-range speed
Vibration follows engine speed
EE
Q
Q
Q
Q
w
w
Q
Exhaust smoke is black

Inspect main bearing and connecting rod bearing directly
Inspect camshaft bushing directly
Inspect engine mounting bolts and cushions directly
When alignment is checked, radial runout or facial runout is detected
Inspect front support spigot joint portion directly
Inspect output shaft or inside of damper directly
Remedy
140E-5 Series
Q Q
Q
Q
w
w
Q
Q
Q
Q
Q Q Q Q
q
q
q
q
q
q
Q
Replace
Replace
Replace
Replace
Replace
Adjust
Replace
Replace
Troubleshooting
Check items
Questions
a If abnormal noise is made and vibration is excessive, carry out troubleshooting for S-15 Abnormal noise is made, too.
29
SEN00152-03

2009 KOMATSU
All Rights Reserved
30
SEN00153-03
ENGINE
1SHOP MANUAL
140E-5 Series
40 Troubleshooting
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
SEN00153-03
40 Troubleshooting
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
140E-5 Series
40 Troubleshooting
SEN00153-03
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

CA123: Charge air pressure sensor low error (for "EGR-less" only)
q CA222: Ambient pressure sensor low error
q
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 other 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 measurement 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
SEN00153-03
40 Troubleshooting
a "Apparent difference" means a difference of 10 or more times.
List of pressure sensor measuring locations and reference values

Sensor
Charge pressure
sensor
Ambient pressure
sensor
Measuring location at
sensor pin
Internal resistance of measured

sensor
(Reference value)
R2: Between (1) and (3)
Approx. 2.9kz
Approx. 4.3kz
Approx. 3.2kz
R1: Between (2) (+) and

(1) (-)
(2) (-)
Approx. 4.6kz
Approx. 2.9kz
Remarks
Sensor is common to engine models 140 for EGR-less, 125, 170 and
12V140
Sensor is common to engine models 95, 125, 140, 170 and 12V140
If polarities are reversed, resistance value changes.
*: 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 sensor (CA222)
Connectors of charge pressure sensor, resistance RES, engine oil pressure sensor, and G sensor
140E-5 Series
40 Troubleshooting
SEN00153-03
Measurement record (For measuring locations, see circuit diagram related to each code)
Sensor
Charge pressure
sensor
Sensor unit (Measuring

location on sensor pin
side)
Ambient pressure
sensor
140E-5 Series

(1) (-)
(2) (-)
Measured value
Sensor + Wiring harness

(Measuring location on
wiring harness side of
engine controller)
(2) (-)
R1': Between (44) and
(47)
R2': Between (37) and
(38) (*)
R1': Between (3) (+)
and (38) (-)
R1': Between (38) (+)
and (3) (-)
Measured value
SEN00153-03
40 Troubleshooting
E-1 Code [111/CA111] Engine Controller Internal Failure

Error code
Failure code
111
CA111
Trouble
Abnormality in engine controller
Contents of trouble
Abnormality occurred in 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.

Cause
1 Defective fuse
Possible causes and

standard value in
normal state

Check fuse or circuit breaker on machine side directly for
defect.
(If fuse is broken or circuit breaker is turned OFF, circuit probably has ground fault.)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (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)
Resistance Max. 1 z
(1), (2) chassis ground
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)
(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
140E-5 Series
40 Troubleshooting
SEN00153-03
E-2 Code [115/CA115] Eng. Ne and Bkup Speed Sensor Error

Error code
Failure code
115
CA115
Trouble
Abnormality in engine Ne and Bkup sensors
Contents of trouble
Abnormality occurred in Ne speed sensor circuit and Bkup speed sensor circuit simultaneously.
None in particular.
Problem that appears Engine cannot be started (if engine has been stopped).
on machine
Engine stops (if engine has been running).
Related information
Cause
Possible causes and

standard value in
normal state
Defective Ne speed sensor

Carry out troubleshooting for code [689/CA689].
system
Defective Bkup speed senCarry out troubleshooting for code [778/CA778].

sor system
Defective mount of Ne
speed sensor
Check mount of Ne speed sensor directly for defect (defective

installation of sensor, internal trouble of flywheel, etc.)
Defective mount of Bkup

speed sensor
Check mount of Bkup speed sensor directly for defect (defective installation of sensor, internal trouble of supply pump, etc.)
Defective connection
(Wrong connection)
Check Ne speed sensor and Bkup speed sensor directly for

defective connection (wrong connection).
140E-5 Series
If causes 1 5 are not detected, engine controller may be

defective. (Since trouble is in system, troubleshooting cannot
be carried out.)
SEN00153-03
40 Troubleshooting
E-3 Code [122/CA122] Charge (boost) Air Press Sensor High Error
a
For with EGR

Error code
Failure code
122
CA122
Trouble
Abnormally high level in charge (boost) pressure sensor
Contents of trouble
Signal voltage in charge (boost) pressure sensor circuit is abnormally high.
Fixes charge (boost) pressure (400 kPa {4.08 kg/cm2}) and continues operation.

Acceleration performance of engine drops.
on machine
Related information
If sensor connector is disconnected, code [123/CA123] for "Low Error" is displayed, even in
normal condition.
Cause
1
Possible causes and

standard value in
normal state
Defective sensor power

supply system
Defective charge boost

pressure sensor

If code [187/CA187] or [227/CA227] is indicated, carry out troubleshooting for it first.
1. Turn starting switch to OFF position.
2. Disconnect connector PIM.
3. Turn starting switch to ON position.
If code changes from [122/CA122] to [123/CA123], charge
(boost) pressure sensor is defective.
1. Turn starting switch to OFF position, then perform troubleshooting.

Short circuit in wiring har- 2. Disconnect connectors ENG and PIM, and connect T-adapter
3
ness
to female side of ENG.
Between ENG (female) (37) and (44)

2. Disconnect connector PIM, and connect T-adapter to female
side or insert T-adapter into connector ENG.
Hot short circuit in wiring
3. Turn starting switch to ON position (with connector PIM
4 harness
disconnected).
(contact with 24 V circuit)
Between PIM (female) (3) and (2), or
Voltage
Max. 1 V
between ENG (44) and (47)
5
If no failure is found by above checks, engine controller is defecDefective engine controltive. (Since this is an internal failure, troubleshooting cannot be
ler
performed.)
140E-5 Series
40 Troubleshooting
SEN00153-03
Circuit diagram related to charge (boost) pressure sensor

a For with EGR
140E-5 Series
SEN00153-03
a
40 Troubleshooting
For EGR-less
Error code
Failure code
122
CA122
Trouble
Abnormally high level in charge (boost) pressure sensor
Contents of trouble
Signal voltage in charge (boost) pressure sensor circuit is abnormally high.

on machine
Related information
If sensor connector is disconnected, code [123/CA123] for "Low Error" is displayed, even in
normal condition.
Cause
1
Possible causes and

standard value in
normal state

supply system
Defective charge boost

pressure sensor

2. Disconnect connector PIM.
If code changes from [122/CA122] to [123/CA123], charge
(boost) pressure sensor is defective.

Short circuit in wiring har- 2. Disconnect connectors ENG and PIM, and connect T-adapter
3
ness
to female side of ENG.

2. Disconnect connector PIM, and insert T-adapter into
connector ENG.
4 harness
3. Turn starting switch to ON position (with connector PIM
disconnected).
Between ENG (44) and (47)
5
10
Voltage
Max. 1 V
ler
performed.)
140E-5 Series
40 Troubleshooting
SEN00153-03

a For EGR-less
140E-5 Series
11
SEN00153-03
40 Troubleshooting
E-4 Code [123/CA123] Charge (boost) Air Press Sensor Low Error
Error code
Failure code
123
CA123
Trouble
Abnormally low level in charge (boost) pressure sensor
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.
For with EGR

Cause

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.
Between PIM (female) (1) and
(2)
Power
input
Voltage
4.75
5.25 V

2. Disconnect connectors ENG and PIM and connect Tadapters to each female side.
Possible causes and

standard value in
normal state
Open circuit in wiring harBetween ENG (female) (37) and PIM

ness
(female) (1)
2
(wire breakage or defective
Between ENG (female) (44) and PIM
contact of connector)
(female) (3)
Resistance
Max.
1z
Resistance
Max.
1z
Between ENG (female) (47) and PIM

(female) (2)
Resistance
Max.
1z
Short circuit in wiring harness

2. Disconnect connectors ENG and PIM.
3. Connect T-adapter to female side of ENG.
Ground fault in wiring har4 ness

(contact with ground circuit)
Defective boost pressure

sensor
12
Min.
1 Mz

2. Disconnect connectors ENG and PIM, and connect Tadapters to either female side.
Between ENG (female) (44) or PIM
(female) (3) and ground
Resistance
Min.
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 defective.
2. Insert T-adapter into connector ENG or PIM.
Between ENG (44) and (47), or
between PIM (3) and (2)
Resistance
Sensor
output
Voltage
0.3 4.7
V
If no failure is found by above checks, engine controller is

defective. (Since this is an internal failure, troubleshooting
cannot be performed.)
140E-5 Series
40 Troubleshooting
SEN00153-03

a For "with EGR"
140E-5 Series
13
SEN00153-03
40 Troubleshooting
For "EGR-less"
Cause
Defective power supply sysIf code [187/CA187] or [227/CA227] is indicated, carry out
1 tem of charge pressure sentroubleshooting for it first.
sor (boost pressure sensor)

2. Disconnect connectors ENG and PIM.
Possible causes and

standard value in
normal state
Ground fault in wiring har3 ness

Min.
1 Mz
1. Turn starting switch to OFF position, then carry out troubleshooting.

2. Disconnect connectors ENG and PIM, and connect Tadapter to female side of ENG.
Between ENG (female) (44) and ground
Resistance
Resistance
Min.
1 Mz
Disconnection in wiring har- If cause is not found by the above checks, wiring harness may
ness
be disconnected. (*)
Defective charge pressure

(boost pressure) sensor
5
(lmproper input voltage of
engine controller)
a If causes 1 - 4 are not the cause for the trouble and check
result of cause 5 is abnormal, sensor is defective.
2. Connect T-adapter to connector ENG.
Sensor
output
Voltage
0.3 4.7
V
If no abnormality is found by the above checks, the engine

controller is defective.
(Since the failure is in it, troubleshooting cannot be performed.)
*: Refer to "Troubleshooting method for disconnected wiring harness of pressure sensor system."
14
140E-5 Series
40 Troubleshooting
SEN00153-03

a For "EGR-less"
140E-5 Series
15
SEN00153-03
40 Troubleshooting
E-5 Code [131/CA131] Throttle Sensor High Error
Throttle sensor of accelerator pedal type (Case of HD325/405-7)

Error code
131
Contents of trouble
Failure code
Trouble Abnormally high level in throttle sensor
CA131
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
Related information Different machine models may have different connector Nos.
Cause
1
supply system
Possible causes and

standard value in
normal state
Defective accelerator pedal

(Internal trouble)
Disconnection in wiring harness (Disconnection in wir3

connector)
Ground fault in wiring har4 ness (Short circuit with GND

circuit)
16

If code [2185/CA2185] or [2186/CA2186] is indicated, carry
out troubleshooting for it first.
Accelerator
WAS1
Voltage
pedal
All range
Between (1) (3)
4.75 5.25 V
(Power supply)
(9 2% of source
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.
Resistance Max. 1 z
(22) WAS1 (female) (1)
Resistance Max. 1 z
Resistance Max. 1 z
(22) WAS1 (female) (1) and chassis Resistance Min. 1 Mz
ground
ground
ground
Accelerator
Voltage
E02
pedal
All range
4.75 5.25 V
Between (22) (23)
(Power supply)
(9 2% of source
Released
voltage)
Between (9) (23)
(73 2% of source
Pressed
voltage)
140E-5 Series
40 Troubleshooting
SEN00153-03
Circuit diagram related to throttle sensor of accelerator pedal type (Case of HD325/405-7)
140E-5 Series
17
SEN00153-03
40 Troubleshooting
1
Throttle sensor of fuel control dial type (Case of PC800/800SE/850/850SE/850LC-8)
Error code
Failure code
131
CA131
Trouble
Abnormally high level in throttle sensor
Contents of trouble
Signal voltage in throttle sensor circuit is abnormally high.
each model).

on machine
Related information

Cause
1
supply system

If code [2185/CA2185] or [2186/CA2186] is indicated, carry
out troubleshooting for it first.
Defective fuel control dial

(Internal trouble)
P20 (male)
Resistance
Between (1) (3)
4.0 6.0 kz
Between (2) (1)
0.25 5.0 kz
Between (2) (3)
0.25 5.0 kz
connector)
Possible causes and
standard value in
normal state

Resistance Max. 1 z
(22) P20 (female) (1)
Resistance Max. 1 z
(9) P20 (female) (2)
Resistance Max. 1 z
(23) P20 (female) (3)
(22) P20 (female) (1) and chassis
ground
Ground fault in wiring har4 ness (Short circuit with GND Wiring harness between E02 (female)
circuit)
ground
ground
18
E02
Voltage
Between (22) (23)
Power supply
4.75 5.25 V
Between (9) (23)
Signal
0.5 4.5 V
140E-5 Series
40 Troubleshooting
SEN00153-03
Circuit diagram related to throttle sensor of fuel control dial type

(Case of PC800/800SE/850/850SE/850LC-8)
140E-5 Series
19
SEN00153-03
40 Troubleshooting
E-6 Code [132/CA132] Throttle Sensor Low Error

Error code
Failure code
132
CA132
Trouble
Abnormally low level in throttle sensor
Contents of trouble
Signal voltage in throttle sensor circuit is abnormally low.
each model).

on machine
Related information
Possible causes and
standard value in
normal state
20
Cause

Carry out troubleshooting for E-5 Code [131/CA131].
140E-5 Series
40 Troubleshooting
140E-5 Series
SEN00153-03
21
SEN00153-03
40 Troubleshooting
E-7 Code [135/CA135] Oil Press. Sensor High Error

Error code
Failure code
135
CA135
Trouble Abnormally high level in oil pressure sensor
Contents of trouble
Signal voltage in oil pressure sensor circuit is abnormally high.
Sets oil pressure to default value (250 kPa {2.55 kg/cm2}) and continues operation.

on machine
Related information
Cause
1

supply system


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.
Possible causes and

standard value in
normal state

2. Disconnect connectors ENG and POIL, and connect TShort circuit in wiring haradapters to either female side.
3
ness
Between ENG (female) (13) and (37), or
between POIL (female) (1) and (3)
2. Disconnect connector POIL.
3. Connect T-adapter to female side of connector POIL or insert
T-adapter into connector ENG.
4 harness
4. Turn starting switch to ON position (with connector POIL
disconnected).
5
22
Voltage
Max. 1 V
ler
performed.)
140E-5 Series
40 Troubleshooting
SEN00153-03
Circuit diagram related to oil pressure sensor

a For with EGR
a There is connector PEVA only for serial No. up to 530896.
For EGR-less
140E-5 Series
23
SEN00153-03
40 Troubleshooting
E-8 Code [141/CA141] Oil Press. Sensor Low Error

Error code
Failure code
141
CA141
Trouble
Abnormally low level in oil pressure sensor
Contents of trouble
Signal voltage in oil pressure sensor circuit is abnormally low.
Sets oil pressure to default value (250 kPa {2.55 kg/cm2}) and continues operation.

on machine
Related information
Cause

If code [187/CA187] or [227/CA227] is displayed, carry out
troubleshooting for it first.

Defective power supply sys2. Disconnect connector POIL and connect T-adapter to
1 tem of engine oil pressure
female side.
sensor
Between POIL (female) (1) and
(2)
Power
input
Voltage
4.75
5.25V

2. Disconnect connectors ENG and POIL and connect Tadapters to each female side.
a If power supply input in checks on
cause 1 is normal, this check is not required.
Between ENG (female) (37) and POIL
(female) (1)
Possible causes and

standard value in
normal state
Open circuit in wiring harness

2
(wire breakage or defective
a If power supply input in checks on
contact of connector)
cause 1 is normal, this check is not required.
(female) (2)
(female) (3) (Sensor output)
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z

2. Disconnect connectors ENG and POIL, and connect Tadapters to either female side.
Ground fault of wiring har3 ness

(contact with ground circuit) Between ENG (female) (13) or POIL
(female) (3) and ground
Resistance
Min.
1 Mz

2. Disconnect connectors ENG and POIL, and connect Tadapters to either female side.
Resistance
Min.
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 pres5 sure sensor (improper input 2. Insert T-adapter into connector ENG or POIL.
voltage to engine controller) 3. Turn starting switch to ON position.
0.3 4.7
Between ENG (13) and (47), or Sensor
Voltage
V
output
between POIL (3) and (2)
24

defective. (Since this is an internal failure, troubleshooting cannot be performed.)
140E-5 Series
40 Troubleshooting
SEN00153-03
Circuit diagram related to oil pressure sensor

a For "with EGR"
a There is connector PEVA only ofr serial No. up to 530896.
For "EGR-less"
140E-5 Series
25
SEN00153-03
40 Troubleshooting
E-9 Code [144/CA144] Coolant Temp. Sensor High Error

Error code
Failure code
144
CA144
Trouble
Abnormally high level in coolant temperature sensor
Contents of trouble
Signal voltage in coolant temperature sensor circuit is abnormally high.
Fixes coolant temperature (90C) and continues operation.

Engine starting performance decreases during low temperature.
on machine
Related information
This failure code is generated if temperature sensor connector is disconnected.

Because troubleshooting "socket" for this sensor features female connector alone, it is not
connectable to female connector of sensor wiring harness, and thus not usable for checking
open circuit (not designed as a T-adapter).
Cause

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.
0 C
Defective coolant temperature sensor
Resistance
25 C Resistance
Between TWTR (male) (A)
and (B)
50 C Resistance
a Coolant temperature -Resistaure characteristics
80 C Resistance
Possible causes and

standard value in
normal state
95 C Resistance
30
37 kz
9.3
10.7 kz
3.2
3.8 kz
1.0
1.3 kz
700
800 z

2. Disconnect connector ENG and connect T-adapter to
female side.
2
Open or short circuit in wir- Between ENG (female) (15) and (38)
(Coolant temperature: Min. 0 C)
ing harness
a The resistance is the same as that
Resistance
shown in the resistance characteristics table of the coolant temperature sensor of cause 1.
26
700 z
37 kz

140E-5 Series
40 Troubleshooting
SEN00153-03
Circuit diagram related to coolant temperature sensor

a For with EGR
There are not connector SBP and line to the SBP for EGR-less in above figure.
140E-5 Series
27
SEN00153-03
40 Troubleshooting
E-10 Code [145/CA145] Coolant Temp. Sensor Low Error

Error code
Failure code
145
CA145
Trouble
Abnormally low level in coolant temperature sensor
Contents of trouble
Signal voltage in coolant temperature sensor circuit is abnormally low.
Fixes coolant temperature (90C) and continues operation.

on machine
Related information
If temperature sensor connector is disconnected, this failure code is not generated but code
[144/CA144] for "High Error" is generated.
Cause

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.
Between TWTR (male) (A) and

Defective coolant tempera(B)
ture sensor
a Coolant temperature-Resistaure characteristics
Possible causes and

standard value in
normal state
Between (B) and ground
0 C
Resistance
30
37 kz
25 C
Resistance
9.3
10.7 kz
50 C
Resistance
3.2
3.8 kz
80 C
Resistance
1.0
1.3 kz
95 C
Resistance
700
800 z
Whole
coolant
temperature
range
Resistance
Min.
1 Mz

female side.
2
Ground fault of wiring har3 ness

28

(Coolant temperature: Min. 0 C)
shown in the resistance characteristics
table of the coolant temperature sensor of cause 1.
Resistance
700 z
37 kz

2. Disconnect connectors ENG and TWTR, and connect Tadapter to female side of ENG.
Resistance
Min.
1 Mz

140E-5 Series
40 Troubleshooting
SEN00153-03
Circuit diagram related to coolant temperature sensor

a For "with EGR"
There are not connector SBP and line to the SBP for "EGR-less" in above figure.
140E-5 Series
29
SEN00153-03
40 Troubleshooting
E-11 Code [153/CA153] Charge (boost) Air Temp. Sensor High Error
Error code
Failure code
153
CA153
Trouble
Abnormally high level in charge (boost) temperature sensor
Contents of trouble
Signal voltage in charge (boost) temperature sensor circuit is abnormally high.
Fixes charge (boost) temperature (intake air temperature) (70C) and continues operation.

on machine
Related information
Because troubleshooting "socket" for this sensor features female connector alone, it is not connectable to female connector of sensor wiring harness, and thus not usable for checking open
circuit (not designed as a T-adapter).
Cause

2. Disconnect connector TIM and connect socket to male side.
a If temperature sensor has resistance of 280 z - 382 kz, regard boost temperature sensor as normal.
Defective boost temperature sensor
Possible causes and

standard value in
normal state
-40 C Resistance
291
382 kz
-20 C Resistance
85
109 kz
Resistance
29
36 kz
30 C Resistance
7.3
8.8 kz
60 C Resistance
2.3
2.7 kz
90 C Resistance
860
970 z
130 C Resistance
280
320 z
0 C
Between TIM (male) (A) and
(B)
a Boost temperature-Resistance characteristic

female side.
2
ing harness
shown in the resistance character- Resistance
istics table of the coolant temperature sensor of cause 1.
30
280 z
382 kz

140E-5 Series
40 Troubleshooting
SEN00153-03
Circuit diagram related to charge (boost) temperature sensor

a For with EGR
Pin number of connector PIM is not "2" but "3" for EGR-less in above figure.
140E-5 Series
31
SEN00153-03
40 Troubleshooting
E-12 Code [154/CA154] Charge (boost) Air Temp. Sensor Low Error
Error code
Failure code
154
CA154
Trouble
Abnormally low level in charge (boost) temperature sensor
Contents of trouble
Signal voltage in charge (boost) temperature sensor circuit is abnormally low.
Fixes charge (boost) temperature (intake air temperature) (70C) and continues operation.

on machine
Related information
If temperature sensor connector is disconnected, this failure code is not generated but code
[153/CA153] for "High Error" is generated.
Cause

2. Disconnect connector TIM and connect socket to male side
of.
a If temperature sensor has resistance of 280 z - 382 kz, regard boost temperature sensor as normal.
Defective boost temperature sensor
Possible causes and

standard value in
normal state
Between TIM (male) (A) and

(B)
a Boost temperature-Resistance characteristic
-40 C
Resistance
291
382 kz
-20 C
Resistance
85
109 kz
0 C
Resistance
29
36 kz
30 C
Resistance
7.3
8.8 kz
60 C
Resistance
2.3
2.7 kz
90 C
Resistance
860
970 z
130 C
Resistance
280
320 z

female side.
2

Resistance
280 z
382 kz

Ground fault of wiring har- 2. Disconnect connectors ENG and TIM and connect Tadapter to female side of ENG.
3 ness
ResisMin.
tance
1 Mz
32

140E-5 Series
40 Troubleshooting
SEN00153-03
Circuit diagram related to charge (boost) temperature sensor

a For "with EGR"
Pin number of connector PIM is not "2" but "3" for "EGR-less" in above figure.
140E-5 Series
33
SEN00153-03
40 Troubleshooting
E-13 Code [187/CA187] Sensor Sup. 2 Volt. Low Error

Error code
Failure code
187
CA187
Trouble
Abnormally low level in sensor power supply 2 circuit
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 operation.
Fixes charge (boost) pressure sensor value (400 kPa {4.08 kg/cm2}) and continues operation.
Sets EGR inlet pressure sensor to default value (102 kPa {1.04 kg/cm2}) and continues operation. ["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
Cause

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 position.
If this failure code is not displayed when a connector is disconnected, 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

harness
Possible causes and

standard value in
normal state
2 Defect in related system
Sensor or harness
Connector
Bkup speed sensor
G connector
Oil pressure sensor
POIL connector
Boost pressure sensor
PIM connector
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

it.
2. Disconnect connector ENG and connect T-adapter to male
side.
3. Turn starting switch to ON position with connector ENG
disconnected.
Between ENG (male) (37) and (47)
Voltage
4.75
5.25 V
*: "with EGR" only

**: "only early model of "with EGR", serial No. up to 530896.
34
140E-5 Series
40 Troubleshooting
SEN00153-03
Circuit diagram related to sensor power supply 2 (5 V)

a For serial No. up to 530896 "with EGR"
140E-5 Series
35
SEN00153-03
40 Troubleshooting

a For serial No. and up 530897 "with EGR"
36
140E-5 Series
40 Troubleshooting
SEN00153-03

a For "EGR-less"
140E-5 Series
37
SEN00153-03
40 Troubleshooting
E-14 Code [221/CA221] Ambient Air Press. Sensor High Error

a
For with EGR

Error code
Failure code
221
CA221
Trouble
Abnormally high level in atmospheric pressure sensor
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 operation.

Output drops.
on machine
Related information
Cause
1
Possible causes and

standard value in
normal state

supply system
Defective ambient pressure sensor

2. Disconnect connector PAMB.
If code changes from [221/CA221] to [222/CA222], sensor is
defective.

Short circuit in wiring har- 2. Disconnect connector ENG and PAMB, and connect T3
adapter to female side of ENG.
ness
1.
2.
Hot short circuit in wiring 3.
4 harness
4.
Turn starting switch to OFF position.

Disconnect connector PAMB.
Insert T-adapter into connector ENG.
Turn starting switch to ON position (with connector PAMB
disconnected).

5
38
Voltage
Max. 1 V
ler
performed.)
140E-5 Series
40 Troubleshooting
SEN00153-03
Circuit diagram related to atmospheric pressure sensor

a For with EGR
140E-5 Series
39
SEN00153-03
40 Troubleshooting
E-15 Code [222/CA222] Ambient Air Press. Sensor Low Error

Error code
Failure code
222
CA222
Trouble
Abnormally low level in atmospheric pressure sensor
Contents of trouble
Signal voltage in atmospheric pressure sensor circuit is abnormally low.
Sets atmospheric pressure to default value (52.44 kPa {0.53 kg/cm2}) and continues operation.

Output drops.
on machine
Related information
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
T-adapter).
If sensor connector is disconnected, this failure code is generated.
Cause
Defective power supply line If failure code [187/CA187] or [227/CA227] is displayed, per1
of ambient pressure sensor form troubleshooting for it first.

2. Disconnect connectors PAMB and ENG.
Possible causes and

standard value in
normal state
Resistance
Min.
1 Mz

Ground fault in wiring har- 2. Disconnect connectors PAMB and ENG and connect Tadapter to female side of ENG.
3 ness
ResisMin.
tance
1 Mz
4
Open circuit in wiring harness
If no failure is found by above checks, wiring harness may have

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)
Sensor
0.3 4.7
Voltage
output
V

*: Refer to "Troubleshooting method for open circuit in wiring harness of pressure sensor system".
40
140E-5 Series
40 Troubleshooting
SEN00153-03
Circuit diagram related to atmospheric pressure sensor

a For "with EGR"
140E-5 Series
41
SEN00153-03
40 Troubleshooting
E-16 Code [227/CA227] Sensor Sup. 2 Volt. High Error

Error code
227
Contents of trouble
Failure code
Trouble Abnormally high level in sensor power supply 2 circuit
CA227
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 operation.
Fixes charge (boost) pressure sensor value (400 kPa {4.08 kg/cm2}) and continues operation.
Sets EGR inlet pressure sensor to default value (102 kPa {1.04 kg/cm2}) and continues operation. ["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 Different machine models may have different connector Nos.
Possible causes and
standard value in
normal state
Cause
1 Carry out troubleshooting for code [187/CA187].
E-17 Code [234/CA234] Eng. Overspeed

Error code
Failure code
234
CA234
Trouble
Engine overspeed
Contents of trouble
Engine speed is above operating range.
Limits fuel injection rate until engine speed lowers to operating range.

Engine speed fluctuates.
on machine
Related information
Cause
Possible causes and
standard value in
normal state
42
1 Defective related system
If another failure code is indicated, carry out troubleshooting for it.
2 Improper way of use
Way of use may be improper. Teach proper way of use to operator.

be carried out.)
140E-5 Series
40 Troubleshooting
140E-5 Series
SEN00153-03
43
SEN00153-03
40 Troubleshooting
E-18 Code [238/CA238] Ne Speed Sensor Sup. Volt. Error

Error code
Failure code
238
CA238
Trouble
Abnormality in Ne speed sensor power supply
Contents of trouble
Abnormality occurred in Ne speed sensor power supply (5 V) circuit.
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).
Related information

Cause

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

in order. If error code disapsor (Internal trouble)
Ne speed
pears when a device is dissensor
connected, that device has
a defect in it.
NE connector
Possible causes and

standard value in
normal state
Disconnection in wiring
harness (Disconnection Wiring harness between ENG (female)
2
in wiring or defective con- (16) NE (female) (1)
tact in connector)
Wiring harness between ENG (female)
(48) NE (female) (2)
Resistance Max. 1 z
Resistance Max. 1 z
Ground fault in wiring
3 harness (Short circuit
with GND circuit)

(16) NE (female) (1) and chassis ground
Short circuit in wiring har4 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 control5
ler
ENG
Voltage
Between (16) (48)
44
4.75 5.25 V
140E-5 Series
40 Troubleshooting
SEN00153-03
Circuit diagram related to Ne speed sensor power supply
140E-5 Series
45
SEN00153-03
40 Troubleshooting
E-19 Code [263/CA263] Fuel Temp. Sensor High Error

Error code
Failure code
263
CA263
Trouble
Abnormally high level in fuel temperature sensor
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
on fuel temperature.
Fixes fuel temperature (90C) and continues operation.

on machine
Related information

Because troubleshooting "socket" for this sensor features female connector alone, it is not
connectable to female connector of sensor wiring harness, and thus not usable for checking
open circuit (not designed as a T-adapter).
Cause

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 temperature sensor as normal.
0 C
Defective fuel temperature

sensor
Between TFUEL (male)(A)
and (B)
a Fuel temperature-Resistance characteristics
Possible causes and

standard value in
normal state
Resistance
30
37 kz
25 C Resistance
9.3
10.7 kz
50 C Resistance
3.2
3.8 kz
80 C Resistance
1.0
1.3 kz
95 C Resistance
700
800 z

female side.
2
(Fuel temperature: Min. 0 C)
ing harness
Resistance
shown in the resistance characteristics table of the coolant temperature sensor of cause 1.
46
700 z
37 kz

140E-5 Series
40 Troubleshooting
SEN00153-03
Circuit diagram related to fuel temperature sensor

a For with EGR
Pin number of connector PIM is not "2" but "3" for EGR-less in above figure.
140E-5 Series
47
SEN00153-03
40 Troubleshooting
E-20 Code [265/CA265] Fuel Temp. Sensor Low Error

Error code
Failure code
265
CA265
Trouble
Abnormally low level in fuel temperature sensor
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
on fuel temperature.
Fixes fuel temperature (90C) and continues operation.

on machine
Related information
If temperature sensor connector is disconnected, this code is not generated but code [263/
CA263] for "High Error" is generated.
Cause

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 temperature sensor as normal.
Defective fuel temperature

sensor
Possible causes and

standard value in
normal state
Between TFUEL (male)(A) and

(B)
a Fuel temperature-Resistance characteristic
Between (B) and ground
0 C
Resistance
30
37 kz
25 C
Resistance
9.3
10.7 kz
50 C
Resistance
3.2
3.8 kz
80 C
Resistance
1.0
1.3 kz
95 C
Resistance
700
800 z
All fuel
temperature
range
Resistance
Min.
1 Mz

female side.
2

(Fuel temperature: Min. 0 C)
Resistance
700 z
37 kz

Ground fault in wiring har- 2. Disconnect connector TFUEL, and connect T-adapter to
female side of ENG.
3 ness
ResisMin.
tance
1 Mz
48

140E-5 Series
40 Troubleshooting
SEN00153-03
Circuit diagram related to fuel temperature sensor

a For "with EGR"
Pin number of connector PIM is not "2" but "3" for "EGR-less" in above figure.
140E-5 Series
49
SEN00153-03
40 Troubleshooting
E-21 Code [271/CA271] PCV1 Short Error

Error code
Failure code
271
CA271
Trouble
Short circuit in PCV1
Contents of trouble
There is short circuit in PCV1 circuit of supply pump.
None in particular.

on machine
Related information

Cause

Defective supply pump

PCV1 (Internal trouble)
PCV1 (male)
Resistance
Between (1) (2)
2.3 5.3 z
Between (1), (2)

chassis ground
Min. 1 Mz
Possible causes and

standard value in
normal state
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)
(female) (5) PCV1 (female) (2) and Resistance Min. 1 Mz
chassis ground
Hot short (Short circuit with
(female) (4) PCV1 (female) (1) and
3 24V circuit) in wiring harchassis ground
ness
chassis ground
Voltage
Max. 1 V
Voltage
Max. 1 V
50
ENG (female)
Resistance
Between (4) (5)
2.3 5.3 z
Between (4), (5)

chassis ground
Min. 1 Mz
140E-5 Series
40 Troubleshooting
SEN00153-03
Circuit diagram related to supply pump PCV1
140E-5 Series
51
SEN00153-03
40 Troubleshooting
E-22 Code [272/CA272] PCV1 Open Error

Error code
Failure code
272
CA272
Trouble
Disconnection in PCV1
Contents of trouble
There is disconnection in PCV1 circuit of supply pump.
None in particular.

on machine
Related information

Cause


1 PCV1 (Internal disconnection)
Possible causes and

standard value in
normal state
PCV1 (male)
Resistance
Between (1) (2)
2.3 5.3 z
Between (1), (2)

chassis ground
Min. 1 Mz
Disconnection in wiring harness (Disconnection in wir- Wiring harness between ENG
2
Resistance Max. 1 z
(female) (4) PCV1 (female) (1)
connector)
Resistance Max. 1 z
chassis ground
circuit)
chassis ground
52
ENG (female)
Resistance
Between (4) (5)
2.3 5.3 z
Between (4), (5)

chassis ground
Min. 1 Mz
140E-5 Series
40 Troubleshooting
SEN00153-03
140E-5 Series
53
SEN00153-03
40 Troubleshooting
E-23 Code [273/CA273] PCV2 Short Error

Error code
Failure code
273
CA273
Trouble
Short circuit in PCV2
Contents of trouble
There is short circuit in PCV2 circuit of supply pump.
None in particular.

on machine
Related information

Cause


PCV2 (Internal trouble)
PCV2 (male)
Resistance
Between (1) (2)
2.3 5.3 z
Between (1), (2)

chassis ground
Min. 1 Mz
Possible causes and

standard value in
normal state

chassis ground
circuit)
chassis ground
Hot short (Short circuit with
3 24V circuit) in wiring harchassis ground
ness
chassis ground
Voltage
Max. 1 V
Voltage
Max. 1 V
54
ENG (female)
Resistance
Between (9) (10)
2.3 5.3 z
Between (9), (10)

chassis ground
Min. 1 Mz
140E-5 Series
40 Troubleshooting
SEN00153-03
140E-5 Series
55
SEN00153-03
40 Troubleshooting
E-24 Code [274/CA274] PCV2 Open Error

Error code
Failure code
274
CA274
Trouble
Disconnection in PCV2
Contents of trouble
There is disconnection in PCV2 circuit of supply pump.
None in particular.

on machine
Related information

Cause
1 PCV2 (Internal disconnection)

PCV2 (male)
Resistance
Between (1) (2)
2.3 5.3 z
2
Resistance Max. 1 z
connector)
Resistance Max. 1 z
Possible causes and
standard value in
normal state
chassis ground
circuit)
chassis ground
56
ENG (female)
Resistance
Between (9) (10)
2.3 5.3 z
Between (9), (10)

chassis ground
Min. 1 Mz
140E-5 Series
40 Troubleshooting
SEN00153-03
140E-5 Series
57
SEN00153-03
40 Troubleshooting
E-25 Code [322/CA322] Injector #1 System Open/Short Error

Error code
Failure code
322
CA322
Trouble
Disconnection or short circuit in injector #1 system
Contents of trouble
There is disconnection or short circuit in injector #1 circuit.
None in particular.
Problem that appears Output drops.

on machine
Rotation is unstable.
Related information
While engine is running normally, pulse voltage of about 70 V is applied to positive (+) side of
injector. This pulse voltage cannot be measured with circuit tester.
Cause

Defective injector #1 (Internal trouble)
CN1 (male)
Resistance
Between (1) (2)
0.4 1.1 z
Between (1), (2)

chassis ground
Min. 1M z
2
Resistance Max. 1 z
(female) (45) CN1 (female) (1)
connector)
Resistance Max. 1 z
Possible causes and
standard value in
normal state
Ground fault in wiring har(female) (45) CN1 (female) (1) and
chassis ground
circuit)
(female) (53) CN1 (female) (2) and
chassis ground
4
Defective injector or wiring If failure code of another cylinder is displayed, carry out trouharness of another cylinder bleshooting for it, too.
58
ENG (female)
Resistance
Between (45) (53)
0.4 1.1 z
Between (45), (53)

chassis ground
Min. 1 Mz
140E-5 Series
40 Troubleshooting
SEN00153-03
Circuit diagram related to injector #1

a For with EGR
For EGR-less
Improper installation of injector wiring harness

(H)
Q: Injector wiring harness (H) is in good condition

being laid close to injector (N)
140E-5 Series
x: Injector wiring harness (H) is in bad condition

without being laid close to injector (N)
a: Injector wiring harness (H) may interfere with
rocker arm.
59
SEN00153-03
40 Troubleshooting

Error code
Failure code
323
CA323
Trouble
Contents of trouble
None in particular.

on machine
Related information
Cause

CN5 (male)
Resistance
Between (1) (2)
0.4 1.1 z
Between (1), (2)

chassis ground
Min. 1 Mz
2
Resistance Max. 1 z
connector)
Resistance Max. 1 z
Possible causes and
standard value in
normal state
chassis ground
circuit)
chassis ground
4
60
ENG (female)
Resistance
Between (46) (60)
0.4 1.1 z
Between (46), (60)

chassis ground
Min. 1 Mz
140E-5 Series
40 Troubleshooting
SEN00153-03

a For with EGR
For EGR-less

(H)

140E-5 Series

rocker arm.
61
SEN00153-03
40 Troubleshooting

Error code
Failure code
324
CA324
Trouble
Contents of trouble
None in particular.

on machine
Related information
Cause

CN3 (male)
Resistance
Between (1) (2)
0.4 1.1 z
Between (1), (2) chassis

ground
Min. 1M z
2
Resistance Max. 1 z
connector)
Resistance Max. 1 z
Possible causes and
standard value in
normal state
chassis ground
circuit)
chassis ground
4
62
ENG (female)
Resistance
Between (55) (52)
0.4 1.1 z
Between (55), (52)

chassis ground
Min. 1M z
140E-5 Series
40 Troubleshooting
SEN00153-03

a For with EGR
For EGR-less

(H)

140E-5 Series

rocker arm.
63
SEN00153-03
40 Troubleshooting

Error code
Failure code
325
CA325
Trouble
Contents of trouble
None in particular.

on machine
Related information
Cause

CN6 (male)
Resistance
Between (1) (2)
0.4 1.1 z
Between (1), (2)

chassis ground
Min. 1 Mz
2
Resistance Max. 1 z
connector)
Resistance Max. 1 z
Possible causes and
standard value in
normal state
chassis ground
circuit)
chassis ground
4
64
ENG (female)
Resistance
Between (57) (59)
0.4 1.1 z
Between (57), (59)

chassis ground
Min. 1 Mz
140E-5 Series
40 Troubleshooting
SEN00153-03

a For with EGR
For EGR-less

(H)

140E-5 Series

rocker arm.
65
SEN00153-03
40 Troubleshooting

Error code
Failure code
331
CA331
Trouble
Contents of trouble
None in particular.

on machine
Related information
Cause

CN2 (male)
Resistance
Between (1) (2)
0.4 1.1 z
Between (1), (2)

chassis ground
Min. 1 Mz
2
Resistance Max. 1 z
connector)
Resistance Max. 1 z
Possible causes and
standard value in
normal state
chassis ground
circuit)
chassis ground
4
66
ENG (female)
Resistance
Between (54) (51)
0.4 1.1 z
Between (54), (51)

chassis ground
Min. 1 Mz
140E-5 Series
40 Troubleshooting
SEN00153-03

a For with EGR
For EGR-less

(H)

140E-5 Series

rocker arm.
67
SEN00153-03
40 Troubleshooting

Error code
Failure code
332
CA332
Trouble
Contents of trouble
None in particular.

on machine
Related information
Cause

CN4 (male)
Resistance
Between (1) (2)
0.4 1.1 z
Between (1), (2)

chassis ground
Min. 1 Mz
2
Resistance Max. 1 z
connector)
Resistance Max. 1 z
Possible causes and
standard value in
normal state
chassis ground
circuit)
chassis ground
4
68
ENG (female)
Resistance
Between (56) (58)
0.4 1.1 z
Between (56), (58)

chassis ground
Min. 1 Mz
140E-5 Series
40 Troubleshooting
SEN00153-03

a For with EGR
For EGR-less

(H)

140E-5 Series

rocker arm.
69
SEN00153-03
40 Troubleshooting
E-31 Code [342/CA342] Engine Controller Data Matching Error

Error code
Failure code
342
CA342
Trouble
Matching error in engine controller data
Contents of trouble
Matching error occurred in engine controller data.
None in particular.
Problem that appears Engine continues operation normally, but it may stop during operation or may not be able to
on machine
start.
Related information
Possible causes and
standard value in
normal state
70
Cause

140E-5 Series
40 Troubleshooting
140E-5 Series
SEN00153-03
71
SEN00153-03
40 Troubleshooting
E-32 Code [351/CA351] INJ. Drive Circuit Error

Error code
Failure code
351
CA351
Trouble
Abnormality in injector drive circuit
Contents of trouble
Abnormality occurred in injector drive circuit.
Limits output and continues operation (Limits common rail pressure).

Output drops.
on machine
Related information

Cause
Possible causes and

standard value in
normal state
If another failure code (code of abnormality in injector system)

is indicated, carry out troubleshooting for it.
2 Defective fuse
Check fuse or circuit breaker on machine side directly for

defect.
(If fuse is broken or circuit breaker is turned OFF, circuit probably has ground fault.)
Disconnection in wiring harness (Disconnection in wir- Wiring harness between E03 (female)
3
Resistance Max. 1 z
(3), (4) battery (+)
connector)
Resistance Max. 1 z
Ground fault in wiring harWiring harness between E03 (female)
(3), (4) battery (+) and chassis ground
circuit)
72
E03
Voltage
Between (3), (4) (1), (2)
20 30 V
140E-5 Series
40 Troubleshooting
SEN00153-03
Circuit diagram related to controller power supply
140E-5 Series
73
SEN00153-03
40 Troubleshooting
E-33 Code [352/CA352] Sensor Sup. 1 Volt. Low Error

Error code
Failure code
352
CA352
Trouble
Abnormally low level in sensor power supply 1 circuit
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
Possible causes and
standard value in
normal state
74
Cause

140E-5 Series
40 Troubleshooting
SEN00153-03
E-34 Code [386/CA386] Sensor Sup. 1 Volt. High Error

Error code
Failure code
386
CA386
Trouble
Abnormally high level in sensor power supply 1 circuit
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
Related information

Cause
1 Defective related system If another failure code is indicated, carry out troubleshooting for it.
Defective sensor (Inter2
nal trouble)
harness (Disconnection
3
in wiring or defective
contact in connector)
Possible causes and
standard value in
normal state
Disconnect devices at
right in order. If error
code disappears when a Common rail
device is disconnected, pressure sensor
that device has a defect
in it.
PFUEL connector
a Prepare with starting switch OFF, then carry out troubleshooting

without turning starting switch ON.
(33) PFUEL (female) (1)
Resistance Max. 1 z

Resistance Max. 1 z

with GND circuit)
Short circuit in wiring

5 harness (with another
wiring harness)

(33) PFUEL (female) (1) and chassis
ground
Wiring harness between CE01 (female)

ground

(33) PFUEL (female) (1) and between
ENG (female) (47) PFUEL (female) (3)

ler
ENG
Voltage
Between (33) (47)
140E-5 Series
4.75 5.25 V
75
SEN00153-03
40 Troubleshooting

a For with EGR
76
There are not connect for PEVA and line to the PEVA for serial No. 530897 and up.
140E-5 Series
40 Troubleshooting
SEN00153-03

a For EGR-less
140E-5 Series
77
SEN00153-03
40 Troubleshooting
E-35 Code [431/CA431] Idle Validation Switch Error

Error code
Failure code
431
CA431
Trouble
Abnormality in idle validation switch
Contents of trouble
Abnormality occurred in idle validation switch.
Sets throttle angle to certain value and continues operation (depending on each model).

on machine
Related information

Cause

Defective accelerator pedal

1
(Internal trouble)
WAS1
Signal name
Between (5) (4)
Signal 1
Between (6) (4)
Signal 2
Voltage
See Fig. 1
If voltage is abnormal, check wiring harness and controller,

too, for another cause of trouble, and then judge.
connector)

Resistance Max. 1 z
Resistance Max. 1 z
Resistance Max. 1 z
Possible causes and

standard value in
normal state
ground
Ground fault in wiring har3 ness (Short circuit with GND Wiring harness between E02 (female)
circuit)
ground
ground
(32) WAS1 (female) (4) and chassis
Hot short (Short circuit with ground
4 24V circuit) in wiring harWiring harness between E02 (female)
ness
ground
ground
78
Voltage
Max. 1 V
Voltage
Max. 1 V
Voltage
Max. 1 V
140E-5 Series
40 Troubleshooting
SEN00153-03
Cause
Possible causes and
standard value in normal state

E02
Signal name
Between (11) (32)
Signal 1
Between (1) (32)
Signal 2
Voltage
See Fig. 1
Fig. 1
Throttle:
Idle validation:
Operating range:
140E-5 Series
Signal voltage of throttle sensor

Signal voltage of idle validation
switch
Operating range of accelerator
pedal
79
SEN00153-03
40 Troubleshooting
E-36 Code [432/CA432] Idle Validation Process Error

Error code
Failure code
432
CA432
Trouble
Abnormality in processing of idle validation
Contents of trouble
Abnormality occurred in processing of idle validation switch circuit.
Sets throttle angle to certain value and continues operation (depending on each model).

on machine
Related information
Possible causes and
standard value in
normal state
80
Cause

140E-5 Series
40 Troubleshooting
SEN00153-03
E-37 Code [441/CA441] Supply Voltage Low Error

Error code
Failure code
441
CA441
Trouble
Abnormally low power supply voltage
Contents of trouble
Power supply voltage is abnormally low.
None in particular.
on machine
start.
Related information
Possible causes and
standard value in
normal state
Cause

E-38 Code [442/CA442] Supply Voltage High Error

Error code
Failure code
442
CA442
Trouble
Abnormally high power supply voltage
Contents of trouble
Power supply voltage is abnormally high.
None in particular.
on machine
start.
Related information
Possible causes and
standard value in
normal state
140E-5 Series
Cause

81
SEN00153-03

2010 KOMATSU
All Rights Reserved
82
SEN00154-02
ENGINE
1SHOP MANUAL
140E-5 Series
40 Troubleshooting
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
SEN00154-02
40 Troubleshooting
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
140E-5 Series
40 Troubleshooting
SEN00154-02
E-39 Code [449/CA449] Rail Press. High Error 2
Error code
Failure code
449
CA449
Trouble
Abnormally high common rail pressure 2
Contents of trouble
Common rail pressure sensor circuit detected abnormally high pressure (level 2).

Output drops.
on machine
Related information
Possible causes and
standard value in
normal state
140E-5 Series
Cause

SEN00154-02
40 Troubleshooting
E-40 Code [451/CA451] Rail Press. Sensor High Error

Error code
Failure code
451
CA451
Trouble
Abnormally high level in common rail pressure sensor
Contents of trouble
Signal voltage in common rail pressure sensor circuit is abnormally high.

Output drops.
on machine
Related information

Cause

1
supply

or start engine and carry out troubleshooting.
PFUEL
Defective common rail

2 pressure sensor (Internal
trouble)
Voltage
Between (1) (3)
Power supply
4.75 5.25 V
Between (2) (3)
Signal
0.25 4.6 V

3
in wiring or defective contact in connector)
Possible causes and

standard value in
normal state

Resistance Max. 1 z

Resistance Max. 1 z

Resistance Max. 1 z

with GND circuit)

ground

ground

ground
(33) PFUEL (female) (1) and between Resistance Min. 1 Mz
Short circuit in wiring har- ENG (female) (25) PFUEL (female) (2)
5 ness (with another wiring Wiring harness between ENG (female)
harness)
140E-5 Series
40 Troubleshooting
SEN00154-02
Cause
Possible causes and
standard value in
normal state

Defective engine controller
ENG
Voltage
Between (33) (47)
4.75 5.25 V
Between (25) (47)
0.25 4.6 V
Circuit diagram related to common rail pressure sensor

a For with EGR
140E-5 Series
SEN00154-02
40 Troubleshooting
Circuit diagram related to common rail pressure sensor

a For EGR-less
140E-5 Series
40 Troubleshooting
SEN00154-02
E-41 Code [452/CA452] Rail Press. Sensor Low Error

Error code
Failure code
452
CA452
Trouble
Abnormally low level in common rail pressure sensor
Contents of trouble
Signal voltage in common rail pressure sensor circuit is abnormally low.

Output drops.
on machine
Related information
Possible causes and
standard value in
normal state
140E-5 Series
Cause

SEN00154-02
40 Troubleshooting
E-42 Code [553/CA553] Rail Press. High Error 1

Error code
Failure code
553
CA553
Trouble
Abnormally high common rail pressure 1
Contents of trouble
Common rail pressure sensor circuit detected abnormally high pressure (level 1).
None in particular.

Output drops.
on machine
Related information
Cause
Possible causes and

standard value in
normal state
If another failure code is indicated, carry out troubleshooting for

it.
2 Use of improper fuel
Check fuel used directly (for high viscosity).

3 of common rail pressure
sensor
Common rail pressure sensor may have electric trouble. Carry

out troubleshooting for code [451/CA451] (E-40).
Defective mechanical sys4 tem of common rail pressure sensor
Check mechanical system of common rail pressure sensor

directly.
5 Defective overflow valve
Check overflow valve directly for broken spring, worn seat, and
stuck ball.
6 Clogging of overflow piping Check overflow piping directly for clogging.

7 Defective pressure limiter
Check pressure limiter directly for mechanical defect.
140E-5 Series
40 Troubleshooting
SEN00154-02
E-43 Code [554/CA554] Rail Press Sensor In Range Error

Error code
Failure code
554
CA554
Trouble
In-range error in common rail pressure sensor
Contents of trouble
In-range error occurred in common rail pressure sensor circuit.

Output drops.
on machine
Related information
Possible causes and
standard value in
normal state
140E-5 Series
Cause

SEN00154-02
40 Troubleshooting
E-44 Code [559/CA559] No-pressure Feed By Supply pump 1

Error code
Failure code
559
CA559
Trouble
No-pressure feed by supply pump 1
Contents of trouble
Supply pump does not feed fuel (level 1).
Limits common rail pressure.

Output drops.
on machine
Related information
Cause
2 Use of improper fuel
Check fuel used directly (for high viscosity).
Possible causes and

standard value in
normal state

it.
Defective low-pressure circuit device
a For contents of troubleshooting, see Note 1. For check of

pressure in fuel low-pressure circuit, see TESTING AND
ADJUSTING, Testing fuel pressure.
Pressure in fuel low-pressure
circuit
(At high idle or equivalent to
rated load [by models])
0.15 0.3 MPa

{1.5 3.0 kg/cm2}
4 Clogging of filter/strainer
a For contents of troubleshooting, see Note 2.

5
of supply pump PCV
Supply pump PCV may have electric trouble. Carry out troubleshooting for following codes;
[271/CA271] (E-21), [272/CA272] (E-22), [273/CA273] (E-23),
[274/CA274] (E-24)
Defective common rail pres- Common rail pressure sensor may be defective. Check wiring
sure sensor
harness for damage.
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 operation [by models])
Max. 10 cc/min
a For testing of return (spill) limit from injector, see Testing and
adjusting, Testing fuel return rate and leakage.
8 Defective injector
9 Defective supply pump
Speed equivalent to rated

output (stall load)
Return (Spill) limit from

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 defective.
<How to use check sheet>

Carry out the above troubleshooting and take a record of the contents of the attached Check sheet for nopressure feed.
10
140E-5 Series
40 Troubleshooting
SEN00154-02
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
SEN00154-02
40 Troubleshooting
Check sheet for no-pressure feed

Model
Machine serial No.
Engine
Engine serial No.
Work No.
Date of check
Service meter
Worker's name
#
#
/
h
A. Visual check
1 Fuel leakage to outside
2 Clogging of fuel tank breather
Good NG
B. Check with machine monitor (Fault history function, monitoring function, and reduced cylinder mode function)
3 Check of error/failure code
/
/
/
/
Check of monitoring information
Standard value
Code
Displayed item
Checking condition
Unit
Measured value
(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
mm3
mand
4
Common rail pres*4
MPa
sure command
Common rail fuel
*5
MPa
pressure
Low idle
CA
Fuel injection tim*6

High idle
CA
ing command
CA
*7
Boost pressure
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
(Reference value)
No. 1 cylinder
Low idle
rpm
No. 2 cylinder
Low idle
rpm
5
No. 3 cylinder
Low idle
rpm
*10
No. 4 cylinder
Low idle
rpm
No. 5 cylinder
Low idle
rpm
No. 6 cylinder
Low idle
rpm
Good NG
C. Check of fuel circuit pressure

6
Checking condition
Fuel low-pressure circuit pres- High idle or equivalent to rated load

sure
[by models])
Unit
MPa
{kg/cm2}
Standard value
(Reference value)
0.15 0.3
{1.5 3.0}
Measured value
D. Check of strainers and filters

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
Checking condition
return rate
Leakage through pressure lim11
Equivalent to rated output [by models])
iter
Equivalent to rating<By models>1,600 rpm
12 Return rate from injector
12
Good NG
Good NG
Good NG
Good NG
Unit
Standard value
(Reference value)
cc/min
Max. 10
cc/min
cc/min
cc/min
cc/min
cc/min
960
1,020
1,080
1,140
1,200
Measured value
Good NG
Speed:
Return rate:
140E-5 Series
40 Troubleshooting
SEN00154-02
*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
SEN00154-02
40 Troubleshooting
E-45 Code [689/CA689] Eng. Ne Speed Sensor Error

Error code
Failure code
689
CA689
Trouble
Abnormality in engine Ne speed sensor
Contents of trouble
Abnormality occurred in engine Ne speed sensor circuit.
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).
Related information

Cause
1
supply system

If code [238/CA238] is indicated, carry out troubleshooting for it
first.
2

Resistance Max. 1 z

Resistance Max. 1 z

Resistance Max. 1 z
with GND circuit)

Possible causes and

standard value in
normal state
(16) NE (female) (1) and between
Short circuit in wiring har- ENG (female) (48) NE (female) (2)
harness)
ENG (female) (27) NE (female) (3)
ENG (female) (27) NE (female) (3)
Defective mount of sen5 sor or defective rotation
sensing part
14
Check Ne speed sensor directly for defective mount (defective

clearance) or check rotation sensing part (flywheel) directly for
defect.
If causes 1 5 are not detected, engine Ne speed sensor may
be defective. (Since trouble is in system, troubleshooting cannot
be carried out.)
Defective engine Ne
speed sensor
If causes 1 6 are not detected, engine controller may be defecDefective engine controltive. (Since trouble is in system, troubleshooting cannot be carler
ried out.)
140E-5 Series
40 Troubleshooting
SEN00154-02
Circuit diagram related to engine Ne speed sensor
140E-5 Series
15
SEN00154-02
40 Troubleshooting
E-46 Code [731/CA731] Eng. Bkup Speed Sensor Phase Error

Error code
Failure code
731
CA731
Trouble
Abnormality in engine Bkup speed sensor phase
Contents of trouble
Engine Bkup sensor circuit detected abnormality in phase.
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
Cause
Possible causes and
standard value in
normal state
Defective engine Ne speed Engine Ne speed sensor may be defective. Carry out trouble1
sensor system
shooting for [689/CA698] (E-45).
2
Defective engine Bkup

speed sensor system
Engine Bkup speed sensor may be defective. Carry out troubleshooting for [778/CA778] (E-48).
E-47 Code [757/CA757] All Engine Controller Data Lost Error

Error code
Failure code
757
CA757
Trouble
Loss of all data in engine controller
Contents of trouble
All data in engine controller are lost.
None in particular.
on machine
start.
Related information
Possible causes and
standard value in
normal state
16
Cause

140E-5 Series
40 Troubleshooting
140E-5 Series
SEN00154-02
17
SEN00154-02
40 Troubleshooting
E-48 Code [778/CA778] Eng. Bkup Speed Sensor Error

Error code
Failure code
778
CA778
Trouble
Abnormality in engine Bkup speed sensor
Contents of trouble
Abnormality occurred in engine Bkup speed sensor circuit.
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).
Related information

Cause

1
supply system

2

(37) G (female) (1)
Resistance Max. 1 z

(47) G (female) (2)
Resistance Max. 1 z

(26) G (female) (3)
Resistance Max. 1 z
with GND circuit)
Possible causes and
standard value in
normal state

(37) G (female) (1) and chassis ground


(37) G (female) (1) and between ENG Resistance Min. 1 Mz
Short circuit in wiring har- (female) (47) G (female) (2)
harness)
(female) (26) G (female) (3)
(female) (26) G (female) (3)
Defective mount of sen5 sor or defective rotation
sensing part
18
Check Bkup speed sensor directly for defective mount (defective

clearance) or check rotation sensing part (in supply pump)
directly for defect.
If causes 1 5 are not detected, engine Bkup speed sensor may
be defective. (Since trouble is in system, troubleshooting cannot
be carried out.)
Defective engine Bkup

speed sensor
If causes 1 6 are not detected, engine controller may be defecDefective engine controltive. (Since trouble is in system, troubleshooting cannot be carler
ried out.)
140E-5 Series
40 Troubleshooting
SEN00154-02
Circuit diagram related to engine Bkup speed sensor

a For with EGR
140E-5 Series
19
SEN00154-02
40 Troubleshooting
Circuit diagram related to engine Bkup speed sensor

a For EGR-less
20
140E-5 Series
40 Troubleshooting
SEN00154-02
E-49 Code [1228/CA1228] EGR Valve Servo Error 1

a
This code applies to only with EGR.

Error code
Failure code
1228
CA1228
Trouble
Abnormality in EGR valve servo 1
Contents of trouble
Abnormality (level 1) occurred in EGR valve servo.
Performs open control.

on machine
Related information
Cause

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

pressure
Engine speed
EGR valve drive 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
standard value in
normal state
Defective engine oil pres3

sure system (main circuit)
Engine speed
Engine oil pressure
Low idle
0.08 MPa {0.8 kg/cm2}
High idle
0.21 MPa {2.1 kg/cm2}
If engine oil pressure is abnormal, carry out troubleshooting for

mechanical system (S-12 Oil pressure lowers).
140E-5 Series
Defective oil pump for EGR

Check oil pump and relief valve for EGR valve circuit directly.
valve
Defective oil feed piping for

Check oil feed piping for EGR valve circuit directly.
EGR valve
Defective oil return piping

for EGR valve
Check oil return piping for EGR valve circuit directly.
7 Defective EGR valve
Check mechanical section of EGR valve directly.

be carried out.)
21
SEN00154-02
40 Troubleshooting
E-50 Code [1625/CA1625] EGR Valve Servo Error 2

a

Error code
Failure code
1625
CA1625
Trouble
Abnormality in EGR valve servo 2
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
Possible causes and
standard value in
normal state
22
Cause

140E-5 Series
40 Troubleshooting
SEN00154-02
E-51 Code [1626/CA1626] Bypass Valve Solenoid Drive Short Circuit

Error
1
a

Error code
Failure code
1626
CA1626
Trouble
Short circuit in bypass valve solenoid drive circuit
Contents of trouble
There is short circuit in drive circuit of bypass valve solenoid.


Output drops.
on machine
Related information

Cause
Defective bypass valve

solenoid (Internal trouble)

BP (male)
Resistance
Between (1) (2)
10 21 z
2
in wiring or defective con- (31) BP (female) (1)
tact in connector)
(11) BP (female) (2)
Possible causes and
standard value in
normal state
Resistance Max. 1 z
Resistance Max. 1 z
with GND circuit)
Wiring harness between ENG (female) (31)

BP (female) (1) and chassis ground
Hot short (Short circuit

4 with 24V circuit) in wiring
harness
Voltage
Max. 1 V
Voltage
Max. 1 V
ler
ENG (female)
Resistance
Between (31) (11)
140E-5 Series
10 21 z
23
SEN00154-02
40 Troubleshooting
Circuit diagram related to bypass valve solenoid & lift sensor
24
140E-5 Series
40 Troubleshooting
SEN00154-02
E-52 Code [1627/CA1627] Bypass Valve Solenoid Drive Open Error

a

Error code
Failure code
1627
CA1627
Trouble
Disconnection in bypass valve solenoid drive circuit
Contents of trouble
There is disconnection in drive circuit of bypass valve solenoid.


Output drops.
on machine
Related information
Possible causes and
standard value in
normal state
140E-5 Series
Cause

25
SEN00154-02
40 Troubleshooting
E-53 Code [1628/CA1628] Bypass Valve Servo Error 1

a

Error code
Failure code
1628
CA1628
Trouble
Abnormality in bypass valve servo 1
Contents of trouble
Abnormality (level 1) occurred in bypass valve servo.
Performs open control.

on machine
Related information
Cause

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

pressure
Engine speed
Bypass valve drive 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
standard value in
normal state
Defective engine oil pres3

sure system (main circuit)
Engine speed
Engine oil pressure
Low idle
0.08 MPa {0.8 kg/cm2}
High idle
0.21 MPa {2.1 kg/cm2}
If engine oil pressure is abnormal, carry out troubleshooting

for mechanical system (S-12 Oil pressure lowers).
26
Defective oil pump for

bypass valve
Check oil pump and relief valve for bypass valve circuit
directly.
Defective oil feed piping for

Check oil feed piping for bypass valve circuit directly.
bypass valve
Defective oil return piping

for bypass valve
Check oil return piping for bypass valve circuit directly.
7 Defective bypass valve
Check mechanical section of bypass valve directly.

be carried out.)
140E-5 Series
40 Troubleshooting
SEN00154-02
E-54 Code [1629/CA1629] Bypass Valve Servo Error 2

a

Error code
Failure code
1629
CA1629
Trouble
Abnormality in bypass valve servo 2
Contents of trouble
Abnormality (level 2) occurred in bypass valve servo.


Output drops.
on machine
Related information
Possible causes and
standard value in
normal state
140E-5 Series
Cause

27
SEN00154-02
40 Troubleshooting
E-55 Code [1631/CA1631] Bypass Valve Lift Sensor High Error

a

Error code
Failure code
1631
CA1631
Trouble
Abnormally high level in bypass valve lift sensor
Contents of trouble
Signal voltage in bypass valve lift sensor circuit is abnormally high.


Output drops.
on machine
Related information

Cause
1
Defective sensor power If code [187/CA187] or [227/CA227] is indicated, carry out troublesupply
shooting for it first.
a Prepare with starting switch OFF, then turn starting switch ON or
start engine and carry out troubleshooting.
SBP
Defective bypass valve

2 lift sensor (Internal trouble)
Voltage
Between (1) (2)
Power supply
4.75 5.25 V
Between (3) (2)
Signal
0.8 1.2 V
Between (4) (2)
Signal
0.8 1.2 V

Accordingly, if voltage is abnormal, check wiring harness and controller, too, for another cause of trouble, and then judge.
3
Possible causes and
standard value in
normal state

(37) SBP (female) (1)
Resistance Max. 1 z

(38) SBP (female) (2)
Resistance Max. 1 z

(29) SBP (female) (3), (4)
Resistance Max. 1 z

with GND circuit)

SBP (female) (1) and chassis ground
SBP (female) (2) and chassis ground
(29) SBP (female) (3), (4) and chassis
ground


wiring harness)

(37) SBP (female) (1) and between ENG Resistance Min. 1 Mz
(female) (38) SBP (female) (2)
(female) (29) SBP (female) (3), (4)
(female) (29) SBP (female) (3), (4)
28
140E-5 Series
40 Troubleshooting
SEN00154-02
Cause
Possible causes and
standard value in
normal state
Defective engine con6

troller

ENG
Voltage
Between (37) (38)
4.75 5.25 V
Circuit diagram related to bypass valve solenoid & lift sensor
140E-5 Series
29
SEN00154-02
40 Troubleshooting
E-56 Code [1632/CA1632] Bypass Valve Lift Sensor Low Error

a

Error code
Failure code
1632
CA1632
Trouble
Abnormally low level in bypass valve lift sensor
Contents of trouble
Signal voltage in bypass valve lift sensor circuit is abnormally low.


Output drops.
on machine
Related information
Possible causes and
standard value in
normal state
Cause

E-57 Code [1633/CA1633] KOMNET Error

Error code
Failure code
1633
CA1633
Trouble
Abnormality in KOMNET
Contents of trouble
Abnormality occurred in circuit of KOMNET communication with machine.
Operates in default mode or maintains condition when abnormality occurs.

on machine
Related information
Cause
Possible causes and
standard value in
normal state
30

1
on machine side

This fault is detected and indicated when KOMNET communication with machine monitor or controller on the machine side
is abnormal. Accordingly, contents of troubleshooting depends
on machine model. See Shop manual for machine.
140E-5 Series
40 Troubleshooting
SEN00154-02
E-58 Code [1642/CA1642] EGR Inlet Press Sensor Low Error

a

Error code
Failure code
1642
CA1642
Trouble
Abnormally low level in EGR inlet pressure sensor
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
Possible causes and
standard value in
normal state
Cause

140E-5 Series
31
SEN00154-02
40 Troubleshooting
E-59 Code [1653/CA1653] EGR Inlet Press Sensor High Error

a

Error code
Failure code
1653
CA1653
Trouble
Abnormally high level in EGR inlet pressure sensor
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
Related information

Cause
1

supply

Defective EGR inlet pres2 sure sensor (Internal

trouble)
PEVA
Between (1) (2)
Voltage
Power supply
4.75 5.25 V

3
Possible causes and

standard value in
normal state

(37) PEVA (female) (1)
Resistance Max. 1 z

Resistance

Resistance Max. 1 z
Max. 1z
with GND circuit)

PEVA (female) (1) and chassis ground

(37) PEVA (female) (1) and between
Short circuit in wiring har- ENG (female) (47) PEVA (female) (2)
harness)
ENG (female) (20) PEVA (female) (3)
ENG (female) (20) PEVA (female) (3)
ler
32

ENG
Voltage
Between (37) (47)
4.75 5.25 V
140E-5 Series
40 Troubleshooting
SEN00154-02
Circuit diagram related to EGR inlet pressure sensor
140E-5 Series
33
SEN00154-02
40 Troubleshooting
E-60 Code [2185/CA2185] Throttle Sens. Sup. Volt. High Error

Error code
Failure code
2185
CA2185
Trouble
Abnormally high level in throttle sensor power supply
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
Related information

Cause

Defective accelerator
pedal (Internal trouble)
Disconnect devices at right

in order. If error code disappears when a device is
disconnected, that device
has a defect in it.
Accelerator
pedal
WAS1 connector

Possible causes and

standard value in
normal state
harness (Disconnection Wiring harness between E02 (female) (22)
2
Resistance Max. 1 z
WAS1 (female) (1)
Wiring harness between E02 (female) (23)
Resistance Max. 1 z
WAS1 (female) (3)

with GND circuit)

WAS1 (female) (1) and chassis ground
WAS1 (female) (3) and chassis ground

wiring harness)
34

WAS1 (female) (1) and between E02
(female) (23) WAS1 (female) (3)
E02
Voltage
Between (22) (23)
4.75 5.25 V
140E-5 Series
40 Troubleshooting
SEN00154-02
Circuit diagram related to throttle sensor of accelerator pedal type (Case of HD325/405-7)
140E-5 Series
35
SEN00154-02
40 Troubleshooting
Throttle sensor of fuel control dial type (Case of PC800/800SE/850/850SE/850LC-8)

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

on machine
Related information

Cause

Defective fuel control

dial (Internal trouble)
Disconnect devices at right

in order. If error code disappears when a device is
disconnected, that device
has a defect in it.
Fuel control
dial
P20 connector

Possible causes and

standard value in
normal state
harness (Disconnection Wiring harness between E02 (female) (22)
2
Resistance Max. 1 z
P20 (female) (1)
Resistance Max. 1 z
P20 (female) (3)

with GND circuit)

P20 (female) (1) and chassis ground
P20 (female) (3) and chassis ground

wiring harness)

troller
36

P20 (female) (1) and between E02
(female) (23) P20 (female) (3)
E02
Voltage
Between (22) (23)
4.75 5.25 V
140E-5 Series
40 Troubleshooting
SEN00154-02
Circuit diagram related to throttle sensor of fuel control dial type (Case of PC800/800SE/850/850SE/
850LC-8)
140E-5 Series
37
SEN00154-02
40 Troubleshooting
E-61 Code [2186/CA2186] Throttle Sens. Sup. Volt. Low Error

Error code
Failure code
2186
CA2186
Trouble
Abnormally low level in throttle sensor power supply
Contents of trouble
Signal voltage in throttle sensor power supply (5 V) circuit is abnormally low.

on machine
Related information
Possible causes and
standard value in
normal state
Cause

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

Error code
Failure code
2249
CA2249
Trouble
No-pressure feed by supply pump 2
Contents of trouble
Supply pump does not feed fuel (level 2).
Limits common rail pressure.

Output drops.
on machine
Related information
Possible causes and
standard value in
normal state
38
Cause

140E-5 Series
40 Troubleshooting
SEN00154-02
E-63 Code [2271/CA2271] EGR Valve Lift Sensor High Error

a

Error code
Failure code
2271
CA2271
Trouble
Abnormally high level in EGR valve lift sensor
Contents of trouble
Signal voltage in EGR valve lift sensor circuit is abnormally high.


Output drops.
on machine
Related information

Cause
1
Defective sensor
power supply

SEGR
Defective EGR valve

2 lift sensor (Internal
trouble)
Voltage
Between (1) (2)
Power supply
4.75 5.25V
Between (3) (2)
Signal
0.8 1.2 V
Between (4) (2)
Signal
0.8 1.2 V

Accordingly, if voltage is abnormal, check wiring harness and controller, too, for another cause of trouble, and then judge.
Possible causes and

standard value in
normal state
harness (Disconnec3 tion in wiring or defective contact in
connector)

Resistance Max. 1 z
SEGR (female) (1)
Resistance Max. 1 z
SEGR (female) (2)
Resistance Max. 1 z
SEGR (female) (3), (4)

with GND circuit)

SEGR (female) (1) and chassis ground
SEGR (female) (2) and chassis ground
SEGR (female) (3), (4) and chassis ground

wiring harness)

SEGR (female) (1) and between ENG
(female) (47) SEGR (female) (2)
(female) (19) SEGR (female) (3), (4)
(female) (19) SEGR (female) (3), (4)
140E-5 Series
39
SEN00154-02
40 Troubleshooting
Cause
Possible causes and
standard value in
normal state

troller

ENG
Voltage
Between (37) (47)
4.75 5.25 V
Circuit diagram related to EGR valve solenoid & lift sensor
40
140E-5 Series
40 Troubleshooting
SEN00154-02
E-64 Code [2272/CA2272] EGR Valve Lift Sensor Low Error

a

Error code
Failure code
2272
CA2272
Trouble
Abnormally low level in EGR valve lift sensor
Contents of trouble
Signal voltage in EGR valve lift sensor circuit is abnormally low.


Output drops.
on machine
Related information
Possible causes and
standard value in
normal state
140E-5 Series
Cause

41
SEN00154-02
40 Troubleshooting
E-65 Code [2351/CA2351] EGR Valve Solenoid Drive Short Error

a

Error code
Failure code
2351
CA2351
Trouble
Short circuit in drive circuit of EGR valve solenoid
Contents of trouble
There is short circuit in drive circuit of EGR valve solenoid.


Output drops.
on machine
Related information

Cause
Defective EGR valve

solenoid (Internal trouble)

EGR (male)
Resistance
Between (1) (2)
10 21 z
2
in wiring or defective con- (22) EGR (female) (1)
tact in connector)
(11) EGR (female) (2)
Resistance Max. 1 z
Resistance Max. 1 z
Possible causes and
standard value in
normal state

with GND circuit)

EGR (female) (1) and chassis ground
EGR (female) (2) and chassis ground

Hot short (Short circuit
(22) EGR (female) (1) and chassis
4 with 24V circuit) in wiring
ground
harness
(11) EGR (female) (2) and chassis
ground
Voltage
Max. 1 V
Voltage
Max. 1 V
ler
ENG (female)
Resistance
Between (22) (11)
42
10 21 z
140E-5 Series
40 Troubleshooting
SEN00154-02
Circuit diagram related to EGR valve solenoid & lift sensor
140E-5 Series
43
SEN00154-02
40 Troubleshooting
E-66 Code [2352/CA2352] EGR Valve Solenoid Drive Open Error

a

Error code
Failure code
2352
CA2352
Trouble
Disconnection in drive circuit of EGR valve solenoid
Contents of trouble
There is disconnection in drive current of EGR valve solenoid.


Output drops.
on machine
Related information
Possible causes and
standard value in
normal state
44
Cause

Carry out troubleshooting E-65 Code [2351/CA2351].
140E-5 Series
40 Troubleshooting
SEN00154-02
E-67 Code [2555/CA2555] Intake Air Heater Relay Open Error

Error code
Failure code
2555
CA2555
Trouble
Disconnection in intake air heater relay
Contents of trouble
There is disconnection in intake air heater relay.
None in particular.

Engine does not start easily at low temperature.
on machine
Related information
Possible causes and
standard value in
normal state
140E-5 Series
Cause

Carry out troubleshooting E-68 Code [2556/CA2556].
45
SEN00154-02
40 Troubleshooting
E-68 Code [2556/CA2556] Intake Air Heater Relay Short Error

Error code
Failure code
2556
CA2556
Trouble
Short circuit in intake air heater relay
Contents of trouble
There is short circuit in intake air heater relay.
None in particular.

Engine does not start easily at low temperature.
on machine
Related information
Condition for driving heater relay depends on machine.

Cause
Defective intake air
1 heater relay (Internal
trouble)

R18 (male)
Resistance
Between (1) (2)
200 400 z
Possible causes and

standard value in
normal state
harness (Disconnection Wiring harness between E02 (female)
2
in wiring or defective con- (40) R18 (female) (1)
tact in connector)
(42) R18 (female) (2)
Resistance Max. 1 z
Resistance Max. 1 z
with GND circuit)

R18 (female) (1) and chassis ground
R18 (female) (2) and chassis ground
E02
Between (40) (42)
46
Heater relay
Voltage
Under operating
condition
Max. 1 V
Under stopping
condition
20 30 V
140E-5 Series
40 Troubleshooting
SEN00154-02
Circuit diagram related to intake air heater (Case of PC800/800SE/850/850SE/850LC-8)
140E-5 Series
47
SEN00154-02
40 Troubleshooting
E-69 Code [(143)/B@BAZG] Eng. Oil Press Low Torque Derate

Error code
Failure code
(143)
B@BAZG
Trouble
Derating of torque by engine oil pressure reduction
Contents of trouble
Engine oil pressure is below operating range.
Limits output and continues operation (Limits fuel injection rate and engine speed).

Output drops.
on machine
Related information
Possible causes and
Cause
1

on machine side
This fault is indicated on only machine side when detected.

Accordingly, contents of troubleshooting depends on machine
model. See Shop manual for machine.
E-70 Code [(146)/B@BCNS] Eng. Overheat

Error code
Failure code
(146)
B@BCNS
Trouble
Engine overheat
Contents of trouble
Engine coolant temperature is above operating range.

Output drops.
on machine
Related information
Possible causes and
48
Cause
1

on machine side

140E-5 Series
40 Troubleshooting
SEN00154-02
E-71 Code [(415)/B@BAZG] Eng. Oil Press. Low Speed Derate

Error code
Failure code
(415)
B@BAZG
Trouble
Derating of speed by engine oil pressure reduction
Contents of trouble
Engine oil pressure is below operating range.
Limits output and continues operation (Limits fuel injection rate and engine speed).

Output drops.
on machine
Related information
Possible causes and
standard value in
normal state
140E-5 Series
Cause
1

on machine side

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
SEN00156-05
General information on disassembly and assembly
(Rev. 2009.01)
How to read this manual

1.
Removal and installation of assemblies

Special tools
q
Special tools which are necessary for
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
described as A1, X1 etc. and their part
numbers, part names and quantities are
described in the special tool list.
q
Also the following information is described in the special tool list.
1) 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
2) Distinction of new and existing special
tools
N:
Tools newly developed for this
model. They have a new part number respectively.
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 forward the
part number of the existing tool.
Blank : Tools already available for other
models. They can be used without
any modification.
3) Circle mark Q in sketch column:
q
The sketch of the special tool is presented in the section of Sketches of
special tools.
q
Part No. of special tools starting with
79 T:
means that they are not available
from Komatsu Ltd. (i.e. tools to be
made locally).
* *** ****
Removal
q
In Removal section, the work procedures,
precautions and know-how to do the work, and
the amount of oil and coolant to be drained are
described.
q
Common tools that are necessary for removal
are described as [1], [2] etc. and their part
numbers, part names and quantities are not
described.
q
Various symbols used in Removal section are
explained and listed below.
k : Precautions related to work safety
a : Guidance or precautions for the work
[*1] : This mark shows that instructions or precautions for parts installation work are given in
Installation section.
6 : Amount of oil or coolant to be drained
4:
Weight of part or component
Installation
q
Unless otherwise instructed, installation of
parts is to be done in the reverse order to
removal.
q
Instructions and precautions for parts installation is shown with the mark ([*1], [*2]...) which
corresponds to the mark in Removal section.
q
Common tools that are necessary for installation are described as [1], [2] etc. and their
part numbers, part names and quantities are
not described.
q
Marks shown in the Installation section stand
for the following.
k
: Precautions related to work safety

: Guidance or precautions for the work
2 : Type of coating material
3 : Tightening torque
: Amount of oil or coolant to be replenished

q
Various special tools are illustrated for the local
manufacture.
140E-5 Series
2.
SEN00156-05
Disassembly and assembly of assemblies

Special tools
q
Special tools which are necessary for disassembly and assembly of parts are
described as A1, X1 etc. and their part
numbers, part names and quantities are
described in the special tool list.
q
Also the following information is described
in the special tool list.
1) 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.
2) Distinction of new and existing special
tools
N:
Tools newly developed for this
model. They have a new part number respectively.
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 forward the
part number of the existing tool.
Blank : Tools already available for other
models. They can be used without
any modification.
3) Circle mark Q in sketch column:
q
The sketch of the special tool is presented in the section of Sketches of
special tools.
q
Part No. of special tools starting with
79 T:
means that they are not available
from Komatsu Ltd. (i.e. tools to be
made locally).
* *** ****
Disassembly
q
In Disassembly section, the work procedures,
the amount of oil and coolant to be drained are
described.
q
Common tools that are necessary for disassembly are described as [1], [2] etc. and
their part numbers, part names and quantities
are not described.
q
The meanings of the symbols used in Disassembly section are as follows.
k

6 : Amount of oil or coolant drained
Assembly
q
In Assembly section, the work procedures,
the amount of oil and coolant to be replenished
are described.
q
Common tools that are necessary for assembly are described as [1], [2] etc. and their
part numbers, part names and quantities are
not described.
q
The meanings of the symbols used in Assembly section are as follows.
k

2 : Type of coating material
3 : Tightening torque
: Amount of oil or coolant to be replenished

Various special tools are illustrated for the local
manufacture.
140E-5 Series
SEN00156-05
Coating materials list

a
a
The recommended coating materials such as adhesives, gasket sealants, and greases used for disassembly and assembly are listed below.
For coating materials not listed below, use the equivalent of products shown in this manual.
Category
Komatsu
code
Part number
Q'ty
Container
Main features and applications
LT-1A
790-129-9030
150 g
Tube
Used to prevent rubber gaskets, rubber cushions, and cork plugs from coming out.
LT-1B
790-129-9050
20 g
(2 pcs.)
Used for plastic (except polyethylene,

polypropylene, tetrafluoroethylene and vinyl
Polyethylene
chloride), rubber, metal, and non-metal parts
container
which require immediate and strong adhesion.
LT-2
09940-00030
50 g
Polyethylene Features: Resistance to heat and chemicals.

container Used to fix and seal bolts and plugs.
Adhesive
LT-3
790-129-9040
250 g
Holtz MH 705
790-129-9120
75 g
790-129-9140
Can
Used to stick and seal metal, glass, and plastics.
Polyethylene
Used to seal plugs.
container
Tube
Heat-resistant seal used to repair engines.
50 g
Quick-setting adhesive.
Polyethylene Setting time: Within 5 sec. to 3 min.
container Used mainly to stick metals, rubbers, plastics,
and woods.
Quick-setting adhesive.
Quick-setting type.
Polyethylene
(max. strength is obtained after 30 minutes)
container
Used mainly to stick rubbers, plastics, and
metals.
Aron-alpha
201
790-129-9130
2g
Loctite
648-50
79A-129-9110
50 cc
Features: Resistance to heat and chemicals.

Polyethylene
Used for fitted portions used at high temperacontainer
tures.
1 kg
Used to seal various threaded portions, pipe

Polyethylene
joints, and flanges.
container Used to seal tapered plugs, elbows, and nipples of hydraulic piping.
LG-5
Gasket sealant
790-129-9060
Adhesive: 1 kg
(Set of adhesive
Hardener: 500 g
and hardener)
LT-4
ThreeBond
1735
790-129-9080
LG-6
790-129-9160
200 g
Tube
Features: Silicon-based heat and cold-resistant sealant.

Used to seal flange surfaces and threaded
portions.
Used to seal oil pan, final drive case, etc.
LG-7
790-129-9170
1 kg
Tube
Features: Silicon-based quick-setting sealant.

Used to seal flywheel housing, intake manifold, oil pan, thermostat housing, etc.
Tube
Features: Silicon-based, heat and cold-resistant, vibration-resistant, impact-resistant sealant.

Used to seal transfer case, etc.
LG-8
ThreeBond
1207B
(Rev. 2009.02)
1
419-15-18131
100 g
140E-5 Series
Gasket sealant
CateKomatsu code
gory
Molybdenum
disulfide
lubricant
Container
790-129-9310
200 g
Tube
Used for rough surfaces such as the circle gear

top seal which does not need to be clamped,
water resistance of the clearance at the welded
area, etc.
Can be coated with paint.
LG-10
ThreeBond
1206E
790-129-9320
200 g
Tube
Used as lubricant/sealant when the radiator

hoses are inserted.
Can be coated with paint.
LG-11
ThreeBond
1121
790-129-9330
200 g
Tube
Feature: Can be used together with gaskets.

Used for covers of the transmission case and
steering case etc.
ThreeBond
1211
790-129-9090
100 g
Tube
Gasket sealant used to repair engine.
Tube
Used to prevent scuffing and seizure of press-fitted portions, shrink-fitted portions, and threaded
portions.
Used to lubricate linkages, bearings, etc.
Can
Spray type
Thin molybdenum disulphide films are made on
metal surfaces to prevent the metals from scuffing each other.
Applicable for the drive shaft splines, needle
bearings, pins and bolts of various links, etc.
Can
Feature: Seizure and scuffing prevention compound with metallic super-fine-grain, etc.
Used for the mounting bolt in the high temperature area of the exhaust manifold and the turbocharger, etc.
Various
Various
Feature: Lithium grease with extreme pressure

lubrication performance.
General purpose type.
LC-G
NEVER-SEEZ
09940-00040
09995-00250
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
G2-LI
SYG2-160LI
G0-LI
SYGA-160CNLI
*: For cold district
SYG0-400LI-A (*)
SYG0-160CNLI
(*)
Grease
Q'ty
LG-9
ThreeBond
1206D
LM-P
Seizure
prevention
compound
Part number
SEN00156-05
Molybdenum
SYG2-400M
disulfide grease SYG2-400M-A
LM-G (G2-M)
SYGA-16CNM
SYG2-400T-A
SYG2-16CNT
SYG0-400T-A (*)
*: For cold district SYG0-16CNT (*)
Hyper White
Grease G2-T,
G0-T (*)
SYG2-400B
Biogrease
G2-B, G2-BT (*) SYGA-16CNB
*: For use at high SYG2-400BT (*)
temperature and SYGA-16CNBT
under high load
(*)
140E-5 Series
200 g
190 g
Used for parts under heavy load.

Caution:
400 g x 10 Bellows-type Do not apply grease to rolling bearings like
swing circle bearings, etc. and spline.
400 g x 20 container
The grease should be applied to work equipment
16 kg
Can
pins at their assembly only, not applied for
greasing afterwards.
400 g
16 kg
400 g
16 kg
Bellows-type
container
Can
Seizure resistance, heat resistance and water

resistance higher than molybdenum disulfide
grease.
Not conspicuous on machine since color is
white.
Bellows-type Since this grease is decomposed by natural baccontainer

teria in short period, it has less effects on microCan
organisms, animals, and plants.
SEN00156-05
G2-U-S
ENS grease
427-12-11871
SUNSTAR
PAINT PRIMER
580 SUPER
Caulking material
Adhesive
Primer
SUNSTAR
GLASS
PRIMER 580
SUPER
SUNSTAR
PAINT PRIMER
435-95
Q'ty
Container
Tube
Feature: Silicone grease with wide using temperature range, high resistance to thermal-oxidative degradation and performance to prevent
deterioration of rubber and plastic parts.
Used for oil seals of the transmission, etc.
2 kg
Can
Feature: Urea (organic system) grease with heat

resistance and long life. Enclosed type.
Used for rubber, bearing and oil seal in damper.
Caution: Do not mix with lithium grease.
20 ml
Glass
container
Used as primer for cab side.

(Using limit: 4 months after date of manufacture)
20 ml
Glass
container
Used as primer for glass side.

20 ml
Glass
container
200 g
417-926-3910
22M-54-27230
Adhesive for cab glass
G2-S
ThreeBond
1855
Part number
Used as primer for painted surface on cab

side.
Used as primer for black ceramic-coated
surface on glass side and for hard polycarbonate-coated surface.
SUNSTAR
GLASS
PRIMER
435-41
22M-54-27240
150 ml
Can
SUNSTAR
SASH PRIMER
GP-402
22M-54-27250
20 ml
Glass
container
Used as primer for sash (Almite).

SUNSTAR
PENGUINE
SEAL 580
SUPER S or
W
417-926-3910
320 ml
Polyethylene
container
S is used for high-temperature season

and W for low-temperature season as
adhesive for glass.
Sika Japan,
Sikaflex 256HV
20Y-54-39850
310 ml
Polyethylene
container
Used as adhesive for glass.

SUNSTAR
PENGUINE
SUPER 560
22M-54-27210
320 ml
Ecocart
(Special
container)
SUNSTAR
PENGUINE
SEAL No. 2505
417-926-3920
320 ml
Polyethylene
container
SEKISUI
SILICONE
SEALANT
20Y-54-55130
333 ml
Polyethylene
container
Used to seal front window.

Cartridge
Used to seal joint of glasses.

Translucent white seal.
GE TOSHIBA
SILICONES
TOSSEAL 381
22M-54-27220
333 ml
Adhesive for cab glass
Grease
CateKomatsu code
gory
Used as adhesive for glass.

Used to seal joints of glass parts.
140E-5 Series
SEN00156-05
Special tools list
Disassembly and assembly of engine

assembly
Part No.
Part name
790-501-2001
Engine repair stand t 1
790-901-1261
Bracket
t 1
Removal and installation of cylinder

head valve spring
795-102-2103
Spring pusher
t 1
Removal and installation of piston ring
795-100-1191
Piston ring tool
t 1
Removal of cylinder liner
795-236-1000
Liner puller
t 1
Press fitting of cylinder liner
795-230-5472
Liner driver
t 1
Insertion of piston assembly
795-921-1100
Piston holder
t 1
Measuring projection of cylinder liner
795-502-1121
Gauge holder
t 1
795-125-1210
Thickness gauge
q 1
Angle tightening of bolt
790-331-1110
Wrench
q 1
795-931-1100
Seal puller
t 1
1
M
2
Removal and installation of engine front
seal and engine rear seal
795T-521-1111 Push tool
t 1
01050-31655
Bolt
t 3
01050-31635
Bolt
Remarks
Removal of oil
seal
N Q
t 3
Press fitting of
engine front seal
795T-521-1150 Push tool
t 1
01050-31635
t 3
N Q Press fitting of
engine front seal
(sleeve type)
795T-421-1260 Push tool
t 1
N Q
01050-31640
Bolt
t 4
01643-31645
Washer
t 8
Bolt
795T-421-1240 Push tool
t 1
01050-31645
Bolt
t 4
01643-31645
Washer
t 4
795T-421-1231 Push tool
t 1
01050-31645
Bolt
t 4
01643-31645
Washer
t 8
795-630-5500
Standard puller
t 1
Bolt
t 2
Removal of fuel supply pump
01010-81090
01643-31032
Washer
t 2
Press fitting of valve stem seal
795-130-1720
Push tool
t 1
140E-5 Series
Sketch
Work item
New / Remodel
Q'ty
Necessity
Tools with part number 79*T-***-**** means that they are not available from Komatsu Ltd. (i.e. tools to be
made locally).
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
New/Redesign: N ............ Tools newly developed for this model. They have a new part number respectively.
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 forward the part number of the existing tool.
Blank ..... Tools already available for other models. They can be used without any modification.
Tools marked with Q in the sketch column are presented in the sketches of the special tools (See
Sketches of special tools).
Symbol
Press fitting of
engine rear seal
(standard type)
N Q
Press fitting of
engine rear seal
N Q (sleeve type)
Used to remove
pump unit
SEN00156-05
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
140E-5 Series
SEN00156-05
drawings.
N1. Push tool
N2. Push tool
140E-5 Series
SEN00156-05
drawings.
N3. Push tool
10
140E-5 Series
140E-5 Series
SEN00156-05
11
SEN00156-05

2011 KOMATSU
All Rights Reserved
12
SEN00157-05
ENGINE
1SHOP MANUAL
140E-5 Series

(with EGR)
Disassembly and assembly, Part 1 (with EGR)............................................................................................... 2
General disassembly of engine............................................................................................................ 2
General assembly of engine .............................................................................................................. 20
140E-5 Series
SEN00157-05
Disassembly and assembly, Part 1 (with EGR)
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 assembly.
a Before cleaning the engine, carefully seal
or remove the openings, electric parts,
and wiring connectors so that water will
not enter them.
2.
Drain the engine coolant and engine oil.

a The quantity of the oil depends on the
applicable machines.
6
Air cleaner bracket

1) Disconnect wiring harness clamp (1).
2) Remove air cleaner bracket (2).
a The type of the bracket depends on
the applicable machines.
4 Air cleaner bracket: 30 kg
5.
EGR cover
1) Remove covers (1), (2), and (3).
Setting engine assembly

1) Prepare stable engine stands (Blocks [1])
and place the engine assembly on them
so that it will not tip over.
a The weight depends on the applicable machines.
4 Engine assembly: 2,000 kg
2)
3.
4.
Engine oil: Approx. 53 l
Starting motor assembly

1) Disconnect wiring harness (1) and connector (2).
2) Remove 3 mounting bolts (3) and remove
starting motor assembly (4).
140E-5 Series
2)
6.
Remove covers (4), (5), (6), and (7).

a Cover (6) is not installed to all the
models.
Tube clamp and bracket

1) Remove clamps (1), (2), (3), and (4).
a The clamps hold the tubes from the
front and rear.
2) Remove brackets (5), (6), and (7).
SEN00157-05
8.
Clamp and bracket

1) Remove clamp (1) and brackets (2) and
(3).
2) Remove bracket (4).
9.
Bypass valve assembly

1) Remove the wiring harness clamp and
disconnect connectors SBP (1) and BP
(2).
2)
7.
Bracket
Remove brackets (1), (2), and (3).
140E-5 Series
3)
Remove clamps (3), (5), and (11) and

remove tubes (6) and (7).
Remove bolts (8) and (9) and remove
bypass valve assembly (10).
SEN00157-05
10. EGR valve assembly

1) Remove the wiring harness clamp and
disconnect connectors SEGR (1) and
EGR (2).
2)
3)
12. EGR tube

1) Remove EGR inlet pressure sensor tube
(1).
Reference: EGR inlet pressure sensor is
applied to only machines Serial No. up to
530896.
2) Remove EGR tube (2).
Remove tubes (3) and (4).

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)
4)
5)
Remove turbocharger drain tube clamps

(6).
Remove air vent tube (7), bracket (8), and
EGR cooler inlet tube (9).
Remove EGR cooler coolant inlet tube
(10).
140E-5 Series
SEN00157-05
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).
15. EGR valve bracket

Remove EGR valve bracket (1).
4
Bracket: 20 kg
140E-5 Series
3)
Remove wiring harness (4) and 4 turbocharger lubrication tube clamps (5) and
remove turbocharger lubrication tube (6).
4)
Remove the 4 nuts and remove air inlet

pipe and turbocharger assembly (7).
4 Air inlet pipe and turbocharger
assembly: 30 kg
SEN00157-05
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 adjustment 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 thermostat assembly (4).
a One of the 5 mounting bolts is used to
clamp the thermostat assembly and
cover together and has been
removed already.
140E-5 Series
22. Oil filter, fuel filter, and corrosion resistor

Remove oil filter (1), pre-fuel filter (2), main fuel
filter (3), and corrosion resistor (4).
a Pre-fuel filter (2) may be installed on the
applicable machine side.
a Corrosion resistor is not set for some
models.
SEN00157-05
25. Oil filter head

1) Remove oil tubes (1) and (2) and the block
on the cylinder block side as a unit.
2) Remove oil filter head (3).
a The type of the oil filter head depends
on the applicable machines.
23. EGR valve and bypass valve oil drain tube

Remove drain tube (5).
24. Controller cover and oil filler

1) Remove controller cover (1).
2) Remove the clamp and oil filler (2).
a The position of the oil filler depends
26. Fuel filter head

1) Remove fuel tube (1).
2) Remove fuel filter head (2) and bracket (3)
as a unit.
a The wiring harness clamp and the
bracket are fixed together.
a The type of the fuel filter head
depends 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
SEN00157-05
6)
Remove corrosion resistor head (10), fuel

filter head (11), priming pump (12), and
bracket as a unit.
models.
28. Air intake connector assembly

1) Disconnect EGR inlet pressure sensor
connector PEVA (1) and clamp of wiring
harness (2).
530896.
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
29. Air intake manifold

1) Sling the air intake manifold temporarily.
2) Disconnect the clamps of connectors
TFUEL (1), TIM(2), PIM (3), and wiring
harness (4).
3) Disconnect fuel tube (5).
4) Remove wiring harness clamp (6) and
tube clamp (7).
5) Remove clamp (8) of the high-pressure
pipe.
a Remove the 5 high-pressure pipe
clamps above the air intake manifold,
too.
6)
7)
a
When replacing the

remove connector (4).
air
heater,
Disconnect clamps (9), (10), (11), (12),

and (13) of the high-pressure pipe.
Remove the mounting bolts and air intake
manifold (14).
4 Air intake manifold: 45 kg
140E-5 Series

Disconnect connector (1) and remove engine
controller (2).

1) Disconnect fuel hose (1).
a Fuel hose (1) may not be installed.
2) Remove engine controller cooler (2).
32. Plate
Remove plate (3).
SEN00157-05
33. Common rail and high-pressure pipe

a Before removing the high-pressure pipe,
loosen all of the clamps, brackets, and
sleeve nuts to give the high-pressure pipe
freedom.
2)
3)
4)
5)
140E-5 Series

a At this time, the clamp of wiring harness (4) comes off.
Remove clamps (5), (6), (7), (8), (9), (10),
and (11).
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.
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.
SEN00157-05
6)
7)
8)
Disconnect fuel pressure sensor connector PFUEL (15) and POIL (16).
Remove clamp (17) and the eye joint of
tube (18) on the common rail side.
Remove special bolts (19) and remove
common rail (20).
34. 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), (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.
35. EGR oil pump assembly

Remove the bolts and EGR oil pump assembly
(1).
36. Corrosion resistor tube and blow-by tube

1) Remove corrosion resistor tubes (1) and
(2).
models.
2) Remove breather remote tube (3).
37. Wiring harness assembly and sensor connector

1) Disconnect the clamps of coolant temperature sensor connector TWTR (1) and wiring harnesses (2) and (3) and remove
bracket (4).
10
140E-5 Series
2)
3)
4)
Disconnect the connectors of Ne sensor

NE (6), and atmospheric pressure sensor
PAMB (7).
Remove the 6 injector connectors and
remove the wiring harness assembly.
Remove bracket (8).
5)
Move lock [1] of the housing of connector (7) in the direction of the arrow,
push down lock [2], and pull out connector (7).
Disconnect the injector connector according to the following procedure.

1] Apply flat-head screwdriver [1] to the
stepped part (part (a)).
2] While pressing stopper (1a), move
flat-head screwdriver [1] in direction
(X) to disconnect the connector.
SEN00157-05
38. Oil pan

1) Move the blocks which are supporting the
engine to positions where you can remove
the oil pan mounting bolts.
2) While supporting oil pan (1) on a pallet lift,
etc., remove the mounting bolts and oil
pan (1).
39. Suction tube

Remove bracket (1) and suction tube (2).
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.
Arrange the above blocks so that you can
rotate the crankshaft.
40. Flywheel
1) Using sling [1], lift up flywheel (1) temporarily.
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
SEN00157-05
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 adjustment 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
SEN00157-05
46. Push rod

Remove push rod (1).
6)
Loosen the bolt of holder (8) of fuel injector (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 injector.
4)
140E-5 Series
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).
13
SEN00157-05
3]
4]
Remove valve stem seal (5) and

lower seat (6).
Raise the cylinder head and remove
valve (7).
49. Front support

Lift up front support (1) temporarily, remove the
mounting bolts, and lift off the front support.
a The shape and weight of the front support
4
48. Damper assembly

Lift up damper assembly (1) temporarily,
remove the 6 mounting bolts (2), and lift off the
damper assembly.
a The fan drive pulley may be installed.
4
Damper assembly: 40 kg
50. Cam follower assembly

1) Remove the 3 cover mounting bolts and
remove cover (1).
2) Remove mounting bolts (3) and cam follower (2).
3)
14
Front support: 65 kg
Remove snap rings (4) and remove lever

assembly (5) from shaft (6).
140E-5 Series
51. Front cover

1) Install eyebolts [1] and lift up the front
cover temporarily.
2) Remove the mounting bolts and sling front
cover (1). Remove the front cover by moving it forward.
4 Front cover: 70 kg
52. Front oil seal

Remove front oil seal (1) from the front cover.
SEN00157-05
4)
54. Camshaft
1) Match the holes of cam gear (1) to mounting bolts (2) and remove bolts (2).
2)
53. Fuel supply pump assembly and drive gear
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
Remove pump mounting bolts (4), bracket

(5), and fuel supply pump assembly (6).
a While supporting the fuel supply
pump assembly, remove the mounting bolts.
Sling camshaft (3) temporarily. Pull out

the camshaft while turning it so that the
cam bushing will not be damaged.
4 Camshaft: 20 kg
15
SEN00157-05
55. Oil pump assembly and sub idler gear

1) Remove oil pump assembly (1).
2) Remove sub idler gear (2).
56. Main idler gear

Remove mounting bolt (1) and main idler gear
(2).
57. Setting of engine repair stand and underframe

1) Install tool A2 to the cylinder block. Sling
the engine and set it to tool A1.
2) Remove the 4 mounting bolts from each of
2 underframes (1) and remove the underframes.
a The number of underframes (1)

Remove the mounting bolts and piston cooling
nozzles (1) and (2).
a Be sure to remove the piston cooling nozzles before pulling out the piston.
59. Piston and connecting rod assembly

a Before removing the piston and connecting rod assembly, measure its end play
with dial gauge [1], if necessary.
1)
2)
3)
4)
5)
16
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.
Rotate the crankshaft and bring the piston
to be removed to the bottom dead center.
Scrub the carbon off the top wall of the cylinder liner with fine sandpaper.
Remove connecting rod cap mounting
bolts (1).
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.
140E-5 Series
SEN00157-05
8)
6)
7)
Push in and remove the piston and connecting rod assembly with a wood bar, etc.
from the oil pan side, while supporting piston (6) on the cylinder head side.
a Take care not to damage the inside of
the cylinder with a corner of the connecting rod.
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.
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.
3]
a
Using tool D, remove piston ring (7).

Keep the piston, connecting rod, connecting rod bearing, piston rings, and
piston pin by cylinder.
60. Crankshaft
a Before removing the crankshaft, measure
its end play with dial gauge [1], if necessary.
140E-5 Series
17
SEN00157-05
1)
2)
4)
Remove upper thrust bearing (5).
5)
The No. 7 main cap has lower thrust

bearing (3).
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.
Lift off crankshaft (4).

a When removing the crankshaft, take
care not to hit its sliding surfaces
against the cylinder block.
4 Crankshaft: 140 kg
61. Cylinder liner

a Before removing the cylinder liner, measure its projection with tool H, if necessary.
Remove mounting bolts (2) of main cap

(1).
Insert the bolts in the bolt holes of the
main cap and remove the cap, while shaking it.
3)
18
140E-5 Series
SEN00157-05
62. Using tool E, remove cylinder liner (1).
140E-5 Series
19
SEN00157-05
General assembly of engine

a
a

Take care.
Clean each part carefully, and check it for
bruise, flaw, cavity, etc. Make sure each oil or
coolant path is through.
Tightening bolts by plastic-region turning angle

method
a Bolts tightened by plastic-region turning angle
method
q
Cylinder head mounting bolt
q
Main cap mounting bolt
q
Connecting rod cap mounting bolt
q
Flywheel mounting bolt
a If the plastic-region turning angle method is
applied, the tightened bolts have permanent
strain. Accordingly, the allowable number of
using times of each bolt is limited. Observe
the following precautions.
q
Before tightening each bolt, measure its
stem length and make sure that the result
is less than the using limit. If the stem is
longer than the using limit, do not reuse it
but replace it.
q
Check each mounting bolt head for punch
marks. If there are punch marks more
than the specified number, do not reuse it
but replace it.
1.
20
2)
Before inserting the cylinder liners, prepare the cylinder block according to the
1] Remove the rust and scales from
faces A and B with sandpaper, etc.
until the machined surfaces are
exposed.
2] Polish part R with sandpaper of about
No. 60 until it becomes a smooth
rounded surface.
3] Polish parts R and h with sandpaper
of about No. 60 until they become
smooth.
If part R is sharp or has burrs, finish it
with a scraper or sandpaper.
Finish this surface particularly
smoothly so that it will not damage
the O-ring.
4] If face B is so pitted that it cannot be
repaired, replace the cylinder block.
5] If faces A and R are pitted, finish
them smoothly.
6] Check the counterbored part and
remove burrs. If chips or dust is on
face C, the liner does not fit and coolant may leak and the projection of the
liner may become improper consequently.
a If the counterbored part is drooping, corroded, or pitted, repair it.
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
140E-5 Series
2.
Cylinder liner
a Replace the O-ring and clevis seal with
new ones.
1) Check that the cylinder liner O-ring groove
and periphery of the liner are not roughened 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
for distinction.
q
O-ring (3): The whole ring is red.
2 Clevis seal and O-ring:
Rubber lubricant (RF-1)
a RF-1: DAIDO CHEMICAL INDUSTRY
CO., LTD.
If RF-1 is not available, apply clean
engine oil SAE No. 30.
a Since the clevis seal and O-ring are
swollen and deteriorated by oil, apply
a small amount of oil to them thinly
with a brush just before fitting them.
140E-5 Series
SEN00157-05
3)
After fitting the liner O-ring, check it for

twist. If it is twisted, correct it with a
smooth rod (about 10 mm in diameter).
4)
Apply gasket sealant to the parts of the

cylinder block and cylinder liner which will
fit to the counterbored parts.
a Wipe off dirt and oil with cloth from
the contact faces of the counterbored
parts of the cylinder block and liner
flange.
2 Cylinder block:
Gasket sealant (LG-6)
q
Gasket sealant:
2 3 mm in diameter
q
Overlap (a) of gasket sealant:
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.
21
SEN00157-05
5)
6)
7)
22
Insert cylinder liner (1) in the cylinder

block slowly, taking care not to damage
the O-ring.
Push in cylinder liner (1) further with both
hands.
a If the liner does not enter the cylinder
smoothly, the O-ring may be broken.
In this case, check the cylinder block
for burrs.
Using tool F, press fit cylinder liner (1) to
the cylinder block.
8)
To prevent the gasket sealant from projecting through the clearance between the
block and liner after the cylinder head is
tightened, tighten the cylinder head temporarily with the used head gasket
inserted.
a At this time, observe the following
tightening torque and tightening
order.
3 Temporary tightening torque:
137 157 Nm {14 16 kgm}
9)
Remove the cylinder head and wipe off

the gasket sealant projected from the
counterbored part.
a Be sure to perform steps 8) and 9)
above since the projected gasket
sealant can deform the grommet of
the head gasket.
10) Using tool H, measure the projection of

the cylinder liner.
a When measuring the projection of the
liner, tighten the liner with a plate so
that it will not be lifted by the O-ring.
q
Projection of liner: 0.07 0.15 mm
a If the gasket sealant is projected from
the fitting parts of the cylinder block
and cylinder liner up to the top of the
cylinder block, wipe it off.
3.
Crankshaft
1) Fit upper main bearing (6) to the cylinder
block, matching the projection of the
former to the cut of the latter.
a An oil hole is made on the upper main
bearing.
a Before fitting the bearing, make sure
that its back side is free from foreign
matter.
2 Inside of bearing: Engine oil (EO30)
2)
Drive the dowel pin so that it will be projected by 2.7 3.4 mm from the block end
and then install upper thrust bearing (5) to
the No. 7 journal.
a Install the thrust bearing with the
grooved surface on the crankshaft
side.
140E-5 Series
3)
4)
5)
Sling crankshaft (4) and install it to the cylinder block.

a When replacing the crank gear, heat it
with a bearing heater (30 A) (Set temperature: 150C) and fit it just after it
is heated.
a When installing the crankshaft, take
2 Cylinder block journal:
Engine oil (EO30)
Fit the lower main bearing to the main cap,

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 matter.
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
side.
140E-5 Series
SEN00157-05
6)
Make sure that the journal No. stamped at

the center of main cap (2) and the journal
No. of the cylinder block are the same and
then install the main cap.
a Install the main cap with the cast letter (F) toward the front of the engine.
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:
Min. 176.3 mm
23
SEN00157-05
8)
Tighten main cap mounting bolts (1)

a Tighten the bolts from the center one
to the outer ones in order.
2 Threaded portion of mounting bolt
and washer:
Engine oil (EO30)
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).
10) Check that the crankshaft turns smoothly.

11) Measure the end play of the crankshaft
with dial gauge [1].
a End play: 0.140 0.315 mm
a If the end play is out of the standard,
correct it. For details, see Structure,
function and maintenance standard.
4.
9)
24
When not using tool J, make

marks (b) on the main cap and
bolt with paint, then tighten the
bolt by 90 (+30/0).
Make punch mark (c) on the mounting bolt
head.
a When a new bolt is used, do not
make a punch mark on its head.
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
1) Using tool D, fit piston rings (7) to the piston.
a Fit the top ring and second ring to the
piston with the stamped mark side up.
q
Stamp on top ring: 1RS
q
Stamp on second ring: 2RX
a Take the expander out of the oil ring
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.
140E-5 Series
2)
Set the abutment joint of each piston ring

as shown in the following figure.
a Adjust oil ring so that the joint of the
expander will be at 180 to the abutment joint of the oil ring.
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 direction, then insert piston pin (5) to
assemble connecting rod (4) and piston (6).
Fit snap rings (3) on both sides of the piston pin to secure the piston pin.
4)
5)
6)
SEN00157-05
7)
Insert piston and connecting rod assembly

(8) in the cylinder block so that the cast
part number on the connecting rod will be
directed to the front of the engine (the
stamped cylinder number will be on the
camshaft side).
a Referring to step 2), check the abutment joint of each piston ring again.
2 Inside of connecting rod bearing and
inside of cylinder:
Engine oil (EO30)
8)
Using tool G, reduce the piston ring and

push in the piston head with a wood bar,
etc. into the cylinder block.
Fit the upper bearing to the connecting

rod, matching the projection of the former
to the cut of the latter.
Set the crankshaft so that the cylinder to
be installed will be at the bottom dead
center.
140E-5 Series
25
SEN00157-05
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.
q
is 5.)
q
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 connecting rod (4), matching yellow marks (a) on
them to each other.
2 Inside of connecting rod cap bearing:
Engine oil (EO30)
26

marks (b) on the connecting rod
cap, and bolt with paint, then
tighten the bolt by 90 (+30/0).
140E-5 Series
SEN00157-05
13) After tightening the bolt, make a punch

mark (c) on its head.
2)
Install piston cooling nozzles (1) and (2) to

each cylinder in order.
a Install the piston cooling nozzles having the stamps of (F1) to the front side
of the cylinder and install those having 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 hexagonal 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 connecting rod with dial gauge [1].
a Side clearance: 0.100 0.274 mm
a If the side clearance is out of the standard, correct it. For details, see
standard.
6.
5.
Underframe
Install underframes (1).
a The number of the underframes depends
Piston cooling nozzle

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.
q
q
140E-5 Series
27
SEN00157-05
7.
Main idler gear

1) Install bearing (3) and shaft (2) to the outside of main idler gear (1) and install bearing (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 crankshaft gear to that of main idler gear (1),
tighten mounting bolt (5).
3 Mounting bolt:
784 44.1 Nm {80 4.5 kgm}
9.
8.
28
Sub idler gear and oil pump assembly

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}
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 240C for 30 60
minutes and then install it by shrink
fit.
4 Camshaft: 20 kg
2 Camshaft journal surface:
Engine oil (EO30)
140E-5 Series
2)
Matching the stamped (C) of the camshaft

gear to that of the main idler gear, tighten
mounting bolt (2).
3 Mounting bolt:
98 123 Nm {10 12.5 kgm}

1) Install 2 lever assemblies (5) to shaft (6).
a Insert the cam followers so that the
ball end of the shaft will be directed
toward the rear of the engine.
2) Install snap rings (4).
3)
SEN00157-05
4)
Fit the O-ring and install cover (3).

3 Mounting bolt:
9.8 12.7 Nm {1.0 1.3 kgm}

1) Fit the key to the shaft of fuel supply pump
assembly (6) and install them to the cylinder block.
2) Tighten mounting bolts (4) and install
bracket (5).
2 Mounting bolt: Adhesive (LT-2)
Install cam follower assembly (1), matching 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
SEN00157-05
3)
Install fuel supply pump drive gear (3) to

the fuel supply pump shaft and tighten
mounting nut (1).
a When installing to the fuel supply
pump shaft, set stamp (B) of fuel supply 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}
Standard backlash of each gear

Position
Range (mm)
0.141 0.425
0.129 0.391
0.129 0.391
0.141 0.425
0.080 0.417
0.095 0.346
0.118 0.369
Standard end play of each gear

Position
Range (mm)
0.1 0.25
0.06 0.24
0.11 0.23
If the end play is out of the standard, correct 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

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].
2)
3)
SEN00157-05
1)
Set large inside diameter side (a) of plastic inside cylinder (2) to the end of crankshaft (3).
a Take care not to mistake the direction
of the plastic inside cylinder.
2)
Push the metal ring of front seal (1)

evenly as if you are passing over the large
inside diameter side of plastic inside cylinder.
a Hit the metal ring of front seal with
plastic hammer evenly.
Do not hit it strongly.
After pushing in the seal, remove plastic
inside cylinder (2).
a When removing the inside cylinder,
take care not to damage the seal lip.
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.
4 Front support: 65 kg
Tighten the front cover mounting bolts permanently.
3)
15. Front oil seal

Install front oil seal (1) according to the following 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
SEN00157-05
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 55mm bolts with the 35-mm bolts and
tighten them.
a Seal driving distance (a) from crankshaft: 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)
5)
Fit inner spring (4) and outer spring (3)

and then install upper seat (2).
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 fitted 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}
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

q
is 5.)
q
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)
SEN00157-05
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}
Mounting bolt:
Tighten the mounting bolts according
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
SEN00157-05
18. Crosshead
Install crosshead (1).
a Adjust the crosshead according to the following procedure.
1] Loosen the locknut and return the
adjustment screw.
2] Holding the top of the crosshead
lightly, tighten the adjustment screw.
3] After the adjustment screw touches
the valve stem, tighten it further by
20.
4] Tighten the locknut at this point.
3 Locknut:
58.7 5.9 Nm {6.0 0.6 kgm}
3)
Insert holder (2) in fuel injector (1), then

insert them simultaneously, directing the
injector connector (5) to the hole to insert
the fuel high-pressure pipe.
4) Fit the ball washer to bolt (3) and tighten
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 common rail side temporarily, too, to prevent the high-pressure pipe from
leaning.
6) Tighten holder (2) permanently.
a While pulling the high-pressure pipe
in the opposite direction to the injector, 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 follower.
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 injector.
34
140E-5 Series
SEN00157-05

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 connecting 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)
1)
2)
3)
Secure common rail (1) temporarily with

special bolts (2).
Fit O-ring (4) to high-pressure pipe sleeve
(3). Matching them to the injector connector, 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.)
Tighten special bolts (2) permanently.
3 Special bolt:
59 74 Nm {6.0 7.5 kgm}
140E-5 Series
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 Oring (4) is not projected from the end
of the sleeve.
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.
a If sleeve nut (5) does not catch the
threads, press its end with a small rod,
etc. toward the injector and turn the spanner.
35
SEN00157-05
5)
6)
7)
8)
9)
10)
11)
12)
13)
36
Tighten clamps and brackets (7), (8), (9),

(10), (11) and (12) with the hand first, then
tighten clamp side permanently.
3 Clamp bolt:
9.8 1.0 Nm {1.0 0.1 kgm}
(10), (11) and (12) of bracket side permanently.
Install covers (13) and (14) to the sleeve
nut.
a Direct the cut of cover (13) down and
direct the cut of cover (14) toward the
cylinder block.
Tighten clamps and brackets (15), (16),

(17), (18), (19) and (20) with the hand.
Tighten clamp (21) and frame (22) with the
hand.
Tighten clamp (21) permanently.
3 Clamp bolt:
9.8 1.0 Nm {1.0 0.1 kgm}
Tighten frame (22) permanently.
(17), (18), (19) and (20) of clamp side permanently.
3 Clamp bolt:
9.8 1.0 Nm {1.0 0.1 kgm}
(17), (18), (19) and (20) of bracket side
permanently.

Install rocker arm and shaft assembly (1) and
tighten mounting bolts (2), (3) and (4).
a Note that the lengths of the mounting bolts
are different.
Mounting bolt (2): Stem length; 120 mm
a Before tightening the mounting bolts,
check that the ball of the adjustment screw
is fitted to the socket of the push rod.
3 Mounting bolt:
93 103 Nm {9.5 10.5 kgm}
23. Adjusting valve clearance

a Adjust the clearance between the crosshead and rocker arm to the following
value.
a Valve clearance (when cold)
Unit: mm
a
1)
Air intake valve
Exhaust valve
0.35 0.02
0.57 0.02
Rotate the crankshaft and adjust the valve

clearance of each cylinder in the firing
order of 1 5 3 6 2 4.
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.
140E-5 Series
2)
3)
SEN00157-05
2
Insert thickness gauge I between rocker

arm (3) and crosshead (4) and tighten
adjustment screw (5) to the degree that
the thickness gauge can be moved lightly.
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 temporarily.
3 Mounting bolt:
29.4 34.3 Nm {3.0 3.5 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
care not to damage the oil seal.
2 Mating face:
140E-5 Series
Threaded portion and seat of

bolt: Engine oil (EO30)
Flywheel housing: 75 kg
Tighten the flywheel housing mounting bolts in the following order in 2

steps.
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}
2)
After installing the flywheel housing, measure its facial runout and radial runout with
dial gauge [1].
q
Radial runout: Max. 0.30 mm
q
Facial runout: Max. 0.30 mm
37
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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)
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
1.
Procedure for installing standard seal

a When installing rear seal (4), do not apply
oil or grease to the shaft and seal lip.
1) Set large inside diameter side (b) of guide
(8) of rear seal (4) to the end of crankshaft
(6).
a Take care extremely not to mistake
the direction of the plastic inside cylinder.
Left: Standard seal, Right: Sleeved seal
2)
3)
a
a
a
38
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
After pushing in the seal, remove guide
(8).
Clean, degrease, and dry the contact surface against the flywheel housing.
Clean, degrease, and dry the seal lip surface (periphery of the crankshaft).
Check that the end corners and lip sliding
surfaces of the crankshaft are free from
flaw, burr, and rust of the housing.
140E-5 Series
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2.
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 crankshaft (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.
not to damage the lip with the tool set
etc.
140E-5 Series
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):
2)
Set sleeve (7) of the rear seal to the end of

crankshaft (6) and tighten the 4 bolts
evenly to press fit sleeve and rear seal
assembly (9) until the end of tool N2
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).
39
SEN00157-05
4)
Tighten the 4 bolts evenly to press fit

sleeve and rear seal assembly (9) until the
end of tool N3 reaches the end of crankshaft (6).
washers.
a Rear seal driving depth:
13.2 0.2 mm from end
of crankshaft
2nd time: Using tool J, tighten the bolts by 90

(+30/0) in the order of (1) (8).
a
a
a

(f) on the flywheel with paint, then
tighten the bolts by 90 (+30/0) in the
order of (1) (8).
After tightening each bolt, make punch
mark (g) on its head to show the number
of tightening times.
When a new bolt is used, do not make a
punch mark on its head.
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 flywheel (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 contact 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
q
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

Install the O-ring to oil pump and install suction
tube (1), then install bracket (2) to the cylinder
block.
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2]
3]
Install holder (3) to connector (1) and

push in connector (1) to the position
where the O-ring is fitted.
Fix holder (3) with mounting bolt (4).
4]
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.
Insert spring clamp (8) in the injector

connector and secure wiring harness
clamp (9) with bolt (10).
5] Install wiring harness terminal (6) to
fuel injector (5) and tighten 2 nuts (7).
a Stretch the wiring harness without 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}
30. Engine wiring harness assembly and sensor connector

1) Install the engine wiring harness assembly.
2) Install the injector wiring harness assembly.
a Since the wiring harness assembly fitted 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
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3)
4)
Install bracket (11).

Connect NE sensor connector NE (13),
and atmospheric pressure sensor connector PAMB (14).
5)
Install bracket (15) and install the clamps

of wiring harnesses (16) and (17).
Connect coolant temperature sensor connector TWTR (18).
6)
31. EGR oil pump assembly

Install EGR oil pump assembly (1).
42
32. Piping and wiring of supply pump

1) Install bracket (1).
2) Install high-pressure pipes (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 common 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))
3 Clamping bolt:
9.8 1.0 Nm {1.0 0.1 kgm}
4) Install fuel tubes (7) and (8).
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}
3 Sleeve nut of tube (11):
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}
140E-5 Series
7)
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Connect sensor connectors PCV2 (18),

PCV1 (19) and G (20).
33. Breather remote tube and corrosion resistor tube

1) Install breather remote tube (1).
2) Install corrosion resistor tubes (2) and (3)
temporarily.
models.

1) Install the O-ring and plate (1).
2) Install engine controller cooler (2) and fuel
hose (3).
a Install the hose on the engine controller 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).
140E-5 Series

Install engine controller (2) and connect connector (1).

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.
3 Mounting bolt:
58.8 73.5 Nm {6.0 7.5 kgm}
43
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2)
3)
Install brackets (7), (8), (9), (10) and (11).

4)
Tighten clamp (12) of the high-pressure

pipe.
3 Clamp bolt:
9.8 1.0 Nm {1.0 0.1 kgm}
Tighten corrosion resistor tube clamp (13)
and wiring harness clamp (14) temporarily.
a The type of the corrosion resistor
models.
Install the clamps of sensor connectors
TFUEL (15), TIM (16), PIM (17) and wiring
harness (18).
Install fuel tube (19).
3 Joint bolt:
(Head side)
9.8 12.7 Nm {1.0 1.3 kgm}
(Block side)
19.6 29.4 Nm {2.0 3.0 kgm}
5)
6)
7)
44

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.)
3)
4)
5)
Fit the gasket and install air intake connector (3) to the air intake manifold and
joint housing.
Install EGR inlet pressure sensor PEVA
(1).
530896.
Install the clamp of wiring harness (2).
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 applicable machines.
models.
1) Install corrosion resistor head (10), fuel filter 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 temporarily in step 33-2).
a Tighten the clamp on the cylinder
block side, too.
3 Tube joint bolt:
24.5 34.3 Nm {2.5 3.5 kgm}
3) Install fuel tube (3).
3 Tube joint bolt:
(Pump side)
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}
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).
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40. Oil filter head

a The type of the oil filter head depends on
1) Install oil filter head (3).
2) Fit the O-ring and install oil tubes (2) and
(1).
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
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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 thermostat (3) and O-ring to thermostat housing
(2).
3)
Fit the gasket and install thermostat

assembly (5).
Insert bypass tube (4) in the water pump
assembly and install snap ring (6).
Tighten the water pump assembly mounting bolts permanently.
Fit the gasket and install tubes (7) and (8).
Install alternator drive pulley (9).

Using eyebolts [1] and guide bolt [2], fit the
gasket, install oil cooler assembly (1) and
tighten the 16 mounting bolts.
4
Oil cooler assembly: 35 kg
4)
5)
6)
7)
44. Water pump assembly and thermostat

assembly
1) Fit the O-ring, install water pump assembly (1) and tighten the mounting bolts temporarily.
a The mounting bolts are also used to
secure the front cover.
46
140E-5 Series
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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}

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.
4 Exhaust manifold: 25 kg
a Tighten the 3 bolts of (1) (3) temporarily 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:
Seizure prevention compound (LC-G)
3 Mounting bolt:
58.8 73.5 Nm {6 7.5 kgm}
140E-5 Series
3)
4)
Fit the gasket and install lubrication tube

(6) and 4 clamps (5).
3 Tube joint bolt:
24.5 34.3 Nm {2.5 3.5 kgm}
Install wiring harness (4).
47
SEN00157-05
5)
6)
Fit the gasket and install turbocharger oil

drain tube (2).
Install exhaust connector (3) and heat
insulation cover (1).
2)
3)
4)
5)
6)

Fit the O-ring and the gasket and install
EGR cooler coolant inlet tube (10).
3 Rubber hose:
(Nut of tube clamp U-bolt)
10.8 26.5 Nm {1.1 2.7 kgm}
Fit the gasket and install EGR cooler gas
inlet tube (9).
3 Mounting bolt:
44.1 53.9 Nm {4.5 5.5 kgm}
Install air vent tube (7).
3 Joint bolt:
19.6 29.4 Nm {2.0 3.0 kgm}
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)
8)
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}
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
SEN00157-05
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 pressure sensor tube (1).
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
SEN00157-05
4)
Connect wiring harness connectors BP (2)

and SBP (1) and install the clamp.
55. Bracket and clamp

2) Install clamp (1).
56. Bracket
Install brackets (3), (2) and (1).
50
57. Bracket and tube clamp

2) Install clamps (4), (3), (2) and (1).
58. EGR cover

1) Install covers (7), (6), (5) and (4).
a Cover (6) may not be installed.
2)
Install covers (3), (2) and (1).
140E-5 Series

1) Fit the gasket and install starting motor
assembly (4) with bolts (3).
2) Install wiring harness (1) and alternator
connector terminal R (2).
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61. Tightening torque for sensor

If a sensor is replaced, tighten the new sensor
to the following torque.
a The engine speed sensor may not be
installed.
Sensor name
NE
60. Air cleaner bracket and wiring harness

1) Install air cleaner bracket (2).
2) Install wiring harness clamp (1).
3)
Tightening torque
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}
Atmospheric pressure
7.3 12.7 Nm {0.7 1.3 kgm}

(Big bolt)
4.1 9.5 Nm {0.4 1.0 kgm}
(Small bolt)
Fuel pressure
Never disassemble.
(*): Reference: EGR inlet pressure sensor is

530896.
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 following procedure.
After assembling, check the installing condition of the wiring harness clamp.
140E-5 Series
51
SEN00157-05
a
1)
2)
3)
4)
5)
6)
7)
8)
9)
52
Clean and degrease the engine and the

parts around it in advance so that you can
test it easily for fuel leakage.
Spray color checker (developer) over the
fuel supply pump, common rail, fuel injector, and joints of the high-pressure piping.
Run the engine at speed below 1,000 rpm
and stop it after its speed is stabilized.
Check the fuel piping and devices for fuel
leakage.
a Check 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 check again from step 2).
leakage.
leakage.
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.
140E-5 Series
140E-5 Series
SEN00157-05
53
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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
SEN00158-05
Disassembly and assembly, Part 2 (EGR-less)
General disassembly of engine 1

a

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 assembly.
a Before cleaning the engine, carefully seal
or remove the openings, electric parts,
and wiring connectors so that water will
not enter them.
2.
Drain the engine coolant and engine oil.

a The quantity of the oil depends on the
applicable machines.
6
Air cleaner bracket

1) Disconnect wiring harness clamp (1).
2) Remove air cleaner bracket (2).
5.
Heat insulation cover

1) Remove covers (1), (2), (3), (4) and (5).
Setting engine assembly

1) Prepare stable engine stands (Blocks [1])
and place the engine assembly on them
so that it will not tip over.
a The weight depends on the applicable machines.
4 Engine assembly: 1,900 kg
2)
3.
4.
Engine oil: Approx. 53 l
Starting motor assembly

1) Disconnect wiring harness (1) and connector (2).
2) Remove 3 mounting bolts (3) and remove
starting motor assembly (4).
140E-5 Series
6.
Bracket
Remove brackets (1) and (2), stay (3), brackets (4) and (5).
7.
Front plate
Remove front plate (1).
4
8.
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Remove wiring harness (3) and turbocharger lubrication tube clamp (4) and
remove turbocharger lubrication tube (5).
3)
Sling turbocharger assembly (6) and

exhaust connector (7).
Remove the mounting nuts to remove the
turbocharger and connector assembly.
4 Turbocharger and intake connector
assembly: 40 kg
4)
Bracket: 20 kg
Turbocharger assembly
1) Remove heat insulation cover (1) and oil
drain tube (2).
2)
9.
Exhaust manifold
Remove the 24 mounting bolts and exhaust
manifold (1).
4
140E-5 Series
Exhaust manifold: 25 kg
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10. 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 adjustment nut (7) and remove V-belt (8).
5) Remove mounting bolt (4) and clamping
bolt (5) and remove alternator assembly
(9).
12. Water pump assembly

1) Remove alternator drive pulley (1).
2) Remove tubes (2) and (3).
3) Remove water pump assembly (4).

1) Using eyebolts [1], sling the oil cooler
assembly temporarily.
2) Remove the 16 mounting bolts and oil
4 Oil cooler assembly: 35 kg
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).
140E-5 Series
14. Corrosion resistor, oil filter and fuel filter

1) Remove corrosion resistor.
2) Remove oil filters (1) and main fuel filters
(2).
a The locations of the fuel filter and oil filter
may be different from the photo, depending on the applicable machine.
models.
15. Controller cover and oil filler head

1) Remove controller cover (1).
2) Remove oil filter head (2).
a The type of the filter head depends on
3) Remove oil tubes (3) and (4) and the block
on the cylinder block side as a unit.
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16. Fuel filter head

1) Remove fuel tube clamp (1), then remove
fuel tubes (2) and (3).
3) Remove fuel filter head (5).
17. Plates, electric priming pump cover and oil

filler
a Manual priming pump is set for some
models. (See the procedure of "with
EGR" )
1) Remove plates (1), (2) and (3).
2) Remove electric priming pump cover (4).
3) Remove the clamp and oil filler (5).
18. Air bleeding valve and oil filler support

bracket
2) Remove air bleeding valve plate (2) and
oil filler support bracket (3).
140E-5 Series
SEN00158-05

a Electric priming pump is not set for some
models.
1) Remove joint bolts (1) and fuel tube (2).
2) Remove joint bolt (3) and fuel tube (4).
3) Remove joint bolts (5) and (6) and fuel
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.
2)
Remove high-pressure
mounting bolts (7).
3)
Remove the mounting bolts and remove

air intake connector (1) and joint housing
(8) together.
4 Air intake connector assembly:
40 kg
pipe
bracket
When replacing air heater

remove connector (10).
(9),

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).
140E-5 Series
3)
4)
5)
Remove wiring harness clamp (5) and

high-pressure pipe clamp (6).
Remove wiring harness clamps (7), (8),

(9), (10) and (11) at the top of the air
intake manifold.
Remove fuel tube (12).
SEN00158-05

Disconnect connector (1) and remove engine
controller (2).

1) Disconnect fuel hose (1).
2) Remove engine controller cooler (2).
24. Plate
Remove plate (3).
6)
7)
Disconnect clamps (13), (14), (15), (16),

(17), and (18) of the high-pressure pipe.
Remove the mounting bolts and air intake
manifold (19).
140E-5 Series
SEN00158-05

a Before removing the high-pressure pipe,
loosen all of the clamps, brackets, and
sleeve nuts to give the high-pressure pipe
freedom.
2)
3)
4)
5)

a At this time, the clamp of wiring harness (4) comes off.
Remove clamps (5), (6), (7), (8), (9), (10),
and (11).
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.
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.
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
(10).
4) Remove oil tube (11).
5) Remove fuel tubes (12), (13), (14) and
(15).
a Before removing the supply pump
unit, remove the front cover.
27. Blow-by tube

Remove breather remote tube (1).
6)
7)
8)
Disconnect fuel pressure sensor connector PFUEL (15) and POIL (16).
Remove clamp (17) and the eye joint of
tube (18) on the common rail side.
Remove special bolts (19) and remove
common rail (20).
140E-5 Series
SEN00158-05
28. Wiring harness assembly and sensor connector

1) Disconnect the clamps of coolant temperature sensor connector TWTR (1) and wiring harnesses (2) and (3) and remove
bracket (4).
2)
3)
Disconnect the connectors of Ne sensor

NE (6), and atmospheric pressure sensor
PAMB (7).
Remove bracket (8).
5)
4)
Remove 6 injector connectors (9) and

remove the wiring harness assembly.
140E-5 Series
Disconnect the injector connector according to the following procedure.

1] Apply flat-head screwdriver [1] to the
stepped part (part (a)).
2] While pressing stopper (1a), move
flat-head screwdriver [1] in direction
(X) to disconnect the connector.
SEN00158-05
29. Oil pan

1) Move the blocks which are supporting the
engine to positions where you can remove
the oil pan mounting bolts.
2) While supporting oil pan (1) on a pallet lift,
etc., remove the mounting bolts and oil
pan (1).
30. Suction tube

Remove bracket (1) and suction tube (2).
31. Flywheel
1) Using sling [1], lift up flywheel (1) temporarily.
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

Lift up housing (1) temporarily and remove the
mounting bolts and the housing.
4
10
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.
Arrange the above blocks so that you can
rotate the crankshaft.
Housing: 75 kg
33. Rear oil seal

Remove rear oil seal (1) from the flywheel
housing.
140E-5 Series
SEN00158-05
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.

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 tension will not be applied the rocker arm and
rocker shaft assembly mounting bolts
when the rocker arm and rocker shaft
assembly is removed.
6)
Remove holder (8) of fuel injector (1).
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 injector.
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
SEN00158-05
37. Push rod

Remove push rod (1).
38. 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.
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).
3]
12
4]
Raise the cylinder head and remove

valve (7).
39. Damper assembly

Lift up damper assembly (1) temporarily,
remove the 6 mounting bolts (2), and lift off the
damper assembly.
4 Damper assembly: 40 kg
40. Front support

Lift up front support (1) temporarily, remove the
mounting bolts, and lift off the front support.
a The shape and weight of the front support
Remove valve stem seal (5) and

lower seat (6).
140E-5 Series

1) Remove the 3 cover mounting bolts and
remove cover (1).
2) Remove mounting bolts (3) and cam follower (2).
3)
Remove snap rings (4) and remove lever

assembly (5) from shaft (6).
42. Front cover

1) Install eyebolts [1] and lift up the front
cover temporarily.
2) Remove the mounting bolts of front cover
(1) and sling the front cover. Remove the
front cover by moving it forward.
140E-5 Series
SEN00158-05
43. Front oil seal

Remove front oil seal (1) from the front cover.

1) Remove nut (1).
2) Set tool P to gear (3).
3) Tighten center bolt [1] of tool P and
remove gear (3).
4)
Remove pump mounting bolts (4), bracket

(5), and fuel supply pump assembly (6).
a While supporting the fuel supply
pump assembly, remove the mounting bolts.
13
SEN00158-05
45. Camshaft
1) Match the holes of cam gear (1) to mounting bolts (2) and remove bolts (2).
2)
Sling camshaft (3) temporarily. Pull out

the camshaft while turning it so that the
cam bushing will not be damaged.
4 Camshaft: 20 kg
46. Oil pump assembly and sub idler gear

1) Remove oil pump assembly (1).
2) Remove sub idler gear (2).
48. Setting of engine repair stand and underframe

1) Install tool A2 to the cylinder block. Sling
the engine and set it to tool A1.
2) Remove the 4 mounting bolts from each of
2 underframes (1) and remove the underframes.
a The number of underframes (1)

Remove the mounting bolts and piston cooling
nozzles (1) and (2).
a Be sure to remove the piston cooling nozzles 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

a Before removing the piston and connecting rod assembly, measure its end play
with dial gauge [1], if necessary.
SEN00158-05
6)
7)
1)
2)
3)
4)
5)
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.
Rotate the crankshaft and bring the piston
to be removed to the bottom dead center.
Scrub the carbon off the top wall of the cylinder liner with fine sandpaper.
Remove connecting rod cap mounting
bolts (1).
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.
140E-5 Series
8)
Push in and remove the piston and connecting rod assembly with a wood bar, etc.
from the oil pan side, while supporting piston (6) on the cylinder head side.
a Take care not to damage the inside of
the cylinder with a corner of the connecting rod.
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.
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.
15
SEN00158-05
3]
a

a
Using tool D, remove piston ring (7).

Keep the piston, connecting rod, connecting rod bearing, piston rings, and
piston pin by cylinder.
3)
Lift off crankshaft (4).

a When removing the crankshaft, take
4)
Remove upper thrust bearing (5).
51. Crankshaft
a Before removing the crankshaft, measure
its end play with dial gauge [1], if necessary.
1)
2)
16
Remove mounting bolts (2) of main cap

(1).
Insert the bolts in the bolt holes of the
main cap and remove the cap, while shaking it.
The No. 7 main cap has lower thrust

bearing (3).
140E-5 Series
5)
SEN00158-05
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, measure its projection with tool H, if necessary.
53. Using tool E, remove cylinder liner (1).
140E-5 Series
17
SEN00158-05
General assembly of engine

a
a

Take care.
Clean each part carefully, and check it for
bruise, flaw, cavity, etc. Make sure each oil or
coolant path is through.
Tightening bolts by plastic-region turning angle

method
a Bolts tightened by plastic-region turning angle
method
q
Cylinder head mounting bolt
q
Main cap mounting bolt
q
Connecting rod cap mounting bolt
q
Flywheel mounting bolt
a If the plastic-region turning angle method is
applied, the tightened bolts have permanent
strain. Accordingly, the allowable number of
using times of each bolt is limited. Observe
the following precautions.
q
Before tightening each bolt, measure its
stem length and make sure that the result
is less than the using limit. If the stem is
longer than the using limit, do not reuse it
but replace it.
q
Check each mounting bolt head for punch
marks. If there are punch marks more
than the specified number, do not reuse it
but replace it.
1.
18
2)
Before inserting the cylinder liners, prepare the cylinder block according to the
1] Remove the rust and scales from
faces A and B with sandpaper, etc.
until the machined surfaces are
exposed.
2] Polish part R with sandpaper of about
No. 60 until it becomes a smooth
rounded surface.
3] Polish parts R and h with sandpaper
of about No. 60 until they become
smooth.
If part R is sharp or has burrs, finish it
with a scraper or sandpaper.
Finish this surface particularly
smoothly so that it will not damage
the O-ring.
4] If face B is so pitted that it cannot be
repaired, replace the cylinder block.
5] If faces A and R are pitted, finish
them smoothly.
6] Check the counterbored part and
remove burrs. If chips or dust is on
face C, the liner does not fit and coolant may leak and the projection of the
liner may become improper consequently.
a If the counterbored part is drooping, corroded, or pitted, repair it.
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
140E-5 Series
2.
Cylinder liner
a Replace the O-ring and clevis seal with
new ones.
1) Check that the cylinder liner O-ring groove
and periphery of the liner are not roughened 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
for distinction.
q
O-ring (3): The whole ring is red.
2 Clevis seal and O-ring:
Rubber lubricant (RF-1)
a RF-1: DAIDO CHEMICAL INDUSTRY
CO., LTD.
If RF-1 is not available, apply clean
swollen and deteriorated by oil, apply
a small amount of oil to them thinly
with a brush just before fitting them.
140E-5 Series
SEN00158-05
3)
After fitting the liner O-ring, check it for

twist. If it is twisted, correct it with a
smooth rod (about 10 mm in diameter).
4)
Apply gasket sealant to the parts of the

cylinder block and cylinder liner which will
fit to the counterbored parts.
a Wipe off dirt and oil with cloth from
the contact faces of the counterbored
parts of the cylinder block and liner
flange.
2 Cylinder block:
q
Gasket sealant:
2 3 mm in diameter
q
Overlap (a) of gasket sealant:
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 minutes.
19
SEN00158-05
5)
6)
7)
20
Insert cylinder liner (1) in the cylinder

block slowly, taking care not to damage
the O-ring.
Push in cylinder liner (1) further with both
hands.
a If the liner does not enter the cylinder
smoothly, the O-ring may be broken.
In this case, check the cylinder block
for burrs.
Using tool F, press fit cylinder liner (1) to
the cylinder block.
8)
To prevent the gasket sealant from projecting through the clearance between the
block and liner after the cylinder head is
tightened, tighten the cylinder head temporarily with the used head gasket
inserted.
a At this time, observe the following
tightening torque and tightening
order.
3 Temporary tightening torque:
137 157 Nm {14 16 kgm}
9)
Remove the cylinder head and wipe off

the gasket sealant projected from the
counterbored part.
a Be sure to perform steps 8) and 9)
above since the projected gasket
sealant can deform the grommet of
the head gasket.
10) Using tool H, measure the projection of

the cylinder liner.
a When measuring the projection of the
liner, tighten the liner with a plate so
that it will not be lifted by the O-ring.
q
Projection of liner: 0.07 0.15 mm
a If the gasket sealant is projected from
the fitting parts of the cylinder block
and cylinder liner up to the top of the
cylinder block, wipe it off.
3.
Crankshaft
1) Fit upper main bearing (6) to the cylinder
block, matching the projection of the
former to the cut of the latter.
a An oil hole is made on the upper main
bearing.
a Before fitting the bearing, make sure
that its back side is free from foreign
matter.
2 Inside of bearing: Engine oil (EO30)
2)
Drive the dowel pin so that it will be projected by 2.7 3.4 mm from the block end
and then install upper thrust bearing (5) to
the No. 7 journal.
a Install the thrust bearing with the
side.
140E-5 Series
3)
4)
5)
Sling crankshaft (4) and install it to the cylinder block.

a When replacing the crank gear, heat it
with a bearing heater (30 A) (Set temperature: 150C) and fit it just after it
is heated.
a When installing the crankshaft, take
2 Cylinder block journal:
Engine oil (EO30)
Fit the lower main bearing to the main cap,

matching the projection of the former to
the cut of the latter.
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
side.
140E-5 Series
SEN00158-05
6)
Make sure that the journal No. stamped at

the center of main cap (2) and the journal
No. of the cylinder block are the same and
then install the main cap.
a Install the main cap with the cast letter (F) toward the front of the engine.
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
is 5.)
q
Min. 176.3 mm
21
SEN00158-05
8)
Tighten main cap mounting bolts (1)

a Tighten the bolts from the center one
to the outer ones in order.
2 Threaded portion of mounting bolt
and washer:
Engine oil (EO30)
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).
10) Check that the crankshaft turns smoothly.

11) Measure the end play of the crankshaft
with dial gauge [1].
a End play: 0.140 0.315 mm
a If the end play is out of the standard,
correct it. For details, see Structure,
function and maintenance standard.
4.
9)
22

marks (b) on the main cap and
bolt with paint, then tighten the
bolt by 90 (+30/0).
Make punch mark (c) on the mounting bolt
head.
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
1) Using tool D, fit piston rings (7) to the piston.
a Fit the top ring and second ring to the
piston with the stamped mark side up.
q
Stamp on top ring: 1RS
q
Stamp on second ring: 2RX
a Take the expander out of the oil ring
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.
140E-5 Series
2)
Set the abutment joint of each piston ring

as shown in the following figure.
a Adjust oil ring so that the joint of the
expander will be at 180 to the abutment joint of the oil ring.
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 direction, then insert piston pin (5) to
assemble connecting rod (4) and piston (6).
Fit snap rings (3) on both sides of the piston pin to secure the piston pin.
4)
5)
6)
SEN00158-05
7)
Insert piston and connecting rod assembly

(8) in the cylinder block so that the cast
part number on the connecting rod will be
directed to the front of the engine (the
stamped cylinder number will be on the
camshaft side).
a Referring to step 2), check the abutment joint of each piston ring again.
2 Inside of connecting rod bearing and
inside of cylinder:
Engine oil (EO30)
8)
Using tool G, reduce the piston ring and

push in the piston head with a wood bar,
etc. into the cylinder block.
Fit the upper bearing to the connecting

rod, matching the projection of the former
Set the crankshaft so that the cylinder to
be installed will be at the bottom dead
center.
140E-5 Series
23
SEN00158-05
9)
Before tightening the connecting rod cap

q
is 5.)
q
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 connecting rod (4), matching yellow marks (a) on
them to each other.
2 Inside of connecting rod cap bearing:
Engine oil (EO30)
24

marks (b) on the connecting rod
cap, and bolt with paint, then
tighten the bolt by 90 (+30/0).
140E-5 Series
SEN00158-05
13) After tightening the bolt, make a punch

mark (c) on its head.
2)
Install piston cooling nozzles (1) and (2) to

each cylinder in order.
a Install the piston cooling nozzles having the stamps of (F1) to the front side
of the cylinder and install those having 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 hexagonal 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 connecting rod with dial gauge [1].
a Side clearance: 0.100 0.274 mm
a If the side clearance is out of the standard, correct it. For details, see
standard.
6.
5.
Underframe
Install underframes (1).
a The number of the underframes depends
Piston cooling nozzle

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
q
q
140E-5 Series
25
SEN00158-05
7.
Main idler gear

1) Install bearing (3) and shaft (2) to the outside of main idler gear (1) and install bearing (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 crankshaft gear to that of main idler gear (1),
tighten mounting bolt (5).
3 Mounting bolt:
784 44.1 Nm {80 4.5 kgm}
9.
8.
26
Sub idler gear and oil pump assembly

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}
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 240C for 30 60
minutes and then install it by shrink
fit.
4 Camshaft: 20 kg
2 Camshaft journal surface:
Engine oil (EO30)
140E-5 Series
2)
Matching the stamped (C) of the camshaft

gear to that of the main idler gear, tighten
mounting bolt (2).
3 Mounting bolt:
98 123 Nm {10 12.5 kgm}

1) Install 2 lever assemblies (5) to shaft (6).
a Insert the cam followers so that the
ball end of the shaft will be directed
toward the rear of the engine.
2) Install snap rings (4).
3)
Install cam follower assembly (1), matching 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
SEN00158-05
4)
Fit the O-ring and install cover (3).

3 Mounting bolt:
9.8 12.7 Nm {1.0 1.3 kgm}

1) Fit the key to the shaft of fuel supply pump
assembly (6) and install them to the cylinder block.
2) Tighten mounting bolts (4) and install
bracket (5).
2 Mounting bolt: Adhesive (LT-2)
3)
Install fuel supply pump drive gear (3) to

the fuel supply pump shaft and tighten
mounting nut (1).
a When installing to the fuel supply
pump shaft, set stamp (B) of fuel supply 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}
27
SEN00158-05

a
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 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.
28
If the end play is out of the standard, correct it. For details, see Structure, function
and maintenance standard.
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.
14. Front cover and front support
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].
Standard backlash of each gear

Position
Range (mm)
0.141 0.425
0.129 0.391
0.129 0.391
0.141 0.425
0.080 0.417
0.095 0.346
Standard end play of each gear

Position
Range (mm)
0.1 0.25
0.06 0.24
0.11 0.23
140E-5 Series
2)
3)
SEN00158-05
Sling and install front support (2) and

a The shape and weight of the front
support depends on the applicable
machines.
Tighten the front cover mounting bolts permanently.
2)
3)
15. Front oil seal
Install front oil seal (1) according to the following procedure.
crankshaft and front cover are free from
flaw, burr, and rust.
seal.
1)

inside diameter side of plastic inside cylinder.
Set large inside diameter side (a) of plastic inside cylinder (2) to the end of crankshaft (3).
140E-5 Series
29
SEN00158-05
4)
Using tool M1, tighten the 3 bolts evenly to

press fit seal (3) until the end of tool M1
tighten them.
the tool set etc.
4)
5)
Fit inner spring (4) and outer spring (3)

and then install upper seat (2).
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 fitted 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}
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

q
is 5.)
q
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)
SEN00158-05

(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}
Mounting bolt:
Tighten the mounting bolts according
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
SEN00158-05
18. Crosshead
Install crosshead (1).
a Adjust the crosshead according to the following procedure.
1] Loosen the locknut and return the
adjustment screw.
2] Holding the top of the crosshead
lightly, tighten the adjustment screw.
3] After the adjustment screw touches
the valve stem, tighten it further by
20.
4] Tighten the locknut at this point.
3 Locknut:
58.7 5.9 Nm {6.0 0.6 kgm}
19. Push rod

Install push rod (1).
a Check that the push rod is in the cam follower.
32
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) Fit the gasket and O-ring to the fuel injector.
3) Insert holder (2) in fuel injector (1), then
insert them simultaneously, directing the
injector connector (5) to the hole to insert
the fuel high-pressure pipe.
4) Fit the ball washer to bolt (3) and tighten
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 common rail side temporarily, too, to prevent the high-pressure pipe from
leaning.
6) Tighten holder (2) permanently.
a While pulling the high-pressure pipe
in the opposite direction to the injector, 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.
140E-5 Series
SEN00158-05
1)
2)
3)
Secure common rail (1) temporarily with

special bolts (2).
Fit O-ring (4) to high-pressure pipe sleeve
(3). Matching them to the injector connector, 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.)
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 connecting 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)
140E-5 Series
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 Oring (4) is not projected from the end
of the sleeve.
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.
33
SEN00158-05
If sleeve nut (5) does not catch the

threads, press its end with a small rod,
etc. toward the injector and turn the spanner.
13) Tighten clamps and brackets (15), (16),

(17), (18), (19) and (20) of bracket side
permanently.
5)

(10), (11) and (12) with the hand first, then
tighten clamp side permanently.
3 Clamp bolt:
9.8 1.0 Nm {1.0 0.1 kgm}
(10), (11) and (12) of bracket side permanently.
Install covers (13) and (14) to the sleeve
nut.
a Direct the cut of cover (13) down and
direct the cut of cover (14) toward the
cylinder block.

Install rocker arm and shaft assembly (1) and
tighten mounting bolts (2), (3) and (4).
a Note that the lengths of the mounting bolts
are different.
a Before tightening the mounting bolts,
check that the ball of the adjustment
screw is fitted to the socket of the push
rod.
3 Mounting bolt:
93 103 Nm {9.5 10.5 kgm}
6)
7)
8)

(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.
12) Tighten clamps and brackets (15), (16),
(17), (18), (19) and (20) of clamp side permanently.
3 Clamp bolt:
9.8 1.0 Nm {1.0 0.1 kgm}
34
140E-5 Series
SEN00158-05
23. Adjusting valve clearance

a Adjust the clearance between the crosshead and rocker arm to the following
value.
a Valve clearance (when cold)
Unit: mm
a
1)
2)
3)
Air intake valve
Exhaust valve
0.35 0.02
0.57 0.02
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 temporarily.
3 Mounting bolt:
29.4 34.3 Nm {3.0 3.5 kgm}
Rotate the crankshaft and adjust the valve

clearance of each cylinder in the firing
order of 1 5 3 6 2 4.
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.
Insert thickness gauge I between rocker

arm (3) and crosshead (4) and tighten
adjustment screw (5) to the degree that
the thickness gauge can be moved lightly.
Tighten locknut (6) to secure adjustment
screw (5).
3 Locknut:
53 64.7 Nm {5.4 6.6 kgm}
140E-5 Series

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 Threaded portion and seat of
bolt: Engine oil (EO30)
4 Flywheel housing: 75 kg
35
SEN00158-05
Tighten the flywheel housing mounting bolts in the following order in 2

steps.
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}
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 (7): Sleeve.
seal.
each other.
q
a
2)
36
After installing the flywheel housing, measure its facial runout and radial runout with
dial gauge [1].
q
q
a
a
140E-5 Series
1.
SEN00158-05
4)

(6).
2)
3)

evenly as if you are passing over the
large inside diameter side of plastic
inside cylinder.
(8).
140E-5 Series
2.

washers.
etc.

37
SEN00158-05
2)

washer stops.
27. Flywheel
Using eyebolt [1] (12 mm, P = 1.75), sling flywheel (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 contact with the speed sensor.
Engine oil (EO30)
4
3)
4)

fitting the seal).
washers.
of crankshaft
Flywheel: 60 kg
Tighten the mounting bolts according to

the following procedure.
3 Flywheel mounting bolt:
1st time: 118 4.9 Nm {12 0.5 kgm}
2nd time: Using tool J, tighten the bolts by 90
(+30/0) in the order of (1) (8).
a
a
a
38

(f) on the flywheel with paint, then
tighten the bolts by 90 (+30/0) in the
order of (1) (8).
After tightening each bolt, make punch
mark (g) on its head to show the number
of tightening times.
When a new bolt is used, do not make a
punch mark on its head.
If there are 5 punch marks on the head of
a bolt, do not reuse that bolt but replace it.
140E-5 Series
SEN00158-05
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.
After installing the flywheel, measure its

facial runout and radial runout with dial
gauge [1].
q
q
28. Suction pipe

Install the O-ring to the oil pump and install
suction tube (1), then install bracket (2) to the
cylinder block.
30. Engine wiring harness assembly and sensor connector

1) Install the engine wiring harness assembly.
2) Install the injector wiring harness assembly.
a Since the wiring harness assembly fitted 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.
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]
140E-5 Series
Insert spring clamp (8) in the injector

connector and secure wiring harness
clamp (9) with bolt (10).
39
SEN00158-05
5]
40
Install wiring harness terminal (6) to

fuel injector (5) and tighten 2 nuts (7).
a Stretch the wiring harness without 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)
4)

Connect NE sensor connector NE (13),
and atmospheric pressure sensor connector PAMB (14).
5)
Install bracket (15) and install the clamps

of wiring harnesses (16) and (17).
6)
Connect coolant temperature sensor connector TWTR (18).
140E-5 Series
31. Piping and wiring of supply pump

1) Install bracket (1).
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 common rail side down.
a Tighten clamps (4), (5) and (6) with
the hand first, and then tighten them
permanently.
a Tighten the clamps permanently in
the order of (4), (5) and (6).
3 Clamping bolt:
9.8 1 Nm {1.0 0.1 kgm}
4) Install fuel tubes (7), (8) and (9).
3
Joint bolt of 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 Joint bolt of tube (8)
(Pump side)
14.8 19.6 Nm {1.5 2.0 kgm}
q Sleeve nut of tube (8)
(Fuel cooler side)
43 47 Nm {4.4 4.8 kgm}
q Joint bolt of tube (9)
(Pump side)
14.8 19.6 Nm {1.5 2.0 kgm}
Install fuel tube (10) temporarily.
a After installing the electric priming
pump, tighten the joint bolt to the
specified torque.
Install oil tube (11).
3 Joint bolt of tube (11):
(Pump side)
7.9 12.7 Nm {0.8 1.3 kgm}
9.8 12.7 Nm {1.0 1.3 kgm}
Tighten clamps (12), (13), (14), (15), (17)
and (18) with the hand first, and then
tighten them permanently.
3 Mounting bolt of clamps (12), (13),
(14): 9.8 1.0 Nm {1.0 0.1 kgm}
Install fuel tube (19) temporarily.
a After installing the electric priming
pump, tighten the joint bolt and sleeve
nut to the specified torque.
q
5)
6)
7)
8)
140E-5 Series
SEN00158-05
9)
Connect sensor connectors PCV2 (20),

PCV1 (21) and G (22).
32. Electric priming pump and air bleeding

valve
a Manual priming pump is set for some
models. (See the procedure of "with
EGR" )
1) Install the assembly of electric priming
pump (1) and bracket (2).
2) Install oil filler bracket (3).
3) Install the assembly of air bleeding valve
(4) and bracket (5).
a Fuel tube (6) was installed temporarily in the previous step.
3 Joint bolt of tube (6)
(Supply pump side)
14.8 19.6 Nm {1.5 2.0 kgm}
(Electric priming pump side)
19.6 29.4 Nm {2.0 3.0 kgm}
19.6 29.4 Nm {2.0 3.0 kgm}
6) Install fuel tubes (8) and (9).
a Fuel tubes (8) and (9) were installed
temporarily in the previous step.
3
Joint bolt of tube (8), (9)

(Supply pump side)
14.8 19.6 Nm {1.5 2.0 kgm}
(Electric priming pump side)
43 47 Nm {4.4 4.8 kgm}
Install fuel tubes (10) and (11).
3 Joint bolt of tubes (10) and (11).
19.6 29.4 Nm {2.0 3.0 kgm}
q
7)
41
SEN00158-05
33. Breather remote tube and corrosion resistor tube

1) Install breather remote tube (1).
2) Install corrosion resistor tubes (2) and (3)
temporarily.
models.

1) Install the O-ring and plate (1).
2) Install engine controller cooler (2) and fuel
hose (3).
a Install the hose on the engine controller 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

Install engine controller (2) and connect connector (1).

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.
3 Mounting bolt:
58.8 73.5 Nm {6.0 7.5 kgm}
140E-5 Series
2)
3)

4)
Tighten clamp (12) of the high-pressure

pipe.
3 Clamp bolt:
9.8 1.0 Nm {1.0 0.1 kgm}
Tighten wiring harness clamp (13) temporarily.
5)
SEN00158-05

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.)
3)
4)
6)
7)
Install clamp (19) of sensor connectors

TFUEL (15), PIM (16), TIM (17) and wiring
harness (18).
Install fuel tube (20).
3 Joint bolt:
(Head side)
9.8 12.7 Nm {1.0 1.3 kgm}
(Block side)
19.6 29.4 Nm {2.0 3.0 kgm}
140E-5 Series
5)
Fit the gasket and install air intake connector (5) to the air intake manifold and
joint housing (2).
Install clamps (7), (8), (9), (10) and (11) of
wiring harness.
Install high-pressure pipe bracket (6) to

the joint housing.
43
SEN00158-05
38. Oil filler and electric priming pump cover

models.
1) Install oil filler (1).
a Tighten fuel tube clamp (2), too.
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 mounting plates (7) and (6).
3)
4)
Install fuel filter head (5).

Install fuel tubes (3) and (2).
3
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.
models.
Joint bolt of tube (3), (2)

24.5 34.3 Nm {2.5 3.5 kgm}
(Electric fuel supply pump side)
43 47 Nm {4.4 4.8 kgm}
Install air bleeding tube (4).
7.8 9.8 Nm {0.8 1.0 kgm}
Install clamp (1).
q
5)
6)
44
140E-5 Series

Using eyebolts [1] and guide bolt [2], fit the
gasket, install oil cooler assembly (1) and
tighten the 16 mounting bolts.
4
Oil cooler assembly: 35 kg
SEN00158-05
3)
4)
5)
6)
7)
43. Water pump assembly and thermostat

assembly
1) Fit the O-ring, install water pump assembly (1) and tighten the mounting bolts temporarily.
a The mounting bolts are also used to
secure the front cover.
2)
Fit the gasket and install thermostat

assembly (5).
Insert bypass tube (4) in the water pump
assembly and install snap ring (6).
Tighten the water pump assembly mounting bolts permanently.
Fit the gasket and install tubes (7) and (8).
Install alternator drive pulley (9).
44. 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).
Install bypass tube (4) fitted with thermostat (3) and O-ring to thermostat housing
(2).
140E-5 Series
45
SEN00158-05

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.
4 Exhaust manifold: 25 kg
a Tighten the 3 bolts of (1) (3) temporarily 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:
58.8 73.5 Nm {6 7.5 kgm}
3)
4)
5)
6)
Fit the gasket and install lubrication tube

(5) and 4 clamps (4).
3 Tube joint bolt:
24.5 34.3 Nm {2.5 3.5 kgm}
Install wiring harness (3).
Fit the gasket and install turbocharger

lubrication drain tube (3) and tube clamps
(4).
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

Fit the gasket to the air intake connector and
sling and install front plate (1).
4
Bracket: 20 kg
48. Bracket
Install brackets (1) and (2), stay (3), brackets
(4) and (5).
SEN00158-05

1) Fit the gasket and install starting motor
assembly (4) with bolts (3).
2) Install wiring harness (1) and alternator
connector terminal R (2).
51. Air cleaner bracket and wiring harness

1) Install air cleaner bracket (2).
2) Install wiring harness clamp (1).
49. Heat insulation cover

Install covers (1), (2), (3), (4) and (5).
3)
After assembling, check the installing condition 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
140E-5 Series
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.
47
SEN00158-05
53. 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 following procedure.
a
1)
2)
3)
4)
5)
6)
7)
8)
48
9)

leakage.
a If no fuel leakage is detected, check
is completed.
Clean and degrease the engine and the

parts around it in advance so that you can
test it easily for fuel leakage.
Spray color checker (developer) over the
fuel supply pump, common rail, fuel injector, and joints of the high-pressure piping.
Run the engine at speed below 1,000 rpm
and stop it after its speed is stabilized.
leakage.
leakage.
leakage.
a When checking while the components
to be checked are mounted on the
relieve the hydraulic pump.
140E-5 Series
140E-5 Series
SEN00158-05
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
SEN00159-04

Removal and installation of fuel
supply pump unit (with EGR)
1
4.
Remove the clamp and EGR oil tubes (4) and

(5).
[*2]
Removal
1. Remove cover (1).
5.
Disconnect sensor connectors PCV1 (8) and G

(9).
2.
6.
Remove the clamp and fuel tubes (10) and

(11) and then disconnect fuel tubes (12) and
(13) and fuel hose (14).
[*3]
7.
Remove the clamp and oil tubes (15) and (16).

[*4]
8.
Remove the splash prevention cover, clamps

(17), (18), (19), and bracket (20), and then
remove high-pressure tube (21).
[*5]
3.
Rotate the crankshaft forward and set intermediate 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.
Remove mounting nut (6).

[*1]
a Take care not to drop the nut into the gear
case.
140E-5 Series
9.
Remove mounting bolts (23) and remove

bracket (24) from supply pump assembly (22).
a Leave bolts (23) tightened by 2 3
threads to prevent the pump from falling
down.
SEN00159-04
Installation
q
Carry out installation in the reverse order to
removal.
[*1]
Nut: 176 196 Nm {18 20 kgm}
[*2]
Sleeve nut of EGR oil tube (4):

43 47 Nm {4.4 4.8 kgm}
[*3]
10. Set tool P to the drive gear, tighten center bolt

of P, and remove gear (25) from the shaft.
11. Remove mounting bolts (23) which have been
left and remove supply pump assembly (22).
a If tool P is removed, the gear falls down.
Accordingly, keep it installed until the
pump is installed.
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}
Joint bolt of fuel tubes (10) and (11):
(Pump side)
14.8 19.6 Nm {1.5 2.0 kgm}
[*4]
Joint bolt of oil tubes (15) and (16):

(Pump side)
7.9 12.7 Nm {0.8 1.3 kgm}
9.8 12.7 Nm {1.0 1.3 kgm}
[*5]
1)
2)
3)
140E-5 Series
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}
Tighten clamps (17), (18), and (19) with
the hand first, and then tighten them permanently.
a Tighten clamps permanently in the
order of (17), (18) and (19).
3 Clamp mounting bolt:
9.8 1 Nm {1 0.1 kgm}
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.
SEN00159-04
Removal and installation of fuel

supply pump unit (EGR-less)
1
4.
Remove fuel filters (1) and oil filters (2).

[*2]
Removal
1. Remove cover (1).
5.
Remove oil filler (3) and electric priming pump

cover (4).
[*3]
models.
6.
Remove clamps (8) and (9) and fuel tubes (5),

(6) and (7).
[*4]
2.
3.
Rotate the crankshaft forward and set intermediate 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.
Remove mounting nut (6).

[*1]
a Take care not to drop the nut into the gear
case.
140E-5 Series
SEN00159-04
7.
Remove sensor connectors (10), (11) and (12).
8.
Remove the scatter prevention cover bracket

(13).
9.
Remove clamps (14), (15) and (16) and highpressure pipes (17) and (18).
[*5]
14. Remove mounting bolts (32) and remove

bracket (33) from supply pump assembly (31).
a Leave bolts (32) tightened by 2 3
threads to prevent the pump from falling
down.
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.
12. Remove fuel tubes (24), (25), (26), (27) and

(28).
[*7]
13. Remove clamp (29) and oil tube (30).
140E-5 Series
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
pump is installed.
[*8]
SEN00159-04
Installation
q
Carry out installation in the reverse order to
removal.
[*7]
3
q
[*1]
Nut: 176 196 Nm {18 20 kgm}
[*2]
a Apply engine oil thinly to the oil filter cartridge
packing and tighten the oil filter cartridge 3/4
1 more turn after the packing touches the sealing face.
[*3]
Oil filler mounting U-clamp nut:

10.8 26.5 Nm {1.1 2.7 kgm}
[*4]
3
q
q
q
Joint bolt of tubes (5), (6):

24.5 34.3 Nm {2.5 3.5 kgm}
Sleeve nut of tube (6):
43 47 Nm {4.4 4.8 kgm}
Joint bolt of tube (7):
(Filter head side)
7.8 9.8 Nm {0.8 1.0 kgm}
(Fuel block side)
19.6 29.4 Nm {2.0 3.0 kgm}

(Both side)
14.8 19.6 Nm {1.5 2.0 kgm}
43 47 Nm {4.4 4.8 kgm}
43 47 Nm {4.4 4.8 kgm}
(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}
(Pump side)
14.8 19.6 Nm {1.5 2.0 kgm}
(Fuel block side)
19.6 29.4 Nm {2.0 3.0 kgm}
[*8]
3
q

9.8 12.7 Nm {1.0 1.3 kgm}
(Pump side)
7.9 12.7 Nm {0.8 1.3 kgm}
[*5]
1)
2)
3)
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}
Tighten clamps (14), (15), and (16) with
the hand first, and then tighten them permanently.
a Tighten clamps permanently in the
order of (14), (15) and (16).
3 Clamp mounting bolt:
9.8 1 Nm {1 0.1 kgm}
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]
Clamps (21), (22) and (23) mounting bolt:

9.8 1 Nm {1 0.1 kgm}
140E-5 Series
Replacement of oil seal of engine

mounted on machine
1
a
SEN00159-04
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).
3) Insert the top end of tool L into the
drilled hole, and remove the front seal
by the impact of slide hammer (SH).
(Apply the slide hammer evenly not to
tilt the rear seal.)
(For sleeved seal)
1) Cut and remove the sleeve (7) with a
chisel and a hammer.
2) Replace the tip of tool L with the
puller type one (PT).
3) Hitch the end of tool L to the metal
ring of rear seal (4) and pull out the
seal with impacts slide hammer (SH).
a Remove the metal powders completely.
a Take care not to damage crankshaft (6).
q
Tool L
Installation
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 (6): Sleeve.
seal.
each other.
q
140E-5 Series
SEN00159-04
a
a
a
1.

(6).
2)
3)

evenly.
a Do not hit it strongly.
(8).
140E-5 Series
4)

washers.
etc.
SEN00159-04
2)

washer stops.
3)

fitting the seal).
washers.
of crankshaft
4)
2.

140E-5 Series
SEN00159-04
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).
Removal with tool L

1) Drill several holes about 3 mm in diameter into
front oil seal (1).
2) Replace the tip of tool L with the drill type one.
3) Insert the top end of tool L into the drilled hole,
and remove the front seal by the impact of
slide hammer (SH). (Apply the slide hammer
evenly not to tilt the front seal.)
a Remove the metal powders completely.
a When the sleeve is attached, cut sleeve
(6) using a gad and hammer to remove it.
a Take care not to damage crankshaft (5).
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
than 10 mm) and does not have any flaw, install
"standard seal A". In other cases, install
"sleeved seal B".
a (7): Plastic inside cylinder which is also used
as installation guide.
a (6): Sleeve.
a Do not remove installation guide (7) from front
seal (3) before installing the front seal.
a Handle front seal (3) and sleeve (6) as an
assembly and never separate them from each
other.
Standard spare seal
10
Sleeved seal
140E-5 Series
1.

crankshaft are free from flaw, burr, and
rust of the housing.
seal.
1) Set large inside diameter side (b) of plastic inside cylinder (7) to the end of crankshaft (5).
SEN00159-04
2)
3)
4)
140E-5 Series

inside diameter side of plastic inside cylinder (7).
a Do not hit it strongly.
Using tool M1, tighten the 3 bolts evenly

to press fit seal (9) until the end of tool M1
tighten them.
the tool set etc.
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
SEN05198-00
Flowchart
Repair of cylinder block top and counterbore by grinding
a
a
For removal, installation, disassembly and assembly of the engine, see the Shop Manual, "Disassembly
and assembly".
If the judgment of No. 9 is NO, examine A.
140E-5 Series
140E-5 Series
SEN05198-00
SEN05198-00
Special tool table

Replacement/Rebuilding
item
Symbol
Part No.
795-611-1300
Pressure test of cylinder

head
Replacement of valve
guide
B
C
Pump assembly
Push tool
795-411-1310
Push tool
795-100-4801
Seat puller
For valve seat insert
790-101-5001
Push tool KIT
KIT
790-101-5081
Plate
For intake valve
790-101-5071
Plate
For exhaust valve
795-100-3005
Seat cutter
KIT
795-100-3100
Body assembly
795-100-3200
Micrometer
795-100-3300
Gauge
795-100-3401
Tool head
795-100-3601
Head support
795-100-3710
Cutter
For oversize machining
795-100-3720
Cutter
For 30
795-100-3730
Cutter
For 45
795-100-4211
Pilot
f10.000 mm
795-100-4221
Pilot
f10.010 mm
795-100-4231
Pilot
f10.020 mm
f10.030 mm
795-100-4241
Pilot
795-140-6410
Guide puller
795-130-1310
Guide driver
Valve refacer
Repair of valve by grinding
Commercially
available
Check of main bearing

mounting hole inside
diameter
Commercially
available
Alignment bar
790-101-2800
Bearing puller
790-101-2300
Push puller
795-240-6401
Push tool
795-240-6411
Push tool
795-240-6420
Push tool
795-240-6431
Block
795-240-6440
Nut
Replacement of crankshaft
gear
K
L
Replacement of connecting
rod small end bushing
Replacement of cam
bushing
KIT
795-100-1522
Replacement of valve seat

insert
Replacement of crosshead
guide
Remarks
79A-471-1050
Coolant tester
Q'ty
1
D
Part name
795-213-1200
Push tool
795-213-1250
Bar
795-213-1210
Push tool
795-213-1240
Collar
795-213-1230
Guide
795-103-0400
Grip
KIT
KIT
140E-5 Series
Replacement/Rebuilding
item
Symbol
Part No.
795-931-1100
1
795T-421-1260 Sleeve jig
For pulling out
For press fitting standard

seal
(For wet type)
01643-31645
Washer
01050-31645
Bolt
01643-31645
Washer
01050-31645
Bolt
01643-31645
Washer
1
3
4
5
6
7

01050-31645
Bolt
01643-31645
Washer

01050-31645
Bolt
01643-31645
Washer
Remarks
Bolt
Seal puller assembly
Q'ty
01050-31640
7
Replacement of engine
rear seal
Part name
2
4
P
140E-5 Series
SEN05198-00
1
3
3
For press fitting sleeved seal

(For wet type)
For press fitting standard

seal
(For dry type)
1
3
3
1
01050-31645
Bolt
01643-31645
Washer
For press fitting sleeved seal

(For dry type)
SEN05198-00
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
140E-5 Series
SEN05198-00
P7. Sleeve jig
Q1. Sleeve jig
140E-5 Series
SEN05198-00
Q7. Sleeve jig
140E-5 Series
140E-5 Series
SEN05198-00
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
SEN05199-02
Part names related to cylinder head
1.
2.
3.
4.
5.
6.
7.
Cylinder head
Crosshead guide
Valve guide
Valve seat insert (intake side)
Valve (intake valve)
Valve (exhaust valve)
Valve seat insert (exhaust side)
140E-5 Series
SEN05199-02
Testing and inspection of cylinder head

Unit: mm
Inspection item
Criteria
Remedy
Presence of crack (External dye check)

Water leakage from and crack Presence of water leakage during air pressure test
of cylinder head
(0.29 0.34 MPa {3.0 3.5 kg/cm2}, 30 sec)
Water pressure test (0.34 0.39 MPa {3.5 4.0 kg/cm2}, 10 min)
Tolerance
Distortion of cylinder head top
and bottom
0 0.06
Damage of valve contact
surface of valve seat insert or
looseness of valve seat insert
Valve sinking quantity
(both intake and exhaust
valves)
Presence of dent on valve seat insert contact surface

Check of valve seat insert contact surface
Airtightness test
Hit cylinder head lightly to check for looseness
a See Fig. A
Sink (a)
Standard value
Repair limit
0 0.1
Repair by welding
or replace cylinder
head
Repair by grinding
or replace cylinder
head
Repair valve seat
insert contact
surface or replace
valve seat insert
Replace valve seat
insert
a See Fig. B
Valve head thickness (c)
Valve
Standard value
Repair limit
Intake
2.4
1.9
Exhaust
2.15
1.6
Valve head thickness
Abnormality in valve
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
Play when new cotter pin is inserted in cotter groove
Uneven wear or bend of valve stem
Presence of dent at valve stem end
Outside diameter of valve

stem
Repair stem
Valve
Standard size
Standard value
Repair limit
Intake
10
9.940 9.955
Exhaust
10
9.911 9.926
Intake
10
9.991 10.011
Exhaust
10
9.991 10.011
Inside diameter of valve guide
Projection of valve guide

Outside diameter of crosshead
guide
Projection of crosshead guide
140E-5 Series
a See Fig. C
Allowable range of projection (d): 22 0.2
Standard size
Standard value
11
11.000 11.011
a See Fig. D
Allowable range of projection (e): 49 0.25
Repair limit
Replace valve
Replace valve
guide
Replace crosshead
guide
Repair crosshead
guide
SEN05199-02
Illustrations related to testing and inspection table

Fig. A
Fig. D
a: Sink
e: Projection
1. Crosshead guide
2. Cylinder head
Fig. B
b: Valve seat contact surface angle

c: Valve head thickness
Fig. C
d: Projection
140E-5 Series
SEN05199-02
Pressure test of cylinder head
Replacement of valve guide
Pressure test tools
Symbol
Part No.
Part name
790-553-1601
Coolant tester
79A-471-1050
Pump assembly
If the cylinder head parts were repaired, perform the test according to the following procedure.
Valve guide replacement tools
Symbol
C
Part No.
Part name
795-100-1522
Push tool
795-411-1310
Push tool
Pulling out of valve guide

q
Using tool C1, pull out the valve guide.
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.
Warm the whole cylinder head and then perform the test with hot water at 80 95C.
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.
2.
3.
a
Machine the valve guide hole of the cylinder

head to the dimension below.
q
Inside diameter: 17(+0.011/0)mm
Press fit the valve guide until the tool C2 end
touches the cylinder head.
Check that the projection of the valve guide is
within the standard value.
Projection tolerance of valve guide:
22 0.2 mm
Air pressure test

1.
Connect the air compressor hose to the cylinder 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 leakage.
If any crack is detected in the cylinder head by

the above tests, replace the cylinder head.
140E-5 Series
SEN05199-02
Replacement of valve seat insert

a
Valve seat insert replacement tools
Symbol
Part No.
D
E
Part name
795-100-4801
Seat puller
790-101-5001
Push tool KIT
790-101-5081
Plate
790-101-5071
Plate
795-100-3005
Seat cutter
795-100-3710
Cutter
795-100-3720
Cutter
795-100-3730
Cutter
795-100-4211
Pilot
Pulling out of valve seat insert

k
k
k
Keep the air pressure at 0.5 0.6 MPa {5 6

kg/cm2} during the work.
When replacing the grinding stone, stop
the air.
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.
Ensure that the grinding stone is free from
damage and install it to the grinder shaft
with no play.
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).
140E-5 Series
6.
Push in 3 claws (10) of puller head (9) of tool D

with the hand and put them in valve seat insert
(a).
7.
Tighten screw (12) to press 3 claws (10)

against the inside groove of valve seat insert
(a).
a If screw (12) is tightened too strongly, the
insert will be broken and become difficult
to pull out. Accordingly, stop tightening
when 3 claws (10) reach the groove fully.
8.
Put bridge (8) in the outside of puller head (9),

place plates (11) and (7) on the bridge, and
tighten nut (6) to pull out valve seat insert (a).
140E-5 Series
SEN05199-02
When pulling out valve seat insert (a) by welding a bar to it

1. Weld bar (b) (Length: 0.1 0.5 mm shorter
than valve seat inside diameter, Diameter:
Approx. 10 mm) to the inside of valve seat
insert (a).
a Take care that welding spatters will not
stick to the head.
2.
After the temperature of the welded parts has

decreased to around the ambient temperature,
insert an unnecessary valve (c) in the reverse
direction and hit its head with a small hammer
to pull out valve seat insert (a).
a If a large impact is given, the welded parts
may come off. Take care.
SEN05199-02
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
140E-5 Series
140E-5 Series
SEN05199-02
SEN05199-02
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.
Limit the increase of the mounting hole diameter to 1.0 mm. If the hole diameter needs to be
increased more than 1.0 mm, replace the cylinder head.
Machining dimensions of valve seat insert and mounting hole

Intake valve side
Valve seat insert size
Unit: mm
Valve seat insert
d1
Valve seat insert mounting hole

c1
d2
d3
c2
Standard
55.0 +0.111
+0.086
0
8.8 0.1
55.0 +0.019
0
58.00 0.2
0
11 0.1
0.25 OS
55.25 +0.111
+0.086
0
8.8 0.1
55.25 +0.019
0
58.25 0.2
0
11 0.1
0.50 OS
55.5 +0.111
+0.086
0
8.92 0.1
55.5 +0.019
0
58.50 0.2
0
11.12 0.1
0.75 OS
55.75 +0.111
+0.086
0
9.05 0.1
55.75 +0.019
0
58.75 0.2
0
11.25 0.1
1.00 OS
56.0 +0.111
+0.086
0
9.18 0.1
56.0 +0.019
0
59.00 0.2
0
11.38 0.1
OS: Oversize
Exhaust valve side

Valve seat insert size
10
Unit: mm
Valve seat insert
d1

c1
d2
d3
c2
Standard
52.0 +0.080
+0.070
0
8.6 0.1
52.0 +0.019
0
55.00 0.2
0
11 0.1
0.25 OS
52.25 +0.080
+0.070
0
8.6 0.1
52.25 +0.019
0
55.25 0.2
0
11 0.1
0.50 OS
52.5 +0.080
+0.070
0
8.72 0.1
52.5 +0.019
0
55.50 0.2
0
11.12 0.1
0.75 OS
52.75 +0.080
+0.070
0
8.85 0.1
52.75 +0.019
0
55.75 0.2
0
11.25 0.1
1.00 OS
53.0 +0.080
+0.070
0
8.98 0.1
53.0 +0.019
0
56.00 0.2
0
11.38 0.1
OS: Oversize
140E-5 Series
Valve seat insert
SEN05199-02
Finish machining of valve contact surface

of valve seat insert
1.
a
Using tool F1 and attached cutters F3 and F4,

machine the valve contact surface of the valve
seat insert to the following dimensions.
Select tool F5 which will be inserted in the
valve guide with no clearance.
g: Cylinder head bottom

a
a
a
a
a
Inside finished surface roughness: Max. 12.5S

Mounting hole bottom surface roughness:
Max. 12.5S
Concentricity of valve guide hole and valve
seat insert hole: Max. 0.07 mm (TIR)
Squareness of valve guide hole to valve seat
insert hole bottom: Max. 0.03 mm (TIR)
TIR is an abbreviation for Total Indicator Reading, which is the difference between the maximum and minimum readings in runout
measurement.
140E-5 Series
EV: Exhaust valve

IV: Intake valve
h: Finish machining width
11
SEN05199-02
2.
Fit the contact surface of the valve seat insert

to the valve by using compound.
1) Thinly apply rough compound mixed with
oil to the seat surface of a valve and insert
that valve in the valve guide.
2) Install the fitting rod to the valve head and
lightly hit valve against the valve seat
while rotating it with both hands to fit the
valve to the valve seat.
3) After the valve and valve seat are fitted
and their surfaces become smooth, wipe
off the compound.
4) Apply fine compound and fit the valve and
valve seat again similarly to the above
until they are fitted to each other without
breakage.
Final inspection
q
q
q
q
q
Thinly apply red lead to the valve seat insert

contact surface of a new valve and insert that
valve in the valve guide.
Lightly press the valve against the valve seat
insert and rotate it 10.
Check the valve seat insert contact surface of
the valve and ensure that the contact is even
and is not broken.
Or, make marks (m) (about 20 places) on the
valve seat insert contact surface of a new
valve with a pencil and insert that valve in the
valve guide.
Ensure that all the pencil marks (m) have been
erased evenly.
When master valve is used
EV:
IV:
j:
k:
Exhaust valve
Intake valve
Cylinder head bottom
Contact width against valve
Concentricity of contact surfaces of valve

guide and valve seat insert:
Max. 0.07 mm (TIR)
measurement.
12
140E-5 Series
Replacement of crosshead guide

a
Crosshead guide replacement tools
Symbol
G
Part No.
1.
795-140-6410
Guide puller
795-130-1310
Guide driver
Using tool G1, pull out crosshead guide (a)

from cylinder head (b).
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
Press fitting of crosshead guide

q
Part name
Pulling out of crosshead guide

q
SEN05199-02
a
a
Using tool G2, insert crosshead guide (a) in

cylinder head (b) and press fit it with a copper
or plastic hammer until the projection is within
the tolerance.
Projection tolerance of crosshead guide:
49 0.25 mm
Diameter of cylinder head crosshead guide
f11 0.027
hole:
0.054 mm
13
SEN05199-02
Repair of cylinder head mounting

face by grinding
1
Grinding
1.
Remove the valve seat insert.

q
For the removal procedure, see "Replacement of valve seat insert".
2.
Remove the distortion and corrosion of the cylinder head by grinding within the tolerance of
cylinder head height (a).
q
Stamp "R" on the left side of the cylinder
head.
Standard cylinder head height (a):

140 0.05 mm
Limit after grinding: 139.65 mm
Grinding depth by 1 grinding: 0.10 0.15 mm
Ground surface roughness: Max. 8S
Flatness (Distortion): Max. 0.05 mm
Grinding depth limit: 0.3 mm
Difference in head height (a) for 1 unit:
Max. 0.15 mm
a
a
a
a
a
a
3.
Press fit the valve seat insert of the next oversize.

q
For the press fitting procedure, see
"Replacement of valve seat insert".
Check after repair by grinding

q
a
a
14
Measure the valve recess and projection of the

injector and ensure that they are within the
standard values and then adjust if necessary.
Valve recess Standard: 0 0.1 mm
Projection of the injector nozzle: 2.3 2.9
140E-5 Series
Repair of valve by grinding

a
SEN05199-02
a
Valve grinding tool
Symbol
Part No.
Commercially
available
Part name
Valve refacer
Grinding of seat contact surface of valve

q
Using tool H, grind the seat contact surface of

the valve.
Seat contact surface angle of valve (a)

Intake valve: 30 015'
Exhaust valve: 45 015'
Check after grinding

q
a
a
Measure the valve head thickness, sinking

quantity of the valve, and contact of the seat
contact surface of the valve, and ensure that
they are within the standard values.
Allowable limit of valve head thickness (b)
Intake valve:
Min. 1.9 mm (Standard size: 2.4 mm)
Exhaust valve:
Min. 1.6 mm (Standard size: 2.15 mm)
Standard of contact surface (c) of valve
Intake valve:
4.32 mm
Exhaust valve: 3.41 mm
Standard of valve sinking quantity:
0 0.10 mm (Both intake and exhaust valves)
140E-5 Series
Apply dial gauge (1) to the facial runout measuring point of seat contact surface (c) of the
valve and rotate the valve to measure its facial
runout while pressing it toward left (d).
Intake valve: Max. 0.045 mm (TIR)
Exhaust valve: Max. 0.030 mm (TIR)
measurement.
e: Block
a
q
q
q
q
q
Check the contact of the seat contact surface

of the valve by either of the following methods.
Thinly apply red lead to the seat contact surface of the ground valve and insert that valve
in the valve guide.
Check the valve seat insert contact surface of
the valve and ensure that the contact is even
and is not broken.
Make marks (f) (about 20 places) on the seat
contact surface of the ground valve with a pencil and insert that valve in the valve guide.
Ensure that all the pencil marks (f) have been
erased evenly.
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
SEN05200-01
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
140E-5 Series
SEN05200-01
Part names related to cylinder block
1.
2.
3.
4.
5.
6.
7.
Cylinder liner
Clevis seal
Cylinder liner O-ring
Cylinder block
Main bearing metal cap bolt
Main bearing metal cap (No. 1, 2, 3, 4, 5 and 6 are same)
Camshaft bushing
140E-5 Series
SEN05200-01
Testing and inspection of cylinder block

Unit: mm
Inspection item
Crack
Repair of contact of packing
Clearance to cylinder liner
Inside diameter of camshaft

bushing
Projection of cylinder liner
Criteria
65
65.000 60.060
Standard value
11
Main bearing mounting hole

diameter
Tighten main bearing metal
cap bolt to specified torque
Measure in range of 10 on
upper and lower sides of
main bearing metal cap
Fit of main bearing metal cap

and cylinder block
(Interference)
Tolerance
0 0.09
a See Fig. E
Standard size
Replace camshaft
bushing
Repair by cutting
Add shim
Repair by cutting or
replace cylinder
block
Standard value
127
Concentricity of
adjacent holes
a See Fig. F
Replace cylinder
liner or cylinder
block
11.000 11.050
Flatness of cylinder block top
General concentricity
Replace cylinder
block
Replace cylinder
liner or repair
cylinder block
a See Fig. C
Allowable range: 0.07 0.15
a See Fig. D
Presence of corrosion
Depth and bottom corrosion of
Standard size
counterbore
Distortion and wear of cylinder

head mounting face
Remedy
Presence of crack (External dye check)

Cylinder head bolt hole etc.
a See Fig. A
Water leakage caused by corrosion
a See Fig. B
Standard value
Standard
Standard size
Bore of
Outside diameter
clearance
cylinder block
of cylinder liner
158.000
157.897
f158
0.073 0.143
158.040
157.927
Inside diameter
Standard size
Standard value
127.000 127.018
Roundness of f127 must be 0.005 from front to
rear of cylinder block
Alignment bar for roundness of 0.010 must go
Replace cylinder
through smoothly
block
Journal
Standard fit
(Interference)
No. 1 6
0.002 0.060
No. 7
0.002 0.060
a See Fig. G
Inside diameter of counterbore

and outside diameter of
cylinder liner flange
Cylinder liner
Standard size
Standard value
Upper section
170.2
170.10 170.20
Lower section
161.2
161.25 161.29
Replace cylinder
liner
Cylinder block
Upper section
170.2
170.200 170.263
Lower section
161.2
161.17 161.23
Replace cylinder
block
140E-5 Series
SEN05200-01
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
d: Cylinder block
e: Projection
h: Fit
140E-5 Series
SEN05200-01
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
Diameter
i: Upper section
j: Lower section
157
0.014
0.039
Roundness
0.005
Straightness
0.010
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 bearing 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.
140E-5 Series
SEN05200-01
Part names related to crankshaft
1.
2.
3.
4.
Crankshaft
Main bearing metal (upper)
Main bearing metal (lower)
Thrust metal (All of upper x 1 and lower x 2 are the same)
140E-5 Series
SEN05200-01
Testing and inspection of crankshaft

Unit: mm
Inspection item
Criteria
Crack
Check for crack by magnaflux inspection
Damage
Presence of damage in journal

Flaw
Seizure
Discoloration
Remedy
Replace crankshaft
If damaged slightly,
repair with oilstone
or by lapping.
If seized, replace
crankshaft
Repair or replace
crankshaft
Damage of tap holes at front and rear ends

Clogging of oil hole
Presence of clogged oil hole
Repair
Standard value
End play of crankshaft
Thrust metal thickness
Outside diameter of crankpin

journal
Size
Standard
0.25 US
0.50 US
0.75 US
1.00 US
Standard
0.25 US
0.50 US
0.75 US
1.00 US
Roundness of crankpin journal
Roundness of crank main

journal
Clearance in crank main
journal
Standard size
4.000
4.125
4.250
4.375
4.500
90.00
89.75
89.50
89.25
89.00
Standard
Tolerance
0.07
0.12
0.050
0.068
Replace thrust
metal or repair with
oversize crankshaft
Repair with
undersize parts or
replace crankshaft
0 0.009
Clearance in crankpin journal
Outside diameter of crank

main journal
Replace thrust
metal or repair with
oversize parts
0.140 0.315
Repair with
undersize parts or
replace connecting
rod bearing metal
0.042 0.110
Size
Standard
0.25 US
0.50 US
0.75 US
1.00 US
Standard size
120.00
119.75
119.50
119.25
119.00
Standard
Tolerance
0.050
0.068
Repair with
undersize parts or
replace crankshaft
0 0.009
Repair with undersize parts or replace
main bearing metal
0.044 0.106
Standard
Bend of crankshaft
(Total indicator reading)
Concentricity of all main journals
0 0.15
Concentricity of adjacent journals
0 0.05
Replace crankshaft
140E-5 Series
SEN05200-01
Part names related to connecting rod
1.
2.
3.
4.
5.
6.
7.
Connecting rod bolt

Cap
Dowel pin
Bearing metal (lower)
Bearing metal (upper)
Rod
Small end bushing
140E-5 Series
SEN05200-01
Testing and inspection of connecting rod

Unit: mm
Inspection item
Crack
Parallelism and twist of small
and large end holes of
connecting rod
Clearance between
connecting rod small end
bushing and piston pin
Criteria
Remedy
Check for crack by dye check or magnaflux inspection

a See Fig. H
Presence of bend (after small end bushing is installed)
Parallelism: 0.20
Twist:
0.30
Tolerance
Standard size
Standard clearance
Shaft
Hole
0
0.006
f52
0.049
0.030
0.030 0.055
Replace connecting
rod
Replace small end

bushing
Surface roughness
of inside of small
end bushing
Max. 3.2S
Standard
Large end hole diameter
Tolerance
size
Without bearing metal.
+0.026
Inside surface roughness of large end hole:
95
0.004
Max. 3.2S
Replace bearing
Connecting rod large end hole
Standard
clearance
metal or connecting
Clearance
to
crankshaft
bearing
diameter
rod
(with bearing metal)
0.042 0.111
Wave of large end hole: Max. 0.004 (All width)
Bearing metal thickness
Even if dimensions of each part are within allowable limits, if any clearance exceeds allowable clearance, replace parts (bearing metal etc.)
Size
Standard size
Tolerance
Standard
3.500
1.00 US
4.000
0
0.75 US
3.875
0.010
0.50 US
3.750
0.25 US
3.625
Replace bearing
metal and
connecting rod
Flaw on inside of or seizure of

Presence of flaw and seizure
bearing metal
Standard size
Distance between large and

small end hole centers
264
Replace bearing
metal
Tolerance
0
0.040
Replace connecting
rod
Streak and bruise on I-portion

of connecting rod
a See Fig. J
Presence of lateral streak
Presence of lateral grinding mark
Replace connecting
rod
If there is bruise,
replace connecting
rod regardless of
size of bruise
Fretting on cap mating face
Presence of fretting on mating face

Mating face roughness: Max. 6.3S
Back fitted area of mating face: Min. 70%
a There must not be non-fitted area on outside of bolt hole center.
If fretting is felt with

nail, replace
connecting rod
Scuffing on cap bolt seat surface
Repair with oilstone
Scuffing on bolt seat surface
Replace bolt
Scuffing on washer surface
Replace washer
Replace connecting
rod
Scuffing on bolt seat surface
Deformation of dowel pin

Damage of bolt
a
a
a
10
Presence of deformation of dowel pin

Presence of deformation of dowel pin hole
Presence of crack and/or damage on threaded portion of bolt
Presence of bend of bolt
Replace bolt
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.
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.
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.
140E-5 Series
Fig. H
SEN05200-01
Replacement of flywheel ring gear

k
Take care not to throw down the flywheel

and get hurt by mistake.
Removal of gear
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.
a: Measured value
Fig. J
Press fitting of gear

1. Check the gear mounting face. If there is a
flaw, repair with an oilstone.
2.
Heat the gear at the specified shrink fit temperature for a certain time.
a Gear shrink fit temperature: Max. 200C
Heating time: Min. 50 min
3.
Press fit the gear with the chamfered side

directed toward the flywheel until its side contacts the flywheel.
b: Inspection range
c: Streaks
d: Lengthwise direction
140E-5 Series
11
SEN05200-01
Replacement of crankshaft gear

a
Crankshaft gear replacement tools
Symbol
K
Part No.
Part name
790-101-2800
Bearing puller
790-101-2300
Push puller
4.
Using the drive tool, press fit the gear with the
timing mark out until its side contacts the
crankshaft flange.
a Press fit the gear quickly before it cools
down.
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 copper 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 crankshaft.
3.
a Gear shrink fit temperature: Max. 200C
Heating time: Min. 30 min
12
140E-5 Series
SEN05200-01
Replacement of camshaft gear

k
When setting the camshaft assembly on the

press stand, take care not to catch your fingers 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 camshaft.
3.
Install the thrust plate.
4.
a Gear shrink fit temperature: 220 240C
Heating time: 30 min
5.
Using the drive tool, press fit the gear with the
timing mark out until its side contacts the camshaft flange.
a Press fit the gear quickly before it cools
down.
140E-5 Series
13
SEN05200-01
Replacement of main bearing

metal cap
a
5.
When replacing the main bearing metal cap,

work on the semi-finished cap according to the
following procedure and install it.
Repair parts
Part No.
Part name
6217-21-1240 No. 1, 2, 3, 4, 5, 6 main bearing metal cap

6217-21-1250 No. 7 main bearing metal cap
Inside machining of main bearing metal cap

1. Remove the cylinder liner.
2.
3.
4.
14
Install the replacement main bearing metal cap

to the cylinder block and tighten it to the specified 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:
While checking the inside diameter of main

bearing metal cap (1), cut little by little.
a Cut to the degree that the boring bar tool
almost touches the inside of cylinder block
(2).
a Inside diameter of main bearing metal cap
q
Machining dimension
mm
Tolerance: f127 +0.018
0
q
After machining, remove the main bearing
metal cap, assemble it again, and check
its inside diameter.
mm
Tolerance: f127 +0.018
0
(Range to upper and lower 10 from mating face of main bearing metal cap)
a Finished surface roughness: Max. 10S
a Do not cut the inside surface of the cylinder block.
Unit: Nm {kgm}
Range
Step
Target
1st time
98 {10}
88 108 {9 11}
2nd time
196 {20}
191 201 {19.5 20.5}
3rd time
Tightening by
90
90 +30
0
Set the cylinder block mounting jig on the table

of the horizontal boring machine and install the
cylinder block by fitting its cylinder liner mounting hole to the datum line of the jig.
Side machining of main bearing metal cap

(Machine only No. 7 main bearing metal cap)
1. Insert cast iron bushing (3) and pass arbor (4)
through it.
2.
Install facing tool (5) to the arbor.
3.
Cut main bearing metal cap (1) to the degree

that facing tool almost touches the cylinder
block surface.
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.
140E-5 Series
4.
SEN05200-01
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
SEN05200-01
Replacement of connecting rod

small end bushing
Press fitting of bushing

1. Set the connecting rod to block (3) of tool L.
2.
Install the bushing to push tool (1), set push

tool (2), and fix them with nut (4).
a Match the oil holes of the bushing and
connecting rod to each other.
3.
Drive push tool (1) with the press to press fit

the bushing.
a Since the bushing is semi-finished, its
inside diameter is small and the piston pin
does not go through it.
After press fitting the bushing, machine its
inside with a reamer or a honing machine
according to the maintenance standard.
a After machining, remove all the chips from
the oil hole and oil groove.
Connecting rod small end bushing replacement tool
Symbol
Part No.
795-240-6401
Part name
Push tool (KIT)
Pulling out of bushing

1. Set the connecting rod to block (3) of tool L.
2.
16
Using push tool (1) and block (3), drive out the
busing with the press.
a After removing the bushing, remove sharp
edges and burrs from and clean the bushing mounting hole.
140E-5 Series
Replacement of cam bushing

a
3.
Pulling out of No. 3, No. 4 and No. 5 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.
4.
After removing the bushing, remove burrs and

foreign matter from and clean the bushing
mounting hole.
Cam bushing replacement tools
Symbol
Part No.
795-213-1200
SEN05200-01
Part name
Push tool (KIT)
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.
Installation
a
2.
Cam bushing installation drawing
Pulling out of No. 2 and No. 6 bushings

1) Assemble bar (1), push tool (2), collar (3)
and guide (4).
140E-5 Series
17
SEN05200-01
1.
Press fitting of No. 3, No. 4 and No. 5 bushings

1) Install bar (1), push tool (2), collar (3) and
guide (4) to 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.
3.
Press fitting of No. 1 and No. 7 bushings

1) Install bar (1), push tool (2) and collar (3)
to the bushing.
2.
Press fitting of No. 2 and No. 6 bushings

1) Install bar (1), push tool (2), collar (3) and
guide (4) to the bushing.
4.
Measurement after bushing is press fitted

1) Using dial inside gauge (a), measure the
inside diameter of the bushing.
2)
18
Measure the clearance between the bushing 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 bushing with a reamer, remove all the
chips from the oil hole and oil groove.
a Inside diameter of cam bushing:
f65 +0.06
mm
0
a Clearance to camshaft journal:
0.016 0.096 mm
140E-5 Series
Repair of cylinder block top by

grinding
SEN05200-01
Repair by grinding
If there is distortion or corrosion on the cylinder
block top, remove it by grinding.
a If the cylinder liner contact surface of counterbore portion is blackened and grained (particularly in the forward and backward directions of
the cylinder block) more than a half of the contact surface or the cylinder block top needs to
be ground, repair the counterbore portion.
a Rough criteria for repairing cylinder block top
by grinding
q
The cylinder block top is worn and corroded in
the shape of the trace of the head gasket.
q
Quantity (a) of the above wear is 0.15 mm or
more.
Grinding of top
q
Measure the wear quantity and distortion of the
cylinder block top. If the measured value is
larger than the allowable limit, repair the cylinder block top by grinding within the allowable
limit of cylinder block height (d).
Flatness of cylinder block

top (per cylinder)
Cylinder block height (d)
Cylinder block top surface
roughness
Standard
dimension
Unit: mm
Repair
dimension
Max. 0.05
Max. 0.05
430.5 0.04 430.1 0.04

Max. 12.5S
Fig. 2
Fig. 1
140E-5 Series
When repairing with grinding stone (Reference)

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
19
SEN05200-01
Repair of counterbore by grinding 1

a
Counterbore grinding tool
Symbol
a
q
q
q
q
Part No.
Part name
79A-513-1710 Basic machine
79A-513-1780 Guide plate
79A-513-1820 Cutter plate
79A-513-1860 Cutter
79A-513-1940 Cutter set gauge
79A-513-1950 Micrometer
79A-513-1960 Driver plate
79A-513-2090 Driver shaft
79A-513-2110
10
79A-513-2120 Service package
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
Machine only the hatched part of counterbore

portion depth (f).
Set the machining margin of counterbore portion depth (f) so that cylinder liner projection (e)
will be within the standard value.
If counterbore portion depth (f) exceeds the
standard dimension and the counterbore portion needs to be ground within the allowable
limit, set the machining margin so that 1 shim
shown next page will be used for 1 cylinder.
Remove burrs and sharp edges from the
tapered portion etc.
Driver handle
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.
Rough criteria for repairing counterbore portion
by grinding
A dimension is out of the standard dimension.
The cylinder liner contact surface of the counterbore portion is blackened and grained (particularly in the forward and backward
directions) more than a half of the whole area.
If counterbore portion depth (f) after the repair
is 11.05 12.525 mm, adjust cylinder liner projection (f) to 0.07 0.15 mm with shims.
Unit: mm
Counterbore portion depth (f)

Cylinder liner projection (e)
Counterbore surface roughness
Grinding shape
20
Standard
size
Repair limit
11 +0.05
+0
12.525
0.07 0.15
Max. 12.5S
See right figure
*: See "b" and "c" in Fig. 2 of previous page for

"Detail B and c".
140E-5 Series
SEN05200-01
When grinding the counterbore portion, use

tool N.
Shims for adjusting counterbore depth (reference)

Unit: mm
Part No.
Weight
(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
Remarks
Outside diameter and inside diameter of shim
140E-5 Series
21
SEN05200-01
Check and identification after

repair by grinding
After repairing by grinding, check the flat portions around the water and oil holes on the cylinder block top for flaw.
Remove all burrs and sharp edges.
After grinding the top surface, check cylinder
block height (d) is 430.1 0.04 mm, and use
the oversize head gasket.
q
q
Unit: mm
Spare parts used
Head gasket
Part No.
Plate thickness
Standard
6210-17-1814
2.0
Oversize
6210-19-1814
2.4
The 2 letters of "OS" are stamped on the plate

for identification.
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
gasket
Shim
Stamp
Unnecessary
OS
SH
WS
(Stamp letter size shall be 5 10 mm)
22
140E-5 Series
Gasket sealant application

procedure
q
SEN05200-01
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)
When using shim for the deck, apply the gasket 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.

At this time, apply a little amount of rubber
lubricant (RF-1) to cylinder block contact surface (d) of the O-ring and seal of the cylinder
liner.
a Apply the engine oil just before press fitting the cylinder liner.
a RF-1: Product of DAIDO CHEMICAL
INDUSTRY CO., LTD.
If RF-1 cannot be obtained, apply clean
swelled and deteriorated with oil, apply a
little amount of oil with a brush just before
installing.
140E-5 Series
4.
Set the cylinder liner to the cylinder block,

install the used head gasket, and tighten the
cylinder head temporarily.
At this time, tighten the bolts in the following
order.
3 Tightening torque:
147 10 Nm {15 1 kgm}
23
SEN05200-01
5.
24
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 grommet 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.
140E-5 Series
SEN05200-01
Repair standard for cylinder liner

O-ring
1
After repairing the bushing at the cylinder liner Oring portion of the cylinder block, finish to the following dimensions.
a Concentricity of (6) to standard (A):
Max. 0.05 mm
Unit: mm
No.
Finish dimension
167
161.45 0.25
160.67 0.064
176 0.25 up to block top surface
184.94 0.18 up to block top surface
158 +0.040
+0
159.03 (Gauge diameter)
140E-5 Series
25
SEN05200-01
Replacement of engine rear seal

a
Engine rear seal replacement tools
Symbol
Part No.
795-931-1100
Part name
Seal puller assembly
For disassembly and assembly of flywheel and

flywheel housing, see "Disassembly and
assembly".
2.
Pull slide hammer (1) of the seal puller to pull

out the seal with impacts.
a Rear seal (c) can be pulled out easily, if it
is driven in a little to separate it from the
flywheel housing in advance.
a Do not damage the crankshaft.
a Do not use a drill since chips will enter the
engine.
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)
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

seal (c) and pull slide hammer (1) of the seal
puller to pull out the seal with impacts.
a Rear seal (c) can be pulled out easily, if it
is driven in a little to separate it from the
flywheel housing in advance.
a Do not damage the crankshaft.
a Do not use a drill since chips will enter the
engine.
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 m) and there is no scratch on it, it
can be used.
2.
SEN05200-01
a
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).
2.
Hold the metal ring of seal (c) with both hands

and push it in evenly.
a Push in the rear seal as if you pass over
large inside diameter side (f) of internal
plastic cylinder (d).
3.
Remove internal plastic cylinder (d), taking

care not to damage lip (h).
In other cases than 1 above, install the sleeved

rear seal.
Installation of rear seal (without sleeve)

a Do not remove internal plastic cylinder (d) of
the spare rear seal (which is used as an installation guide) before installing the rear seal
since it is also used to protect the seal lip.
140E-5 Series
Before installing the rear seal, remove all

flaws, sharp edges, burrs, rust, etc. from the
end corners and sliding surfaces of the crankshaft and from the flywheel housing.
Do not apply oil or grease to the sliding surfaces of the crankshaft and lip (e) of the rear
seal.
Wipe off the oil from the sliding surfaces of the
crankshaft thoroughly.
27
SEN05200-01
4.
Install sleeve jig (1) and clamp bolts (2) (Stem

length: 40 mm (wet), 45 mm (dry)).
a Do not install washers to the bolts.
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.
Installation of rear seal (with sleeve)

a Handle the spare rear seal and sleeve (n) as
an assembly and do not separate them.
a
6.
28
Remove clamp bolts (2) (Stem length: 40 mm

(wet), 45 mm (dry)), install 2 washers (3) each,
and tighten bolts (2) evenly again to press fit
the rear seal until end (k) of sleeve jig (1)
touches end (m) of the crankshaft.
a Take care not to damage the end of lip (j)
on the transmission side.
a After press fitting, remove the gasket sealant projected around the periphery.
1.
Before installing the rear seal, remove all

flaws, sharp edges, burrs, rust, etc. from the
end corners and sliding surfaces of the crankshaft and from the flywheel housing.
Do not apply oil or grease to the sliding surfaces of the crankshaft and lip (e) of the rear
seal.
Wipe off the oil from the sliding surfaces of the
crankshaft thoroughly.
Apply gasket sealant to inside wall (p) of rear
seal (c) and set it to sleeve jig (4).
2 Inside wall (p) of rear seal (c):
Gasket seal (LG-7)
140E-5 Series
2.
Install sleeve jig (4), clamp bolts (5) (Stem

length: 45 mm), and 1 washer (6).
3.
Evenly tighten clamp bolts (5) to press fit the

rear seal until they stop.
a Be sure to press fit rear seal (c) and
sleeve (n) as an assembly.
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
SEN05200-01
5.
Remove clamp bolts (8) (Stem length: 45 mm),

install 2 washers (9) each, and tighten bolts (8)
evenly again to press fit the rear seal until end
(q) of sleeve jig (7) touches end (r) of the
crankshaft.
a After press fitting, remove the gasket sealant projected around the periphery.
29
SEN05200-01
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.
30
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.
140E-5 Series
Repair of crankshaft by grinding

q
When the crankshaft is worn, seized or damaged slightly and needs to be repaired, grind it
to one of the following undersizes.
Undersizes: 0.25, 0.50, 0.75, 1.00 mm
If the crankshaft is bent or worn unevenly, it
should not be repaired but should be replaced.
(Repairing the crankshaft requires high technologies)
Finish fillet portion (R), shoulder portion (r) and
area (R) around the hole of the crankshaft with
extreme care.
SEN05200-01
Pin journal oil hole (See figure below)

q
Finish part (d) with sandpaper.
q
Check part (e) extremely carefully since
quenching crack tends to occur in that part.
Finish dimensions of fillet portion

(R): 5.3 +0.3
0 mm
Surface roughness: 3.2S
Finish the main journal and pin journal according to the following procedure.
Main journal oil hole (See figure below)

Dimension of tapered part (a) of oil hole:
12 mm
q
Angle (b) of tapered part of oil hole: 120
q
Surface roughness of oil hole top (c):
1.6S (Finished with sandpaper)
q
Dimension of parts (R) at 2 places: 1 2 mm
140E-5 Series
The outside surface roughness of the pin journal and main journal must be maximum of
0.6S.
Equipment necessary for grinding

Magnaflux inspection machine
q
Shore hardness tester
q
Etching kit
q
Crankshaft grinding machine
q
Crankshaft polishing machine
q
Surface roughness gauge
q
Fillet (R) gauge
q
31
SEN05200-01
Inspection before repair by grinding
Check during and after repair by grinding
Visual check
q
Check for crack, damage, discoloration by seizure, wear, etc. and judge if the crankshaft can
be repaired by grinding.
Check of fillet (R) portion

q
Check that each fillet (R) portion is connected
to the journal shoulder smoothly.
q
Using fillet (R) gauges [1] and [2], check that
"dimension (R)" is between the minimum value
gauge and maximum value gauge.
q
(c) is the contact point of minimum value gauge.
q
(d) are the contact points of maximum value
gauge.
Fillet (R) Min. radius: 5.3 mm
Max. radius: 5.6 mm
Hardness check of journal surface

Allowable range: HRC55 60
a If the hardness is below the allowable limit, discard the crankshaft.
Check for twist
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

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.
q
Magnaflux inspection
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.
q
32
140E-5 Series
SEN05200-01
Measurement of bend (Measurement of alignment)

q
Measure the bend of the ground crankshaft
and ensure that it is within the standard value.
q
Measure the bend (alignment) at the following
4 places.
Tolerance of overall length alignment:
Max. 0.15 mm
Tolerance of adjacent alignment: Max. 0.05 mm
Tolerance of front end alignment: Max. 0.03 mm
Tolerance of rear end alignment: Max. 0.03 mm
Grinding of thrust surface

a It is not always required to grind the thrust surfaces of the front and rear to the same undersize dimension.
a If the thrust surface was repaired by grinding,
ensure that the end play of the crankshaft is
within the allowable range.
(See the section of general assembly)
Undersize dimensions of thrust surface
Unit: mm
Rear thrust surface

Standard
Front thrust surface
Standard
0.125
OS
0.25
OS
Standard
size
Repair
limit
0.125 OS
0.25 OS
52.125 +0.050
52.25 +0.050
52 +0.050
0
0
0
52.060
52.185
52.310
Standard 52.125 +0.050 52.25 +0.050 52.375 +0.050

0
0
0
size
Repair
limit
52.185
52.310
52.435
Standard
52.375 +0.050
52.50 +0.050
52.25 +0.050
0
0
0
size
Repair
limit
52.310
52.435
52.560
Squareness of thrust surface (TIR)

Permissible deviation: 0.04 mm
Grinding of main journal

a Grind all the main journals to the same undersize.
a When grinding, leave the polish finishing margin of 0.007 0.008 mm.
Grinding of pin journal

a Grind all the pin journals to the same undersize.
a When grinding, leave the polish finishing margin of 0.007 0.008 mm.
Undersize dimensions of main journal
Undersize dimensions of pin journal
Size
Standard size
Standard
0.25 US
0.50 US
0.75 US
1.00 US
120.000
119.750
119.500
119.250
119.000
Unit: mm
Tolerance
0.050
0.068
Roundness, cylindricality (TIR) and surface

roughness of main journal
Permissible deviation: Max. 0.009 mm
140E-5 Series
Size
Standard size
Standard
0.25 US
0.50 US
0.75 US
1.00 US
90.000
89.750
89.500
89.250
89.000
Unit: mm
Tolerance
0.050
0.068
Roundness, cylindricality (TIR) and surface

roughness of pin journal
Permissible deviation: Max. 0.009 mm
33
SEN05200-01
Grinding of sides of main journal and pin journal

q
When repairing worn surfaces (c) of main journal (a) and pin journal (b), limit the grinding
quantity to the minimum.
q
(d) is thickness of worn surface.
q
Width of crankpin journal
When only 1 side is ground
Standard: 58 +0.074
mm
0
q
Width of main journal (#7 only)
Standard: 52 +0.05
mm
0
q
Squareness of thrust surface (TIR)
Permissible deviation: 0.04 mm
Prevention of grinding burn

q
Apply the flange grinding method.
q
Use all the width of the grinding stone.
Avoid grinding the boss surface.
q
Apply cooling oil sufficiently.
q
Set the standard peripheral speed of the grinding stone to 2,000 m/min when the crankshaft
rotation speed is 50 rpm.
Finishing of surface
Surface roughness standard
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
q
Dressing of grinding stone

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 checking with gauges.
q
34
140E-5 Series
Work after repair by grinding

q
Ensure again that each dimension is as specified.
q
Clean each part thoroughly and apply rust-preventive oil.
q
When storing the crankshaft for a long period,
support it on 3 points or keep it erected with a
sling.
SEN05200-01
2.
Measure the outside diameter of the main journal in directions (X) and (Y) at 2 places ((1)
and (2)) and that of the pin journal in directions
(X) and (Y) at 2 places ((1) and (2)) with a
micrometer or an air micrometer.
Balancing (Reference)
Avoid performing repair that may affect the crankshaft 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 corrections.
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 minimum and maximum values.
140E-5 Series
35
SEN05200-01
Improvement of surface
roughness of crankshaft journal 1
q
If the surface roughness of the journal portions

of the crankshaft is out of the standard or the
journal surface has a flaw, bruise or rust which
can be removed, improve the surface roughness.
1.
Cleaning and blowing air

Before starting grinding, brush the oil holes
and blow air into them.
2.
3.
Check the surface roughness with the standard piece.

a Measure the surface roughness of the
journal by comparing it with the standard
piece.
Surface roughness standard (Pin journal
and main journal)
Journal surface: Max. 0.8S
Round part: Max. 3.2S
4.
If the surface roughness does not satisfy the

standard, make round polishing with the sandpaper (#500) again between both ends.
a After improving the surface roughness, be
sure to brush the oil holes and blow air
into them.
a Ensure that the there is no flaw or bruise
on the journal portion and the round part
of each fillet.
If there is any flaw or bruise, polish again
from step 1.
Improvement of surface roughness of journal

portions
When improving with special polishing machine

q
Use the special polishing machine shown
below.
1.
Set the rotation speed of the crank shaft to 40

50 rpm.
Improve the surface roughness by making
round polishing with sandpaper (belt type)
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 handle (1) to move the sandpaper by the play.
a Move the sandpaper smoothly without
stopping at a place.
If the special polishing machine is not available,

use the following clamp jig for polishing to
improve the surface roughness.
1.
36
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
140E-5 Series
2.
SEN05200-01
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.
2.
Cut off sandpaper (#800) (a, b) to the shapes

shown below.
q
(a) is for the pin journal and its size is as
follows;
L: 171 mm, W: 82 mm
q
(b) is for the main journal and its size is as
follows.
L: 218 mm, W: 75 mm
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
3.
Insert 2 pieces of upper and lower sandpapers

(a) or (b) in slit (e) and fix the ends with tape
(f).
Fold slit portion (d) of the sandpaper along the

round part of the clamp.
5.
Hold the journal with the clamp and fix the

lever ends with rubber tube (g) etc.
37
SEN05200-01
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
SEN05200-01
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

Manual de Taller Komatsu Saa6d140e 5

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Manual de Taller Komatsu Saa6d140e 5

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SEN00074-16

00 Index and foreword

00 Index and foreword

Composition of shop manual

00 Index and foreword

00 Index and foreword

00 Index and foreword

Fuel system .................................................................................................................................

20 Standard value table

00 Index and foreword

Testing compression pressure.................................................................................................

00 Index and foreword

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

00 Index and foreword

E-69 Code [(143)/B@BAZG] Eng. Oil Press Low Torque Derate............................................ 48

00 Index and foreword

Gasket sealant application procedure .....................................................................................

00 Index and foreword

KOMATSU 140E-5 Series engine

00 Index and foreword

Foreword and general information

00 Index and foreword

Important safety notice

If welding repairs are needed, always

Prohibition of operation and handling by

6 Safety check before starting work

Wearing protective goggles

Wearing shielding goggles and protectors

9 Good physical condition and preparation

Precautions against work which you are

00 Index and foreword

Preparations for work

Precautions during work

When removing a cover which is under

Precautions for sling work and making

00 Index and foreword

When installing wire ropes to an angular

11) Do not use twisted or kinked wire ropes.

00 Index and foreword

If the load is unstable or the wire rope

Precautions for using mobile crane

Selecting wire ropes

The allowable load is one-sixth of the

00 Index and foreword

Example of O-ring (Fitted to every joint of

For tightening torque, see the precautions for

00 Index and foreword

How to read the shop manual

Revision and distribution

00 Index and foreword

Revised edition mark

Weight of parts of component or parts. Caution necessary when

Places that require special attention for tightening torque during

00 Index and foreword

Explanation of terms for maintenance standard

Standard size and tolerance

The tolerance may be indicated in the text

Usually, the size of a hole and the size of

Standard clearance and standard value

Repair limit and allowable value or allowable dimension

00 Index and foreword

00 Index and foreword

Handling of electric equipment and hydraulic component