Sie sind auf Seite 1von 764

SEN00074-16

ENGINE 140E -5 SERIES


SEN00076-16

ENGINE 1SHOP MANUAL

140E-5 Series

00 Index and foreword 1


Index
Composition of shop manual .......................................................................................................................... 2
Table of contents ............................................................................................................................................. 3

140E-5 Series 1
SEN00076-16 00 Index and foreword

Composition of shop manual 1


The contents of this shop manual are shown together with Form No. in a list.
Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly.
The marks shown to the right of Form No. denote the following:
Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.)
Note 2: This shop manual can be supplied for each Form No.
Note 3: To file this shop manual in the special binder for management, handle it as follows:
• Place a divider on the top of each section in the file after matching the Tub No. with No. indicated
next to each Section Name shown in the table below:
• File overview and other materials in sections in the order shown below and utilize them accord-
ingly.

Section Title Form Number

Shop Manual, contents binder, binder label and tabs ............................................................ SEN00074-16

00 Index and foreword ......................................................................................................... SEN00075-16


Index ............................................................................................................................... SEN00076-16 q
Foreword and general information .................................................................................. SEN00077-07

01 Specification.................................................................................................................... SEN00078-07
Specification and technical data...................................................................................... SEN00079-07 q

10 Structure, function and maintenance standard ............................................................... SEN00080-08


Structure, function and maintenance standard, Part 1.................................................... SEN00081-08 q
Structure, function and maintenance standard, Part 2.................................................... SEN00082-06 q

20 Standard value table ....................................................................................................... SEN00083-07


Standard service value table........................................................................................... SEN00147-07 q

30 Testing and adjusting ...................................................................................................... SEN00148-05


Testing and adjusting ...................................................................................................... SEN00149-05

40 Troubleshooting .............................................................................................................. SEN00150-06


General information on troubleshooting.......................................................................... SEN00151-04
Troubleshooting of mechanical system (S-mode)........................................................... SEN00152-03
Troubleshooting of electrical system (E-mode), Part 1 ................................................... SEN00153-03
Troubleshooting of electrical system (E-mode), Part 2 ................................................... SEN00154-02

50 Disassembly and assembly ............................................................................................ SEN00155-07


General information on disassembly and assembly ....................................................... SEN00156-05
Disassembly and assembly, Part 1 (with EGR) .............................................................. SEN00157-05
Disassembly and assembly, Part 2 (EGR-less) .............................................................. SEN00158-05
Disassembly and assembly, Part 3 ................................................................................. SEN00159-04

90 Repair and replacement of parts..................................................................................... SEN05197-02


Information related to repair and replacement ................................................................ SEN05198-00
Cylinder head.................................................................................................................. SEN05199-02
Cylinder block ................................................................................................................. SEN05200-01

2 140E-5 Series
00 Index and foreword SEN00076-16

Table of contents 1
00 Index and foreword
Index SEN00076-16
Composition of shop manual ................................................................................................... 2
Table of contents ..................................................................................................................... 3
Foreword and general information SEN00077-07
Safety notice............................................................................................................................ 2
How to read the shop manual.................................................................................................. 7
Explanation of terms for maintenance standard ...................................................................... 9
Handling of electric equipment and hydraulic component ....................................................... 11
Handling of connectors newly used for engines ...................................................................... 20
How to read electric wire code ................................................................................................ 23
Precautions when carrying out operation ................................................................................ 26
Method of disassembling and connecting push-pull type coupler ........................................... 29
Standard tightening torque table.............................................................................................. 32
Conversion table...................................................................................................................... 36

01 Specification
Specification and technical data SEN00079-07
Outline ..................................................................................................................................... 2
Specifications........................................................................................................................... 6
General view............................................................................................................................ 24
Weight table............................................................................................................................. 61
Engine performance curves..................................................................................................... 65

10 Structure, function and maintenance standard


Structure, function and maintenance standard, Part 1 SEN00081-08
Air intake and exhaust unit ...................................................................................................... 3
Air cleaner ............................................................................................................................... 5
Turbocharger ........................................................................................................................... 8
Aftercooler ............................................................................................................................... 19
Muffler...................................................................................................................................... 20
EGR system ............................................................................................................................ 25
Cylinder head .......................................................................................................................... 32
Cylinder block .......................................................................................................................... 36
Cylinder liner............................................................................................................................ 39
Main moving parts ................................................................................................................... 40
Crankshaft ............................................................................................................................... 42
Camshaft ................................................................................................................................. 43
Cam follower and push rod...................................................................................................... 44
Piston, piston ring and piston pin............................................................................................. 46
Connecting rod ........................................................................................................................ 48
Flywheel and flywheel housing................................................................................................ 49
Vibration damper ..................................................................................................................... 52
Timing gear.............................................................................................................................. 54
Valve system ........................................................................................................................... 58
Valve and valve guide.............................................................................................................. 60
Rocker arm and shaft .............................................................................................................. 62
Crosshead and guide .............................................................................................................. 63
Structure, function and maintenance standard, Part 2 SEN00082-06
Lubrication system ...................................................................................................................... 4
Lubrication system diagram..................................................................................................... 4
Oil pump .................................................................................................................................. 8
EGR oil pump .......................................................................................................................... 9
Oil filter .................................................................................................................................... 10
Oil cooler ................................................................................................................................. 12

140E-5 Series 3
SEN00076-16 00 Index and foreword

Fuel system ................................................................................................................................. 14


CRI system diagram ................................................................................................................ 14
Outline of CRI system.............................................................................................................. 16
Fuel piping ............................................................................................................................... 38
Fuel cooler ............................................................................................................................... 42
Fuel filter .................................................................................................................................. 43
Priming pump........................................................................................................................... 46
Electric priming pump .............................................................................................................. 47
Engine controller cooler ........................................................................................................... 48
Cooling system............................................................................................................................ 49
Cooling system diagram .......................................................................................................... 49
Water pump ............................................................................................................................. 54
Thermostat............................................................................................................................... 57
Corrosion resistor .................................................................................................................... 58
Cooling fan drive...................................................................................................................... 60
Accessories ................................................................................................................................. 63
Front PTO ................................................................................................................................ 63
Electrical equipment .................................................................................................................... 65
Alternator ................................................................................................................................. 65
Starting motor .......................................................................................................................... 76
Starting aid............................................................................................................................... 78
Engine controller...................................................................................................................... 79

20 Standard value table


Standard service value table SEN00147-07
Standard service value table for testing, adjusting, and troubleshooting ................................. 2
Running-in standard and performance test standard .............................................................. 19

30 Testing and adjusting


Testing and adjusting SEN00149-05
Testing and adjusting (with EGR) ................................................................................................ 3
Testing and adjusting tools list ................................................................................................. 3
Sketches of special tools ......................................................................................................... 5
Testing air boost pressure........................................................................................................ 6
Testing exhaust temperature ................................................................................................... 7
Adjusting valve clearance ........................................................................................................ 8
Testing compression pressure ................................................................................................. 9
Testing blow-by pressure ......................................................................................................... 11
Testing engine oil pressure ...................................................................................................... 12
Testing EGR valve and bypass valve drive oil pressure .......................................................... 13
Handling fuel system parts ...................................................................................................... 14
Releasing residual pressure in fuel system ............................................................................. 14
Testing fuel pressure................................................................................................................ 15
Reduced cylinder mode operation ........................................................................................... 16
No-injection cranking ............................................................................................................... 16
Testing fuel return rate and leakage ........................................................................................ 17
Bleeding air from fuel circuit .................................................................................................... 20
Testing fuel system for leakage ............................................................................................... 22
Testing and adjusting alternator belt tension ........................................................................... 23
Testing and adjusting fan belt tension...................................................................................... 24
Handling controller high-voltage circuit.................................................................................... 25
Testing and adjusting (EGR-less)................................................................................................ 26
Testing and adjusting tools list ................................................................................................. 26
Sketches of special tools ......................................................................................................... 28
Testing air boost pressure........................................................................................................ 29
Testing exhaust temperature ................................................................................................... 30
Adjusting valve clearance ........................................................................................................ 31

4 140E-5 Series
00 Index and foreword SEN00076-16

Testing compression pressure................................................................................................. 32


Testing blow-by pressure......................................................................................................... 34
Testing engine oil pressure...................................................................................................... 35
Handling fuel system parts ...................................................................................................... 36
Releasing residual pressure in fuel system ............................................................................. 36
Testing fuel pressure ............................................................................................................... 37
Reduced cylinder mode operation........................................................................................... 38
No-injection cranking ............................................................................................................... 38
Testing fuel return rate and leakage ........................................................................................ 39
Bleeding air from fuel circuit .................................................................................................... 42
Testing fuel system for leakage ............................................................................................... 44
Testing and adjusting alternator belt tension ........................................................................... 45
Testing and adjusting fan belt tension ..................................................................................... 46
Handling controller high-voltage circuit.................................................................................... 47

40 Troubleshooting
General information on troubleshooting SEN00151-04
Points to remember when troubleshooting .............................................................................. 2
Method of displaying trouble diagnosis lamps (Method of displaying error code) ................... 3
Error codes and failure codes list ............................................................................................ 5
Information in troubleshooting table ........................................................................................ 10
Connection table for connector pin numbers ........................................................................... 12
T- branch box and T- branch adapter table ............................................................................. 48
Troubleshooting of mechanical system (S-mode) SEN00152-03
Troubleshooting of mechanical system (S-mode) ....................................................................... 4
Method of using troubleshooting charts................................................................................... 4
S-1 Starting performance is poor ............................................................................................. 8
S-2 Engine does not start ........................................................................................................ 10
S-3 Engine does not pick up smoothly .................................................................................... 14
S-4 Engine stops during operations ........................................................................................ 15
S-5 Engine does not rotate smoothly ...................................................................................... 16
S-6 Engine lacks output (or lacks power) ................................................................................ 17
S-7 Exhaust smoke is black (incomplete combustion) ............................................................ 18
S-8 Oil consumption is excessive (or exhaust smoke is blue)................................................. 20
S-9 Oil becomes contaminated quickly ................................................................................... 21
S-10 Fuel consumption is excessive ....................................................................................... 22
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down).............................. 23
S-12 Oil pressure drops........................................................................................................... 24
S-13 Oil level rises (Entry of coolant/fuel) ............................................................................... 25
S-14 Coolant temperature becomes too high (overheating).................................................... 27
S-15 Abnormal noise is made ................................................................................................. 28
S-16 Vibration is excessive ..................................................................................................... 29
Troubleshooting of electrical system (E-mode), Part 1 SEN00153-03
Troubleshooting of electrical system (E-mode), Part 1 ............................................................... 3
Troubleshooting method for disconnecting wiring harness of pressure sensor system .......... 3
E-1 Code [111/CA111] Engine Controller Internal Failure........................................................ 6
E-2 Code [115/CA115] Eng. Ne and Bkup Speed Sensor Error .............................................. 7
E-3 Code [122/CA122] Charge (boost) Air Press Sensor High Error ...................................... 8
E-4 Code [123/CA123] Charge (boost) Air Press Sensor Low Error....................................... 12
E-5 Code [131/CA131] Throttle Sensor High Error ................................................................. 16
E-6 Code [132/CA132] Throttle Sensor Low Error .................................................................. 20
E-7 Code [135/CA135] Oil Press. Sensor High Error .............................................................. 22
E-8 Code [141/CA141] Oil Press. Sensor Low Error............................................................... 24
E-9 Code [144/CA144] Coolant Temp. Sensor High Error ...................................................... 26
E-10 Code [145/CA145] Coolant Temp. Sensor Low Error ..................................................... 28
E-11 Code [153/CA153] Charge (boost) Air Temp. Sensor High Error.................................... 30
E-12 Code [154/CA154] Charge (boost) Air Temp. Sensor Low Error .................................... 32

140E-5 Series 5
SEN00076-16 00 Index and foreword

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-26 Code [323/CA323] Injector #5 System Open/Short Error ............................................... 60
E-27 Code [324/CA324] Injector #3 System Open/Short Error ............................................... 62
E-28 Code [325/CA325] Injector #6 System Open/Short Error ............................................... 64
E-29 Code [331/CA331] Injector #2 System Open/Short Error ............................................... 66
E-30 Code [332/CA332] Injector #4 System Open/Short Error ............................................... 68
E-31 Code [342/CA342] Engine Controller Data Matching Error............................................. 70
E-32 Code [351/CA351] INJ. Drive Circuit Error...................................................................... 72
E-33 Code [352/CA352] Sensor Sup. 1 Volt. Low Error .......................................................... 74
E-34 Code [386/CA386] Sensor Sup. 1 Volt. High Error ......................................................... 75
E-35 Code [431/CA431] Idle Validation Switch Error............................................................... 78
E-36 Code [432/CA432] Idle Validation Process Error ............................................................ 80
E-37 Code [441/CA441] Supply Voltage Low Error ................................................................. 81
E-38 Code [442/CA442] Supply Voltage High Error ................................................................ 81
Troubleshooting of electrical system (E-mode), Part 2 SEN00154-02
Troubleshooting of electrical system (E-mode), Part 2................................................................ 3
E-39 Code [449/CA449] Rail Press. High Error 2.................................................................... 3
E-40 Code [451/CA451] Rail Press. Sensor High Error .......................................................... 4
E-41 Code [452/CA452] Rail Press. Sensor Low Error ........................................................... 7
E-42 Code [553/CA553] Rail Press. High Error 1.................................................................... 8
E-43 Code [554/CA554] Rail Press Sensor In Range Error .................................................... 9
E-44 Code [559/CA559] No-pressure Feed By Supply pump 1 .............................................. 10
E-45 Code [689/CA689] Eng. Ne Speed Sensor Error ............................................................ 14
E-46 Code [731/CA731] Eng. Bkup Speed Sensor Phase Error ............................................. 16
E-47 Code [757/CA757] All Engine Controller Data Lost Error ............................................... 16
E-48 Code [778/CA778] Eng. Bkup Speed Sensor Error ........................................................ 18
E-49 Code [1228/CA1228] EGR Valve Servo Error 1.............................................................. 21
E-50 Code [1625/CA1625] EGR Valve Servo Error 2.............................................................. 22
E-51 Code [1626/CA1626] Bypass Valve Solenoid Drive Short Circuit Error .......................... 23
E-52 Code [1627/CA1627] Bypass Valve Solenoid Drive Open Error ..................................... 25
E-53 Code [1628/CA1628] Bypass Valve Servo Error 1.......................................................... 26
E-54 Code [1629/CA1629] Bypass Valve Servo Error 2.......................................................... 27
E-55 Code [1631/CA1631] Bypass Valve Lift Sensor High Error............................................. 28
E-56 Code [1632/CA1632] Bypass Valve Lift Sensor Low Error ............................................. 30
E-57 Code [1633/CA1633] KOMNET Error ............................................................................. 30
E-58 Code [1642/CA1642] EGR Inlet Press Sensor Low Error............................................... 31
E-59 Code [1653/CA1653] EGR Inlet Press Sensor High Error .............................................. 32
E-60 Code [2185/CA2185] Throttle Sens. Sup. Volt. High Error ............................................. 34
E-61 Code [2186/CA2186] Throttle Sens. Sup. Volt. Low Error .............................................. 38
E-62 Code [2249/CA2249] No-pressure Feed By Supply pump 2 .......................................... 38
E-63 Code [2271/CA2271] EGR Valve Lift Sensor High Error................................................. 39
E-64 Code [2272/CA2272] EGR Valve Lift Sensor Low Error ................................................. 41
E-65 Code [2351/CA2351] EGR Valve Solenoid Drive Short Error ......................................... 42
E-66 Code [2352/CA2352] EGR Valve Solenoid Drive Open Error ......................................... 44
E-67 Code [2555/CA2555] Intake Air Heater Relay Open Error.............................................. 45
E-68 Code [2556/CA2556] Intake Air Heater Relay Short Error .............................................. 46

6 140E-5 Series
00 Index and foreword 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 7
SEN00076-16 00 Index and foreword

Gasket sealant application procedure ..................................................................................... 23


Repair standard for cylinder liner O-ring .................................................................................. 25
Replacement of engine rear seal............................................................................................. 26
Replacement of wear sleeve (when sleeve is installed) .......................................................... 30
Repair of crankshaft by grinding .............................................................................................. 31
Improvement of surface roughness of crankshaft journal........................................................ 36

8 140E-5 Series
00 Index and foreword SEN00076-16

140E-5 Series 9
SEN00076-16

KOMATSU 140E-5 Series engine

Form No. SEN00076-16

© 2012 KOMATSU
All Rights Reserved
Printed in Japan 12-12 (01)

10
SEN00077-07

ENGINE 1SHOP MANUAL

140E-5 Series

00 Index and foreword 1


Foreword and general information

Safety notice ................................................................................................................................................... 2


How to read the shop manual ......................................................................................................................... 7
Explanation of terms for maintenance standard ............................................................................................. 9
Handling of electric equipment and hydraulic component .............................................................................11
Handling of connectors newly used for engines ........................................................................................... 20
How to read electric wire code...................................................................................................................... 23
Precautions when carrying out operation...................................................................................................... 26
Method of disassembling and connecting push-pull type coupler................................................................. 29
Standard tightening torque table ................................................................................................................... 32
Conversion table ........................................................................................................................................... 36

140E-5 Series 1
SEN00077-07 00 Index and foreword

Safety notice 1
(Rev. 2008/08)
Important safety notice
Proper service and repair are extremely important for safe machine operation. The service and repair
techniques recommended by Komatsu and described in this manual are both effective and safe.
Some of these techniques require the use of tools specially designed by Komatsu for the specific
purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The
cautions accompanying these symbols should always be followed carefully. If any dangerous situa-
tion arises or may possibly arise, first consider safety, and take the necessary actions to deal with
the situation.

1. General precautions 7) If welding repairs are needed, always


k Mistakes in operation are extremely have a trained and experienced welder
dangerous. Read the Operation and carry out the work. When carrying out
Maintenance Manual carefully before w elding work, alw ays wear welding
operating the machine. In addition, gloves, apron, shielding goggles, cap and
read this manual and understand its other clothes suited for welding work.
contents before starting the work. 8) Before starting work, warm up your body
1) Before carrying out any greasing or thoroughly to start work under good condi-
repairs, read all the safety labels stuck to tion.
the machine. For the locations of the 9) Avoid continuing work for long hours and
safety labels and detailed explanation of take rests at proper intervals to keep your
precautions, see the Operation and Main- body in good condition. Take rests in
tenance Manual. specified safe places.
2) Decide a place in the repair workshop to
keep tools and removed parts. Always Safety points
keep the tools and parts in their correct
places. Always keep the work area clean 1 Good arrangement
and make sure that there is no dirt, water, 2 Correct work clothes
or oil on the floor. Smoke only in the areas 3 Following work standard
provided for smoking. Never smoke while
working. 4 Making and checking signs
3) When carrying out any operation, always Prohibition of operation and handling by
5
wear safety shoes and helmet. Do not unlicensed workers
wear loose work clothes, or clothes with 6 Safety check before starting work
buttons missing.
q Always wear safety glasses when hit- Wearing protective goggles
7
(for cleaning or grinding work)
ting parts with a hammer.
q Always wear safety glasses when Wearing shielding goggles and protectors
8
grinding parts with a grinder, etc. (for welding work)
4) When carrying out any operation with 2 or 9 Good physical condition and preparation
more workers, always agree on the oper- Precautions against work which you are
ating procedure before starting. Always 10
not used to or you are used to too much
inform your fellow workers before starting
any step of the operation. Before starting
work, hang UNDER REPAIR warning
signs in the operator's compartment.
5) Only qualified workers must carry out work
and operation which require license or
qualification.
6) Keep all tools in good condition, learn the
correct way to use them, and use the
proper ones of them. Before starting work,
thoroughly check the tools, machine, fork-
lift, service car, etc.

2 140E-5 Series
00 Index and foreword SEN00077-07

2. Preparations for work 6) When removing a cover which is under


1) Before adding oil or making any repairs, internal pressure or under pressure from a
park the machine on a hard and level spring, always leave 2 bolts in diagonal
ground, and apply the parking brake and positions. Loosen those bolts gradually
block the wheels or tracks to prevent the and alternately to release the pressure,
machine from moving. and then remove the cover.
2) Before starting work, lower the work 7) When removing components, be careful
equipment (blade, ripper, bucket, etc.) to not to break or damage the electrical wir-
the ground. If this is not possible, insert ing. Damaged wiring may cause electrical
the lock pin or use blocks to prevent the fires.
work equipment from falling. In addition, 8) When removing piping, stop the fuel or oil
be sure to lock all the control levers and from spilling out. If any fuel or oil drips
hang warning signs on them. onto the floor, wipe it up immediately. Fuel
3) When disassembling or assembling, sup- or oil on the floor can cause you to slip
port the machine with blocks, jacks, or and can even start fires.
stands before starting work. 9) As a general rule, do not use gasoline to
4) Remove all mud and oil from the steps or wash parts. Do not use it to clean electri-
other places used to get on and off the cal parts, in particular.
machine. Always use the handrails, lad- 10) Be sure to assemble all parts again in their
ders or steps when getting on or off the original places. Replace any damaged
m a c h i n e . N e v e r j u m p o n o r o ff t h e parts and parts which must not be reused
machine. If it is impossible to use the with new parts. When installing hoses and
handrails, ladders or steps, use a stand to wires, be sure that they will not be dam-
provide safe footing. aged by contact with other parts when the
machine is operated.
3. Precautions during work 11) When installing high pressure hoses,
1) Before disconnecting or removing compo- make sure that they are not twisted. Dam-
nents of the oil, water, or air circuits, first aged tubes are dangerous, so be
release the pressure completely from the extremely careful when installing tubes for
circuit. When removing the oil filler cap, a high pressure circuits. In addition, check
drain plug, or an oil pressure pickup plug, t h a t c o n n e c t i n g pa r ts a r e c o r r e c t l y
loosen it slowly to prevent the oil from installed.
spurting out. 12) When assembling or installing parts,
2) The coolant and oil in the circuits are hot always tighten them to the specified
when the engine is stopped, so be careful torques. When installing protective parts
not to get scalded. Wait for the oil and such as guards, or parts which vibrate vio-
coolant to cool before carrying out any lently or rotate at high speed, be particu-
work on the oil or water circuits. larly careful to check that they are
3) Before starting work, stop the engine. installed correctly.
When working on or around a rotating 13) When aligning 2 holes, never insert your
part, in particular, stop the engine. When fingers or hand. Be careful not to get your
checking the machine without stopping fingers caught in a hole.
the engine (measuring oil pressure, 14) When measuring hydraulic pressure,
revolving speed, temperature, etc.), take check that the measuring tools are cor-
extreme care not to get rolled or caught in rectly assembled.
rotating parts or moving parts. 15) Take care when removing or installing the
4) Before starting work, remove the leads tracks of track-type machines. When
from the battery. Always remove the lead removing the track, the track separates
from the negative (–) terminal first. suddenly, so never let anyone stand at
5) When raising a heavy component (heavier either end of the track.
than 25 kg), use a hoist or crane. Before 16) If the engine is operated for a long time in
starting work, check that the slings (wire a place which is not ventilated well, you
ropes, chains, and hooks) are free from may suffer from gas poisoning. Accord-
damage. Always use slings which have ingly, open the windows and doors to ven-
ample capacity and install them to proper tilate well.
places. Operate the hoist or crane slowly
to prevent the component from hitting any
other part. Do not work with any part still
raised by the hoist or crane.

140E-5 Series 3
SEN00077-07 00 Index and foreword

4. Precautions for sling work and making


signs
1) Only one appointed worker must make
signs and co-workers must communicate
with each other frequently. The appointed
sign maker must make specified signs
clearly at a place where he is well seen
from the operator's seat and where he can
see the working condition easily. The sign
maker must always stand in front of the
load and guide the operator safely.
q Do not stand under the load.
q Do not step on the load.
2) Check the slings before starting sling
work.
8) When installing wire ropes to an angular
3) Keep putting on gloves during sling work.
load, apply pads to protect the wire ropes.
(Put on leather gloves, if available.)
If the load is slippery, apply proper mate-
4) Measure the weight of the load by the eye
rial to prevent the wire rope from slipping.
and check its center of gravity.
9) Use the specified eyebolts and fix wire
5) Use proper sling according to the weight
ropes, chains, etc. to them with shackles,
of the load and method of slinging. If too
etc.
thick wire ropes are used to sling a light
10) Apply wire ropes to the middle portion of
load, the load may slip and fall.
the hook.
6) Do not sling a load with 1 wire rope alone.
q Slinging near the tip of the hook may
If it is slung so, it may rotate and may slip
cause the rope to slip off the hook
out of the rope. Install 2 or more wire
during hoisting. The hook has the
ropes symmetrically.
k Slinging with 1 rope may cause
maximum strength at the middle por-
tion.
turning of the load during hoisting,
untwisting of the rope, or slipping
of the rope from its original wind-
ing position on the load, which can
result in a dangerous accident.
7) Limit the hanging angle to 60°, as a rule.
Do not sling a heavy load with ropes form-
ing a wide hanging angle from the hook.
When hoisting a load with 2 or more
ropes, the force subjected to each rope
will increase with the hanging angle. The
table below shows the variation of allow-
able load in kN {kg} when hoisting is made
with 2 ropes, each of which is allowed to
sling up to 9.8 kN {1,000 kg} vertically, at
various hanging angles. When the 2 ropes 11) Do not use twisted or kinked wire ropes.
sling a load vertically, up to 19.6 kN {2,000 12) When lifting up a load, observe the follow-
kg} of total weight can be suspended. ing.
This weight is reduced to 9.8 kN {1,000 q Wind in the crane slowly until wire
kg} when the 2 ropes make a hanging ropes are stretched. When settling
angle of 120°. If the 2 ropes sling a 19.6 the wire ropes with the hand, do not
kN {2,000 kg} load at a lifting angle of grasp them but press them from
150°, each of them is subjected to a force above. If you grasp them, your fingers
as large as 39.2 kN {4,000 kg}. may be caught.
q After the wire ropes are stretched,
stop the crane and check the condi-
tion of the slung load, wire ropes, and
pads.

4 140E-5 Series
00 Index and foreword SEN00077-07

q If the load is unstable or the wire rope 13) If the hoist stops because of a power fail-
or chains are twisted, lower the load ure, turn the power switch OFF. When
and lift it up again. turning on a switch which was turned OFF
q Do not lift up the load slantingly. by the electric shock prevention earth
13) When lifting down a load, observe the fol- leakage breaker, check that the devices
lowing. related to that switch are not in operation
q When lifting down a load, stop it tem- state.
porarily at 30 cm above the floor, and 14) If you find an obstacle around the hoist,
then lower it slowly. stop the operation.
q Check that the load is stable, and 15) After finishing the work, stop the hoist at
then remove the sling. the specified position and raise the hook
q Remove kinks and dirt from the wire to at least 2 m above the floor. Do not
ropes and chains used for the sling leave the sling installed to the hook.
work, and put them in the specified
place. 7. Selecting wire ropes
1) Select adequate ropes depending on the
5. Precautions for using mobile crane weight of parts to be hoisted, referring to
a Read the Operation and Maintenance the table below.
Manual of the crane carefully in advance
and operate the crane safely. Wire ropes
(Standard “Z” twist ropes without galvanizing)
6. Precautions for using overhead hoist crane (JIS G3525, No. 6, Type 6X37-A)
k When raising a heavy part (heavier Nominal
Allowable load
than 25 kg), use a hoist, etc. In Disas- diameter of rope
sembly and assembly, the weight of a mm kN ton
part heavier than 25 kg is indicated 10 8.8 0.9
after the mark of 4. 12 12.7 1.3
1) Before starting work, inspect the wire 14 17.3 1.7
ropes, brake, clutch, controller, rails, over 16 22.6 2.3
wind stop device, electric shock preven- 18 28.6 2.9
tion earth leakage breaker, crane collision 20 35.3 3.6
prevention device, and power application
25 55.3 5.6
warning lamp, and check safety.
30 79.6 8.1
2) Observe the signs for sling work.
40 141.6 14.4
3) Operate the hoist at a safe place.
4) Check the direction indicator plates (east, 50 221.6 22.6
west, south, and north) and the directions 60 318.3 32.4
of the control buttons without fail.
5) Do not sling a load slantingly. Do not move a The allowable load is one-sixth of the
the crane while the slung load is swinging. breaking strength of the rope used
6) Do not raise or lower a load while the (Safety coefficient: 6).
crane is moving longitudinally or laterally.
7) Do not drag a sling.
8) When lifting up a load, stop it just after it
leaves the ground and check safety, and
then lift it up.
9) Consider the travel route in advance and
lift up a load to a safe height.
10) Place the control switch on a position
where it will not be an obstacle to work
and passage.
11) After operating the hoist, do not swing the
control switch.
12) Remember the position of the main switch
so that you can turn off the power immedi-
ately in an emergency.

140E-5 Series 5
SEN00077-07 00 Index and foreword

8. Precautions for disconnecting and con- a Example of O-ring (Fitted to every joint of
necting hoses and tubes in air conditioner hoses and tubes)
circuit
1) Disconnection
k For the environment, the air condi-
tioner of this machine uses the
refrigerant (air conditioner gas:
R134a) which has fewer factors of
the depletion of the ozone layer.
However, it does not mean that you
may discharge the refrigerant into
the atmosphere as it is. Be sure to
recover the refrigerant when dis-
connecting the refrigerant gas cir-
cuit and then reuse it.
a Ask professional traders for collecting a For tightening torque, see the precautions for
and filling operation of refrigerant installation in each section of "Disassembly
(R134a). and assembly".
a Never release the refrigerant (R134a)
to the atmosphere.
k If the refrigerant gas gets in your
eyes or contacts your skin, you
may lose your sight and your skin
may be frozen. Accordingly, put
on safety glasses, safety gloves
and safety clothes when recover-
ing or adding the refrigerant.
Refrigerant gas must be recovered
and added by a qualified person.

2) Connection
1] When installing the air conditioner cir-
cuit hoses and tubes, take care that
dirt, dust, water, etc. will not enter
them.
2] When connecting the air conditioner
hoses and tubes, check that O-rings
(1) are fitted to their joints.
3] Check that each O-ring is not dam-
aged or deteriorated.
4] When connecting the refrigerant pip-
ing, apply compressor oil for refriger-
ant (R134a) (DENSO: ND-OIL8,
VA L E O T H E R M A L S Y S T E M S :
ZXL100PG (equivalent to PAG46))
to its O-rings.

6 140E-5 Series
00 Index and foreword SEN00077-07

How to read the shop manual 1

q Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one
of them is required, consult KOMATSU distributors.
q Materials and specifications are subject to change without notice.
q Shop manuals are divided into the “Chassis volume” and “Engine volume”. For the engine unit, see the
engine volume of the engine model mounted on the machine.

1. Composition of shop manual


This shop manual contains the necessary technical information for services performed in a workshop.
For ease of understanding, the manual is divided into the following sections.

00. Index and foreword


This section explains the shop manuals list, table of contents, safety, and basic information.

01. Specification
This section explains the specifications of the machine.

10. Structure, function and maintenance standard


This section explains the structure, function, and maintenance standard values of each component.
The structure and function sub-section explains the structure and function of each component. It
serves not only to give an understanding of the structure, but also serves as reference material for
troubleshooting. The maintenance standard sub-section explains the criteria and remedies for dis-
assembly and service.

20. Standard value table


This section explains the standard values for new machine and judgement criteria for testing,
adjusting, and troubleshooting. This standard value table is used to check the standard values in
testing and adjusting and to judge parts in troubleshooting.

30. Testing and adjusting


This section explains measuring instruments and measuring methods for testing and adjusting, and
method of adjusting each part. The standard values and judgement criteria for testing and adjusting
are explained in Testing and adjusting.

40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is
divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also
explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.

50. Disassembly and assembly


This section explains the special tools and procedures for removing, installing, disassembling, and
assembling each component, as well as precautions for them. In addition, tightening torque and
quantity and weight of coating material, oil, grease, and coolant necessary for the work are also
explained.

90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
This section explains the method of reproducing, repairing, and replacing parts.

2. Revision and distribution


Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most
up-to-date information before you start any work.

140E-5 Series 7
SEN00077-07 00 Index and foreword

3. Filing method
File by the brochures in the correct order of the form number printed in the shop manual composition
table.

q Revised edition mark


When a manual is revised, the ones and tens digits of the form number of each brochure is
increased by 1. (Example: 00, 01, 02 …)

q Revisions
Revised brochures are shown in the shop manual composition table.

4. Symbols
Important safety and quality portions are marked with the following symbols so that the shop manual will
be used practically.

Symbol Item Remarks

k Safety Special safety precautions are necessary when performing work.

Special technical precautions or other precautions for preserving stan-


a Caution
dards are necessary when performing work.

4
Weight of parts of component or parts. Caution necessary when
Weight
selecting hoisting wire, or when working posture is important, etc.

3
Tightening Places that require special attention for tightening torque during
torque assembly.

2 Coat Places to be coated with adhesives, etc. during assembly.

5
Oil, coolant Places where oil, etc. must be added, and capacity.

6
Drain Places where oil, etc. must be drained, and quantity to be drained.

5. Units
In this shop manual, the units are indicated with International System of units (SI). For reference, con-
ventionally used Gravitational System of units is indicated in parentheses { }.

8 140E-5 Series
00 Index and foreword SEN00077-07

Explanation of terms for maintenance standard 1


The maintenance standard chapter explains the criteria for replacing or reusing products and parts in the
machine maintenance work. The following terms are used to explain the criteria.

1. Standard size and tolerance


q To be accurate, the finishing size of parts
is a little different from one to another.
q To specify a finishing size of a part, a tem-
porary standard size is set and an allow-
able difference from that size is indicated.
q The above size set temporarily is called
the “standard size” and the range of differ-
ence from the standard size is called the
“tolerance”.
q The tolerance with the symbols of + or – is
indicated on the right side of the standard
size.

Example:
Standard size Tolerance
–0.022
120
–0.126

a The tolerance may be indicated in the text


and a table as [standard size (upper limit
of tolerance/lower limit of tolerance)].
Example) 120 (–0.022/–0.126)

q Usually, the size of a hole and the size of


the shaft to be fitted to that hole are indi-
cated by the same standard size and dif-
ferent tolerances of the hole and shaft.
The tightness of fit is decided by the toler-
ance.
q Indication of size of rotating shaft and hole
and relationship drawing of them

Example:
Tolerance
Standard size
Shaft Hole
–0.030 +0.046
60
–0.076 +0

140E-5 Series 9
SEN00077-07 00 Index and foreword

2. Standard clearance and standard value 5. Clearance limit


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

4. Repair limit and allowable value or allow-


able dimension
q The size of a part changes because of
wear and deformation while it is used. The
limit of changed size is called the “repair
limit”.
q If a part is worn to the repair limit, it must
be replaced or repaired.
q The performance and function of a prod-
uct lowers while it is used. A value which
the product can be used without causing a
problem is called the “allowable value” or
“allowable dimension”.
q If a product is worn to the allowable value,
it must be checked or repaired. Since the
permissible value is estimated from vari-
ous tests or experiences in most cases,
however, it must be judged after consider-
ing the operating condition and customer's
requirement.

10 140E-5 Series
00 Index and foreword SEN00077-07

Handling of electric equipment and hydraulic component 1


To maintain the performance of the machine over a long period, and to prevent failures or other troubles
before they occur, correct “operation“, “maintenance and inspection“, “troubleshooting“, and “repairs” must
be carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at
improving the quality of repairs. For this purpose, it gives sections on “Handling electric equipment” and
“Handling hydraulic equipment” (particularly gear oil and hydraulic oil).

Points to remember when handling electric


equipment
1. Handling wiring harnesses and connectors
Wiring harnesses consist of wiring connecting
one component to another component, con-
nectors used for connecting and disconnecting
one wire from another wire, and protectors or
tubes used for protecting the wiring.
Compared with other electrical components fit-
ted in boxes or cases, wiring harnesses are
more likely to be affected by the direct effects
of rain, water, heat, or vibration. Furthermore,
during inspection and repair operations, they
are frequently removed and installed again, so
they are likely to suffer deformation or damage.
For this reason, it is necessary to be extremely
careful when handling wiring harnesses.

2. Main failures occurring in wiring harness


1) Defective contact of connectors (defec-
tive contact between male and female)
Problems with defective contact are likely
to occur because the male connector is
not properly inserted into the female con-
nector, or because one or both of the con-
nectors is deformed or the position is not
correctly aligned, or because there is cor-
rosion or oxidization of the contact sur-
faces. The corroded or oxidized contact
surfaces may become shiny again (and
contact may become normal) by connect-
ing and disconnecting the connector about
10 times.

2) Defective crimping or soldering of connec-


tors
The pins of the male and female connec-
tors are in contact at the crimped terminal
or soldered portion, but if there is exces-
sive force brought to bear on the wiring,
the plating at the joint will peel and cause
improper connection or breakage.

140E-5 Series 11
SEN00077-07 00 Index and foreword

3) Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with
a crane with the wiring still connected, or a
heavy object hits the wiring, the crimping
of the connector may separate, or the sol-
dering may be damaged, or the wiring
may be broken.

4) High-pressure water entering connector


The connector is designed to make it diffi-
cult for water to enter (drip-proof struc-
ture), but if high-pressure water is sprayed
directly on the connector, water may enter
the connector, depending on the direction
of the water jet. Accordingly, take care not
to splash water over the connector. The
connector is designed to prevent water
from entering, but at the same time, if
water does enter, it is difficult for it to be
drained. Therefore, if water should get into
the connector, the pins will be short-cir-
cuited by the water, so if any water gets in,
immediately dry the connector or take
other appropriate action before passing
electricity through it.

5) Oil or dirt stuck to connector


If oil or grease are stuck to the connector
and an oil film is formed on the mating sur-
face between the male and female pins,
the oil will not let the electricity pass, so
there will be defective contact. If there is
oil or grease stuck to the connector, wipe it
off with a dry cloth or blow it dry with com-
pressed air and spray it with a contact
restorer.
a When wiping the mating portion of the
connector, be careful not to use
excessive force or deform the pins.
a If there is oil or water in the com-
pressed air, the contacts will become
even dirtier, so remove the oil and
water from the compressed air com-
pletely before cleaning with com-
pressed air.

12 140E-5 Series
00 Index and foreword SEN00077-07

3. Removing, installing, and drying connec-


tors and wiring harnesses
1) Disconnecting connectors
1] Hold the connectors when discon-
necting.
When disconnecting the connectors,
hold the connectors. For connectors
held by a screw, loosen the screw
fully, then hold the male and female
connectors in each hand and pull
apart. For connectors which have a
lock stopper, press down the stopper
with your thumb and pull the connec-
tors apart.
a Never pull with one hand.

2] When removing from clips


q Both of the connector and clip have
stoppers, which are engaged with
each other when the connector is
installed.

q When removing a connector from a


clip, pull the connector in a parallel
direction to the clip for removing stop-
pers.
a If the connector is twisted up and
down or to the left or right, the
housing may break.

3] Action to take after removing connec-


tors
After removing any connector, cover it
with a vinyl bag to prevent any dust,
dirt, oil, or water from getting in the
connector portion.
a If the machine is left disassem-
bled for a long time, it is particu-
larly easy for improper contact to
occur, so always cover the con-
nector.

140E-5 Series 13
SEN00077-07 00 Index and foreword

2) Connecting connectors
1] Check the connector visually.
Check that there is no oil, dirt, or
water stuck to the connector pins
(mating portion).
Check that there is no deformation,
defective contact, corrosion, or dam-
age to the connector pins.
Check that there is no damage or
breakage to the outside of the con-
nector.
a If there is any oil, water, or dirt
stuck to the connector, wipe it off
with a dry cloth. If any water has
got inside the connector, warm
the inside of the wiring with a
dryer, but be careful not to make
it too hot as this will cause short
circuits.
a If there is any damage or break-
age, replace the connector.
2] Fix the connector securely.
Align the position of the connector
correctly, and then insert it securely.
For connectors with the lock stopper,
push in the connector until the stop-
per clicks into position.
3] Correct any protrusion of the boot and
any misalignment of the wiring har-
ness.
For connectors fitted with boots, cor-
rect any protrusion of the boot. In
addition, if the wiring harness is mis-
aligned, or the clamp is out of posi-
tion, adjust it to its correct position.
a If the connector cannot be cor-
rected easily, remove the clamp
and adjust the position.
q If the connector clamp has been
removed, be sure to return it to
its original position. Check also
that there are no loose clamps.

14 140E-5 Series
00 Index and foreword SEN00077-07

3) Heavy duty wire connector (DT 8-pole, 12- q Disconnection q Connection (Example of
pole) incomplete setting of (a))
Disconnection (Left of figure)
While pressing both sides of locks (a)
and (b), pull out female connector (2).
Connection (Right of figure)
1] Push in female connector (2) horizon-
tally until the lock clicks.
Arrow: 1)
2] Since locks (a) and (b) may not be set
completely, push in female connector
(2) while moving it up and down until
the locks are set normally.
Arrow: 1), 2), 3)
a Right of figure: Lock (a) is pulled
down (not set completely) and
lock (b) is set completely.
(1): Male connector
(2): Female connector
(a), (b): Locks

140E-5 Series 15
SEN00077-07 00 Index and foreword

4) Drying wiring harness


If there is any oil or dirt on the wiring har-
ness, wipe it off with a dry cloth. Avoid
washing it in water or using steam. If the
connector must be washed in water, do
not use high-pressure water or steam
directly on the wiring harness. If water
gets directly on the connector, do as fol-
lows.
1] Disconnect the connector and wipe
off the water with a dry cloth.
a If the connector is blown dry with
compressed air, there is the risk
that oil in the air may cause
defective contact, so remove all
oil and water from the com-
pressed air before blowing with
air.
2] Dry the inside of the connector with a
dryer.
If water gets inside the connector, use
a dryer to dry the connector.
a Hot air from the dryer can be
used, but regulate the time that
the hot air is used in order not to
make the connector or related
parts too hot, as this will cause
deformation or damage to the
connector.
3] Carry out a continuity test on the con-
nector.
After drying, leave the wiring harness
disconnected and carry out a continu-
ity test to check for any short circuits
between pins caused by water.
a After completely drying the con-
n e c t o r, b l o w i t w i t h c o n ta c t
restorer and reassemble.

16 140E-5 Series
00 Index and foreword SEN00077-07

4. Handling controller
1) The controller contains a microcomputer
and electronic control circuits. These con-
trol all of the electronic circuits on the
machine, so be extremely careful when
handling the controller.
2) Do not place objects on top of the control-
ler.
3) Cover the control connectors with tape or
a vinyl bag. Never touch the connector
contacts with your hand.
4) During rainy weather, do not leave the
controller in a place where it is exposed to
rain.
5) Do not place the controller on oil, water, or
soil, or in any hot place, even for a short
time. (Place it on a suitable dry stand).
6) Precautions when carrying out arc welding
When carrying out arc welding on the
body, disconnect all wiring harness con-
nectors connected to the controller. Fit an
arc welding ground close to the welding
point.

5. Points to remember when troubleshooting


electric circuits
1) Always turn the power OFF before discon-
necting or connecting connectors.
2) Before carrying out troubleshooting, check
that all the related connectors are properly
inserted.
a Disconnect and connect the related
connectors several times to check.
3) Always connect any disconnected con-
nectors before going on to the next step.
a If the power is turned ON with the
connectors still disconnected, unnec-
essary abnormality displays will be
generated.
4) When carrying out troubleshooting of cir-
cuits (measuring the voltage, resistance,
continuity, or current), move the related
wiring and connectors several times and
check that there is no change in the read-
ing of the tester.
a If there is any change, there is proba-
bly defective contact in that circuit.

140E-5 Series 17
SEN00077-07 00 Index and foreword

Points to remember when handling hydraulic equipment


With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt
(foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling
hydraulic equipment, it is necessary to be particularly careful.

1. Be careful of the operating environment.


Avoid adding hydraulic oil, replacing filters, or
repairing the machine in rain or high winds, or
places where there is a lot of dust.

2. Disassembly and maintenance work in the


field
If disassembly or maintenance work is carried
out on hydraulic equipment in the field, there is
danger of dust entering the equipment. It is
also difficult to check the performance after
repairs, so it is desirable to use unit exchange.
Disassembly and maintenance of hydraulic
equipment should be carried out in a specially
prepared dustproof workshop, and the perfor-
mance should be checked with special test
equipment.

3. Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from
entering. If the opening is left open or is
blocked with a rag, there is danger of dirt
entering or of the surrounding area being
made dirty by leaking oil so never do this. Do
not simply drain oil out onto the ground, but
collect it and ask the customer to dispose of it,
or take it back with you for disposal.

4. Do not let any dirt or dust get in during


refilling operations
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers. If an oil clean-
ing device is used, it is possible to filter out the
dirt that has collected during storage, so this is
an even more effective method.

18 140E-5 Series
00 Index and foreword SEN00077-07

5. Change hydraulic oil when the temperature


is high
When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be
drained out easily from the circuit together with
the oil, so it is best to change the oil when it is
still warm. When changing the oil, as much as
possible of the old hydraulic oil must be
drained out. (Drain the oil from the hydraulic
tank; also drain the oil from the filter and from
the drain plug in the circuit.) If any old oil is left,
the contaminants and sludge in it will mix with
the new oil and will shorten the life of the
hydraulic oil.

6. Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit. Normally, flushing is
carried out twice: primary flushing is carried
out with flushing oil, and secondary flushing is
carried out with the specified hydraulic oil.

7. Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the
machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil cir-
cuit. The oil cleaning equipment is used to
remove the ultra fine (about 3 m) particles that
the filter built in the hydraulic equipment can-
not remove, so it is an extremely effective
device.

140E-5 Series 19
SEN00077-07 00 Index and foreword

Handling of connectors newly used for engines 1


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

Disconnect connector (1) according to the fol-


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

20 140E-5 Series
00 Index and foreword SEN00077-07

3. Push lock type


q 95, 107, 114 engines
Example)
Fuel pressure sensor in common rail
(BOSCH-03)

Disconnect connector (3) according to the fol-


lowing procedure.
1) While pressing lock (C), pull out connector
(3) in the direction of the arrow.

q 114 engine

q 107, 114 engines


Example)
Intake air pressure/temperature sensor in
intake manifold
(SUMITOMO-04)

3) While pressing lock (D), pull out connector


(4) in the direction of the arrow.

q 107 engine

a If the lock is on the underside, use


flat-head screwdriver [1] since you
cannot insert your fingers.
2) While pressing up lock (C) of the connec-
tor with flat-head screwdriver [1], pull out
connector (3) in the direction of the arrow.

140E-5 Series 21
SEN00077-07 00 Index and foreword

q 95, 125 – 170, 12V140 engines 4. Turn-housing type (Round green connector)
4) While pressing lock (E) of the connector, q 140 engine
pull out connector (5) in the direction of Example)
the arrow. Intake air pressure sensor in intake mani-
fold (CANNON-04): PIM etc.
Example)
Fuel pressure sensor in common rail: 1) Disconnect connector (6) according to the
PFUEL etc. (AMP-3) following procedure.
1] Turn housing (H1) in the direction of
the arrow.
a When connector is unlocked,
housing (H1) becomes heavy to
turn.
2] Pull out housing (H1) in the direction
of the arrow.
a Housing (H1) is left on the wiring har-
ness side.

Example)
Injection pressure control valve of fuel
supply pump: PCV (SUMITOMO-2)

2) Connect the connector according to the


following procedure.
1] Insert the connector to the end, while
setting its groove.
2] Turn housing (H1) in the direction of
the arrow until it “clicks”.

Example)
Speed sensor of fuel supply pump:
G (SUMITOMO-3)
a Pull the connector straight up.

22 140E-5 Series
00 Index and foreword SEN00077-07

How to read electric wire code 1


a The information about the wires unique to each machine model is described in Troubleshooting section,
Relational information of troubleshooting.

In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by sym-
bols. The electric wire code is helpful in understanding the electric circuit diagram.

Example: AEX 0.85 L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nomi-
nal No. of 0.85
Indicates color of wire by color code.
Color codes are shown in Table 3.

Indicates size of wire by nominal No.


Size (Nominal No.) is shown in Table 2.

Indicates type of wire by symbol.


Type, symbol, and material of wire are shown in Table 1.
(Since AV and AVS are classified by size (nominal No.), they are not indi-
cated.)

1. Type, symbol, and material


AV and AVS are different in only thickness and outside diameter of the cover. AEX is similar to AV in
thickness and outside diameter of AEX and different from AV and AVS in material of the cover.

(Table 1)
Using
Sym-
Type Material temperature Example of use
bol
range (°C)
Low-voltage Conduc- Annealed copper for elec-
tor tric appliance General wiring
wire for AV
(Nominal No. 5 and above)
automobile Insulator Soft polyvinyl chloride
Thin-cover Conduc- Annealed copper for elec- –30 to +60
low-voltage tor tric appliance General wiring
AVS
wire for (Nominal No. 3 and below)
automobile Insulator Soft polyvinyl chloride

Heat-resis- Conduc- Annealed copper for elec-


General wiring in extremely
tant low-volt- tor tric appliance
AEX –50 to +110 cold district, wiring at high-tem-
age wire for Heat-resistant crosslinked
Insulator perature place
automobile polyethylene

140E-5 Series 23
SEN00077-07 00 Index and foreword

2. Dimensions

(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5
Number of
strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32
eter of strand
Conductor
Sectional
0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
area (mm2)
d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0
AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 –
Cov-
AV Standard – – – – – – – 4.6
er D
AEX Standard 2.0 2.2 2.7 3.0 3.1 – 3.8 4.6

Nominal No. 8 15 20 30 40 50 60 85 100


Number of
strands/Diam- 50/0.45 84/0.45 41/0.80 70/0.80 85/0.80 108/0.80 127/0.80 169/0.80 217/0.80
eter of strand
Conductor
Sectional
7.95 13.36 20.61 35.19 42.73 54.29 63.84 84.96 109.1
area (mm2)
d (approx.) 3.7 4.8 6.0 8.0 8.6 9.8 10.4 12.0 13.6
AVS Standard – – – – – – – – –
Cov-
AV Standard 5.5 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
er D
AEX Standard 5.3 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6

“f” of nominal No. denotes flexible”.

24 140E-5 Series
00 Index and foreword SEN00077-07

3. Color codes table

(Table 3)
Color Code Color of wire Color Code Color of wire
B Black LgW Light green & White
Br Brown LgY Light green & Yellow
BrB Brown & Black LR Blue & Red
BrR Brown & Red LW Blue & White
BrW Brown & White LY Blue & Yellow
BrY Brown & Yellow O Orange
Ch Charcoal P Pink
Dg Dark green R Red
G Green RB Red & Black
GB Green & Black RG Red & Green
GL Green & Blue RL Red & Blue
Gr Gray RW Red & White
GR Green & Red RY Red & Yellow
GW Green & White Sb Sky Blue
GY Green & Yellow Y Yellow
L Blue YB Yellow & Black
LB Blue & Black YG Yellow &Green
Lg Light green YL Yellow & Blue
LgB Light green & Black YR Yellow & Red
LgR Light green & Red YW Yellow & White

Remarks: In a color code consisting of 2 colors, the first color is the color of the background and
the second color is the color of the marking.
Example: “GW” means that the background is Green and marking is White.

4. Types of circuits and color codes

(Table 4)
Type of wire AVS or AV AEX
Charge R WG – – – – R –
Ground B – – – – – B –
Start R – – – – – R –
Light RW RB RY RG RL – D –
Instrument Y YR YB YG YL YW Y Gr
Signal G GW GR GY GB GL G Br
L LW LR LY LB – L –
Type of
Br BrW BrR BrY BrB – – –
circuit
Lg LgR LgY LgB LgW – – –
O – – – – – – –
Others Gr – – – – – – –
P – – – – – – –
Sb – – – – – – –
Dg – – – – – – –
Ch – – – – – – –

140E-5 Series 25
SEN00077-07 00 Index and foreword

Precautions when carrying out operation 1


[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general
precautions given below when carrying out the operation.]

1. Precautions when carrying out removal work


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

2) Split flange type hoses and tubes


Nominal
Flange (hose end) Sleeve head (tube end) Split flange
number
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500

3) If the part is not under hydraulic pressure, the following corks can be used.
Nominal Dimensions
Part Number
number D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34

26 140E-5 Series
00 Index and foreword SEN00077-07

2. Precautions when carrying out installation work


q Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
q Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any.
q Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
q Bend the cotter pins and lock plates securely.
q When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded por-
tion with 2 – 3 drops of adhesive.
q When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is
no dirt or damage, then coat uniformly with gasket sealant.
q Clean all parts, and correct any damage, dents, burrs, or rust.
q Coat rotating parts and sliding parts with engine oil.
q When press fitting parts, coat the surface with anti-friction compound (LM-P).
q After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
q When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
securely.
q When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align
the direction of the hook.
q When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.

a When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other
hydraulic equipment removed for repair, always bleed the air as follows:
1) Start the engine and run at low idle.
2) Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times, stopping the
cylinder 100 mm from the end of its stroke.
3) Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke.
4) After doing this, run the engine at normal speed.
a When using the machine for the first time after repair or long storage, follow the same procedure.

3. Precautions when completing the operation


1) Refilling with coolant, oil and grease
q If the coolant has been drained, tighten the drain valve, and add coolant to the specified level.
Run the engine to circulate the coolant through the system. Then check the coolant level
again.
q If the hydraulic equipment has been removed and installed again, add engine oil to the speci-
fied level. Run the engine to circulate the oil through the system. Then check the oil level
again.
q If the piping or hydraulic equipment have been removed, always bleed the air from the system
after reassembling the parts.
a For details, see Testing and adjusting, “Bleeding air”.
q Add the specified amount of grease (molybdenum disulphide grease) to the work equipment
parts.
2) Checking cylinder head and manifolds for looseness
Check the cylinder head and intake and exhaust manifold for looseness.
If any part is loosened, retighten it.
q For the tightening torque, see “Disassembly and assembly”.
3) Checking engine piping for damage and looseness
Intake and exhaust system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for air
suction and exhaust gas leakage.
If any part is loosened or damaged, retighten or repair it.
Cooling system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for
coolant leakage.
If any part is loosened or damaged, retighten or repair it.
Fuel system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel
leakage.
If any part is loosened or damaged, retighten or repair it.

140E-5 Series 27
SEN00077-07 00 Index and foreword

4) Checking muffler and exhaust pipe for damage and looseness


1] Visually check the muffler, exhaust pipe and their mounting parts for a crack and damage.
If any part is damaged, replace it.
2] Check the mounting bolts and nuts of the muffler, exhaust pipe and their mounting parts for
looseness.
If any bolt or nut is loosened, retighten it.
5) Checking muffler function
Check the muffler for abnormal sound and sound different from that of a new muffler.
If any abnormal sound is heard, repair the muffler, referring to “Troubleshooting” and “Disassembly
and assembly”.

28 140E-5 Series
00 Index and foreword SEN00077-07

Method of disassembling and connecting push-pull type coupler 1


k Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to
release the residual pressure from the hydraulic tank.
k Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly, prepare an oil receiving container.

Type 1

1. Disconnection
1) Hold adapter (1) and push hose joint (2)
into mating adapter (3). (Fig. 1)
a The adapter can be pushed in about
3.5 mm.
a Do not hold rubber cap portion (4).
2) After hose joint (2) is pushed into adapter
(3), press rubber cap portion (4) against
adapter (3) until it clicks. (Fig. 2)
3) Hold hose adapter (1) or hose (5) and pull
it out. (Fig. 3)
a Since some hydraulic oil flows out,
prepare an oil receiving container.

2. Connection
1) Hold hose adapter (1) or hose (5) and
insert it in mating adapter (3), aligning
them with each other. (Fig. 4)
a Do not hold rubber cap portion (4).
2) After inserting the hose in the mating
adapter perfectly, pull it back to check its
connecting condition. (Fig. 5)
a When the hose is pulled back, the
rubber cap portion moves toward the
hose about 3.5 mm. This does not
indicate abnormality, however.

140E-5 Series 29
SEN00077-07 00 Index and foreword

Type 2

1. Disconnection
1) Hold the tightening portion and push body
(7) straight until sliding prevention ring (6)
contacts contact surface (a) of the hexag-
onal portion at the male end. (Fig. 6)
2) While holding the condition of Step 1), turn
lever (8) to the right (clockwise). (Fig. 7)
3) While holding the condition of Steps 1)
and 2), pull out whole body (7) to discon-
nect it. (Fig. 8)

2. Connection
q Hold the tightening portion and push body
(7) straight until sliding prevention ring (6)
contacts contact surface (a) of the hexag-
onal portion at the male end. (Fig. 9)

30 140E-5 Series
00 Index and foreword SEN00077-07

Type 3

1. Disconnection
1) Hold the tightening portion and push body
(9) straight until sliding prevention ring (8)
contacts contact surface (b) of the hexag-
onal 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 por-
tion at the male end. (Fig. 11)
3) While holding the condition of Steps 1)
and 2), pull out whole body (9) to discon-
nect it. (Fig. 12)

2. Connection
q Hold the tightening portion and push body
(9) straight until the sliding prevention ring
contacts contact surface (b) of the hexag-
onal portion at the male end. (Fig. 13)

140E-5 Series 31
SEN00077-07 00 Index and foreword

Standard tightening torque table 1


1. Table of tightening torques for bolts and nuts
a Unless there are special instructions, tighten metric nuts and bolts to the torque below.

a The following table applies to the bolts in Fig. A.

Thread diameter of bolt Width across flats Tightening torque


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

a The following table applies to the bolts in Fig. B.

Thread diameter of bolt Width across flats Tightening torque


mm mm Nm kgm
6 10 5.9 – 9.8 0.6 – 1.0
8 12 13.7 – 23.5 1.4 – 2.4
10 14 34.3 – 46.1 3.5 – 4.7
12 17 74.5 – 90.2 7.6 – 9.2

a Fig. A a Fig. B

Remarks: The widths across flats against the thread diameters of flanged bolts (marks with "*") in Fig. A are
the ones indicated in the table for bolts shown in Fig. B.
(Values of tightening torques shown in the table for Fig. A are applied.)

32 140E-5 Series
00 Index and foreword SEN00077-07

2. Table of tightening torques for split flange bolts


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

Thread diameter of bolt Width across flats Tightening torque


mm mm Nm kgm
10 14 59 – 74 6.0 – 7.5
12 17 98 – 123 10.0 – 12.5
16 22 235 – 285 23.5 – 29.5

3. Table of tightening torques for O-ring boss piping joints


a Unless there are special instructions, tighten O-ring boss piping joints to the torque below.

Thread diameter Width across flats Tightening torque Nm {kgm}


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

4. Table of tightening torques for O-ring boss plugs


a Unless there are special instructions, tighten O-ring boss plugs to the torque below.

Nominal Thread diameter Width across flats Tightening torque Nm {kgm}


No. mm mm Range Target
08 8 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}
10 10 17 9.81 – 12.74 {1.0 – 1.3} 11.27 {1.15}
12 12 19 14.7 – 19.6 {1.5 – 2.0} 17.64 {1.8}
14 14 22 19.6 – 24.5 {2.0 – 2.5} 22.54 {2.3}
16 16 24 24.5 – 34.3 {2.5 – 3.5} 29.4 {3.0}
18 18 27 34.3 – 44.1 {3.5 – 4.5} 39.2 {4.0}
20 20 30 44.1 – 53.9 {4.5 – 5.5} 49.0 {5.0}
24 24 32 58.8 – 78.4 {6.0 – 8.0} 68.6 {7.0}
30 30 32 93.1 – 122.5 { 9.5 – 12.5} 107.8 {11.0}
33 33 – 107.8 – 147.0 {11.0 – 15.0} 127.4 {13.0}
36 36 36 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5}
42 42 – 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5}
52 52 – 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0}

140E-5 Series 33
SEN00077-07 00 Index and foreword

5. Table of tightening torques for hoses (taper seal type and face seal type)
a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the
torque below.
a Apply the following torque when the threads are coated (wet) with engine oil.

Tightening torque Nm {kgm} Taper seal Face seal


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

6. Table of tightening torques for face seal joints


a Tighten the face seal joints (sleeve nut type) made of plated steel pipes for low pressure service to
be used for engines etc. to the torque shown in the following table.
a Apply the following torque to the face seal joint while their threaded parts are coated with engine oil
(wetted).

Outer Width Tightening torque Nm {kgm} Face seal


diameter across Nominal No. – Thread diameter
of pipe flats Range Target Number of threads, (mm)
(mm) (mm) type of thread (Reference)
8 19 14 – 16 {1.4 – 1.6} 15 {1.5} 9/16-18UN 14.3
10 22 24 – 27 {2.4 – 2.7} 25.5 {2.6} 11/16-16UN 17.5
12 24 (27) 43 – 47 {4.4 – 4.8} 45 {4.6} 13/16-16UN 20.6
15 (16) 30 (32) 60 – 68 {6.1 – 6.8} 64 {6.5} 1-14UN 25.4
22 (20) 36 90 – 95 {9.2 – 9.7} 92.5 {9.4} 1-3/16-12UN 30.2
Reference: The face seal joints of the dimensions in ( ) are also used, depending on the specification.

7. Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts)
a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114
engine series to the torque below.

Tightening torque
Thread size
Bolts and nuts
mm Nm kgm
6 10 ± 2 1.02 ± 0.20
8 24 ± 4 2.45 ± 0.41
10 43 ± 6 4.38 ± 0.61
12 77 ± 12 7.85 ± 1.22
14 — —

34 140E-5 Series
00 Index and foreword SEN00077-07

8. Table of tightening torques for 102, 107 and 114 engine series (Eye joints)
a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine
series to the torque below.

Thread size Tightening torque


mm Nm kgm
6 8±2 0.81 ± 0.20
8 10 ± 2 1.02 ± 0.20
10 12 ± 2 1.22 ± 0.20
12 24 ± 4 2.45 ± 0.41
14 36 ± 5 3.67 ± 0.51

9. Table of tightening torques for 102, 107 and 114 engine series (Taper screws)
a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114
engine series to the torque below.

Tightening torque
Material In cast iron or steel In aluminum
Thread size (inch) Nm kgm Nm kgm
1/16 15 ± 2 1.53 ± 0.20 5±1 0.51 ± 0.10
1/8 20 ± 2 2.04 ± 0.20 15 ± 2 1.53 ± 0.20
1/4 25 ± 3 2.55 ± 0.31 20 ± 2 2.04 ± 0.20
3/8 35 ± 4 3.57 ± 0.41 25 ± 3 2.55 ± 0.31
1/2 55 ± 6 5.61 ± 0.61 35 ± 4 3.57 ± 0.41
3/4 75 ± 8 7.65 ± 0.82 45 ± 5 4.59 ± 0.51

140E-5 Series 35
SEN00077-07 00 Index and foreword

Conversion table 1
Method of using the conversion table
The conversion table in this section is provided to enable simple conversion of figures. For details of the
method of using the conversion table, see the example given below.

Example: Method of using the conversion table to convert from millimeters to inches

1. Convert 55 mm into inches.


1) Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a hori-
zontal line from (A).
2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down
from (B).
3) Take the point where the 2 lines cross as (C). This point (C) gives the value when converting from
millimeters to inches. Therefore, 55 mm = 2.165 inches.

2. Convert 550 mm into inches.


1) The number 550 does not appear in the table, so divide it by 10 (move the decimal point one place
to the left) to convert it to 55 mm.
2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal
point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.

Millimeters to inches (B)


1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
(C)
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
(A)
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898

36 140E-5 Series
00 Index and foreword SEN00077-07

Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929

50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898

Kilogram to pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03

50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26

Liters to U.S. Gallons


1 l = 0.2642 U.S.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944

50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153

140E-5 Series 37
SEN00077-07 00 Index and foreword

Liters to U.K. Gallons


1 l = 0.21997 U.K.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.699 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778

50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777

kgm to ft.lb
1 kgm = 7.233 ft.lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4

50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1

100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7

150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4

38 140E-5 Series
00 Index and foreword SEN00077-07

kg/cm2 to lb/in2
1 kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9

50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1,010 1,024 1,038 1,053 1,067 1,081 1,095 1,109 1,124
80 1,138 1,152 1,166 1,181 1,195 1,209 1,223 1,237 1,252 1,266
90 1,280 1,294 1,309 1,323 1,337 1,351 1,365 1,380 1,394 1,408

100 1,422 1,437 1,451 1,465 1,479 1,493 1,508 1,522 1,536 1,550
110 1,565 1,579 1,593 1,607 1,621 1,636 1,650 1,664 1,678 1,693
120 1,707 1,721 1,735 1,749 1,764 1,778 1,792 1,806 1,821 1,835
130 1,849 1,863 1,877 1,892 1,906 1,920 1,934 1,949 1,963 1,977
140 1,991 2,005 2,020 2,034 2,048 2,062 2,077 2,091 2,105 2,119

150 2,134 2,148 2,162 2,176 2,190 2,205 2,219 2,233 2,247 2,262
160 2,276 2,290 2,304 2,318 2,333 2,347 2,361 2,375 2,389 2,404
170 2,418 2,432 2,446 2,460 2,475 2,489 2,503 2,518 2,532 2,546
180 2,560 2,574 2,589 2,603 2,617 2,631 2,646 2,660 2,674 2,688
190 2,702 2,717 2,731 2,745 2,759 2,773 2,788 2,802 2,816 2,830

200 2,845 2,859 2,873 2,887 2,901 2,916 2,930 2,944 2,958 2,973
210 2,987 3,001 3,015 3,030 3,044 3,058 3,072 3,086 3,101 3,115
220 3,129 3,143 3,158 3,172 3,186 3,200 3,214 3,229 3,243 3,257
230 3,271 3,286 3,300 3,314 3,328 3,343 3,357 3,371 3,385 3,399
240 3,414 3,428 3,442 3,456 3,470 3,485 3,499 3,513 3,527 3,542

140E-5 Series 39
SEN00077-07 00 Index and foreword

Temperature

Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centi-
grade temperature reading or vice versa is to enter the accompanying table in the center (boldface column)
of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahren-
heit temperatures and read the corresponding Centigrade temperature in the column at the left.
When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centi-
grade values, and read the corresponding Fahrenheit temperature on the right.

1°C = 33.8°F
°C °F °C °F °C °F °C °F
–40.4 –40 –40.0 –11.7 11 51.8 7.8 46 114.8 27.2 81 177.8
–37.2 –35 –31.0 –11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
–34.4 –30 –22.0 –10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
–31.7 –25 –13.0 –10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
–28.9 –20 –4.0 –9.4 15 59.0 10.0 50 122.0 29.4 85 185.0

–28.3 –19 –2.2 –8.9 16 60.8 10.6 51 123.8 30.0 86 186.8


–27.8 –18 –0.4 –8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
–27.2 –17 1.4 –7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
–26.7 –16 3.2 –7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
–26.1 –15 5.0 –6.7 20 68.0 12.8 55 131.0 32.2 90 194.0

–25.6 –14 6.8 –6.1 21 69.8 13.3 56 132.8 32.8 91 195.8


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

–22.8 –9 15.8 –3.3 26 78.8 16.1 61 141.8 35.6 96 204.8


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

–20.0 –4 24.8 –0.6 31 87.8 18.9 66 150.8 40.6 105 221.0


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

–17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0


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

–14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0


–13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
–13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
–12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
–12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0

40 140E-5 Series
00 Index and foreword SEN00077-07

140E-5 Series 41
SEN00077-07

KOMATSU 140E-5 Series engine

Form No. SEN00077-07

© 2009 KOMATSU
All Rights Reserved
Printed in Japan 01-09 (01)

42
SEN00079-07

ENGINE 1SHOP MANUAL

140E-5 Series

01 Specification 1
Specification and technical data
Outline............................................................................................................................................................. 2
Specifications .................................................................................................................................................. 6
General view ................................................................................................................................................. 24
Weight table .................................................................................................................................................. 61
Engine performance curves .......................................................................................................................... 65

140E-5 Series 1
SEN00079-07 01 Specification

Outline 1
1. Applicable machine

Engine Engine serial No. Machine models


PC600-8, PC600LC-8, PC600-8R, PC600LC-8R Hydraulic excavator
PC600-8E0, PC600LC-8E0, Hydraulic excavator
PC600-8R1, PC600LC-8R1, Hydraulic excavator
PC700-8E0, PC700LC-8E0 Hydraulic excavator
PC700-8R, PC700LC-8R, PC700LC-8R1 Hydraulic excavator
PC800-8, PC800SE-8, PC800LC-8 Hydraulic excavator
PC850-8, PC850SE-8 Hydraulic excavator
PC800-8R, PC800SE-8R, PC800LC-8R Hydraulic excavator
PC850-8R, PC850SE-8R Hydraulic excavator
PC800-8R1, PC800SE-8R1, PC800LC-8R1 Hydraulic excavator
SAA6D140E-5 PC850-8R1, PC850SE-8R1 Hydraulic excavator
PC800-8E0, PC800SE-8E0, PC800LC-8E0 Hydraulic excavator
PC850-8E0, PC850SE-8E0 Hydraulic excavator
D155AX-6, D155A-6 Bulldozer
D275AX-5E0, D275A-5R Bulldozer
WA500-6, WA500-6R Wheel loader
HD325-7, HD405-7, HD325-7R, HD405-7R Dump truck
HM350-2, HM350-2R Articulated dump truck
HM400-2, HM400-2R Articulated dump truck
HM400-3M0, HM400-3R Articulated dump truck
SDG400S-6B1 (HOKUETSU INDUSTRIES) Generator

2 140E-5 Series
01 Specification SEN00079-07

2. Outline of engine
(With EGR)

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

140E-5 Series 3
SEN00079-07 01 Specification

9) By using the above-mentioned high-pressure


fuel injection system controlled electronically,
the multiple injection and injection characteris-
tics are set most properly to improve the start-
ability and reduce the white exhaust smoke
when the temperature is low.

10) Since the controller is mounted on the engine


and equipped with the automatic high-altitude
compensation function, the engine can be
operated at high altitude without replacing the
controller. As a result, the serviceability is
improved.

11) The improved type of the KTR110 turbo-


charger manufactured by KOMATSU which
has been employed for the 140E-2 engine and
after models and which has high reliability and
high performance is mounted. Besides; the
efficiency of the blower impeller is heightened
and the strength of its material is improved to
obtain higher efficiency and pressure ratio.
Since the design of the shaft is improved to
increase the reliability, high performance is
obtained from the low-speed range to the high-
speed range. As a result, the engine has high
performance and consumes less fuel and
attains high reliability.

12) The cylinder block is changed partly to add the


cooled EGR system. Since its overall length,
overall width, and overall height are the same
as before, however, its size is not increased.

4 140E-5 Series
01 Specification SEN00079-07

(EGR-less)

q The 140E-5 engine is a high-performance and 4) As the injection pressure of the common rail
high-efficiency engine, which attained low fuel injection system employed for the 140E-3
consumption and low noise. Accordingly, this engine and after models is increased, the pres-
newly developed engine is suitable as a power sure resistance of the common rail, injector,
source of construction machinery and indus- and supply pump is improved for higher reli-
trial machinery used for various purposes. ability.

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

140E-5 Series 5
SEN00079-07 01 Specification

Specifications 1

Engine name SAA6D140E-5


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

Overall width mm 1,151


Overall height (excluding exhaust pipe) mm 1,467
Overall height (including exhaust pipe) mm 1,863
kW{HP}/ 323 {433.3}/1,800 {1,800}
Rated horsepower
min-1{rpm} (Gross)
Nm{kgm}/ 1,944 {198.4}/1,400 {1,400}
Max. torque
Performance

min-1{rpm} (Gross)
Max. speed with no load
min-1{rpm} 1,950 ± 50 {1,950 ± 50}
(High idle speed)
Min. speed with no load
min-1{rpm} 800 ± 25 {800 ± 25}
(Low idle speed)
g/kW·h
Fuel consumption ratio at rated point 209 {156}
{g/HP·h}
Dry weight kg 1,845
Fuel supply pump — DENSO ECD-U2
Governor — Electronic control type
Quantity of lubricating oil (refill capacity) l 48 (40)
Quantity of coolant l 24
Alternator — 24V, 60A, 90A
Starting motor — 24V, 11kW
Battery — 12V, 170Ah × 2
Turbocharger — KOMATSU KTR110L
Air compressor — —
Others — With air-cooled aftercooler
With cooled EGR

6 140E-5 Series
01 Specification SEN00079-07

Engine name SAA6D140E-5


PC600-8R, PC600LC-8R
Machine models PC600-8R1, PC600LC-8R1
PC700-8R, PC700LC-8R, PC700LC-8R1
Number of cylinders – Bore × Stroke mm 6 – 140 × 165
Total displacement l{cc} 15.2 {15,230}
Firing order — 1–5–3–6–2–4
Overall length mm 1,482
Dimensions

Overall width mm 1,191


Overall height (excluding exhaust pipe) mm 1,467
Overall height (including exhaust pipe) mm 1,863
kW{HP}/ 323 {433.3}/1,800 {1,800}
Rated horsepower
min-1{rpm} (Gross)
Nm{kgm}/ 1,944 {198.4}/1,400 {1,400}
Max. torque
Performance

min-1{rpm} (Gross)
Max. speed with no load
min-1{rpm} 1,950 ± 50 {1,950 ± 50}
(High idle speed)
Min. speed with no load
min-1{rpm} 800 ± 25 {800 ± 25}
(Low idle speed)
g/kW·h
Fuel consumption ratio at rated point 205 {153}
{g/HP·h}
Dry weight kg 1,770
Fuel supply pump — DENSO ECD-U2
Governor — Electronic control type
Quantity of lubricating oil (refill capacity) l 48 (40)
Quantity of coolant l 24
Alternator — 24V, 60A, 90A
Starting motor — 24V, 11kW
Battery — 12V, 170Ah × 2
Turbocharger — KOMATSU KTR110L
Air compressor — —
Others — With air-cooled aftercooler

140E-5 Series 7
SEN00079-07 01 Specification

Engine name SAA6D140E-5


PC800-8, PC800SE-8, PC800LC-8,
PC850-8, PC850SE-8
Machine models
PC800-8E0, PC800SE-8E0, PC800LC-8E0,
PC850-8E0, PC850SE-8E0
Number of cylinders – Bore × Stroke mm 6 – 140 × 165
Total displacement l{cc} 15.2 {15,230}
Firing order — 1–5–3–6–2–4
Overall length mm 1,762
Dimensions

Overall width mm 1,176


Overall height (excluding exhaust pipe) mm 1,686
Overall height (including exhaust pipe) mm 1,902
kW{HP}/ 370 {496.4}/1,800 {1,800}
Rated horsepower
min-1{rpm} (Gross)
Nm{kgm}/ 2,195 {223.8}/1,350 {1,350}
Max. torque
Performance

min-1{rpm} (Gross)
Max. speed with no load
min-1{rpm} 1,980 ± 50 {1,980 ± 50}
(High idle speed)
Min. speed with no load
min-1{rpm} 825 ± 25 {825 ± 25}
(Low idle speed)
g/kW·h
Fuel consumption ratio at rated point 204 {152}
{g/HP·h}
Dry weight kg 1,920
Fuel supply pump — DENSO ECD-U2
Governor — Electronic control type
Quantity of lubricating oil (refill capacity) l 58 (53)
Quantity of coolant l 25 (In only engine)
Alternator — 24V, 60A, 90A
Starting motor — 24V, 11kW
Battery — 12V, 170Ah × 2
Turbocharger — KOMATSU KTR110L
Air compressor — —
Others — With air-cooled aftercooler
With cooled EGR

8 140E-5 Series
01 Specification SEN00079-07

Engine name SAA6D140E-5


PC800-8R, PC800SE-8R, PC800LC-8R,
PC850-8R, PC850SE-8R
Machine models
PC800-8R1, PC800SE-8R1, PC800LC-8R1
PC850-8R1, PC850SE-8R1
Number of cylinders – Bore × Stroke mm 6 – 140 × 165
Total displacement l{cc} 15.2 {15,230}
Firing order — 1–5–3–6–2–4
Overall length mm 1,718
Dimensions

Overall width mm 1,176


Overall height (excluding exhaust pipe) mm 1,686
Overall height (including exhaust pipe) mm 1,902
kW{HP}/ 370 {496.4}/1,800 {1,800}
Rated horsepower
min-1{rpm} (Gross)
Nm{kgm}/ 2,195 {223.8}/1,350 {1,350}
Max. torque
Performance

min-1{rpm} (Gross)
Max. speed with no load
min-1{rpm} 1,980 ± 50 {1,980 ± 50}
(High idle speed)
Min. speed with no load
min-1{rpm} 825 ± 25 {825 ± 25}
(Low idle speed)
g/kW·h
Fuel consumption ratio at rated point 204 {152}
{g/HP·h}
Dry weight kg 1,850
Fuel supply pump — DENSO ECD-U2
Governor — Electronic control type
Quantity of lubricating oil (refill capacity) l 58 (53)
Quantity of coolant l 25 (In only engine)
Alternator — 24V, 60A, 90A
Starting motor — 24V, 11kW
Battery — 12V, 170Ah × 2
Turbocharger — KOMATSU KTR110L
Air compressor — —
Others — With air-cooled aftercooler

140E-5 Series 9
SEN00079-07 01 Specification

Engine name SAA6D140E-5


Machine models D155AX-6
Number of cylinders – Bore × Stroke mm 6 – 140 × 165
Total displacement l{cc} 15.2 {15,230}
Firing order — 1–5–3–6–2–4
Overall length mm 1,477
Dimensions

Overall width mm 1,109


Overall height (excluding exhaust pipe) mm 1,157
Overall height (including exhaust pipe) mm 1,950
kW{HP}/ 268 {359.9}/1,900 {1,900}
Rated horsepower
min-1{rpm} (Gross)
Nm{kgm}/ 1,834 {187}/1,300 {1,300}
Max. torque
Performance

min-1{rpm} (Gross)
Max. speed with no load
min-1{rpm} 2,100 (0/–50) {2,100 (0/–50)}
(High idle speed)
Min. speed with no load
min-1{rpm} 740 (+40/0) {740 (+40/0)}
(Low idle speed)
g/kW·h
Fuel consumption ratio at rated point 215 {160}
{g/HP·h}
Dry weight kg 1,800
Fuel supply pump — DENSO ECD-U2
Governor — Electronic control type
Quantity of lubricating oil (refill capacity) l 45 (37)
Quantity of coolant l 25 (In only engine)
Alternator — 24V, 60A, 75A, 90A
Starting motor — 24V, 11kW
Battery — 12V, 170Ah × 2
Turbocharger — KOMATSU KTR110L
Air compressor — —
Others — With air-cooled aftercooler
With cooled EGR

10 140E-5 Series
01 Specification SEN00079-07

Engine name SAA6D140E-5


Machine models D155A-6
Number of cylinders – Bore × Stroke mm 6 – 140 × 165
Total displacement l{cc} 15.2 {15,230}
Firing order — 1–5–3–6–2–4
Overall length mm 1,461
Dimensions

Overall width mm 1,109


Overall height (excluding exhaust pipe) mm 1,157
Overall height (including exhaust pipe) mm 1,950
kW{HP}/ 268 {359.9}/1,900 {1,900}
Rated horsepower
min-1{rpm} (Gross)
Nm{kgm}/ 1,834 {187}/1,300 {1,300}
Max. torque
Performance

min-1{rpm} (Gross)
Max. speed with no load
min-1{rpm} 2,100 (0/–50) {2,100 (0/–50)}
(High idle speed)
Min. speed with no load
min-1{rpm} 740 (+40/0) {740 (+40/0)}
(Low idle speed)
g/kW·h
Fuel consumption ratio at rated point 215 {160}
{g/HP·h}
Dry weight kg 1,725
Fuel supply pump — DENSO ECD-U2
Governor — Electronic control type
Quantity of lubricating oil (refill capacity) l 45 (37)
Quantity of coolant l 25 (In only engine)
Alternator — 24V, 60A, 75A, 90A
Starting motor — 24V, 11kW
Battery — 12V, 170Ah × 2
Turbocharger — KOMATSU KTR110L
Air compressor — —
Others — With air-cooled aftercooler

140E-5 Series 11
SEN00079-07 01 Specification

Engine name SAA6D140E-5


Machine models D275AX-5E0
Number of cylinders – Bore × Stroke mm 6 – 140 × 165
Total displacement l{cc} 15.2 {15,230}
Firing order — 1–5–3–6–2–4
Overall length mm 1,477
Dimensions

Overall width mm 966


Overall height (excluding exhaust pipe) mm 2,020
Overall height (including exhaust pipe) mm —
kW{HP}/ 337 {451.6}/2,000 {2,000}
Rated horsepower
min-1{rpm} (Gross)
Nm{kgm}/ 2,030 {207}/1,400 {1,400}
Max. torque
Performance

min-1{rpm} (Gross)
Max. speed with no load
min-1{rpm} 2,200 ± 50 {2,200 ± 50}
(High idle speed)
Min. speed with no load
min-1{rpm} 700 ± 50 {700 ± 50}
(Low idle speed)
g/kW·h
Fuel consumption ratio at rated point 218 {162.3}
{g/HP·h}
Dry weight kg 1,869
Fuel supply pump — DENSO ECD-U2
Governor — Electronic control type
Quantity of lubricating oil (refill capacity) l 58 (50)
Quantity of coolant l 25 (In only engine)
Alternator — 24V, 75A, 90A
Starting motor — 24V, 11kW
Battery — 12V, 170Ah × 2
Turbocharger — KOMATSU KTR110L
Air compressor — —
Others — With air-cooled aftercooler
With cooled EGR

12 140E-5 Series
01 Specification SEN00079-07

Engine name SAA6D140E-5


Machine models D275A-5R
Number of cylinders – Bore × Stroke mm 6 – 140 × 165
Total displacement l{cc} 15.2 {15,230}
Firing order — 1–5–3–6–2–4
Overall length mm 1,461
Dimensions

Overall width mm 966


Overall height (excluding exhaust pipe) mm 2,020
Overall height (including exhaust pipe) mm —
kW{HP}/ 337 {451.6}/2,000 {2,000}
Rated horsepower
min-1{rpm} (Gross)
Nm{kgm}/ 2,030 {207}/1,400 {1,400}
Max. torque
Performance

min-1{rpm} (Gross)
Max. speed with no load
min-1{rpm} 2,200 ± 50 {2,200 ± 50}
(High idle speed)
Min. speed with no load
min-1{rpm} 700 ± 50 {700 ± 50}
(Low idle speed)
g/kW·h
Fuel consumption ratio at rated point 215 {160}
{g/HP·h}
Dry weight kg 1,800
Fuel supply pump — DENSO ECD-U2
Governor — Electronic control type
Quantity of lubricating oil (refill capacity) l 58 (50)
Quantity of coolant l 25 (In only engine)
Alternator — 24V, 75A, 90A
Starting motor — 24V, 11kW
Battery — 12V, 170Ah × 2
Turbocharger — KOMATSU KTR110L
Air compressor — —
Others — With air-cooled aftercooler

140E-5 Series 13
SEN00079-07 01 Specification

Engine name SAA6D140E-5


Machine models WA500-6
Number of cylinders – Bore × Stroke mm 6 – 140 × 165
Total displacement l{cc} 15.2 {15,230}
Firing order — 1–5–3–6–2–4
Overall length mm 1,477
Dimensions

Overall width mm 1,094


Overall height (excluding exhaust pipe) mm 1,435
Overall height (including exhaust pipe) mm 1,727
kW{HP}/ 266 {356.9}/1,900 {1,900}
Rated horsepower
min-1{rpm} (Gross)
Nm{kgm}/ 1,803 {184}/1,250 {1,250}
Max. torque
Performance

min-1{rpm} (Gross)
Max. speed with no load
min-1{rpm} 2,150 ± 50 {2,150 ± 50}
(High idle speed)
Min. speed with no load
min-1{rpm} 700 ± 25 {700 ± 25}
(Low idle speed)
g/kW·h
Fuel consumption ratio at rated point 216.2 {161.3}
{g/HP·h}
Dry weight kg 1,750
Fuel supply pump — DENSO ECD-U2
Governor — Electronic control type
Quantity of lubricating oil (refill capacity) l 45 (37)
Quantity of coolant l 25
Alternator — 24V, 75A, 90A
Starting motor — 24V, 11kW
Battery — 12V, 170Ah × 2
Turbocharger — KOMATSU KTR110L
Air compressor — —
Others — With air-cooled aftercooler
With cooled EGR

14 140E-5 Series
01 Specification SEN00079-07

Engine name SAA6D140E-5


Machine models WA500-6R
Number of cylinders – Bore × Stroke mm 6 – 140 × 165
Total displacement l{cc} 15.2 {15,230}
Firing order — 1–5–3–6–2–4
Overall length mm 1,461
Dimensions

Overall width mm 1,094


Overall height (excluding exhaust pipe) mm 1,435
Overall height (including exhaust pipe) mm 1,727
kW{HP}/ 266 {356.9}/1,900 {1,900}
Rated horsepower
min-1{rpm} (Gross)
Nm{kgm}/ 1,803 {184}/1,250 {1,250}
Max. torque
Performance

min-1{rpm} (Gross)
Max. speed with no load
min-1{rpm} 2,150 ± 50 {2,150 ± 50}
(High idle speed)
Min. speed with no load
min-1{rpm} 700 ± 25 {700 ± 25}
(Low idle speed)
g/kW·h
Fuel consumption ratio at rated point 211.4 {157.7}
{g/HP·h}
Dry weight kg 1,680
Fuel supply pump — DENSO ECD-U2
Governor — Electronic control type
Quantity of lubricating oil (refill capacity) l 45 (37)
Quantity of coolant l 25
Alternator — 24V, 75A, 90A
Starting motor — 24V, 11kW
Battery — 12V, 170Ah × 2
Turbocharger — KOMATSU KTR110L
Air compressor — —
Others — With air-cooled aftercooler

140E-5 Series 15
SEN00079-07 01 Specification

Engine name SAA6D140E-5


Machine models HD325-7, HD405-7
Number of cylinders – Bore × Stroke mm 6 – 140 × 165
Total displacement l{cc} 15.2 {15,230}
Firing order — 1–5–3–6–2–4
Overall length mm 1,775
Dimensions

Overall width mm 1,009


Overall height (excluding exhaust pipe) mm 1,604
Overall height (including exhaust pipe) mm —
kW{HP}/ 386 {517.7}/2,000 {2,000}
Rated horsepower
min-1{rpm} (Gross)
Nm{kgm}/ 2,170 {221.3}/1,400 {1,400}
Max. torque
Performance

min-1{rpm} (Gross)
Max. speed with no load
min-1{rpm} 2,300 ± 25 {2,300 ± 25}
(High idle speed)
Min. speed with no load
min-1{rpm} 725 ± 25 {725 ± 25}
(Low idle speed)
g/kW·h
Fuel consumption ratio at rated point 212 {158}
{g/HP·h}
Dry weight kg 1,810
Fuel supply pump — DENSO ECD-U2
Governor — Electronic control type
Quantity of lubricating oil (refill capacity) l 58 (50)
Quantity of coolant l 25 (In only engine)
Alternator — 24V, 60A, 75A
Starting motor — 24V, 11kW
Battery — 12V, 170Ah × 2
Turbocharger — KOMATSU KTR110L
Air compressor — —
Others — With air-cooled aftercooler
With cooled EGR

16 140E-5 Series
01 Specification SEN00079-07

Engine name SAA6D140E-5


Machine models HD325-7R, HD405-7R
Number of cylinders – Bore × Stroke mm 6 – 140 × 165
Total displacement l{cc} 15.2 {15,230}
Firing order — 1–5–3–6–2–4
Overall length mm 1,775
Dimensions

Overall width mm 1,009


Overall height (excluding exhaust pipe) mm 1,604
Overall height (including exhaust pipe) mm —
kW{HP}/ 386 {517.7}/2,000 {2,000}
Rated horsepower
min-1{rpm} (Gross)
Nm{kgm}/ 2,170 {221.3}/1,400 {1,400}
Max. torque
Performance

min-1{rpm} (Gross)
Max. speed with no load
min-1{rpm} 2,300 ± 25 {2,300 ± 25}
(High idle speed)
Min. speed with no load
min-1{rpm} 725 ± 25 {725 ± 25}
(Low idle speed)
g/kW·h
Fuel consumption ratio at rated point 207 {154}
{g/HP·h}
Dry weight kg 1,740
Fuel supply pump — DENSO ECD-U2
Governor — Electronic control type
Quantity of lubricating oil (refill capacity) l 58 (50)
Quantity of coolant l 25 (In only engine)
Alternator — 24V, 60A, 75A
Starting motor — 24V, 11kW
Battery — 12V, 170Ah × 2
Turbocharger — KOMATSU KTR110L
Air compressor — —
Others — With air-cooled aftercooler

140E-5 Series 17
SEN00079-07 01 Specification

Engine name SAA6D140E-5


Machine models HM350-2
Number of cylinders – Bore × Stroke mm 6 – 140 × 165
Total displacement l{cc} 15.2 {15,230}
Firing order — 1–5–3–6–2–4
Overall length mm 1,724
Dimensions

Overall width mm 1,250


Overall height (excluding exhaust pipe) mm 1,496
Overall height (including exhaust pipe) mm —
kW{HP}/ 304 {407.2}/2,000 {2,000}
Rated horsepower
min-1{rpm} (Gross)
Nm{kgm}/ 1,991 {203}/1,400 {1,400}
Max. torque
Performance

min-1{rpm} (Gross)
Max. speed with no load
min-1{rpm} 2,200 (+50/0) {2,200 (+50/0)}
(High idle speed)
Min. speed with no load
min-1{rpm} 725 ± 25 {725 ± 25}
(Low idle speed)
g/kW·h
Fuel consumption ratio at rated point 223 {166}
{g/HP·h}
Dry weight kg 1,820
Fuel supply pump — DENSO ECD-U2
Governor — Electronic control type
Quantity of lubricating oil (refill capacity) l 58 (50)
Quantity of coolant l 25 (In only engine)
Alternator — 24V, 60A, 75A
Starting motor — 24V, 11kW
Battery — 12V 170Ah × 2
Turbocharger — KOMATSU KTR110L
Air compressor — —
Others — With air-cooled aftercooler
With cooled EGR

18 140E-5 Series
01 Specification SEN00079-07

Engine name SAA6D140E-5


Machine models HM350-2R
Number of cylinders – Bore × Stroke mm 6 – 140 × 165
Total displacement l{cc} 15.2 {15,230}
Firing order — 1–5–3–6–2–4
Overall length mm 1,724
Dimensions

Overall width mm 1,250


Overall height (excluding exhaust pipe) mm 1,496
Overall height (including exhaust pipe) mm —
kW{HP}/ 304 {407.2}/2,000 {2,000}
Rated horsepower
min-1{rpm} (Gross)
Nm{kgm}/ 1,991 {203}/1,400 {1,400}
Max. torque
Performance

min-1{rpm} (Gross)
Max. speed with no load
min-1{rpm} 2,200 (+50/0) {2,200 (+50/0)}
(High idle speed)
Min. speed with no load
min-1{rpm} 725 ± 25 {725 ± 25}
(Low idle speed)
g/kW·h
Fuel consumption ratio at rated point 222 {165}
{g/HP·h}
Dry weight kg 1,750
Fuel supply pump — DENSO ECD-U2
Governor — Electronic control type
Quantity of lubricating oil (refill capacity) l 58 (50)
Quantity of coolant l 25 (In only engine)
Alternator — 24V, 60A, 75A
Starting motor — 24V, 11kW
Battery — 12V 170Ah × 2
Turbocharger — KOMATSU KTR110L
Air compressor — —
Others — With air-cooled aftercooler

140E-5 Series 19
SEN00079-07 01 Specification

Engine name SAA6D140E-5


Machine models HM400-2, HM400-3M0
Number of cylinders – Bore × Stroke mm 6-140 × 165
Total displacement l{cc} 15.2 {15,230}
Firing order — 1–5–3–6–2–4
Overall length mm 1,724
Dimensions

Overall width mm 1,250


Overall height (excluding exhaust pipe) mm 1,496
Overall height (including exhaust pipe) mm —
kW{HP}/ 338 {452.6}/2,000 {2,000}
Rated horsepower
min-1{rpm} (Gross)
Nm{kgm}/ 2,089 {213}/1,400 {1,400}
Max. torque
Performance

min-1{rpm} (Gross)
Max. speed with no load
min-1{rpm} 2,200 (+50/0) {2,200 (+50/0)}
(High idle speed)
Min. speed with no load
min-1{rpm} 725 ± 25 {725 ± 25}
(Low idle speed)
g/kW·h
Fuel consumption ratio at rated point 213 {159}
{g/HP·h}
Dry weight kg 1,820
Fuel supply pump — DENSO ECD-U2
Governor — Electronic control type
Quantity of lubricating oil (refill capacity) l 58 (50)
Quantity of coolant l 25 (In only engine)
Alternator — 24V, 60A, 75A
Starting motor — 24V, 11kW
Battery — 12V, 170Ah × 2
Turbocharger — KOMATSU KTR110L
Air compressor — —
Others — With air-cooled aftercooler
With cooled EGR

20 140E-5 Series
01 Specification SEN00079-07

Engine name SAA6D140E-5


Machine models HM400-2R, HM400-3R
Number of cylinders – Bore × Stroke mm 6-140 × 165
Total displacement l{cc} 15.2 {15,230}
Firing order — 1–5–3–6–2–4
Overall length mm 1,724
Dimensions

Overall width mm 1,250


Overall height (excluding exhaust pipe) mm 1,496
Overall height (including exhaust pipe) mm —
kW{HP}/ 338 {452.6}/2,000 {2,000}
Rated horsepower
min-1{rpm} (Gross)
Nm{kgm}/ 2,089 {213}/1,400 {1,400}
Max. torque
Performance

min-1{rpm} (Gross)
Max. speed with no load
min-1{rpm} 2,200 (+50/0) {2,200 (+50/0)}
(High idle speed)
Min. speed with no load
min-1{rpm} 725 ± 25 {725 ± 25}
(Low idle speed)
g/kW·h
Fuel consumption ratio at rated point 218 {162}
{g/HP·h}
Dry weight kg 1,750
Fuel supply pump — DENSO ECD-U2
Governor — Electronic control type
Quantity of lubricating oil (refill capacity) l 58 (50)
Quantity of coolant l 25 (In only engine)
Alternator — 24V, 60A, 75A
Starting motor — 24V, 11kW
Battery — 12V, 170Ah × 2
Turbocharger — KOMATSU KTR110L
Air compressor — —
Others — With air-cooled aftercooler

140E-5 Series 21
SEN00079-07 01 Specification

Engine name SAA6D140E-5


SDG400S-6B1
Machine models
(HOKUETSU INDUSTRIES GENERATOR)
Number of cylinders – Bore × Stroke mm 6 – 140 × 165
Total displacement l{cc} 15.2 {15,230}
Firing order — 1–5–3–6–2–4
Overall length mm 1,785
Dimensions

Overall width mm 1,242


Overall height (excluding exhaust pipe) mm 1,523
Overall height (including exhaust pipe) mm —
kW{HP}/ 357 {478}/1,800 {1,800}
Rated horsepower
min-1{rpm} (Net)
Nm{kgm}/ —
Max. torque
Performance

min-1{rpm} —
Max. speed with no load
min-1{rpm} —
(High idle speed)
Min. speed with no load
min-1{rpm} —
(Low idle speed)
g/kW·h
Fuel consumption ratio at rated point 222 {163}
{g/HP·h}
Dry weight kg 1,950
Fuel supply pump — DENSO ECD-U2
Governor — Electronic control type
Quantity of lubricating oil (refill capacity) l 82 (73)
Quantity of coolant (with radiator) l 53
Alternator — 24V, 35A
Starting motor — 24V, 7.5kW
Battery — —
Turbocharger — KOMATSU KTR110L
Air compressor — —
Others — With air-cooled aftercooler
With cooled EGR

22 140E-5 Series
01 Specification SEN00079-07

140E-5 Series 23
SEN00079-07 01 Specification

General view 1
SAA6D140E-5 (Left side view of engine)
Machine model: PC600-8, PC600LC-8

a The shape is subject to machine models.

1. Center of crankshaft
2. Rear face of flywheel housing

24 140E-5 Series
01 Specification SEN00079-07

SAA6D140E-5 (Front view of engine)


Machine model: PC600-8, PC600LC-8

a The shape is subject to machine models.

1. Center of crankshaft
2. Center of cylinder liner

140E-5 Series 25
SEN00079-07 01 Specification

SAA6D140E-5 (Left side view of engine)


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

a The shape is subject to machine models.


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

1. Center of crankshaft
2. Rear face of flywheel housing

26 140E-5 Series
01 Specification SEN00079-07

SAA6D140E-5 (Front view of engine)


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

a The shape is subject to machine models.


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

1. Center of crankshaft
2. Center of cylinder liner

140E-5 Series 27
SEN00079-07 01 Specification

SAA6D140E-5 (Left side view of engine)


Machine model: PC600-8E0, PC600LC-8E0, PC700-8E0, PC700LC-8E0

a The shape is subject to machine models.

1. Center of crankshaft
2. Rear face of flywheel housing

28 140E-5 Series
01 Specification SEN00079-07

SAA6D140E-5 (Front view of engine)


Machine model: PC600-8E0, PC600LC-8E0, PC700-8E0, PC700LC-8E0

a The shape is subject to machine models.

1. Center of crankshaft
2. Center of cylinder liner

140E-5 Series 29
SEN00079-07 01 Specification

SAA6D140E-5 (Left side view of engine)


Machine model: PC600-8R1, PC600LC-8R1,
PC700-8R, PC700LC-8R, PC700LC-8R1

a The shape is subject to machine models.

1. Center of crankshaft
2. Rear face of flywheel housing

30 140E-5 Series
01 Specification SEN00079-07

SAA6D140E-5 (Front view of engine)


Machine model: PC600-8R1, PC600LC-8R1,
PC700-8R, PC700LC-8R, PC700LC-8R1

a The shape is subject to machine models.

1. Center of crankshaft
2. Center of cylinder liner

140E-5 Series 31
SEN00079-07 01 Specification

SAA6D140E-5 (Left side view of engine)


Machine model: PC800-8, PC800SE-8, PC800LC-8, PC850-8, PC850SE-8
PC800-8E0, PC800SE-8E0, PC800LC-8E0, PC850-8E0, PC850SE-8E0

a The shape is subject to machine models.

1. Center of crankshaft
2. Rear face of flywheel housing

32 140E-5 Series
01 Specification SEN00079-07

SAA6D140E-5 (Front view of engine)


Machine model: PC800-8, PC800SE-8, PC800LC-8, PC850-8, PC850SE-8
PC800-8E0, PC800SE-8E0, PC800LC-8E0, PC850-8E0, PC850SE-8E0

a The shape is subject to machine models.

1. Center of crankshaft
2. Center of cylinder liner

140E-5 Series 33
SEN00079-07 01 Specification

SAA6D140E-5 (Left side view of engine)


Machine model: PC800-8R, PC800SE-8R, PC800LC-8R, PC850-8R, PC850SE-8R

a The shape is subject to machine models.

1. Center of crankshaft
2. Rear face of flywheel housing

34 140E-5 Series
01 Specification SEN00079-07

SAA6D140E-5 (Front view of engine)


Machine model: PC800-8R, PC800SE-8R, PC800LC-8R, PC850-8R, PC850SE-8R

a The shape is subject to machine models.

1. Center of crankshaft
2. Center of cylinder liner

140E-5 Series 35
SEN00079-07 01 Specification

SAA6D140E-5 (Left side view of engine)


Machine model: PC800-8R1, PC800SE-8R1, PC800LC-8R1, PC850-8R1,
PC850SE-8R1

a The shape is subject to machine models.

1. Center of crankshaft
2. Rear face of flywheel housing

36 140E-5 Series
01 Specification SEN00079-07

SAA6D140E-5 (Front view of engine)


Machine model: PC800-8R1, PC800SE-8R1, PC800LC-8R1, PC850-8R1,
PC850SE-8R1

a The shape is subject to machine models.

1. Center of crankshaft
2. Center of cylinder liner

140E-5 Series 37
SEN00079-07 01 Specification

SAA6D140E-5 (Left side view of engine)


Machine model: D275AX-5E0

a The shape is subject to machine models.

1. Center of crankshaft
2. Rear face of flywheel housing

38 140E-5 Series
01 Specification SEN00079-07

SAA6D140E-5 (Front view of engine)


Machine model: D275AX-5E0

a The shape is subject to machine models.

1. Center of crankshaft
2. Center of cylinder liner

140E-5 Series 39
SEN00079-07 01 Specification

SAA6D140E-5 (Left side view of engine)


Machine model: D275A-5R

a The shape is subject to machine models.

1. Center of crankshaft
2. Rear face of flywheel housing

40 140E-5 Series
01 Specification SEN00079-07

SAA6D140E-5 (Front view of engine)


Machine model: D275A-5R

a The shape is subject to machine models.

1. Center of crankshaft
2. Center of cylinder liner

140E-5 Series 41
SEN00079-07 01 Specification

SAA6D140E-5 (Left side view of engine)


Machine model: WA500-6

a The shape is subject to machine models.

1. Center of crankshaft
2. Rear face of flywheel housing

42 140E-5 Series
01 Specification SEN00079-07

SAA6D140E-5 (Front view of engine)


Machine model: WA500-6

a The shape is subject to machine models.

1. Center of crankshaft
2. Center of cylinder liner

140E-5 Series 43
SEN00079-07 01 Specification

SAA6D140E-5 (Left side view of engine)


Machine model: WA500-6R

a The shape is subject to machine models.

1. Center of crankshaft
2. Rear face of flywheel housing

44 140E-5 Series
01 Specification SEN00079-07

SAA6D140E-5 (Front view of engine)


Machine model: WA500-6R

a The shape is subject to machine models.

1. Center of crankshaft
2. Center of cylinder liner

140E-5 Series 45
SEN00079-07 01 Specification

SAA6D140E-5 (Left side view of engine)


Machine model: HD325-7, HD405-7

a The shape is subject to machine models.

1. Center of crankshaft
2. Rear face of flywheel housing

46 140E-5 Series
01 Specification SEN00079-07

SAA6D140E-5 (Front view of engine)


Machine model: HD325-7, HD405-7

a The shape is subject to machine models.

1. Center of crankshaft
2. Center of cylinder liner

140E-5 Series 47
SEN00079-07 01 Specification

SAA6D140E-5 (Left side view of engine)


Machine model: HD325-7R, HD405-7R

a The shape is subject to machine models.

1. Center of crankshaft
2. Rear face of flywheel housing

48 140E-5 Series
01 Specification SEN00079-07

SAA6D140E-5 (Front view of engine)


Machine model: HD325-7R, HD405-7R

a The shape is subject to machine models.

1. Center of crankshaft
2. Center of cylinder liner

140E-5 Series 49
SEN00079-07 01 Specification

SAA6D140E-5 (Left side view of engine)


Machine model: HM350-2, HM400-2

a The shape is subject to machine models.

1. Center of crankshaft
2. Rear face of flywheel housing

50 140E-5 Series
01 Specification SEN00079-07

SAA6D140E-5 (Front view of engine)


Machine model: HM350-2, HM400-2

a The shape is subject to machine models.

1. Center of crankshaft
2. Center of cylinder liner

140E-5 Series 51
SEN00079-07 01 Specification

SAA6D140E-5 (Left side view of engine)


Machine model: HM350-2R, HM400-2R

a The shape is subject to machine models.

1. Center of crankshaft
2. Rear face of flywheel housing

52 140E-5 Series
01 Specification SEN00079-07

SAA6D140E-5 (Front view of engine)


Machine model: HM350-2R, HM400-2R

a The shape is subject to machine models.

1. Center of crankshaft
2. Center of cylinder liner

140E-5 Series 53
SEN00079-07 01 Specification

SAA6D140E-5 (Left side view of engine)


Machine model: HM400-3M0

a The shape is subject to machine models.

1. Center of crankshaft
2. Rear face of flywheel housing

54 140E-5 Series
01 Specification SEN00079-07

SAA6D140E-5 (Front view of engine)


Machine model: HM400-3M0

a The shape is subject to machine models.

1. Center of crankshaft
2. Center of cylinder liner

140E-5 Series 55
SEN00079-07 01 Specification

SAA6D140E-5 (Left side view of engine)


Machine model: HM400-3R

a The shape is subject to machine models.

1. Center of crankshaft
2. Rear face of flywheel housing

56 140E-5 Series
01 Specification SEN00079-07

SAA6D140E-5 (Front view of engine)


Machine model: HM400-3R

a The shape is subject to machine models.

1. Center of crankshaft
2. Center of cylinder liner

140E-5 Series 57
SEN00079-07 01 Specification

SAA6D140E-5 (Left side view of engine)


Machine model: SDG400S-6B1 (HOKUETSU INDUSTRIES GENERATOR)

a The shape is subject to machine models.

1. Center of crankshaft
2. Rear face of flywheel housing

58 140E-5 Series
01 Specification SEN00079-07

SAA6D140E-5 (Front view of engine)


Machine model: SDG400S-6B1 (HOKUETSU INDUSTRIES GENERATOR)

a The shape is subject to machine models.

1. Center of crankshaft
2. Center of cylinder liner

140E-5 Series 59
SEN00079-07 01 Specification

Dimensions table 1
Unit: mm
Dimension of each part
Engine Machine model
A B C D E F G H
PC600-8, PC600LC-8 1,494 1,863 441 227 143 920 1,155 1,151
PC600-8E0, PC600LC-8E0
1,412 1,867 444 227 143 920 1,155 1,061
PC700-8E0, PC700LC-8E0
PC600-8R, PC600LC-8R
PC600-8R1, PC600LC-8R1,
1,482 1,863 411 227 143 920 1,155 1,151
PC700-8R, PC700LC-8R
PC700LC-8R1
PC800-8, PC800LC-8,
PC800SE-8,
PC850-8, PC850SE-8,
PC800-8E0,
PC800LC-8E0,
PC800SE-8E0,
PC850-8E0,
1,350 1,902 594 196 196 1,000 1,185 1,176
PC850SE-8E0,
PC800-8R, PC800LC-8R,
PC800SE-8R,
PC850-8R, PC850SE-8R
SAA6D140E-5 PC800-8R1, PC800LC-8R1,
PC800SE-8R1,
PC850-8R1, PC850SE-8R1
D155AX-6, D155A-6 1,477 1,950 419 14 14 918 1,090 1,109
D275AX-5E0 1,505 2,178 542 15 15 794 966 1,135
D275A-5R 1,461 2,178 542 15 15 794 966 1,180
WA500-6 1,477 1,727 419 150 150 815 945 1,094
WA500-6R 1,465 1,727 419 150 150 815 945 1,094
HD325-7, HD405-7,
1,775 1,604 542 80 80 875 1,005 1,025
HD325-7R, HD405-7R
HM350-2, HM350-2R,
1,724 1,496 542 147 147 815 945 1,250
HM400-2, HM400-2R
HM400-3M0 1,477 1,509 542 147 147 815 945 1,112
HM400-3R 1,451 1,509 542 147 147 815 945 1,112
SDG400S-6B1
(HOKUETSU INDUS- 1,785 1,523 403 213 213 877 956 1,242
TRIES GENERATOR)
a These dimensions are given for reference when the engine is set on a test bench.

60 140E-5 Series
01 Specification SEN00079-07

Weight table 1
(With EGR)
Unit: kg
No. Item Main parts SAA6D140E-5
24 (Air-cooled) /
1 Turbocharger KOMATSU KTR110L
28 (Water-cooled)
Cylinder head, valve,
2 Cylinder head assembly 23 × 6
valve spring
Cylinder block, bearing, cap,
3 Cylinder block assembly 480
cylinder liner
4 Front cover 60
PC800-8, PC800SE-8, PC800LC-8
PC850-8, PC850SE-8
PC800-8E0, PC800SE-8E0, 36
PC800LC-8E0
PC850-8E0, PC850SE-8E0
PC600-8, PC600LC-8
PC600-8E0, PC600LC-8E0
PC700-8E0, PC700LC-8E0 30
5 Oil pan D155AX-6
WA500-6
D275AX-5E0
HD325-7, HD405-7
28
HM350-2, HM400-2
HM400-3M0
SDG400S-6B1 (HOKUETSU
62
INDUSTRIES GENERATOR)
PC600-8, PC600LC-8
PC800-8, PC800SE-8, PC800LC-8
PC850-8, PC850SE-8
PC800-8E0, PC800SE-8E0,
PC800LC-8E0 60
PC850-8E0, PC850SE-8E0
D155AX-6
6 Flywheel assembly Flywheel ring gear D275AX-5E0
WA500-6
HD325-7, HD405-7
HM350-2, HM400-2 47
HM400-3M0
SDG400S-6B1 (HOKUETSU
123
INDUSTRIES GENERATOR)
65
7 Flywheel housing assembly SDG400S-6B1 (HOKUETSU
63
INDUSTRIES GENERATOR)
8 Crankshaft assembly Crankshaft, crank gear 136
Camshaft, cam gear, thrust
9 Camshaft assembly 20
plate
Piston and connecting rod Piston, piston ring, piston
10 11 × 6
assembly pin, connecting rod
11 Oil pump 7
12 Fuel supply pump 13
13 Water pump 18

140E-5 Series 61
SEN00079-07 01 Specification

Unit: kg
No. Item Main parts SAA6D140E-5
24V, 35A 8
24V, 50A 11
14 Alternator 24V, 60A 11
24V, 75A 12.5
24V, 90A 19
24V, 7.5kW 15.5
15 Starting motor
24V, 11kW 18
16 EGR oil pump 6
17 EGR valve 10
18 Bypass valve 10
19 EGR cooler 10

62 140E-5 Series
01 Specification SEN00079-07

(EGR-less)
Unit: kg
No. Item Main parts SAA6D140E-5
24 (Air-cooled) /
1 Turbocharger KOMATSU KTR110L
28 (Water-cooled)
Cylinder head, valve,
2 Cylinder head assembly 23 × 6
valve spring
Cylinder block, bearing, cap,
3 Cylinder block assembly 480
cylinder liner
4 Front cover 60
PC800-8R, PC800SE-8R,
PC800LC-8R
PC850-8R, PC850SE-8R
36
PC800-8R1, PC800SE-8R1
PC800LC-8R1
PC850-8R1, PC850SE-8R1
PC600-8R, PC600LC-8R
PC600-8R1, PC600LC-8R1
5 Oil pan
PC700-8R, PC700LC-8R
30
PC700LC-8R1
D155A-6
WA500-6R
D275A-5R
HD325-7R, HD405-7R
28
HM350-2R, HM400-2R
HM400-3R
PC600-8R, PC600LC-8R
PC600-8R1, PC600LC-8R1
PC700LC-8R1
PC800-8R, PC800SE-8R,
PC800LC-8R
PC850-8R, PC850SE-8R
60
PC800-8R1, PC800SE-8R1
6 Flywheel assembly Flywheel ring gear PC800LC-8R1
PC850-8R1, PC850SE-8R1
D155A-6
D275A-5R
WA500-6R
HD325-7R, HD405-7R
HM350-2R, HM400-2R 47
HM400-3R
7 Flywheel housing assembly 65
8 Crankshaft assembly Crankshaft, crank gear 136
Camshaft, cam gear,
9 Camshaft assembly 20
thrust plate
Piston and connecting rod Piston, piston ring, piston pin,
10 11 × 6
assembly connecting rod
11 Oil pump 7
12 Fuel supply pump 13
13 Water pump 18

140E-5 Series 63
SEN00079-07 01 Specification

Unit: kg
No. Item Main parts SAA6D140E-5
24V, 35A 8
24V, 50A 11
14 Alternator 24V, 60A 11
24V, 75A 12.5
24V, 90A 19
15 Starting motor 24V, 11kW 18

64 140E-5 Series
01 Specification SEN00079-07

Engine performance curves 1

Engine Engine serial No. Machine model Page


PC600-8, PC600-8R,
PC600LC-8, PC600LC-8R
PC600-8E0, PC600-8R1,
PC600LC-8E0, PC600LC-8R1, 66
PC700-8E0, PC700LC-8E0,
PC700-8R, PC700LC-8R,
PC700LC-8R1
PC800-8, PC800LC-8,
PC800-8R, PC800LC-8R
PC800SE-8, PC800SE-8R
PC850-8, PC850-8R
PC850SE-8, PC850SE-8R
PC800-8E0, PC800SE-8E0, 67
SAA6D140E-5 PC800LC-8E0,
PC850-8E0, PC850SE-8E0
PC800-8R1, PC800SE-8R1
PC800LC-8R1
PC850-8R1, PC850SE-8R1
D155AX-6, D155A-6 68
D275AX-5E0, D275A-5R 69
WA500-6, WA500-6R 70
HD325-7, HD325-7R
71
HD405-7, HD405-7R
HM350-2, HM350-2R 72
HM400-2, HM400-2R
73
HM400-3M0, HM400-3R

140E-5 Series 65
SEN00079-07 01 Specification

SAA6D140E-5
(Machine model: PC600-8, PC600LC-8, PC600-8R, PC600LC-8R, PC600-
8E0, PC600LC-8E0, PC600-8R1, PC600LC-8R1, PC700-8E0, PC700LC-8E0,
PC700-8R, PC700LC-8R, PC700LC-8R1)
Rated horsepower: 323 kW {433.3 HP}/1,800 min-1 {1,800 rpm} (Gross)
Max. torque: 1,944 Nm {198.4 kgm}/1,400 min-1 {1,400 rpm} (Gross)

66 140E-5 Series
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, PC800-
8R1, PC800SE-8R1, PC800LC-8R1, PC850-8R1, PC850SE-8R1)
Rated horsepower: 370 kW {496.4 HP}/1,800 min-1 {1,800 rpm} (Gross)
Max. torque: 2,195 Nm {223.8 kgm}/1,350 min-1 {1,350 rpm} (Gross)

140E-5 Series 67
SEN00079-07 01 Specification

SAA6D140E-5 (Machine model: D155AX-6, D155A-6)


Rated horsepower: 268 kW {359.9 HP}/1,900 min-1 {1,900 rpm} (Gross)
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)


Rated horsepower: 337 kW {451.6 HP}/2,000 min-1 {2,000 rpm} (Gross)
Max. torque: 2,030 Nm {207 kgm}/1,400 min-1 {1,400 rpm} (Gross)

140E-5 Series 69
SEN00079-07 01 Specification

SAA6D140E-5 (Machine model: WA500-6, WA500-6R)


Rated horsepower: 266 kW {356.9 HP}/1,900 min-1 {1,900 rpm} (Gross)
Max. torque: 1,803 Nm {184 kgm}/1,250 min-1 {1,250 rpm} (Gross)

70 140E-5 Series
01 Specification SEN00079-07

SAA6D140E-5 (Machine model: HD325-7, HD405-7, HD325-7R, HD405-7R)


Rated horsepower: 386 kW {517.7 HP}/2,000 min-1 {2,000 rpm} (Gross)
Max. torque: 2,170 Nm {221.3 kgm}/1,400 min-1 {1,400 rpm} (Gross)

140E-5 Series 71
SEN00079-07 01 Specification

SAA6D140E-5 (Machine model: HM350-2, HM350-2R)


Rated horsepower: 304 kW {407.2 HP}/2,000 min-1 {2,000 rpm} (Gross)
Max. torque: 1,991 Nm {203 kgm}/1,400 min-1 {1,400 rpm} (Gross)

72 140E-5 Series
01 Specification SEN00079-07

SAA6D140E-5
(Machine model: HM400-2, HM400-2R, HM400-3M0, HM400-3R)
Rated horsepower: 338 kW {452.6 HP}/2,000 min-1 {2,000 rpm} (Gross)
Max. torque: 2,089 Nm {213 kgm}/1,400 min-1 {1,400 rpm} (Gross)

140E-5 Series 73
SEN00079-07

KOMATSU 140E-5 Series engine

Form No. SEN00079-07

© 2012 KOMATSU
All Rights Reserved
Printed in Japan 12-12 (01)

74
SEN00081-08

ENGINE 1SHOP MANUAL

140E-5 Series

10 Structure, function and


maintenance standard 1
Structure, function and maintenance
standard, Part 1
Air intake and exhaust unit.............................................................................................................................. 3
Air cleaner....................................................................................................................................................... 5
Turbocharger................................................................................................................................................... 8
Aftercooler..................................................................................................................................................... 19
Muffler ........................................................................................................................................................... 20
EGR system.................................................................................................................................................. 25
Cylinder head................................................................................................................................................ 32
Cylinder block ............................................................................................................................................... 36
Cylinder liner ................................................................................................................................................. 39
Main moving parts......................................................................................................................................... 40
Crankshaft..................................................................................................................................................... 42

140E-5 Series 1
SEN00081-08 10 Structure, function and maintenance standard

Camshaft....................................................................................................................................................... 43
Cam follower and push rod ........................................................................................................................... 44
Piston, piston ring and piston pin .................................................................................................................. 46
Connecting rod.............................................................................................................................................. 48
Flywheel and flywheel housing ..................................................................................................................... 49
Vibration damper ........................................................................................................................................... 52
Timing gear ................................................................................................................................................... 54
Valve system ................................................................................................................................................. 58
Valve and valve guide ................................................................................................................................... 60
Rocker arm and shaft.................................................................................................................................... 62
Crosshead and guide .................................................................................................................................... 63

2 140E-5 Series
10 Structure, function and maintenance standard SEN00081-08

Air intake and exhaust unit 1


SAA6D140E-5 (Left side view of engine)

a The above illustration shows the engine for PC600-8.

A: Air intake unit (Between air-cooled aftercooler and air intake manifold)

1. Electrical intake air heater (ribbon heater)


2. Diffuser
3. Air intake manifold

140E-5 Series 3
SEN00081-08 10 Structure, function and maintenance standard

SAA6D140E-5 (Right side view of engine)

a The above illustration shows the engine for PC600-8.

A: To EGR cooler
B: To turbocharger
C: From bypass valve

1. Exhaust manifold (rear)


2. Exhaust manifold (center)
3. Exhaust manifold (front)

4 140E-5 Series
10 Structure, function and maintenance standard SEN00081-08

Air cleaner 1
ERB type
[Air cleaner of automatic exhaust gas discharge type (radial seal type)]

a The shape is subject to machine models.

A: Air inlet
B: To turbocharger (intake air)
C: To muffler (dust)

1. Pre-cleaner
2. Air cleaner casing
3. Outer element
4. Inner element

Machine Method of discharging


Engine Type Number of elements
model dust from pre-cleaner
D155AX-6,
D155A-6, Komaclone, multi-cyclone Automatic discharge Inner cylinder: 1,
SAA6D140E-5
D275AX-5E0 (ERB type) (Exhaust ejector) Outer cylinder: 1
D275A-5R

140E-5 Series 5
SEN00081-08 10 Structure, function and maintenance standard

FRG type
[Air cleaner of cyclone pack type with evacuator valve (radial seal type)]

a The shape is subject to machine models.

1. Inlet
2. Outlet
3. Guide vane
4. Primary element
5. Safety element
6. Evacuator valve
7. Dust pan
8. Guide plate (sleeve)
9. Body
10. Element

6 140E-5 Series
10 Structure, function and maintenance standard SEN00081-08

Number of
Engine Machine model Type Evacuator valve
elements
PC600-8, PC600-8R,
PC600LC-8, PC600LC-8R
PC600-8E0, PC600-8R1,
PC600LC-8E0, PC600LC-8R1,
PC700-8E0, PC700LC-8E0,
PC700-8R, PC700LC-8R,
PC700LC-8R1
PC800-8, PC800LC-8,
PC800-8R, PC800LC-8R
PC800SE-8, PC800SE-8R
PC850-8, PC850-8R
PC850SE-8, PC850SE-8R FRG Automatic Inner cylinder: 1,
SAA6D140E-5
PC800-8E0, PC800LC-8E0, (radial seal type) discharge Outer cylinder: 1
PC800SE-8E0, PC850-8E0,
PC850SE-8E0
PC800-8R1, PC800LC-8R1,
PC800SE-8R1, PC850-8R1,
PC850SE-8R1
WA500-6, WA500-6R
HD325-7, HD325-7R
HD405-7, HD405-7R
HM350-2, HM350-2R,
HM400-2, HM400-2R
HM400-3M0, HM400-3R

Structure Operation
q The size of the body is reduced from the con- q Air containing dust is sucked in vertically
ventional type without changing the diameter through inlet (1) and the dust is separated by
of the element. the centrifugal effect of guide vane (3).
q Since the inlet is set in the tangential direction, q More than 99.9% of the dust is removed by pri-
air is given sufficient centrifugal force by the mary element (4) and clean air is sucked in the
simple spiral guide vane, not by the guide engine through safety element (5) and outlet
plate. (2).
q The dust and water separated by guide vane
(3) swirl along the inside wall of body (9) and
enter evacuator valve (6) and then are dis-
charged out automatically.

140E-5 Series 7
SEN00081-08 10 Structure, function and maintenance standard

Turbocharger 1
(With EGR)

Air-cooled type
Model: KTR110L
PC600-8, PC600LC-8, PC600-8E0, PC600LC-8E0, PC700-8E0, PC700LC-8E0, HD325-7, HD405-7,
WA500-6, HM350-2, HM400-2, HM400-3M0,
SDG400S-6B1 (HOKUETSU INDUSTRIES GENERATOR)

8 140E-5 Series
10 Structure, function and maintenance standard SEN00081-08

A: Intake air inlet


B: Intake air outlet
C: Exhaust gas inlet
D: Exhaust gas outlet
E: Oil inlet
F: Oil outlet

1. Blower housing
2. V-band
3. Diffuser plate
4. Center housing
5. Shroud
6. Turbine housing
7. Blower impeller
8. Seal ring
9. Bearing metal
10. Journal bearing
11. Seal ring
12. Turbine impeller

Specifications
Model: KOMATSU KTR110L (air-cooled)
Overall length: 308 mm
Overall width: 305 mm
Overall height: 287 mm
Weight: 24 kg

140E-5 Series 9
SEN00081-08 10 Structure, function and maintenance standard

(EGR-less)

Air-cooled type
Model: KTR110L
PC600-8R, PC600-8R1, PC600LC-8R, PC600LC-8R1, PC700-8R, PC700LC-8R, PC700LC-8R1, HD325-
7R, HD405-7R, WA500-6R, HM350-2R, HM400-2R, HM400-3R

10 140E-5 Series
10 Structure, function and maintenance standard SEN00081-08

A: Intake air inlet


B: Intake air outlet
C: Exhaust gas inlet
D: Exhaust gas outlet
E: Oil inlet
F: Oil outlet

1. Blower housing
2. V-band
3. Diffuser plate
4. Center housing
5. Shroud
6. Turbine housing
7. Blower impeller
8. Seal ring
9. Bearing metal
10. Journal bearing
11. Seal ring
12. Turbine impeller

Specifications
Model: KOMATSU KTR110L (air-cooled)
Overall length: 308 mm
Overall width: 305 mm
Overall height: 287 mm
Weight: 24 kg

140E-5 Series 11
SEN00081-08 10 Structure, function and maintenance standard

(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
10 Structure, function and maintenance standard SEN00081-08

A: Intake air inlet


B: Intake air outlet
C: Exhaust gas inlet
D: Exhaust gas outlet
E: Oil inlet
F: Oil outlet
G: Coolant

1. Blower housing
2. V-band
3. Diffuser plate
4. Center housing
(water-cooled center housing: standard for D275AX, D155AX and PC800, and
optional for other machine models)
5. Shroud
6. Turbine housing
7. Blower impeller
8. Seal ring
9. Bearing metal
10. Journal bearing
11. Seal ring
12. Turbine impeller

Specifications
Model: KOMATSU KTR110L (water-cooled)
Overall length: 308 mm
Overall width: 305 mm
Overall height: 287 mm
Weight: 28 kg

140E-5 Series 13
SEN00081-08 10 Structure, function and maintenance standard

(EGR-less)

Water-cooled type
Model: KTR110L
PC800-8R, PC800LC-8R, PC800SE-8R, PC850-8R, PC850SE-8R, PC800-8R1, PC800LC-8R1, PC800SE-
8R1, PC850-8R1, PC850SE-8R1, D155A-6, D275A-5R

14 140E-5 Series
10 Structure, function and maintenance standard SEN00081-08

A: Intake air inlet


B: Intake air outlet
C: Exhaust gas inlet
D: Exhaust gas outlet
E: Oil inlet
F: Oil outlet
G: Coolant

1. Blower housing
2. V-band
3. Diffuser plate
4. Center housing
(water-cooled center housing: standard for D275A, D155A and PC800, and
optional for other machine models)
5. Shroud
6. Turbine housing
7. Blower impeller
8. Seal ring
9. Bearing metal
10. Journal bearing
11. Seal ring
12. Turbine impeller

Specifications
Model: KOMATSU KTR110L (water-cooled)
Overall length: 308 mm
Overall width: 305 mm
Overall height: 287 mm
Weight: 28 kg

140E-5 Series 15
SEN00081-08 10 Structure, function and maintenance standard

Model: KTR110L

a The above illustration shows the air-cooled turbocharger.

16 140E-5 Series
10 Structure, function and maintenance standard SEN00081-08

Unit: mm

No. Check item Criteria Remedy


Standard Repair limit Replace thrust
1 End play (play in axial direction)
0.08 to 0.13 0.18 parts

Replace bearing
2 Radial play (play in radial direction) 0.43 to 0.68 0.84
parts
Clearance between blower housing and Replace bearing
3 Clearance limit (min.): 0.14
impeller parts

140E-5 Series 17
SEN00081-08 10 Structure, function and maintenance standard

Turbocharger mounting

a The above illustration shows the engine for PC600-8.


a The shape is subject to machine models.

A: Intake air inlet


B: Intake air (between turbocharger and air-cooled aftercooler)

1. Muffler
2. Turbocharger

18 140E-5 Series
10 Structure, function and maintenance standard SEN00081-08

Aftercooler 1
Air-cooled type
SAA6D140E-5 (HD325-7, HD325-7R, HD405-7, HD405-7R)

a The shape is subject to machine models.

a. Inlet/Outlet of intake air


(between turbocharger and air intake manifold)

1. Tank
2. Side support
3. Tube
4. Fin

140E-5 Series 19
SEN00081-08 10 Structure, function and maintenance standard

Muffler 1
For PC600-8, PC600-8R, PC600LC-8, PC600LC-8R, PC600-8E0, PC600-8R1, PC600LC-8E0, PC600LC-
8R1, PC700-8E0, PC700-8R,PC700LC-8E0, PC700LC-8R, PC700LC-8R1

A: Exhaust gas inlet (from turbocharger)


B: Exhaust gas outlet
C: Water drain

20 140E-5 Series
10 Structure, function and maintenance standard 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: Exhaust gas inlet (from turbocharger)


B: Exhaust gas outlet
C: Water drain

140E-5 Series 21
SEN00081-08 10 Structure, function and maintenance standard

For PC800-8E0, PC800SE-8E0, PC800LC-8E0, PC850-8E0, PC850SE-8E0


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

A: Exhaust gas inlet (from turbocharger)


B: Exhaust gas outlet
C: Water drain

22 140E-5 Series
10 Structure, function and maintenance standard SEN00081-08

For D155AX-6, D155A-6

A: Exhaust gas inlet (from turbocharger)


B: Exhaust gas outlet
C: Water drain
D: From air cleaner (dust)

140E-5 Series 23
SEN00081-08 10 Structure, function and maintenance standard

For D275AX-5E0, D275A-5R

A: Exhaust gas inlet (from turbocharger)


B: Exhaust gas outlet
C: Water drain
D: From air cleaner (dust)

24 140E-5 Series
10 Structure, function and maintenance standard SEN00081-08

EGR system 1

No. Component part Function


EGR valve • Controls the gas flow from the exhaust system to the air intake system.
1 (driven hydrauli- • Since the exhaust pressure (PEX) is higher than the boost pressure (PIN), the
cally) exhaust gas flows to the air intake valve.
• Opens the bypass valve when the boost pressure (PIN) is higher than the
exhaust pressure (PEX).
2 Bypass valve
• Makes the intake air flow to the exhaust side to increase the exhaust pressure
so that the exhaust gas will be returned to the air intake side easily.
3 EGR cooler • Lowers the exhaust temperature and returns the exhaust gas to the air intake side.
4 Venturi system • Generates negative pressure with the venturi effect and takes in the exhaust gas.
• Controls the EGR according to the operating condition.
5 Each sensor
• Troubleshoots the system.

Features
q The exhaust gas is kept clean by sensing each
part of the EGR circuit and controlling the EGR
rate according to the operating condition.
q Since the EGR circuit is monitored and trouble-
shooted, a serious trouble is prevented.

140E-5 Series 25
SEN00081-08 10 Structure, function and maintenance standard

a The above illustration shows the engine for D155AX-6.

26 140E-5 Series
10 Structure, function and maintenance standard SEN00081-08

1. EGR valve
2. Bypass valve
3. EGR cooler
4. Venturi system
5. EGR valve position sensor
6. Bypass valve position sensor
7. Bypass piping
8. EGR piping
9. EGR oil pump

Operation
q The engine controller outputs signals for open-
ing EGR valve (1) most properly according to
the load on the engine to attain both clean
exhaust gas and low fuel consumption.
q If EGR valve (1) opens, a part of the exhaust
gas (EGR gas) flows from the exhaust mani-
fold through EGR piping (8) to EGR cooler (3).
q The exhaust gas cooled by EGR cooler (3)
flows through EGR valve (1) and mixes with
the intake air in venturi system (4), and then
flows in the air intake manifold.
q In the operating range where the boost pres-
sure is higher than the exhaust pressure on the
high load side, the EGR gas does not flow to
the air intake side easily. At this time, the
engine controller opens bypass valve (2).
q If bypass valve (2) opens, the intake air flows
through bypass piping (7). As a result, the
exhaust pressure rises and more EGR gas
mixes with the intake air.

140E-5 Series 27
SEN00081-08 10 Structure, function and maintenance standard

EGR valve and bypass valve

A: Oil inlet 1. Stick prevention device


B: Oil outlet 2. Oil pressure control valve
C: EGR gas passage (EGR valve) 3. Solenoid
D: Boost air passage (bypass valve) 4. Position sensor
5. Hydraulic piston
6. Spring
7. Valve

Function q Valve (7) is closed by spring (6) but pushed


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

28 140E-5 Series
10 Structure, function and maintenance standard SEN00081-08

EGR cooler

A: EGR gas inlet D: Coolant outlet


B: EGR gas outlet E: Air bleeder
C: Coolant inlet

1. Heat exchange tube (corrugated tube)

Function
q The EGR cooler cools the high-temperature
EGR gas taken out of the exhaust gas to
increase the gas density, or the EGR effi-
ciency.

Structure
q The EGR cooler is a multi-tube heat
exchanger. When the high-temperature EGR
gas flows through heat exchange tube (1), it is
cooled by the coolant flowing outside of the
tube.
q Heat exchange tube (1) is made of corrosion-
resistant stainless steel and corrugated to
increase the cooling efficiency.

140E-5 Series 29
SEN00081-08 10 Structure, function and maintenance standard

Venturi system

A: Air inlet 1. Venturi nozzle


B: EGR gas inlet 2. Throat
3. Diffuser

Structure
q The EGR gas and intake air mix together in the
venturi system.
q The venturi system consists of throat (2), ven-
turi nozzle (1), and diffuser (3).

Operation
q The boost pressure increased by the turbo-
charger is set negative temporarily with the
venturi effect of the throat to take the EGR gas
into the intake air through venturi nozzle (1).
q When the mixture of the EGR gas and intake
air flows through diffuser (3), its pressure is
increased again to the normal level and then it
flows in the intake manifold.

30 140E-5 Series
10 Structure, function and maintenance standard SEN00081-08

140E-5 Series 31
SEN00081-08 10 Structure, function and maintenance standard

Cylinder head 1

a The shape is subject to machine models.

32 140E-5 Series
10 Structure, function and maintenance standard SEN00081-08

A: Intake air
B: Exhaust gas
C: To fuel tank
D: To radiator

1. Rocker cover bolt


2. Cylinder head bolt
3. Air bleeding pipe from coolant
4. Fuel spill pipe
5. Rocker cover
6. Cylinder head
7. Injector connector
8. Injector assembly
9. Injector holder mounting bolt
10. Injector holder retainer

Specifications
Cylinder head
q Direct injection type
q 4-valve type
q Split-type 1-cylinder, 1-head
q Centralized cooling system for valve bridge
and injector
q Cylinder head bolt: Plastic-region tightening

Valve seat
q Valve seat inserts are press fitted to both
intake and exhaust valves

Rocker cover
q O-ring seal

Injector
q Installation: Dry type (without sleeve)

140E-5 Series 33
SEN00081-08 10 Structure, function and maintenance standard

a Tighten the cylinder head mounting bolts in the order of (1) to (7).

Unit: mm
No. Check item Criteria Remedy

Strain of cylinder head mount- Tolerance Repair limit Correct by grinding


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

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


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

Tightening torque for head


6 cover mounting bolt
32.4{3.3} 29.4 to 34.3{3.0 to 3.5}

a Do not use a cylinder head mounting bolt more than 5 times.


Each time the bolt is used, make a punch mark on its head.

34 140E-5 Series
10 Structure, function and maintenance standard SEN00081-08

140E-5 Series 35
SEN00081-08 10 Structure, function and maintenance standard

Cylinder block 1

36 140E-5 Series
10 Structure, function and maintenance standard SEN00081-08

1. Front cover
2. Cylinder block
3. Cylinder liner
4. Clevis seal
5. Liner O-ring (water)
6. Liner O-ring (oil)
7. Thrust bearing metal
8. Main bearing metal
9. Main bearing metal cap
10. Main bearing metal cap bolt
11. Front oil seal
12. Piston cooling nozzle (front side)
13. Piston cooling nozzle (rear side)

Specifications
Cylinder block
q Crankshaft section: 7 bearings
q Camshaft section: High cam type, 7 bearings
q Main cap bolt: Plastic-region tightening

Front seal
q Single lip with dust seal
(lay-down seal)

Piston cooling
q With piston cooling nozzle
(2 pieces for each cylinder)

Cylinder liner
q Wet type
q Machining on inside: Plateau honing
Soft nitriding process

Liner ring
q Upper: Clevis seal
q Middle: O-ring (ethylene-propylene rubber)
q Lower: O-ring (silicone rubber)

140E-5 Series 37
SEN00081-08 10 Structure, function and maintenance standard

Unit: mm

No. Check item Criteria Remedy

Strain of cylinder head mount- Tolerance Repair limit Correct by grinding


1 ing face or replace
0 to 0.09 0.135
Standard dimension Tolerance
Diameter of main bearing metal Replace main bear-
mounting hole +0.018 ing metal cap
127
–0.006
2
Thickness of main bearing –0.010
3.5 Replace bearing
metal –0.010
metal
Roundness of mounting hole Repair limit: 0.005
Standard dimension Tolerance Repair limit
Inside diameter of main bearing Replace bearing
3 metal +0.038 metal
120 120.15
–0.006
Diameter of cam bushing +0.030 Correct or replace
4 mounting hole
69
+0.030

block
+0.040 Replace cam bush-
5 Inside diameter of cam bushing 65
+0.040
65.15
ing
Level difference between
6 underside faces of cylinder Repair limit: 0.14 Reassemble
block and front cover
Procedure Target(Nm{kgm}) Range(Nm{kgm})
Tightening torque for main cap 1st stage 118{12} 108 to 127{11 to 13}
7 mounting bolt (Apply engine oil
to threads) 2nd stage 235{24} 230 to 240{23.5 to 24.5}
Retighten
3rd stage Retighten 90 deg. 90(+30/0) deg.
Tightening torque for crank pul-
8 ley mounting bolt
— 275{28} 245 to 309{25 to 31.5}

a Do not use a main cap mounting bolt more than 5 times.


Each time the bolt is used, make a punch mark on its head.

38 140E-5 Series
10 Structure, function and maintenance standard SEN00081-08

Cylinder liner 1

Unit: mm

No. Check item Criteria Remedy


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

Interference of cylinder liner and Standard interference Interference limit Replace or correct cylin-
block 0.02 to 0.12 Min. 0.02 der liner or block

Standard size Tolerance


Outside diameter of cylinder liner
–0.073 Replace cylinder liner
(at O-ring) 158
5 –0.103
Clearance between cylinder liner Replace cylinder liner or
Standard clearance: 0.024 to 0.089
and block (at O-ring) block

140E-5 Series 39
SEN00081-08 10 Structure, function and maintenance standard

Main moving parts 1

a The shape is subject to machine models.

1. Piston (FCD piston) 9. Connecting rod cap bolt


2. Piston pin 10. Connecting rod bearing metal
3. Connecting rod bushing 11. Crank gear (number of teeth: 36)
4. Top ring 12. Key (crank gear)
5. Second ring 13. Crankshaft
6. Oil ring 14. Vibration damper
7. Connecting rod 15. Pin (flange)
8. Connecting rod cap 16. Flange

40 140E-5 Series
10 Structure, function and maintenance standard SEN00081-08

Specifications
Crankshaft: Closed die forging
Journal, fillet
Induction hardening

Piston: Special thin ductile cast iron


(FCD piston)
Re-entrant piston

Connecting rod: Closed die forging


Cap bolt is screw type, installed
by plastic-region tightening, with
lubricating oil hole.

Piston rings

Top ring (1): Double-side keystone, inner cut,


barrel face, hard chromium-plated

Second ring (2): Double-side keystone, inner cut,


taper face, hard chromium-plated

Oil ring (3): M-shaped steel, with coil


expander, nitrided surface

140E-5 Series 41
SEN00081-08 10 Structure, function and maintenance standard

Crankshaft 1

Unit: mm

No. Check item Criteria Remedy


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

Standard dimension Tolerance Repair limit


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

Standard clearance Repair limit


Coaxiallity of all main journals:
0.20 Use undersize crankshaft
4 Bend of crankshaft Max. 0.150
or replace
Coaxiallity of adjacent journals:
0.10
Max. 0.050

a US: Undersize

42 140E-5 Series
10 Structure, function and maintenance standard SEN00081-08

Camshaft 1

Unit: mm

No. Check item Criteria Remedy


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

140E-5 Series 43
SEN00081-08 10 Structure, function and maintenance standard

Cam follower and push rod 1

Unit: mm

No. Check item Criteria Remedy


Standard dimension Tolerance Repair limit
Diameter of cam follower shaft –0.021
22 21.92
1 –0.034
Diameter of cam follower shaft +0.021
22 22.07
hole +0.021
+0.05
2 Outside diameter of cam roller 31.7
+0.02
31.50

+0.038
Inside diameter of cam roller 12.7 12.78 Replace
3 +0.013
Diameter of cam roller pin 12.63 ±0.006 12.56
Standard dimension Tolerance
4 Diameter of push rod ball end –0.20
12.7
–0.20
Diameter of push rod socket –0.20
5 end
13.4
–0.20
6 Bend of push rod Repair limit: 0.3 (Overall swing of indicator)

44 140E-5 Series
10 Structure, function and maintenance standard SEN00081-08

140E-5 Series 45
SEN00081-08 10 Structure, function and maintenance standard

Piston, piston ring and piston pin 1

46 140E-5 Series
10 Structure, function and maintenance standard SEN00081-08

Unit: mm

No. Check item Criteria Remedy


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

2 to 4 No. Measuring point Standard clearance Allowable clearance

Clearance between piston ring 2 No. 1 ring Replace piston or


Judge using groove wear gauge
and piston ring groove 3 No. 2 ring piston ring

4 Oil ring 0.035 to 0.060 0.14


0.42 to 0.57
2 No. 1 ring (Tension 16.5 to 23.5N 2.0
{1.68 to 2.40kg})
No. 2 ring 1.15 to 1.30
Replace piston ring
Closed gap of piston ring 3 (Identification: 2RN (Tension 16.2 to 24.2N 1.8
or cylinder liner
white mark) {1.65 to 2.47kg})
0.30 to 0.50
4 Oil ring (Tension 84.5 to 111.7N 1.0
{8.61 to 11.39kg})
Standard dimension Tolerance
Outside diameter of piston pin –0.006 Replace piston pin
52
–0.006
5 Diameter of piston pin hole 52
+0.045
Replace piston
+0.035

Clearance between piston pin Standard clearance Allowable clearance Replace piston or
and piston 0.035 to 0.051 0.10 piston pin

a *1: Part No. (groove wear gauge) 795-901-1150


a *2: Part No. (groove wear gauge) 795-901-1130

140E-5 Series 47
SEN00081-08 10 Structure, function and maintenance standard

Connecting rod 1

Unit: mm

No. Check item Criteria Remedy

Inside diameter of connecting Standard dimension Tolerance Repair limit Replace bushing
rod small end bushing +0.049 (Spare is half
(Ream after press fitting) 52 52.09 worked)
+0.030
1
Clearance between connect- Standard clearance Allowable clearance
Replace bushing or
ing rod small end bushing and
0.030 to 0.055 0.11 piston pin
piston pin

Diameter of connecting rod Standard dimension Tolerance


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

Parallelism and twist of con- Parallelism a 0.20 0.25 Replace connecting


5 necting rod rod
Twist b 0.30 0.35
Dimension c 264 —

Tightening torque for connect- Procedure Target(Nm{kgm}) Range(Nm{kgm})


ing rod cap mounting bolt 117.7 to 132.4
6 (Apply engine oil to bolt
1st stage 127.5{13}
{12.5 to 13.5}
Retighten
threads and nut seat)
2nd stage Retighten 90 deg. 90(+30/0) deg.
Permissible range: Dispersion of weight of connecting rods in one engine
— Weight of connecting rod Replace
must not exceed 154 g.

a Do not use a connecting rod cap mounting bolt more than 5 times.
Each time the bolt is used, make a punch mark on its head.

48 140E-5 Series
10 Structure, function and maintenance standard SEN00081-08

Flywheel and flywheel housing 1

a The shape is subject to machine models.

1. Rear seal
2. Ring gear
3. Flywheel
4. Engine speed sensor (for monitor)
5. Flywheel housing
6. Engine speed sensor
(NE sensor for engine control)

140E-5 Series 49
SEN00081-08 10 Structure, function and maintenance standard

a Tighten the flywheel mounting bolts with an


impact wrench in the 1st stage and then
tighten them with a torque wrench in the 2nd
stage.

A: Tightening order of flywheel mounting bolts


B: Tightening order of flywheel housing mounting
bolts

50 140E-5 Series
10 Structure, function and maintenance standard SEN00081-08

Unit: mm

No. Check item Criteria Remedy


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

Radial runout of flywheel hous-


2 ing
Repair limit: 0.20 Reassemble

3 Facial runout of flywheel Repair limit: 0.20

4 Radial runout of flywheel Repair limit: 0.13


Tightening torque for flywheel Procedure Target(Nm{kgm}) Range(Nm{kgm})
Tighten in order
housing mounting bolt
5 (Apply engine oil to bolt threads
1st stage 191{19.5} 147 to 235{15 to 24} shown in above fig-
ure
and seat surface) 2nd stage 275{28.0} 245 to 309{25 to 31.5}
Tightening torque for flywheel Procedure Target(Nm{kgm}) Range(Nm{kgm}) Tighten and
mounting bolt retighten in order
6 (Apply engine oil to bolt threads
1st stage 118{12} 113 to 123{11.5 to 12.5}
shown in above fig-
and seat surface) 2nd stage Retighten 90 deg. 90(+30/0) deg. ure

a Do not use a flywheel mounting bolt more than


5 times.
Each time the bolt is used, make a punch mark
on its head.

140E-5 Series 51
SEN00081-08 10 Structure, function and maintenance standard

Vibration damper 1

a The shape is subject to machine models.

1. Adapter
2. Pin (between adapter and crankshaft pulley)
3. Vibration damper
4. Bolt (between adapter and vibration damper)
5. Bolt (between crankshaft and adapter)
6. Pin (between adapter and vibration damper)

52 140E-5 Series
10 Structure, function and maintenance standard SEN00081-08

140E-5 Series 53
SEN00081-08 10 Structure, function and maintenance standard

Timing gear 1
(With EGR)

a The shape is subject to machine models.

54 140E-5 Series
10 Structure, function and maintenance standard SEN00081-08

A: Timing mark
[Between crank gear and main idler gear (large)]
B: Timing mark
[Between main idler gear (small) and fuel supply pump drive gear]
C: Timing mark
[Between main idler gear (small) and cam gear]

1. Water pump drive gear (Number of teeth: 23)


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

Unit: mm

No. Check item Criteria Remedy

Standard Tolerance Standard Allowable


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

Standard Repair limit


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

Sub idler gear and water pump drive


20 0.095 to 0.346
gear
Cam gear and air conditioner drive
21 0.118 to 0.369
gear
Fuel supply pump gear and EGR oil
22 0.118 to 0.369
pump drive gear

140E-5 Series 55
SEN00081-08 10 Structure, function and maintenance standard

(EGR-less)

a The shape is subject to machine models.

56 140E-5 Series
10 Structure, function and maintenance standard SEN00081-08

A: Timing mark
[Between crank gear and main idler gear (large)]
B: Timing mark
[Between main idler gear (small) and fuel supply pump drive gear]
C: Timing mark
[Between main idler gear (small) and cam gear]

1. Water pump drive gear (Number of teeth: 23)


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

Unit: mm

No. Check item Criteria Remedy

Standard Tolerance Standard Allowable


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

Standard Repair limit


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

140E-5 Series 57
SEN00081-08 10 Structure, function and maintenance standard

Valve system 1

58 140E-5 Series
10 Structure, function and maintenance standard SEN00081-08

A: Lubricating oil inlet Valve timing

1. Cam gear (Number of teeth: 48)


2. Thrust plate
3. Camshaft
4. Cam roller
5. Cam roller pin
6. Cam follower shaft
7. Cam follower
8. Push rod
9. Rocker arm shaft
10. Locknut
11. Rocker arm adjustment screw
12. Rocker arm
13. Crosshead adjustment screw
14. Locknut
15. Crosshead
16. Valve retainer
17. Outer valve spring
18. Inner valve spring
19. Air intake valve
20. Valve guide
21. Spring seat
22. Exhaust valve

Specifications
Camshaft: Drawn steel bar (turning)
Journal and cam sections:
Induction hardening

140E-5 Series 59
SEN00081-08 10 Structure, function and maintenance standard

Valve and valve guide 1

60 140E-5 Series
10 Structure, function and maintenance standard SEN00081-08

Unit: mm

No. Check item Criteria Remedy


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

140E-5 Series 61
SEN00081-08 10 Structure, function and maintenance standard

Rocker arm and shaft 1

Unit: mm

No. Check item Criteria Remedy


Standard dimension Tolerance
Diameter of rocker arm shaft Replace rocker arm shaft
32.0 ±0.0065
Inside diameter of rocker arm +0.087
1 bushing
32.0
+0.035
Replace rocker arm

Clearance between rocker arm Standard clearance Allowable clearance Replace rocker arm shaft
shaft and rocker arm 0.0285 to 0.0935 0.13 or rocker arm

Valve Standard Tolerance


2 Valve clearance (when cold) Intake 0.35 ±0.02 Adjust
Exhaust 0.57 ±0.02

Tightening torque for locknut of Target(Nm{kgm}) Range(Nm{kgm})


3 rocker arm adjustment screw
Tighten
58.8{6} 52.9 to 64.7{5.4 to 6.6}

62 140E-5 Series
10 Structure, function and maintenance standard SEN00081-08

Crosshead and guide 1

Unit: mm

No. Check item Criteria Remedy


Standard dimension Tolerance Repair limit
Depth of crosshead stem
1 receiver +0.3
6.2 6.61
+0.3
Replace
Inside diameter of crosshead 11.04 ±0.02 11.17
2 Outside diameter of crosshead +0.011
11 10.95
guide +0.011
3 Projection of crosshead guide 49.0 ±0.25 — Correct

140E-5 Series 63
SEN00081-08

KOMATSU 140E-5 Series engine

Form No. SEN00081-08

© 2012 KOMATSU
All Rights Reserved
Printed in Japan 12-12 (01)

64
SEN00082-06

ENGINE 1SHOP MANUAL

140E-5 Series

10 Structure, function and


maintenance standard 1
Structure, function and maintenance
standard, Part 2
Lubrication system .......................................................................................................................................... 4
Lubrication system diagram ................................................................................................................. 4
Oil pump............................................................................................................................................... 8
EGR oil pump....................................................................................................................................... 9
Oil filter ............................................................................................................................................... 10
Oil cooler ............................................................................................................................................ 12
Fuel system................................................................................................................................................... 14
CRI system diagram........................................................................................................................... 14
Outline of CRI system ........................................................................................................................ 16
Fuel piping.......................................................................................................................................... 38
Fuel cooler ......................................................................................................................................... 42

140E-5 Series 1
SEN00082-06 10 Structure, function and maintenance standard

Fuel filter............................................................................................................................................. 43
Priming pump ..................................................................................................................................... 46
Electric priming pump......................................................................................................................... 47
Engine controller cooler...................................................................................................................... 48
Cooling system.............................................................................................................................................. 49
Cooling system diagram..................................................................................................................... 49
Water pump ........................................................................................................................................ 54
Thermostat ......................................................................................................................................... 57
Corrosion resistor ............................................................................................................................... 58
Cooling fan drive ................................................................................................................................ 60
Accessories................................................................................................................................................... 63
Front PTO........................................................................................................................................... 63
Electrical equipment...................................................................................................................................... 65
Alternator............................................................................................................................................ 65
Starting motor ..................................................................................................................................... 76
Starting aid ......................................................................................................................................... 78
Engine controller ................................................................................................................................ 79

2 140E-5 Series
10 Structure, function and maintenance standard SEN00082-06

140E-5 Series 3
SEN00082-06 10 Structure, function and maintenance standard

Lubrication system 1
Lubrication system diagram 1
(With EGR)

a The layout of the oil filter, shapes of the oil pan and piping, etc. are subject to machine models.

4 140E-5 Series
10 Structure, function and maintenance standard 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 5
SEN00082-06 10 Structure, function and maintenance standard

(EGR-less)

a The layout of the oil filter, shapes of the oil pan and piping, etc. are subject to machine models.

6 140E-5 Series
10 Structure, function and maintenance standard 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. Main gallery

140E-5 Series 7
SEN00082-06 10 Structure, function and maintenance standard

Oil pump 1

A: From oil pan Specifications


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

8 140E-5 Series
10 Structure, function and maintenance standard SEN00082-06

EGR oil pump 1

A: From main gallery Specifications


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

140E-5 Series 9
SEN00082-06 10 Structure, function and maintenance standard

Oil filter 1
Except SDG400S-6B1 (HOKUETSU INDUSTRIES GENERATOR)

a The shape is subject to machine models.

A: Oil inlet Specifications


B: Oil outlet Oil filter
Filtration area: 0.44 m2 (full flow)
1. Safety valve
2. Filter head Safety valve
3. Cartridge
Cracking pressure: 343 ± 19.6 kPa {3.5 ± 0.2 kg/cm2}

10 140E-5 Series
10 Structure, function and maintenance standard SEN00082-06

For SDG400S-6B1 (HOKUETSU INDUSTRIES GENERATOR)

a The shape is subject to machine models.

A: Oil inlet Specifications


B: Oil outlet Oil filter
Filtration area: 0.44 m2 (full flow)
1. Safety valve
2. Filter head Safety valve
3. Cartridge
Cracking pressure: 343 ± 19.6 kPa {3.5 ± 0.2 kg/cm2}
4. Clogging switch
Clogging switch
q Operating differential pressure:
147 +39 +0.4 2
+0 kPa {1.5 +0 kg/cm }
q Contact type: NO (Normal Open)

140E-5 Series 11
SEN00082-06 10 Structure, function and maintenance standard

Oil cooler 1

a The shape is subject to machine models.

12 140E-5 Series
10 Structure, function and maintenance standard 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 ± 1.5°C
Full opening temperature: 100°C
Lift at full opening: 8 mm

Oil cooler
Heat dissipation surface area
SAA6D140E-5: 1.23 m2
Heat exchange rate
SAA6D140E-5: Min. 39,800 kcal/h

Unit: mm
No. Check item Criteria Remedy
Lift of thermostat at full opening Min. 8 mm (Before checking, leave valve in oil of 100°C for 4 to 5 minutes)

6 Check that valve closes fully when its temperature is lowered from 100°C Replace
Opening/Closing of thermostat for full opening to 85°C. (Before checking valve, leave it in oil for 4 to 5
minutes)

140E-5 Series 13
SEN00082-06 10 Structure, function and maintenance standard

Fuel system 1
CRI system diagram 1
(With EGR)

a CRI is an abbreviation for common rail injection.

1. NE speed sensor 9C. Priming pump (sub)


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

14 140E-5 Series
10 Structure, function and maintenance standard SEN00082-06

(EGR-less)

a CRI is an abbreviation for common rail injection.

1. NE speed sensor 9C. Priming pump


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

140E-5 Series 15
SEN00082-06 10 Structure, function and maintenance standard

Outline of CRI system 1


Outline 1. Fuel system
q The CRI system checks the condition of the
engine (engine speed, accelerator angle, cool-
ant temperature, etc.) with sensors.
q The microcomputer of the CRI system controls
the fuel injection rate, fuel injection timing, fuel
injection pressure, etc. totally to operate the
engine under the best condition.
q The CRI system has a diagnosis function and
an alarm function, with which the computer of
the system checks the main component parts
and notifies the operator of detected failures.
q In addition, the CRI system has a failsafe func-
tion which stops the engine when a certain
parts fail and a backup function which contin-
ues the operation by changing the control
method in such a case.
q The CRI system has the same basic structure
as the current Tier 2 engine.
q The maximum service pressure is heightened.
(120 MPa {1,200 kg/cm2}  160 MPa {1,600
kg/cm2})

Configuration
q The CRI system is divided by the function into
the fuel system and control system.

q The fuel system distributes the high-pressure


fuel supplied by the fuel supply pump to the
cylinders through the common rail.
q The solenoid valve in the injector opens and
closes the nozzle needle valve to start and fin-
ish injection.

16 140E-5 Series
10 Structure, function and maintenance standard SEN00082-06

2. Control system

a Parts marked with * (2 places) are installed to only the engines with EGR.

q The engine controller calculates and controls


the energizing timing and energizing period of
the injector with the signals from the sensors
installed to the machine to inject proper quan-
tity of fuel in proper timing.
q The control system is roughly divided by the
electric parts into the sensors, computer, and
actuators.

140E-5 Series 17
SEN00082-06 10 Structure, function and maintenance standard

Structure and operation of CRI system 1

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

18 140E-5 Series
10 Structure, function and maintenance standard SEN00082-06

Structure and operation of component parts 1


1. Fuel supply pump

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


2. Overflow valve 7. Priming pump
3. Drive gear 8. Feed pump
4. No. 1 high-pressure pump 9. Gear for Bkup speed sensor (G sensor)
5. PCV (pressure control valve)

Outline q Since the number of the times of feeding fuel


q The fuel supply pump consists of priming to the common rail is the same as the number
pump (7), feed pump (8), and high-pressure of the times of fuel injection, the common rail
pumps (4) and (6). fuel pressure is smooth and stable.
q The function of the fuel supply pump is to gen- q The fuel fed by high-pressure pumps (4) and
erate common rail fuel pressure by controlling (6) to the common rail is divided as follows.
the fuel delivery. q No. 1 high-pressure pump (on the drive gear
side) (4) compensates for drop in the common
Structure rail fuel pressure caused by fuel injection into
q High-pressure pumps (4) and (6) have the the No. 1, 3, and 5 cylinders.
pressure feed systems similar to those of the q No. 2 high-pressure pump (on the feed pump
conventional in-line fuel injection pump and the side) (6) compensates for drop in the common
PCVs (pressure control valves) for each cylin- rail fuel pressure caused by fuel injection into
der to control the fuel delivery. the No. 2, 4, and 6 cylinders.
q By employing the 3-head cam, the necessary
number of the cylinders of high-pressure
pumps (4) and (6) is reduced to 1/3 of the
engine cylinders.

140E-5 Series 19
SEN00082-06 10 Structure, function and maintenance standard

Operation

q (A): During the lowering stroke of the plunger,


the PCV is open and the low-pressure fuel
is sucked in the plunger chamber through
the PCV.
q (B): While the PCV is not energized and is
open after the plunger starts the rising
stroke, the sucked fuel is returned through
the PCV without being pressurized.
q (C): If the PCV is energized and closed in the
timing for the necessary delivery, the
return passage is closed and the pressure
in the plunger chamber rises. Accordingly,
the fuel is fed through the delivery valve
(check valve) to the common rail. That is,
the quantity of the fuel corresponding to
the plunger lift after the PCV is closed is
the delivery. The delivery is changed and
the common rail fuel pressure is controlled
by changing the opening timing of the
PCV.
q (D): After the cam passes the maximum lift
point, the plunger starts the lowering
stroke and the pressure in it lowers. At
this time, the delivery valve closes to stop
feeding the fuel. Since the PCV is de-
energized, it opens and the low-pressure
fuel is sucked in the plunger chamber, or
the state of (A) starts again.

20 140E-5 Series
10 Structure, function and maintenance standard SEN00082-06

1) PCV (pressure control valve) 2) Feed pump


q The PCV adjusts the fuel delivery from the fuel q The feed pump built in the fuel supply pump
supply pump to adjust the common rail fuel assembly draws the fuel from the fuel tank and
pressure. The delivery from the fuel supply sends it through the fuel filter to the high-pres-
pump to the common rail is decided by the tim- sure pump chamber.
ing of energizing the PCV. q The outer and inner rotors of the feed pump
are rotated by the camshaft.
q The fuel is sucked in on the suction side and
discharged on the delivery side according to
the increase and decrease of the spaces
between the outer and inner rotors.

140E-5 Series 21
SEN00082-06 10 Structure, function and maintenance standard

2. Common rail

Structure When fuel is stopped


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

1) Flow damper

Function
q The flow dampers damp the pressure pulses in
the high pressure piping and supply the fuel to
the injectors with stable pressure.
q If excessive fuel flows out, the flow dampers
block the fuel passage to prevent abnormal
outflow of the fuel.
q If the fuel flows out abnormally, high pressure
is applied to the piston, which moves to the
right until it reaches the seat to stop the fuel.

Operation
When fuel is not injected
q Piston (2) is in contact with stopper (1) (initial
position).
q The fuel for static leakage is supplied through
orifice (a) of piston (2) and clearance in the
sliding parts.

When fuel is injected


q The fuel pressure is applied to piston (2), which
compresses spring (3) and moves to the right.
q The fuel for static leakage is supplied through
orifice (a) of piston (2) and clearance in the
sliding parts.

22 140E-5 Series
10 Structure, function and maintenance standard SEN00082-06

2) Pressure limiter 3) Common rail fuel pressure sensor


q If abnormally high pressure is generated, the q The common rail fuel pressure sensor is
pressure limiter opens to release that pres- installed to the common rail to sense the fuel
sure. pressure.
q If the common rail fuel pressure reaches about q This sensor is a semiconductor pressure sen-
200 MPa {2,040 kg/cm2}, the pressure limiter sor, which utilizes the phenomenon that the
operates (opens). electric resistance of silicon changes according
q If the common rail fuel pressure lowers to 30 to pressure applied to it.
MPa {310 kg/cm2}, the pressure limiter resets
itself (closes) to maintain the pressure.
q Under the normal condition, the pressure lim-
iter does not reset itself (close) until the engine
is stopped.

1. Ball
2. Housing
3. Spring
4. Guide
5. Body

140E-5 Series 23
SEN00082-06 10 Structure, function and maintenance standard

3. Injector

Outline
q The function of the injector is to inject the high-
pressure fuel from the common rail into each
combustion chamber of the engine in the opti-
mum timing, by the optimum quantity, at the
optimum injection rate, and under the optimum
spray condition.
q The TWV (2-way solenoid valve) controls the
start and finish of fuel injection by controlling
the pressure in the control chamber.
q The orifice limits the opening speed of the noz-
zle and controls the fuel injection rate.
q The hydraulic piston transmits the force gener-
ated by the pressure in the control chamber to
the needle valve of the nozzle.
q The nozzle sprays the fuel.

24 140E-5 Series
10 Structure, function and maintenance standard SEN00082-06

Structure

1. Inlet connector 7. Orifice (in)


2. Terminal 8. Pressure control chamber
3. Upper body 9. Control piston
4. Solenoid 10. Spring
5. Valve body 11. Pressure pin
6. Orifice (out) 12. Nozzle assembly

q The injector consists of the nozzle section, ori-


fice to control the fuel injection rate, hydraulic
piston section, and 2-way solenoid valve sec-
tion.

140E-5 Series 25
SEN00082-06 10 Structure, function and maintenance standard

A: No fuel injection C: Finish of fuel injection


B: Start of fuel injection D: From common rail

1. Nozzle 5. Valve body


2. Control piston 6. Solenoid
3. Orifice (in) 7. Spring
4. Orifice (out) 8. Pressure control chamber

Operation
1) No fuel injection (A) 3) Finish of fuel injection (C)
q While solenoid (6) is not energized, valve body q If solenoid (6) is de-energized, valve body (5)
(5) is pressed down by spring (7). is lowered by spring (7) and the fuel passage is
q Since the high-pressure fuel is applied from closed.
the common rail to pressure control chamber q At this time, the high-pressure fuel in the com-
(8), nozzle (1) is closed and the fuel is not mon rail is applied to pressure control chamber
injected. (8) suddenly and nozzle (1) is closed quickly,
fuel injection is finished sharply.
2) Start of fuel injection (B)
q If solenoid (6) is energized, valve body (5) is
pulled up by the electromagnetic force and the
fuel passage is opened.
q Since the fuel in pressure control chamber (8)
flows out through orifices (3) and (4), nozzle
(1) rises and fuel injection pump starts.
q The fuel injection rate is increased gradually by
the function of orifices (3) and (4).
q If solenoid (6) is kept energized, the fuel injec-
tion rate is increased to the maximum.

26 140E-5 Series
10 Structure, function and maintenance standard SEN00082-06

Electric circuit diagram

k Since high voltage (65 V) is applied to the


wiring harnesses connected to the engine
controller, COMMON 1 and COMMON 2 of
the supply pump, and TWV #1 to #6 of the
injector, take care not get an electric shock.

140E-5 Series 27
SEN00082-06 10 Structure, function and maintenance standard

28 140E-5 Series
10 Structure, function and maintenance standard SEN00082-06

Various controls

a Parts marked with * (3 places) are installed to only the engines with EGR.

q The CRI system controls the fuel injection rate 2. Fuel injection timing control function
and fuel injection timing more properly than the q The fuel injection timing control function is
mechanical governor or timer of the conven- employed instead of the function of the con-
tional fuel injection pump. ventional timer. It controls the fuel injection
q For the control of the system, calculations nec- timing most properly from the engine speed
essary to the engine controller are performed and fuel injection rate.
fr om th e si gn als se nt fr om the s en so rs
installed to the engine and machine.
q The energizing timing and energizing period of 3. Fuel injection pressure control func-
the injector are so controlled that the optimum tion (Common rail fuel pressure control
quantity of fuel will be injected in the optimum
function)
timing.
q The fuel injection pressure control function
(common rail fuel pressure control function) is
a function of measuring the fuel pressure with
1. Fuel injection rate control function
the common rail fuel pressure sensor and
q The fuel injection rate control function is
feeding it back to the engine controller to con-
employed instead of the function of the con-
trol the delivery of the fuel supply pump.
ventional governor. It controls the fuel injection
q This function performs pressure feedback con-
according to the signals of engine speed and
trol so that the fuel injection pressure will be
accelerator angle so that the fuel injection rate
the same as the optimum value (command
will be most proper.
value) set according to the engine speed and
fuel injection rate.

140E-5 Series 29
SEN00082-06 10 Structure, function and maintenance standard

4. Various sensors and relays

a Nos. 1 to 13 in the above illustration correspond to title Nos. 1) to 13).


a The above illustration shows the engine for HD325-7.
a Parts *1, *3 and *4 are installed to only the engines with EGR.

30 140E-5 Series
10 Structure, function and maintenance standard SEN00082-06

140E-5 Series 31
SEN00082-06 10 Structure, function and maintenance standard

1) EGR inlet pressure sensor (with EGR) 2) Fuel temperature sensor


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

q The following graph shows the output charac-


teristics of the EGR inlet pressure sensor.

32 140E-5 Series
10 Structure, function and maintenance standard 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 charac-


teristics of the position sensor.

140E-5 Series 33
SEN00082-06 10 Structure, function and maintenance standard

5) Engine controller 7) Atmospheric pressure sensor


q This sensor is used to correct altitude.
6) NE speed sensor (crank angle sensor) (with EGR)
q If the signal hole made on the flywheel passes
the sensor, the magnetic line of force changes.
q If the magnetic line of force changes, the out-
put of the Hall element sensor changes linearly
and it is converted into pulse of 0 to 5 V by the
wave form shaping circuit in the sensor, and
then output.

A: Pressure inlet
B: Mounting screw: M5
Tightening torque: 4.1 to 9.5 Nm {0.4 to 1.0 kgm}

q The following graph shows the output charac-


teristics of the atmospheric pressure sensor.

34 140E-5 Series
10 Structure, function and maintenance standard 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.
q The disc gear installed to the central part of the
camshaft of the high-pressure pump has teeth
(cut parts) around it at intervals of 120 degree.
q In addition to the above teeth, one more tooth
is installed. Accordingly, 7 pulses are gener-
ated every 2 revolutions of the engine.
q The standard pulse of the No. 1 cylinder is rec-
ognized by the combination of the NE speed
sensor pulse and Bkup speed sensor pulse.
A: Pressure inlet
B: Mounting screw: M5
Tightening torque: 4.5 ± 0.5 Nm {0.46 ± 0.05 kgm}

q The following graph shows the output charac-


teristics of the atmospheric pressure sensor.

8) Common rail pressure sensor

9) Oil pressure sensor

140E-5 Series 35
SEN00082-06 10 Structure, function and maintenance standard

11) Charge pressure sensor (EGR-less)


q This sensor is used to sense the charge pres-
sure (boost pressure).
(with EGR)

1. Sensor
2. O-ring

q The following graph shows the output charac-


teristics of the charge pressure sensor.

A: Mounting screw: M6
Tightening torque: 5.5 ± 0.5 Nm {0.56 ± 0.05 kgm}

1. Sensor
2. O-ring

q The following graph shows the output charac-


teristics of the charge pressure sensor.

36 140E-5 Series
10 Structure, function and maintenance standard SEN00082-06

12) Charge temperature sensor 13) Coolant temperature sensor


q The charge temperature sensor senses the q The coolant temperature sensor senses the
intake air temperature (boost temperature) and coolant temperature and sends it to the engine
sends it to the engine controller. controller.
q The sensor unit is a thermistor the resistance q The sensor unit is a thermistor the resistance
of which changes according to the tempera- of which changes according to the tempera-
ture. The engine controller applies voltage to ture. The engine controller applies voltage to
the thermistor and senses the temperature by the thermistor and senses the temperature by
the voltage divided by the resistance in the the voltage divided by the resistance in the
computer and the resistance of the thermistor. computer and the resistance of the thermistor.

140E-5 Series 37
SEN00082-06 10 Structure, function and maintenance standard

Fuel piping 1
(with EGR)

a The above illustration shows the engine for PC600-8.


a The shape is subject to machine models.

Specifications A: Fuel inlet


Fuel supply pump B: To engine controller cooler
Manufacturer: DENSO CORPORATION C: To main fuel filter
Model: DENSO ECD-U2 D: From main fuel filter
Lubrication method: E: To injector
Forced lubrication with engine oil F: Return fuel (between overflow valve and main
fuel tank)
G: Return fuel (between injector and main fuel tank)
H: Engine oil (to fuel supply pump)

38 140E-5 Series
10 Structure, function and maintenance standard SEN00082-06

a The above illustration shows the engine for PC600-8.


a The shape is subject to machine models.

1. Fuel injection pipe (No. 1 cylinder) 11. Oil inlet pipe (for pump lubricating oil)
2. Fuel injection pipe (No. 2 cylinder) 12. Fuel supply pump
3. Fuel injection pipe (No. 3 cylinder) 13. Drive gear (Number of teeth: 48)
4. Fuel injection pipe (No. 4 cylinder) 14. Overflow valve
5. Fuel injection pipe (No. 5 cylinder) 15. PCV
6. Fuel injection pipe (No. 6 cylinder) 16. Priming pump (main)
7. Common rail 17. Pre-fuel filter
8. Fuel return pipe 18. Main fuel filter
9. Priming pump (sub)
10. Feed pump

140E-5 Series 39
SEN00082-06 10 Structure, function and maintenance standard

(EGR-less)

a The above illustration shows the engine for D275A-5R.


a The shape is subject to machine models.

Specifications A: Fuel inlet


Fuel supply pump B: To engine controller cooler
Manufacturer: DENSO CORPORATION C: To main fuel filter
Model: DENSO ECD-U2 D: From main fuel filter
Lubrication method: E: To injector
Forced lubrication with engine oil F: Return fuel (between overflow valve and main
fuel tank)
G: Return fuel (between injector and main fuel tank)
H: Engine oil (to fuel supply pump)

40 140E-5 Series
10 Structure, function and maintenance standard SEN00082-06

a The above illustration shows the engine for D275A-5R.


a The shape is subject to machine models.

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

140E-5 Series 41
SEN00082-06 10 Structure, function and maintenance standard

Fuel cooler 1
(installed on the machine)

a The shape is subject to machine models.

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
10 Structure, function and maintenance standard SEN00082-06

Fuel filter 1
Main fuel filter
(with EGR)

a The shape is subject to machine models.

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 10 Structure, function and maintenance standard

(EGR-less)

a The shape is subject to machine models.

A: Fuel inlet
B: Fuel outlet

1. Air bleeding plug


2. Filter head
3. Cartridge (double cartridges)
a Single cartridge is set for some models.

Specifications
Filtration area: 1.06 m2 x 2

44 140E-5 Series
10 Structure, function and maintenance standard SEN00082-06

Pre-fuel filter

a The shape is subject to machine models.

A: Fuel inlet
B: Fuel outlet

1. Air bleeding plug


2. Filter head
3. Cartridge

Specifications
Filtration area: 1.06 m2
with water separator

140E-5 Series 45
SEN00082-06 10 Structure, function and maintenance standard

Priming pump 1
(with EGR)

1. Spring 9. Valve stopper


2. Cover 10. Packing
3. Shaft 11. Check valve body
4. Bushing 12. Lever pin
5. Diaphragm 13. E-ring
6. Diaphragm cover 14. Washer
7. Body 15. Bolt
8. Check valve 16. Lever

46 140E-5 Series
10 Structure, function and maintenance standard SEN00082-06

Electric priming pump 1


(EGR-less)
a Manual priming pump is set for some models (see the"with EGR")

A: Fuel IN
B: Fuel OUT

1. Connector
2. Vibration prevention rubber

140E-5 Series 47
SEN00082-06 10 Structure, function and maintenance standard

Engine controller cooler 1

A: Fuel IN (from feed pump of fuel supply pump)


B: Fuel OUT (main fuel filter)

1. Engine controller
2. Engine controller cooler

Outline
q The fuel is circulated as refrigerant through
engine controller cooler (2) to prevent engine
controller (1) from overheating.

48 140E-5 Series
10 Structure, function and maintenance standard SEN00082-06

Cooling system 1
Cooling system diagram 1
SAA6D140E-5 (For construction machinery)

1. Hydraulic cooling fan (With EGR)


(PC600-8, PC600LC-8, PC600-8E0, PC600LC-8E0, PC700-8E0, PC700LC-8E0, PC800-
8, PC800SE-8, PC850-8, PC850SE-8, PC800LC-8, PC800-8E0, PC800SE-8E0, PC850-
8E0, PC850SE-8E0, PC800LC-8E0, D155AX-6, D275AX-5E0, WA500-6, HM400-3M0)

A: Oil inlet
B: Oil outlet
C: Exhaust gas inlet
D: Exhaust gas outlet

1. Radiator 6. Corrosion resistor


2. Thermostat a Corrosion resistor is not set for some models.
3. Oil cooler 7. Hydraulic cooling fan
4. Water pump 8. Hydraulic fan motor
5. EGR cooler

140E-5 Series 49
SEN00082-06 10 Structure, function and maintenance standard

2. Hydraulic cooling fan (EGR-less)


(PC600-8R, PC600LC-8R, PC600-8R1, PC600LC-8R1, PC700-8R, PC700LC-8R,
PC700LC-8R1, PC800-8R, PC800LC-8R, PC800SE-8R, PC850-8R, PC850SE-8R,
PC800-8R1, PC800LC-8R1, PC800SE-8R1, PC850-8R1, PC850SE-8R1, D155A-6,
D275A-5R, WA500-6R, HM400-3R)

A: Oil inlet
B: Oil outlet

1. Radiator
2. Thermostat
3. Oil cooler
4. Water pump
5. Corrosion resistor
a Corrosion resistor is not set for some models.
6. Hydraulic cooling fan
7. Hydraulic fan motor

50 140E-5 Series
10 Structure, function and maintenance standard 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
6. Corrosion resistor
a Corrosion resistor is not set for some models.
7. Engine-driven cooling fan

140E-5 Series 51
SEN00082-06 10 Structure, function and maintenance standard

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
5. Corrosion resistor
a Corrosion resistor is not set for some models.
6. Engine-driven cooling fan

52 140E-5 Series
10 Structure, function and maintenance standard SEN00082-06

140E-5 Series 53
SEN00082-06 10 Structure, function and maintenance standard

Water pump 1
SAA6D140E-5

a The shape is subject to machine models.

54 140E-5 Series
10 Structure, function and maintenance standard SEN00082-06

A: From radiator
B: To oil cooler
C: Rotation direction
D: Pump mounting face

1. Alternator drive pulley


2. Oil seal
3. Ball bearing
4. Pump shaft
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. Check item Criteria Remedy
Standard Tolerance Standard inter-
Interference between impeller and dimension Shaft Hole ference
10 shaft –0.082 –0.120
16 0.025 to 0.068
–0.095 –0.150
Interference between drive gear and +0.015 –0.023
11 shaft
28
+0.002 –0.055
0.025 to 0.070 Replace

+0.015 –0.023
12 Interference between flange and shaft 25
+0.002 –0.053
0.025 to 0.068

13 Clearance between impeller and body Standard clearance: 0.6 to 0.9 (including end play)
14 Wear of water seal ring Limits of size: 1.5

140E-5 Series 55
SEN00082-06 10 Structure, function and maintenance standard

Water pump mounting 1


SAA6D140E-5

a The above illustration shows the engine for PC600-8.


a The shape is subject to machine models.

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
10 Structure, function and maintenance standard SEN00082-06

Thermostat 1

a The shape is subject to machine models.

A: To radiator inlet Specifications


B: From radiator outlet Opening temperature: 76.5 ± 2°C
Full opening temperature: 90°C
1. Thermostat housing Lift at full opening: Min. 9 mm
2. Thermostat

Unit: mm
No. Check item Criteria Remedy
Min. 9 mm (Before checking, leave valve in water of 90°C for 4 to 5 min-
Lift of thermostat at full opening
utes)
3 Check that valve closes fully when its temperature is lowered from 90°C Replace
Opening/Closing of thermostat for full opening to 76.5°C. (Before checking valve, leave it in water for 4 to
5 minutes)

140E-5 Series 57
SEN00082-06 10 Structure, function and maintenance standard

Corrosion resistor 1

a The shape is subject to machine models.


a Corrosion resistor is not set for some models.

A: Coolant inlet Specifications


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

58 140E-5 Series
10 Structure, function and maintenance standard SEN00082-06

Corrosion resistor mounting

a The shape is subject to machine models.


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 10 Structure, function and maintenance standard

Cooling fan drive 1


Mounting (Adjustment bolt type)
SAA6D140E-5 [HD325-7, HD405-7, HM350-2, HM400-2, HD325-7R, HD405-7R,
HM350-2R, HM400-2R,
SDG400S-6B1 (HOKUETSU INDUSTRIES GENERATOR)]

a The shape is subject to machine models.

1. Crankshaft pulley 4. Fan belt


2. Tension pulley 5. Fan pulley
3. Adjustment bolt

Outside diameter of pulley


Unit: mm
Engine Machine model Crankshaft pulley Tension pulley Fan pulley
HD325-7, HD405-7,
166 120 322
HD325-7R, HD405-7R
HM350-2, HM350-2R 166 120 262
SAA6D140E-5 HM400-2, HM400-2R 166 120 262
SDG400S-6B1
(HOKUETSU INDUS- 203 120 277
TRIES GENERATOR)

60 140E-5 Series
10 Structure, function and maintenance standard SEN00082-06

Tension pulley
SAA6D140E-5 [HD325-7, HD405-7, HM350-2, HM400-2, HD325-7R, HD405-7R,
HM350-2R, HM400-2R,
SDG400S-6B1 (HOKUETSU INDUSTRIES GENERATOR)]

a The shape is subject to machine models.

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 10 Structure, function and maintenance standard

Fan mounting case


SAA6D140E-5 [HD325-7, HD405-7, HM350-2, HM400-2, HD325-7R, HD405-7R,
HM350-2R, HM400-2R,
SDG400S-6B1 (HOKUETSU INDUSTRIES GENERATOR)]

a The shape is subject to machine models.

1. Fan pulley hub


2. Ball bearing
3. Shaft
4. Case

62 140E-5 Series
10 Structure, function and maintenance standard SEN00082-06

Accessories 1
Front PTO 1

a The shape is subject to machine models.

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 10 Structure, function and maintenance standard

Front PTO mounting

a The shape is subject to machine models.

1. Front PTO (for driving air conditioner compressor)


2. O-ring

64 140E-5 Series
10 Structure, function and maintenance standard SEN00082-06

Electrical equipment 1
Alternator 1
1. Alternator with built-in regulator (open type, 35 A)

a The shape is subject to machine models.

1. Alternator 6. Internal electric circuit diagram


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

140E-5 Series 65
SEN00082-06 10 Structure, function and maintenance standard

2. Alternator with built-in regulator (open type, 50 A)

a The shape is subject to machine models.

1. Alternator 6. Internal electric circuit diagram


2. Alternator pulley 6A. Field coil
3. Terminal B 6B. Initial excitation resistor
4. Terminal E 6C. Regulator
5. Terminal R

66 140E-5 Series
10 Structure, function and maintenance standard SEN00082-06

3. Alternator with built-in regulator (open type, 50 A)

a The shape is subject to machine models.

1. Alternator 6. Internal electric circuit diagram


2. Alternator pulley 6A. Stator
3. Terminal B 6B. Regulator
4. Terminal E
5. Terminal R

140E-5 Series 67
SEN00082-06 10 Structure, function and maintenance standard

4. Alternator with built-in regulator (open type, 60 A)

a The shape is subject to machine models.

1. Alternator 6. Internal electric circuit diagram


2. Alternator pulley 6A. Field coil
3. Terminal B 6B. Initial excitation resistor
4. Terminal E 6C. Regulator
5. Terminal R

68 140E-5 Series
10 Structure, function and maintenance standard SEN00082-06

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

140E-5 Series 69
SEN00082-06 10 Structure, function and maintenance standard

5. Alternator with built-in regulator (open type, 75 A)

a The shape is subject to machine models.

1. Alternator 6. Internal electric circuit diagram


2. Alternator pulley 6A. Stator
3. Terminal B 6B. Regulator
4. Terminal E
5. Terminal R

Outside diameter of
Engine Machine model Type Specification Weight (kg)
pulley (mm)
D155AX-6, D155A-6 Open type (brushless) manufactured
24V, 75A
(If equipped) by SAWAFUJI DENKI
D275AX-5E0, Open type (brushless) manufactured
24V, 75A
D275A-5R by SAWAFUJI DENKI
Open type (brushless) manufactured
WA500-6, WA500-6R 24V, 75A
by SAWAFUJI DENKI
SAA6D140E-5 HD325-7, HD325-7R
Open type (brushless) manufactured
HD405-7, HD405-7R 24V, 75A
by SAWAFUJI DENKI
(If equipped)
HM350-2, HM350-2R
HM400-2, HM400-2R Open type (brushless) manufactured
24V, 75A
HM400-3M0, HM400-3R by SAWAFUJI DENKI
(If equipped)

70 140E-5 Series
10 Structure, function and maintenance standard SEN00082-06

140E-5 Series 71
SEN00082-06 10 Structure, function and maintenance standard

6. Alternator with built-in regulator (open type, 90 A)

a The shape is subject to machine models.

1. Alternator 6. Internal electric circuit diagram


2. Alternator pulley 6A. Field coil
3. Terminal B 6B. Initial excitation resistor
4. Terminal E 6C. Regulator
5. Terminal R

72 140E-5 Series
10 Structure, function and maintenance standard SEN00082-06

Outside diameter
Engine Machine model Type Specification Weight (kg)
of pulley (mm)
PC600-8, PC600LC-8,
PC600-8R, PC600LC-8R,
PC600-8E0, PC600LC-8E0,
PC600-8R1, PC600LC-8R1, Open type (brushless)
24V, 90A
PC700-8E0, PC700LC-8E0, manufactured by NIKKO DENKI
PC700-8R, PC700LC-8R,
PC700LC-8R1
(If equipped)
PC800-8, PC800LC-8, PC800-8R,
PC800LC-8R, PC800SE-8,
PC800SE-8R
PC850-8, PC850-8R
PC850SE-8, PC850SE-8R
SAA6D140E-5 PC800-8E0, PC800SE-8E0, Open type (brushless)
24V, 90A
PC850-8E0, PC850SE-8E0, manufactured by NIKKO DENKI
PC800LC-8E0
PC800-8R1, PC800SE-8R1
PC850-8R1, PC850SE-8R1
PC800LC-8R1
(If equipped)
D155AX-6, D155A-6 Open type (brushless)
24V, 90A
(If equipped) manufactured by NIKKO DENKI
D275AX-5E0, D275A-5R Open type (brushless)
24V, 90A
(If equipped) manufactured by NIKKO DENKI
WA500-6, WA500-6R Open type (brushless)
24V, 90A
(If equipped) manufactured by NIKKO DENKI

140E-5 Series 73
SEN00082-06 10 Structure, function and maintenance standard

Alternator mounting

a The shape is subject to machine models.

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
10 Structure, function and maintenance standard SEN00082-06

140E-5 Series 75
SEN00082-06 10 Structure, function and maintenance standard

Starting motor 1

For 7.5kW (for SDG400S-6B1 (HOKUETSU INDUSTRIES GENERATOR))

a The shape is subject to machine models.

E: To chassis ground 5. Terminal C


R: To alternator terminal R 6. Safety relay
S: To starting switch terminal C 7. External connection diagram
(2-pole connector type)
1. Pinion gear 7A. Safety relay section
2. Starting motor assembly 7B. Starting motor section
3. Magnetic switch 8. Jump start prohibition label
4. Terminal B 9. Jump start prevention cover

Number of Type of
Engine Machine model Type Specification Weight (kg)
pinion teeth connector
SDG400S-6B1
Water-resistant, oil-resistant
(HOKUETSU
SAA6D140E-5 type manufactured by 24V, 7.5kW 12 15.5 DT
INDUSTRIES
NIKKO DENKI
GENERATOR)

76 140E-5 Series
10 Structure, function and maintenance standard SEN00082-06

For 11kW (except SDG400S-6B1 (HOKUETSU INDUSTRIES GENERATOR))

a The shape is subject to machine models.

E: To chassis ground 5. Terminal C


R: To alternator terminal R 6. Safety relay
S: To starting switch terminal C 7. External connection diagram
(2-pole connector type)
1. Pinion gear 7A. Safety relay section
2. Starting motor assembly 7B. Starting motor section
3. Magnetic switch 8. Jump start prohibition label
4. Terminal B 9. Jump start prevention cover

Number of Type of
Engine Machine model Type Specification Weight (kg)
pinion teeth connector
Water-resistant, oil-resistant
SAA6D140E-5 All machines type manufactured by 24V, 11kW 12 18 DT
NIKKO DENKI

140E-5 Series 77
SEN00082-06 10 Structure, function and maintenance standard

Starting aid 1
Electric heater
For SAA6D140E-5

a The shape is subject to machine models.

1. Body Specifications
2. Heater coil Type of heater: Electrical intake air heater
3. Terminal q Rated voltage: 22 V (DC)
4. Connection diagram q Load current: 175 A

78 140E-5 Series
10 Structure, function and maintenance standard SEN00082-06

Engine controller 1

Features
Mounting of engine controller on engine
q Since the engine controller is mounted on the
engine, the operator can service it easily in the
field.
q The engine controller cooler (if equipped) is
prepared to cool the engine controller with the
fuel to secure the reliability of the mounted
engine controller.
q Vibrations are damped by the vibration-proof
rubber.

Unified specifications of engine controller


q Engine controller CM850 developed by the
cooperation between KOMATSU and CUM-
MINS is employed.

140E-5 Series 79
SEN00082-06

KOMATSU 140E-5 Series engine

Form No. SEN00082-06

© 2012 KOMATSU
All Rights Reserved
Printed in Japan 12-12 (01)

80
SEN00147-07

ENGINE 1SHOP MANUAL

140E-5 Series

20 Standard value table 1


Standard service value table
Standard service value table for testing, adjusting, and troubleshooting ........................................................ 2
Running-in standard and performance test standard.................................................................................... 19

140E-5 Series 1
SEN00147-07 20 Standard value table

Standard service value table for testing, adjusting, and troubleshooting

Engine SAA6D140E-5
Machine models D155AX-6
Performance Category

Standard value for


Item Measurement conditions Unit Repair limit
new machine

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


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

{mmHg} {Min. 950} {810}


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

At rated horsepower kPa Max. 2.94 3.92


Blow-by pressure
Engine coolant temperature: Min. 70°C {mmH2O} {Max. 300} {400}
At rated horsepower
MPa Min. 0.34 0.21
Engine oil temperature: SAE0W30EOS
Lubrication system

2
SAE5W40EOS {kg/cm } {Min. 3.5} {2.1}
Min. 80°C
Oil pressure SAE10W30DH
At low idle SAE15W40DH MPa Min. 0.10 0.08
Engine oil temperature: SAE30DH
{kg/cm2} {Min. 1.0} {0.8}
Min. 80°C
Oil temperature Whole speed range °C 90 to 110 120
Ratio to fuel consumption at continuous
Oil consumption % Max. 0.15 0.3
rated horsepower
Function of radiator Cracking pressure kPa
— —
pressure valve (Differential pressure) {kg/cm2}
Cooling system

Fan speed At rated speed rpm Hydraulically driven on machine side


Deflection under finger pressure of 98 N
Fan belt tension mm Hydraulically driven on machine side
{10 kg}
Deflection under finger pressure of 98 N
Alternator belt tension mm 13 to 16 13 to 16
{10 kg}

2 140E-5 Series
20 Standard value table SEN00147-07

Engine SAA6D140E-5
Machine models D155A-6
Performance Category

Standard value for


Item Measurement conditions Unit Repair limit
new machine

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


Speed
Min. speed with no load rpm 740(+40/0) 740(+40/0)
Necessary speed for At 0°C (without starting aid) rpm Min. 110 —
starting At –20°C (with starting aid) rpm Min. 85 —
kPa Max. 3.73 7.47
Air intake resistance Whole speed range
{mmH2O} {Max. 380} {762}
kPa Min. 85 72
Air boost pressure At rated horsepower
Air intake and exhaust system

{mmHg} {Min. 640} {540}


kPa Min. 92 77
Exhaust pressure At rated horsepower
{mmHg} {Min. 690} {580}
Exhaust temperature Whole speed range (20°C) °C 670 720
% (Bosch Max. 30 40
At sudden acceleration (Low  High)
index) (Max. 3.0) (4.0)
Bosch
Exhaust gas color At rated horsepower Max. 1.5 2.5
index
Bosch
At high idle Max. 1.0 2.0
index
Intake valve mm 0.35 —
Valve clearance
Exhaust valve mm 0.57 —
Engine oil temperature: 40 to 60°C MPa Min. 4.1 2.8
Compression pressure
Engine speed: 200 to 250 rpm {kg/cm2} {Min. 42} {29}
Body

At rated horsepower kPa Max. 2.94 3.92


Blow-by pressure
Engine coolant temperature: Min. 70°C {mmH2O} {Max. 300} {400}
At rated horsepower
MPa Min. 0.34 0.21
Engine oil temperature: SAE0W30EOS
Lubrication system

SAE5W40EOS {kg/cm2} {Min. 3.5} {2.1}


Min. 80°C
Oil pressure SAE10W30DH
At low idle SAE15W40DH MPa Min. 0.10 0.08
Engine oil temperature: SAE30DH
{kg/cm2} {Min. 1.0} {0.8}
Min. 80°C
Oil temperature Whole speed range °C 90 to 110 120
Ratio to fuel consumption at continuous
Oil consumption % Max. 0.15 0.3
rated horsepower
Function of radiator Cracking pressure kPa
— —
pressure valve (Differential pressure) {kg/cm2}
Cooling system

Fan speed At rated speed rpm Hydraulically driven on machine side


Deflection under finger pressure of 98 N
Fan belt tension mm Hydraulically driven on machine side
{10 kg}
Deflection under finger pressure of 98 N
Alternator belt tension mm 13 to 16 13 to 16
{10 kg}

140E-5 Series 3
SEN00147-07 20 Standard value table

Engine SAA6D140E-5
Machine models D275AX-5E0
Performance Category

Standard value for


Item Measurement conditions Unit Repair limit
new machine

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


Speed
Min. speed with no load rpm 700 ± 50 700 ± 50
Necessary speed for At 0°C (without starting aid) rpm Min. 110 —
starting At –20°C (with starting aid) rpm Min. 85 —
kPa Max. 3.73 7.47
Air intake resistance Whole speed range
{mmH2O} {Max. 380} {762}
kPa Min. 169 144
Air boost pressure At rated horsepower
{mmHg} {Min. 1,270} {1,080}
kPa Min. 169 144
Exhaust pressure At rated horsepower
Air intake and exhaust system

{mmHg} {Min. 1,270} {1,080}


Exhaust temperature Whole speed range (20°C) °C Max. 620 670
% (Bosch Max. 25 35
At sudden acceleration (Low  High)
index) (Max. 2.5) (3.5)
Bosch
Exhaust gas color At rated horsepower Max. 1.5 2.5
index
Bosch
At high idle Max. 1.0 2.0
index
Intake valve mm 0.35 —
Valve clearance
Exhaust valve mm 0.57 —
MPa Min. 1.18 Min. 1.18
At low idle
EGR valve and bypass {kg/cm2} {Min. 12} {Min. 12}
valve drive oil pressure MPa Min. 1.43 Min. 1.43
At high idle
{kg/cm2} {Min. 14.6} {Min. 14.6}
Engine oil temperature: 40 to 60°C MPa Min. 4.1 2.8
Compression pressure
Engine speed: 200 to 250 rpm {kg/cm2} {Min. 42} {29}
Body

At rated horsepower kPa Max. 2.94 3.92


Blow-by pressure
Engine coolant temperature: Min. 70°C {mmH2O} {Max. 300} {400}
At rated horsepower
SAE0W30EOS MPa Min. 0.34 0.21
Engine oil temperature:
{kg/cm2} {Min. 3.5} {2.1}
Lubrication system

Min. 80°C SAE5W40EOS


Oil pressure SAE10W30DH
At low idle SAE15W40DH MPa Min. 0.10 0.08
Engine oil temperature:
SAE30DH {kg/cm2} {Min. 1.0} {0.8}
Min. 80°C
Oil temperature Whole speed range °C 90 to 110 120
Ratio to fuel consumption at continuous
Oil consumption % Max. 0.15 0.3
rated horsepower
Function of radiator Cracking pressure kPa
— —
pressure valve (Differential pressure) {kg/cm2}
Cooling system

Fan speed At rated speed rpm Hydraulically driven on machine side


Deflection under finger pressure of 98 N
Fan belt tension mm Hydraulically driven on machine side
{10 kg}
Deflection under finger pressure of 98 N
Alternator belt tension mm 13 to 16 13 to 16
{10 kg}

4 140E-5 Series
20 Standard value table SEN00147-07

Engine SAA6D140E-5
Machine models D275A-5R
Performance Category

Standard value for


Item Measurement conditions Unit Repair limit
new machine

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


Speed
Min. speed with no load rpm 700 ± 50 700 ± 50
Necessary speed for At 0°C (without starting aid) rpm Min. 110 —
starting At –20°C (with starting aid) rpm Min. 85 —
kPa Max. 3.73 7.47
Air intake resistance Whole speed range
{mmH2O} {Max. 380} {762}
kPa Min. 116 99
Air boost pressure At rated horsepower
Air intake and exhaust system

{mmHg} {Min. 870} {740}


kPa Min. 116 99
Exhaust pressure At rated horsepower
{mmHg} {Min. 870} {740}
Exhaust temperature Whole speed range (20°C) °C Max. 670 720
% (Bosch Max. 40 50
At sudden acceleration (Low  High)
index) (Max. 4.0) (5.0)
Bosch
Exhaust gas color At rated horsepower Max. 1.5 2.5
index
Bosch
At high idle Max. 1.0 2.0
index
Intake valve mm 0.35 —
Valve clearance
Exhaust valve mm 0.57 —
Engine oil temperature: 40 to 60°C MPa Min. 4.1 2.8
Compression pressure
Engine speed: 200 to 250 rpm {kg/cm2} {Min. 42} {29}
Body

At rated horsepower kPa Max. 2.94 3.92


Blow-by pressure
Engine coolant temperature: Min. 70°C {mmH2O} {Max. 300} {400}
At rated horsepower
SAE0W30EOS MPa Min. 0.34 0.21
Engine oil temperature:
{kg/cm2} {Min. 3.5} {2.1}
Lubrication system

Min. 80°C SAE5W40EOS


Oil pressure SAE10W30DH
At low idle SAE15W40DH MPa Min. 0.10 0.08
Engine oil temperature:
SAE30DH {kg/cm2} {Min. 1.0} {0.8}
Min. 80°C
Oil temperature Whole speed range °C 90 to 110 120
Ratio to fuel consumption at continuous
Oil consumption % Max. 0.15 0.3
rated horsepower
Function of radiator Cracking pressure kPa
— —
pressure valve (Differential pressure) {kg/cm2}
Cooling system

Fan speed At rated speed rpm Hydraulically driven on machine side


Deflection under finger pressure of 98 N
Fan belt tension mm Hydraulically driven on machine side
{10 kg}
Deflection under finger pressure of 98 N
Alternator belt tension mm 13 to 16 13 to 16
{10 kg}

140E-5 Series 5
SEN00147-07 20 Standard value table

Engine SAA6D140E-5
PC600-8, PC600LC-8
Machine models PC600-8E0, PC600LC-8E0
PC700-8E0, PC700LC-8E0
Performance Category

Standard value for


Item Measurement conditions Unit Repair limit
new machine

Max. speed with no load rpm 1,950 ± 50 1,950 ± 50


Speed
Min. speed with no load rpm 800 ± 25 800 ± 25
Necessary speed for At 0°C (without starting aid) rpm Min. 110 —
starting At –20°C (with starting aid) rpm Min. 85 —
kPa Max. 3.73 7.47
Air intake resistance Whole speed range
{mmH2O} {Max. 380} {762}
kPa Min. 147 125
Air boost pressure At rated horsepower
{mmHg} {Min. 1,100} {940}
kPa Min. 145 128
Exhaust pressure At rated horsepower
Air intake and exhaust system

{mmHg} {Min. 1,090} {930}


Exhaust temperature Whole speed range (20°C) °C Max. 650 700
% (Bosch Max. 25 35
At sudden acceleration (Low  High)
index) (Max. 2.5) (3.5)
Bosch
Exhaust gas color At rated horsepower Max. 1.5 2.5
index
Bosch
At high idle Max. 1.0 2.0
index
Intake valve mm 0.35 —
Valve clearance
Exhaust valve mm 0.57 —
MPa Min. 1.18 Min. 1.18
At low idle
EGR valve and bypass {kg/cm2} {Min. 12} {Min. 12}
valve drive oil pressure MPa Min. 1.43 Min. 1.43
At high idle
{kg/cm2} {Min. 14.6} {Min. 14.6}
Engine oil temperature: 40 to 60°C MPa Min. 4.1 2.8
Compression pressure
Engine speed: 200 to 250 rpm {kg/cm2} {Min. 42} {29}
Body

At rated horsepower kPa Max. 2.94 3.92


Blow-by pressure
Engine coolant temperature: Min. 70°C {mmH2O} {Max. 300} {400}
At rated horsepower
SAE0W30EOS MPa Min. 0.34 0.21
Engine oil temperature:
{kg/cm2} {Min. 3.5} {2.1}
Lubrication system

Min. 80°C SAE5W40EOS


Oil pressure SAE10W30DH
At low idle SAE15W40DH MPa Min. 0.10 0.08
Engine oil temperature:
SAE30DH {kg/cm2} {Min. 1.0} {0.8}
Min. 80°C
Oil temperature Whole speed range °C 90 to 110 120
Ratio to fuel consumption at continuous
Oil consumption % Max. 0.15 0.3
rated horsepower
Function of radiator Cracking pressure kPa
— —
pressure valve (Differential pressure) {kg/cm2}
Cooling system

Fan speed At rated speed rpm Hydraulically driven on machine side


Deflection under finger pressure of 98 N
Fan belt tension mm Hydraulically driven on machine side
{10 kg}
Deflection under finger pressure of 98 N
Alternator belt tension mm 13 to 16 13 to 16
{10 kg}

6 140E-5 Series
20 Standard value table SEN00147-07

Engine SAA6D140E-5
PC600-8R, PC600LC-8R,
PC600-8R1, PC600LC-8R1,
Machine models
PC700-8R, PC700LC-8R,
PC700LC-8R1
Performance Category

Standard value for


Item Measurement conditions Unit Repair limit
new machine

Max. speed with no load rpm 1,950 ± 50 1,950 ± 50


Speed
Min. speed with no load rpm 800 ± 25 800 ± 25
Necessary speed for At 0°C (without starting aid) rpm Min. 110 —
starting At –20°C (with starting aid) rpm Min. 85 —
kPa Max. 3.73 7.47
Air intake resistance Whole speed range
{mmH2O} {Max. 380} {762}
kPa Min. 120 102
Air boost pressure At rated horsepower
Air intake and exhaust system

{mmHg} {Min. 900} {760}


kPa Min. 116 99
Exhaust pressure At rated horsepower
{mmHg} {Min. 870} {740}
Exhaust temperature Whole speed range (20°C) °C Max. 700 750
% (Bosch Max. 30 40
At sudden acceleration (Low  High)
index) (Max. 3.0) (4.0)
Bosch
Exhaust gas color At rated horsepower Max. 1.5 2.5
index
Bosch
At high idle Max. 1.0 2.0
index
Intake valve mm 0.35 —
Valve clearance
Exhaust valve mm 0.57 —
Engine oil temperature: 40 to 60°C MPa Min. 4.1 2.8
Compression pressure
Engine speed: 200 to 250 rpm {kg/cm2} {Min. 42} {29}
Body

At rated horsepower kPa Max. 2.94 3.92


Blow-by pressure
Engine coolant temperature: Min. 70°C {mmH2O} {Max. 300} {400}
At rated horsepower
SAE0W30EOS MPa Min. 0.34 0.21
Engine oil temperature:
{kg/cm2} {Min. 3.5} {2.1}
Lubrication system

Min. 80°C SAE5W40EOS


Oil pressure SAE10W30DH
At low idle SAE15W40DH MPa Min. 0.10 0.08
Engine oil temperature:
SAE30DH {kg/cm2} {Min. 1.0} {0.8}
Min. 80°C
Oil temperature Whole speed range °C 90 to 110 120
Ratio to fuel consumption at continuous
Oil consumption % Max. 0.15 0.3
rated horsepower
Function of radiator Cracking pressure kPa
— —
pressure valve (Differential pressure) {kg/cm2}
Cooling system

Fan speed At rated speed rpm Hydraulically driven on machine side


Deflection under finger pressure of 98 N
Fan belt tension mm Hydraulically driven on machine side
{10 kg}
Deflection under finger pressure of 98 N
Alternator belt tension mm 13 to 16 13 to 16
{10 kg}

140E-5 Series 7
SEN00147-07 20 Standard value table

Engine SAA6D140E-5
PC800-8, PC800SE-8, PC800LC-8
PC850-8, PC850SE-8
Machine models PC800-8E0, PC800SE-8E0,
PC800LC-8E0
PC850-8E0, PC850SE-8E0
Performance Category

Standard value for


Item Measurement conditions Unit Repair limit
new machine

Max. speed with no load rpm 1,980 ± 50 1,980 ± 50


Speed
Min. speed with no load rpm 825 ± 25 825 ± 25
Necessary speed for At 0°C (without starting aid) rpm Min. 110 —
starting At –20°C (with starting aid) rpm Min. 85 —
kPa Max. 3.73 7.47
Air intake resistance Whole speed range
{mmH2O} {Max. 380} {762}
kPa Min. 184 157
Air boost pressure At rated horsepower
{mmHg} {Min. 1,380} {1,180}
kPa Min. 172 147
Exhaust pressure At rated horsepower
Air intake and exhaust system

{mmHg} {Min. 1,290} {1,100}


Exhaust temperature Whole speed range (20°C) °C Max. 650 700
% (Bosch Max. 25 35
At sudden acceleration (Low  High)
index) (Max. 2.5) (3.5)
Bosch
Exhaust gas color At rated horsepower Max. 1.5 2.5
index
Bosch
At high idle Max. 1.0 2.0
index
Intake valve mm 0.35 —
Valve clearance
Exhaust valve mm 0.57 —
MPa Min. 1.18 Min. 1.18
At low idle
EGR valve and bypass {kg/cm2} {Min. 12} {Min. 12}
valve drive oil pressure MPa Min. 1.43 Min. 1.43
At high idle
{kg/cm2} {Min. 14.6} {Min. 14.6}
Engine oil temperature: 40 to 60°C MPa Min. 4.1 2.8
Compression pressure
Engine speed: 200 to 250 rpm {kg/cm2} {Min. 42} {29}
Body

At rated horsepower kPa Max. 2.94 3.92


Blow-by pressure
Engine coolant temperature: Min. 70°C {mmH2O} {Max. 300} {400}
At rated horsepower SAE0W30EOS MPa Min. 0.34 0.21
Engine oil temperature:
SAE5W40EOS {kg/cm2}
Lubrication system

{Min. 3.5} {2.1}


Min. 80°C
Oil pressure SAE10W30DH
At low idle
SAE15W40DH MPa Min. 0.10 0.08
Engine oil temperature: 2
SAE30DH {kg/cm } {Min. 1.0} {0.8}
Min. 80°C
Oil temperature Whole speed range °C 90 to 110 120
Ratio to fuel consumption at continuous
Oil consumption % Max. 0.15 Max. 0.3
rated horsepower
Function of radiator Cracking pressure kPa
— —
pressure valve (Differential pressure) {kg/cm2}
Cooling system

Fan speed At rated speed rpm Hydraulically driven on machine side


Deflection under finger pressure of 98 N
Fan belt tension mm Hydraulically driven on machine side
{10 kg}
Deflection under finger pressure of 98 N
Alternator belt tension mm 13 to 16 13 to 6
{10 kg}

8 140E-5 Series
20 Standard value table SEN00147-07

Engine SAA6D140E-5
PC800-8R, PC800SE-8R,
PC800LC-8R
PC850-8R, PC850SE-8R
Machine models
PC800-8R1, PC800SE-8R1,
PC800LC-8R1, PC850-8R1,
PC850SE-8R1
Performance Category

Standard value for


Item Measurement conditions Unit Repair limit
new machine

Max. speed with no load rpm 1,980 ± 50 1,980 ± 50


Speed
Min. speed with no load rpm 825 ± 25 825 ± 25
Necessary speed for At 0°C (without starting aid) rpm Min. 110 —
starting At –20°C (with starting aid) rpm Min. 85 —
kPa Max. 3.73 7.47
Air intake resistance Whole speed range
{mmH2O} {Max. 380} {762}
kPa Min. 128 108
Air boost pressure At rated horsepower
Air intake and exhaust system

{mmHg} {Min. 960} {810}


kPa Min. 113 96
Exhaust pressure At rated horsepower
{mmHg} {Min. 850} {720}
Exhaust temperature Whole speed range (20°C) °C Max. 700 750
% (Bosch Max. 30 40
At sudden acceleration (Low  High)
index) (Max. 3.0) (4.0)
Bosch
Exhaust gas color At rated horsepower Max. 1.5 2.5
index
Bosch
At high idle Max. 1.0 2.0
index
Intake valve mm 0.35 —
Valve clearance
Exhaust valve mm 0.57 —
Engine oil temperature: 40 to 60°C MPa Min. 4.1 2.8
Compression pressure
Engine speed: 200 to 250 rpm {kg/cm2} {Min. 42} {29}
Body

At rated horsepower kPa Max. 2.94 3.92


Blow-by pressure
Engine coolant temperature: Min. 70°C {mmH2O} {Max. 300} {400}
At rated horsepower SAE0W30EOS MPa Min. 0.34 0.21
Engine oil temperature:
SAE5W40EOS {kg/cm2}
Lubrication system

{Min. 3.5} {2.1}


Min. 80°C
Oil pressure SAE10W30DH
At low idle
SAE15W40DH MPa Min. 0.10 0.08
Engine oil temperature:
SAE30DH {kg/cm2} {Min. 1.0} {0.8}
Min. 80°C
Oil temperature Whole speed range °C 90 to 110 120
Ratio to fuel consumption at continuous
Oil consumption % Max. 0.15 Max. 0.3
rated horsepower
Function of radiator Cracking pressure kPa
— —
pressure valve (Differential pressure) {kg/cm2}
Cooling system

Fan speed At rated speed rpm Hydraulically driven on machine side


Deflection under finger pressure of 98 N
Fan belt tension mm Hydraulically driven on machine side
{10 kg}
Deflection under finger pressure of 98 N
Alternator belt tension mm 13 to 16 13 to 6
{10 kg}

140E-5 Series 9
SEN00147-07 20 Standard value table

Engine SAA6D140E-5
Machine models WA500-6
Performance Category

Standard value for


Item Measurement conditions Unit Repair limit
new machine

Max. speed with no load rpm 2,150 ± 50 2,150 ± 50


Speed
Min. speed with no load rpm 700 ± 25 700 ± 25
Necessary speed for At 0°C (without starting aid) rpm Min. 110 —
starting At –20°C (with starting aid) rpm Min. 85 —
kPa Max. 3.73 7.47
Air intake resistance Whole speed range
{mmH2O} {Max. 380} {762}
kPa Min. 116 89
Air boost pressure At rated horsepower
{mmHg} {Min. 870} {670}
kPa Min. 121 91
Exhaust pressure At rated horsepower
Air intake and exhaust system

{mmHg} {Min. 910} {680}


Exhaust temperature Whole speed range (20°C) °C Max. 650 700
% (Bosch Max. 25 35
At sudden acceleration (Low  High)
index) (Max. 2.5) (3.5)
Bosch
Exhaust gas color At rated horsepower Max. 1.5 2.5
index
Bosch
At high idle Max. 1.0 2.0
index
Intake valve mm 0.35 —
Valve clearance
Exhaust valve mm 0.57 —
MPa Min. 1.18 Min. 1.18
At low idle
EGR valve and bypass {kg/cm2} {Min. 12} {Min. 12}
valve drive oil pressure MPa Min. 1.43 Min. 1.43
At high idle
{kg/cm2} {Min. 14.6} {Min. 14.6}
Engine oil temperature: 40 to 60°C MPa Min. 4.1 2.8
Compression pressure
Engine speed: 200 to 250 rpm {kg/cm2} {Min. 42} {29}
Body

At rated horsepower kPa Max. 2.94 3.92


Blow-by pressure
Engine coolant temperature: Min. 70°C {mmH2O} {Max. 300} {400}
At rated horsepower
MPa Min. 0.34 0.21
Engine oil temperature: SAE0W30EOS
Lubrication system

SAE5W40EOS {kg/cm2} {Min. 3.5} {2.1}


Min. 80°C
Oil pressure SAE10W30DH
At low idle SAE15W40DH MPa Min. 0.10 0.08
Engine oil temperature: SAE30DH
{kg/cm2} {Min. 1.0} {0.8}
Min. 80°C
Oil temperature Whole speed range °C 90 to 110 120
Ratio to fuel consumption at continuous
Oil consumption % Max. 0.15 0.3
rated horsepower
Function of radiator Cracking pressure kPa
— —
pressure valve (Differential pressure) {kg/cm2}
Cooling system

Fan speed At rated speed rpm Hydraulically driven on machine side


Deflection under finger pressure of 98 N
Fan belt tension mm Hydraulically driven on machine side
{10 kg}
Deflection under finger pressure of 98 N
Alternator belt tension mm 13 to 16 13 to 16
{10 kg}

10 140E-5 Series
20 Standard value table SEN00147-07

Engine SAA6D140E-5
Machine models WA500-6R
Performance Category

Standard value for


Item Measurement conditions Unit Repair limit
new machine

Max. speed with no load rpm 2,150 ± 50 2,150 ± 50


Speed
Min. speed with no load rpm 700 ± 25 700 ± 25
Necessary speed for At 0°C (without starting aid) rpm Min. 110 —
starting At –20°C (with starting aid) rpm Min. 85 —
Air intake kPa Max. 3.73 7.47
Whole speed range
resistance {mmH2O} {Max. 380} {762}
Air boost kPa Min. 89 76
At rated horsepower
pressure {mmHg} {Min. 670} {570}
Air intake and exhaust system

Exhaust kPa Min. 101 85


At rated horsepower
pressure {mmHg} {Min. 760} {640}
Exhaust
Whole speed range (20°C) °C Max. 670 720
temperature
% (Bosch Max. 40 50
At sudden acceleration (Low  High)
index) (Max. 4.0) (5.0)
Bosch
Exhaust gas color At rated horsepower Max. 1.5 2.5
index
Bosch
At high idle Max. 1.0 2.0
index
Intake valve mm 0.35 —
Valve clearance
Exhaust valve mm 0.57 —
Engine oil temperature: 40 to 60°C MPa Min. 4.1 2.8
Compression pressure
Engine speed: 200 to 250 rpm {kg/cm2} {Min. 42} {29}
Body

Blow-by At rated horsepower kPa Max. 2.94 3.92


pressure Engine coolant temperature: Min. 70°C {mmH2O} {Max. 300} {400}
At rated horsepower
MPa Min. 0.34 0.21
Engine oil temperature: SAE0W30EOS
Lubrication system

2
SAE5W40EOS {kg/cm } {Min. 3.5} {2.1}
Min. 80°C
Oil pressure SAE10W30DH
At low idle SAE15W40DH MPa Min. 0.10 0.08
Engine oil temperature: SAE30DH
{kg/cm2} {Min. 1.0} {0.8}
Min. 80°C
Oil temperature Whole speed range °C 90 to 110 120
Ratio to fuel consumption at continuous
Oil consumption % Max. 0.15 0.3
rated horsepower
Function of
Cracking pressure kPa
radiator — —
(Differential pressure) {kg/cm2}
Cooling system

pressure valve
Fan speed At rated speed rpm Hydraulically driven on machine side
Deflection under finger pressure of 98 N
Fan belt tension mm Hydraulically driven on machine side
{10 kg}
Deflection under finger pressure of 98 N
Alternator belt tension mm 13 to 16 13 to 16
{10 kg}

140E-5 Series 11
SEN00147-07 20 Standard value table

Engine SAA6D140E-5
HD325-7
Machine models
HD405-7
Performance Category

Standard value for


Item Measurement conditions Unit Repair limit
new machine

Max. speed with no load rpm 2,300 ± 25 2,300 ± 25


Speed
Min. speed with no load rpm 725 ± 25 725 ± 25
Necessary speed for At 0°C (without starting aid) rpm Min. 110 —
starting At –20°C (with starting aid) rpm Min. 85 —
kPa Max. 3.73 7.47
Air intake resistance Whole speed range
{mmH2O} {Max. 380} {762}
kPa Min. 183 156
Air boost pressure At rated horsepower
{mmHg} {Min. 1,370} {1,170}
kPa Min. 163 139
Exhaust pressure At rated horsepower
Air intake and exhaust system

{mmHg} {Min. 1,220} {1,040}


Exhaust temperature Whole speed range (20°C) °C Max. 650 700
% (Bosch Max. 25 35
At sudden acceleration (Low  High)
index) (Max. 2.5) (3.5)
Bosch
Exhaust gas color At rated horsepower Max. 1.5 2.5
index
Bosch
At high idle Max. 1.0 2.0
index
Intake valve mm 0.35 —
Valve clearance
Exhaust valve mm 0.57 —
MPa Min. 1.18 Min. 1.18
At low idle
EGR valve and bypass {kg/cm2} {Min. 12} {Min. 12}
valve drive oil pressure MPa Min. 1.43 Min. 1.43
At high idle
{kg/cm2} {Min. 14.6} {Min. 14.6}
Engine oil temperature: 40 to 60°C MPa Min. 4.1 2.8
Compression pressure
Engine speed: 200 to 250 rpm {kg/cm2} {Min. 42} {29}
Body

At rated horsepower kPa Max. 2.94 3.92


Blow-by pressure
Engine coolant temperature: Min. 70°C {mmH2O} {Max. 300} {400}
At rated horsepower SAE0W30EOS MPa Min. 0.34 0.21
Engine oil temperature:
SAE5W40EOS {kg/cm2}
Lubrication system

{Min. 3.5} {2.1}


Min. 80°C
Oil pressure SAE10W30DH
At low idle
SAE15W40DH MPa Min. 0.10 0.08
Engine oil temperature:
SAE30DH {kg/cm2} {Min. 1.0} {0.8}
Min. 80°C
Oil temperature Whole speed range °C 90 to 110 120
Ratio to fuel consumption at continuous
Oil consumption % Max. 0.15 0.3
rated horsepower
Function of radiator Cracking pressure kPa
— —
pressure valve (Differential pressure) {kg/cm2}
Cooling system

Fan speed At rated speed rpm 1,020 ± 30 1,020 ± 30


17 to 19
Deflection under finger pressure of 98 N 13 to 15
Fan belt tension mm (when retight-
{10 kg} (when new)
ened)
Deflection under finger pressure of 98 N
Alternator belt tension mm 13 to 16 13 to 16
{10 kg}

12 140E-5 Series
20 Standard value table SEN00147-07

Engine SAA6D140E-5
HD325-7R
Machine models
HD405-7R
Performance Category

Standard value for


Item Measurement conditions Unit Repair limit
new machine

Max. speed with no load rpm 2,300 ± 25 2,300 ± 25


Speed
Min. speed with no load rpm 725 ± 25 725 ± 25
Necessary speed for At 0°C (without starting aid) rpm Min. 110 —
starting At –20°C (with starting aid) rpm Min. 85 —
kPa Max. 3.73 7.47
Air intake resistance Whole speed range
{mmH2O} {Max. 380} {762}
kPa Min. 135 115
Air boost pressure At rated horsepower
Air intake and exhaust system

{mmHg} {Min. 1,010} {860}


kPa Min. 121 103
Exhaust pressure At rated horsepower
{mmHg} {Min. 910} {770}
Exhaust temperature Whole speed range (20°C) °C Max. 680 730
% (Bosch Max. 40 50
At sudden acceleration (Low  High)
index) (Max. 4.0) (5.0)
Bosch
Exhaust gas color At rated horsepower Max. 1.5 2.5
index
Bosch
At high idle Max. 1.0 2.0
index
Intake valve mm 0.35 —
Valve clearance
Exhaust valve mm 0.57 —
Engine oil temperature: 40 to 60°C MPa Min. 4.1 2.8
Compression pressure
Engine speed: 200 to 250 rpm {kg/cm2} {Min. 42} {29}
Body

At rated horsepower kPa Max. 2.94 3.92


Blow-by pressure
Engine coolant temperature: Min. 70°C {mmH2O} {Max. 300} {400}
At rated horsepower SAE0W30EOS MPa Min. 0.34 0.21
Engine oil temperature:
SAE5W40EOS {kg/cm2}
Lubrication system

{Min. 3.5} {2.1}


Min. 80°C
Oil pressure SAE10W30DH
At low idle
SAE15W40DH MPa Min. 0.10 0.08
Engine oil temperature: 2
SAE30DH {kg/cm } {Min. 1.0} {0.8}
Min. 80°C
Oil temperature Whole speed range °C 90 to 110 120
Ratio to fuel consumption at continuous
Oil consumption % Max. 0.15 0.3
rated horsepower
Function of radiator Cracking pressure kPa
— —
pressure valve (Differential pressure) {kg/cm2}
Cooling system

Fan speed At rated speed rpm 1,020 ± 30 1,020 ± 30


17 to 19
Deflection under finger pressure of 98 N 13 to 15
Fan belt tension mm (when retight-
{10 kg} (when new)
ened)
Deflection under finger pressure of 98 N
Alternator belt tension mm 13 to 16 13 to 16
{10 kg}

140E-5 Series 13
SEN00147-07 20 Standard value table

Engine SAA6D140E-5
Machine models HM350-2
Performance Category

Standard value for


Item Measurement conditions Unit Repair limit
new machine

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


Speed
Min. speed with no load rpm 725 ± 25 725 ± 25
Necessary speed for At 0°C (without starting aid) rpm Min. 110 —
starting At –20°C (with starting aid) rpm Min. 85 —
kPa Max. 3.73 7.47
Air intake resistance Whole speed range
{mmH2O} {Max. 380} {762}
kPa Min. 145 124
Air boost pressure At rated horsepower
{mmHg} {Min. 1,090} {930}
kPa Min. 148 127
Exhaust pressure At rated horsepower
Air intake and exhaust system

{mmHg} {Min. 1,110} {950}


Exhaust temperature Whole speed range (20°C) °C Max. 620 670
% (Bosch Max. 25 35
At sudden acceleration (Low  High)
index) (Max. 2.5) (3.5)
Bosch
Exhaust gas color At rated horsepower Max. 1.5 2.5
index
Bosch
At high idle Max. 1.0 2.0
index
Intake valve mm 0.35 —
Valve clearance
Exhaust valve mm 0.57 —
MPa Min. 1.18 Min. 1.18
At low idle
EGR valve and bypass {kg/cm2} {Min. 12} {Min. 12}
valve drive oil pressure MPa Min. 1.43 Min. 1.43
At high idle
{kg/cm2} {Min. 14.6} {Min. 14.6}
Engine oil temperature: 40 to 60°C MPa Min. 4.1 2.8
Compression pressure
Engine speed: 200 to 250 rpm {kg/cm2} {Min. 42} {29}
Body

At rated horsepower kPa Max. 2.94 3.92


Blow-by pressure
Engine coolant temperature: Min. 70°C {mmH2O} {Max. 300} {400}
At rated horsepower SAE0W30EOS MPa Min. 0.34 0.21
Engine oil temperature:
SAE5W40EOS {kg/cm2}
Lubrication system

{Min. 3.5} {2.1}


Min. 80°C
Oil pressure SAE10W30DH
At low idle
SAE15W40DH MPa Min. 0.10 0.08
Engine oil temperature:
SAE30DH {kg/cm2} {Min. 1.0} {0.8}
Min. 80°C
Oil temperature Whole speed range °C 90 to 110 120
Ratio to fuel consumption at continuous
Oil consumption % Max. 0.15 0.3
rated horsepower
Function of radiator Cracking pressure kPa
— —
pressure valve (Differential pressure) {kg/cm2}
Cooling system

Fan speed At rated speed rpm 1,256 ± 38 1,256 ± 38


17 to 19
Deflection under finger pressure of 98 N 13 to 15
Fan belt tension mm (when retight-
{10 kg} (when new)
ened)
Deflection under finger pressure of 98 N
Alternator belt tension mm 13 to 16 13 to 16
{10 kg}

14 140E-5 Series
20 Standard value table SEN00147-07

Engine SAA6D140E-5
Machine models HM350-2R
Performance Category

Standard value for


Item Measurement conditions Unit Repair limit
new machine

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


Speed
Min. speed with no load rpm 725 ± 25 725 ± 25
Necessary speed for At 0°C (without starting aid) rpm Min. 110 —
starting At –20°C (with starting aid) rpm Min. 85 —
kPa Max. 3.73 7.47
Air intake resistance Whole speed range
{mmH2O} {Max. 380} {762}
kPa Min. 98 83
Air boost pressure At rated horsepower
Air intake and exhaust system

{mmHg} {Min. 730} {620}


kPa Min. 104 88
Exhaust pressure At rated horsepower
{mmHg} {Min. 780} {660}
Exhaust temperature Whole speed range (20°C) °C Max. 670 720
% (Bosch Max. 40 50
At sudden acceleration (Low  High)
index) (Max. 4.0) (5.0)
Bosch
Exhaust gas color At rated horsepower Max. 1.5 2.5
index
Bosch
At high idle Max. 1.0 2.0
index
Intake valve mm 0.35 —
Valve clearance
Exhaust valve mm 0.57 —
Engine oil temperature: 40 to 60°C MPa Min. 4.1 2.8
Compression pressure
Engine speed: 200 to 250 rpm {kg/cm2} {Min. 42} {29}
Body

At rated horsepower kPa Max. 2.94 3.92


Blow-by pressure
Engine coolant temperature: Min. 70°C {mmH2O} {Max. 300} {400}
At rated horsepower
SAE0W30EOS MPa Min. 0.34 0.21
Engine oil temperature:
{kg/cm2} {Min. 3.5} {2.1}
Lubrication system

Min. 80°C SAE5W40EOS


Oil pressure SAE10W30DH
At low idle SAE15W40DH MPa Min. 0.10 0.08
Engine oil temperature:
SAE30DH {kg/cm2} {Min. 1.0} {0.8}
Min. 80°C
Oil temperature Whole speed range °C 90 to 110 120
Ratio to fuel consumption at continuous
Oil consumption % Max. 0.15 0.3
rated horsepower
Function of radiator Cracking pressure kPa
— —
pressure valve (Differential pressure) {kg/cm2}
Cooling system

Fan speed At rated speed rpm 1,256 ± 38 1,256 ± 38


17 to 19
Deflection under finger pressure of 98 N 13 to 15
Fan belt tension mm (when retight-
{10 kg} (when new)
ened)
Deflection under finger pressure of 98 N
Alternator belt tension mm 13 to 16 13 to 16
{10 kg}

140E-5 Series 15
SEN00147-07 20 Standard value table

Engine SAA6D140E-5
Machine models HM400-2, HM400-3M0
Performance Category

Standard value for


Item Measurement conditions Unit Repair limit
new machine

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


Speed
Min. speed with no load rpm 725 ± 25 725 ± 25
Necessary speed for At 0°C (without starting aid) rpm Min. 110 —
starting At –20°C (with starting aid) rpm Min. 85 —
kPa Max. 3.73 7.47
Air intake resistance Air intake resistance
{mmH2O} {Max. 380} {762}
kPa Min. 160 136
Air boost pressure At rated horsepower
{mmHg} {Min. 1,200} {1,020}
kPa Min. 163 139
Exhaust pressure At rated horsepower
Air intake and exhaust system

{mmHg} {Min. 1,220} {1,040}


Exhaust temperature Whole speed range (20°C) °C Max. 650 700
% (Bosch Max. 25 35
At sudden acceleration (Low  High)
index) (Max. 2.5) (3.5)
Bosch
Exhaust gas color At rated horsepower Max. 1.5 2.5
index
Bosch
At high idle Max. 1.0 2.0
index
Intake valve mm 0.35 —
Valve clearance
Exhaust valve mm 0.57 —
MPa Min. 1.18 Min. 1.18
At low idle
EGR valve and bypass {kg/cm2} {Min. 12} {Min. 12}
valve drive oil pressure MPa Min. 1.43 Min. 1.43
At high idle
{kg/cm2} {Min. 14.6} {Min. 14.6}
Engine oil temperature: 40 to 60°C MPa Min. 4.1 2.8
Compression pressure
Engine speed: 200 to 250 rpm {kg/cm2} {Min. 42} {29}
Body

At rated horsepower kPa Max. 2.94 3.92


Blow-by pressure
Engine coolant temperature: Min. 70°C {mmH2O} {Max. 300} {400}
At rated horsepower SAE0W30EOS MPa Min. 0.34 0.21
Engine oil temperature:
Lubrication system

SAE5W40EOS {kg/cm2} {Min. 3.5} {2.1}


Min. 80°C
Oil pressure SAE10W30DH
At low idle
SAE15W40DH MPa Min. 0.10 0.08
Engine oil temperature:
SAE30DH {kg/cm2} {Min. 1.0} {0.8}
Min. 80°C
Oil temperature Whole speed range °C 90 to 110 120
Ratio to fuel consumption at continuous
Oil consumption % Max. 0.15 0.3
rated horsepower
Function of radiator Cracking pressure kPa
— —
pressure valve (Differential pressure) {kg/cm2}
Cooling system

Fan speed At rated speed rpm Hydraulically driven on machine side


Deflection under finger pressure of 98 N
Fan belt tension mm Hydraulically driven on machine side
{10 kg}
Deflection under finger pressure of 98 N
Alternator belt tension mm 13 to 16 13 to 16
{10 kg}

16 140E-5 Series
20 Standard value table SEN00147-07

Engine SAA6D140E-5
Machine models HM400-2R, HM400-3R
Performance Category

Standard value for


Item Measurement conditions Unit Repair limit
new machine

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


Speed
Min. speed with no load rpm 725 ± 25 725 ± 25
Necessary speed for At 0°C (without starting aid) rpm Min. 110 —
starting At –20°C (with starting aid) rpm Min. 85 —
kPa Max. 3.73 7.47
Air intake resistance Air intake resistance
{mmH2O} {Max. 380} {762}
kPa Min. 111 94
Air boost pressure At rated horsepower
Air intake and exhaust system

{mmHg} {Min. 830} {700}


kPa Min. 115 98
Exhaust pressure At rated horsepower
{mmHg} {Min. 860} {730}
Exhaust temperature Whole speed range (20°C) °C Max. 670 720
% (Bosch Max. 40 50
At sudden acceleration (Low  High)
index) (Max. 4.0) (5.0)
Bosch
Exhaust gas color At rated horsepower Max. 1.5 2.5
index
Bosch
At high idle Max. 1.0 2.0
index
Intake valve mm 0.35 —
Valve clearance
Exhaust valve mm 0.57 —
Engine oil temperature: 40 to 60°C MPa Min. 4.1 2.8
Compression pressure
Engine speed: 200 to 250 rpm {kg/cm2} {Min. 42} {29}
Body

At rated horsepower kPa Max. 2.94 3.92


Blow-by pressure
Engine coolant temperature: Min. 70°C {mmH2O} {Max. 300} {400}
At rated horsepower SAE0W30EOS MPa Min. 0.34 0.21
Engine oil temperature:
Lubrication system

SAE5W40EOS {kg/cm2} {Min. 3.5} {2.1}


Min. 80°C
Oil pressure SAE10W30DH
At low idle
SAE15W40DH MPa Min. 0.10 0.08
Engine oil temperature:
SAE30DH {kg/cm2} {Min. 1.0} {0.8}
Min. 80°C
Oil temperature Whole speed range °C 90 to 110 120
Ratio to fuel consumption at continuous
Oil consumption % Max. 0.15 0.3
rated horsepower
Function of radiator Cracking pressure kPa
— —
pressure valve (Differential pressure) {kg/cm2}
Cooling system

Fan speed At rated speed rpm Hydraulically driven on machine side


Deflection under finger pressure of 98 N
Fan belt tension mm Hydraulically driven on machine side
{10 kg}
Deflection under finger pressure of 98 N
Alternator belt tension mm 13 to 16 13 to 16
{10 kg}

140E-5 Series 17
SEN00147-07 20 Standard value table

Engine SAA6D140E-5
SDG400S-6B1
Machine models
(HOKUETSU INDUSTRIES GENERATOR)
Performance Category

Standard value for


Item Measurement conditions Unit Repair limit
new machine

Max. speed with no load rpm 1,890 ± 50 1,890 ± 50


Speed
Min. speed with no load rpm 875 ± 25 875 ± 25
Necessary speed for At 0°C (without starting aid) rpm Min. 110 —
starting At –20°C (with starting aid) rpm Min. 85 —
kPa Max. 3.73 7.47
Air intake resistance Whole speed range
{mmH2O} {Max. 380} {762}
kPa Min. 207 171
Air boost pressure At rated horsepower
{mmHg} {Min. 1,550} {1,280}
kPa Min. 185 153
Exhaust pressure At rated horsepower
Air intake and exhaust system

{mmHg} {Min. 1,390} {1,150}


Exhaust temperature Whole speed range (20°C) °C Max. 670 700
% (Bosch — —
At sudden acceleration (Low  High)
index) (—) (—)
Bosch
Exhaust gas color At rated horsepower Max. 1.5 2.5
index
Bosch
At high idle Max. 1.0 2.0
index
Intake valve mm 0.35 —
Valve clearance
Exhaust valve mm 0.57 —
MPa Min. 1.18 Min. 1.18
At low idle
EGR valve and bypass {kg/cm2} {Min. 12} {Min. 12}
valve drive oil pressure MPa Min. 1.43 Min. 1.43
At high idle
{kg/cm2} {Min. 14.6} {Min. 14.6}
Engine oil temperature: 40 to 60°C MPa Min. 4.1 2.8
Compression pressure
Engine speed: 200 to 250 rpm {kg/cm2} {Min. 42} {29}
Body

At rated horsepower kPa Max. 2.94 3.92


Blow-by pressure
Engine coolant temperature: Min. 70°C {mmH2O} {Max. 300} {400}
At rated horsepower
MPa Min. 0.34 0.21
Engine oil temperature: SAE0W30EOS 2
Lubrication system

SAE5W40EOS {kg/cm } {Min. 3.5} {2.1}


Min. 80°C
Oil pressure SAE10W30DH
At low idle SAE15W40DH MPa Min. 0.10 0.08
Engine oil temperature: SAE30DH
{kg/cm2} {Min. 1.0} {0.8}
Min. 80°C
Oil temperature Whole speed range °C 90 to 110 120
Ratio to fuel consumption at continuous
Oil consumption % Max. 0.15 0.3
rated horsepower
Function of radiator Cracking pressure kPa
— —
pressure valve (Differential pressure) {kg/cm2}
Cooling system

Fan speed At rated speed rpm 1,329 ± 40 1,329 ± 40


Deflection under finger pressure of 98 N 13 to 15 17 to 19
Fan belt tension mm
{10 kg} (When new)
Deflection under finger pressure of 98 N
Alternator belt tension mm 13 to 16 13 to 16
{10 kg}

18 140E-5 Series
20 Standard value table SEN00147-07

Running-in standard and performance test standard 1


Running-in standard

Engine SAA6D140E-5
Machine models D155AX-6
Procedure
Item
1 2 3 4 5
Running time min. 1 3 6 8 2
Speed rpm 740 1,197 1,501 1,729 1,900
Dynamometer load N{kg} 0{0} 747{76} 1,192{122} 1,552{158} 1,883{192}
Output kW{HP} 0{0} 67{90} 134{181} 201{270} 268{360}

a This table shows the values when the fan is not installed.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.

Performance test standard

Engine SAA6D140E-5
Machine models D155AX-6
Test item Rated horsepower Max. torque High idle speed Low idle speed
Specification value 268 kW/1,900 rpm 1,834 Nm/1,300 rpm
— 2,100(0/–50) rpm 740(+40/0) rpm
(Gross value) {359.9 HP/1,900 rpm} {187 kgm/1,300 rpm}
Speed rpm 1,900 1,300 2,100(0/–50) 740(+40/0)
N 1,823 to 1,940 2,460 to 2,607
Dynamometer load — —
{kg} {186 to 198} {251 to 266}
kW 260 to 277
Output (Gross value) — — —
{HP} {349 to 371}
Nm 1,758 to 1,868
Torque (Gross value) — — —
{kgm} {179.4 to 190.6}
Fuel consumption sec/300cc Min. 16.0 — — —
Coolant temperature °C 70 to 90 70 to 90 70 to 90 70 to 90
Lubricating oil
°C 90 to 110 90 to 110 90 to 110 80 to 110
temperature
Lubricating oil kPa 340 to 490 340 to 490 340 to 490 Min. 120
pressure {kg/cm2} {3.5 to 5.0} {3.5 to 5.0} {3.5 to 5.0} {Min. 1.2}
Exhaust temperature °C Max. 650 Max. 650 — —

a This table shows the standard values obtained by using the JIS correction coefficients.
a Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.
a This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
a Use ASTM No.1 or No. 2 diesel fuel as fuel.
a Use SAE15W-40 as lubricating oil.

140E-5 Series 19
SEN00147-07 20 Standard value table

Running-in standard

Engine SAA6D140E-5
Machine models D155A-6
Procedure
Item
1 2 3 4 5
Running time min. 1 3 6 8 2
Speed rpm 740 1,197 1,501 1,729 1,900
Dynamometer load N{kg} 0{0} 747{76} 1,192{122} 1,552{158} 1,883{192}
Output kW{HP} 0{0} 67{90} 134{181} 201{270} 268{360}

a This table shows the values when the fan is not installed.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.

Performance test standard

Engine SAA6D140E-5
Machine models D155A-6
Test item Rated horsepower Max. torque High idle speed Low idle speed
Specification value 268 kW/1,900 rpm 1,834 Nm/1,300 rpm
— 2,100(0/–50) rpm 740(+40/0) rpm
(Gross value) {359.9 HP/1,900 rpm} {187 kgm/1,300 rpm}
Speed rpm 1,900 1,300 2,100(0/–50) 740(+40/0)
N 1,823 to 1,940 2,482 to 2,635
Dynamometer load — —
{kg} {186 to 198} {253 to 269}
kW 260 to 277
Output (Gross value) — — —
{HP} {349 to 371}
Nm 1,778 to 1,888
Torque (Gross value) — — —
{kgm} {181.4 to 192.6}
Fuel consumption sec/300cc Min. 16.0 — — —
Coolant temperature °C 70 to 90 70 to 90 70 to 90 70 to 90
Lubricating oil
°C 90 to 110 90 to 110 90 to 110 80 to 110
temperature
Lubricating oil kPa 340 to 490 340 to 490 340 to 490 Min. 120
pressure {kg/cm2} {3.5 to 5.0} {3.5 to 5.0} {3.5 to 5.0} {Min. 1.2}
Exhaust temperature °C Max. 670 Max. 670 — —

a This table shows the standard values obtained by using the JIS correction coefficients.
a Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.
a This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
a Use ASTM No.1 or No. 2 diesel fuel as fuel.
a Use SAE15W-40 as lubricating oil.

20 140E-5 Series
20 Standard value table SEN00147-07

Running-in standard

Engine SAA6D140E-5
Machine models D275AX-5E0
Procedure
Item
1 2 3 4 5
Running time min. 1 3 6 8 2
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 This table shows the values when the fan is not installed.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.

Performance test standard

Engine SAA6D140E-5
Machine models D275AX-5E0
Test item Rated horsepower Max. torque High idle speed Low idle speed
Specification value 337 kW/2,000 rpm 2,030 Nm/1,400 rpm
— 2,200 ± 50 rpm 700 ± 50 rpm
(Gross value) {451.6 HP/2,000 rpm} {207 kgm/1,400 rpm}
Speed rpm 2,000 1,400 2,200 ± 50 700 ± 50
N 2,177 to 2,314 2,753 to 2,917
Dynamometer load — —
{kg} {222.0 to 236.0} {280.7 to 297.5}
Output kW 327 to 347
— — —
(Gross value) {HP} {438 to 465}
Nm 1,970 to 2,087
Torque (Gross value) — — —
{kgm} {201 to 213}
Fuel consumption sec/300cc Min. 12.8 — — —
Coolant temperature °C 70 to 90 70 to 90 70 to 90 70 to 90
Lubricating oil
°C 90 to 110 90 to 110 90 to 110 90 to 110
temperature
Lubricating oil kPa 340 to 490 340 to 490 340 to 490 Min. 120
pressure {kg/cm2} {3.5 to 5.0} {3.5 to 5.0} {3.5 to 5.0} {Min. 1.2}
Exhaust temperature °C Max. 650 Max. 650 — —

a This table shows the standard values obtained by using the JIS correction coefficients.
a Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.
a This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
a Use ASTM No.1 or No. 2 diesel fuel as fuel.
a Use SAE15W-40 as lubricating oil.

140E-5 Series 21
SEN00147-07 20 Standard value table

Running-in standard

Engine SAA6D140E-5
Machine models D275A-5R
Procedure
Item
1 2 3 4 5
Running time min. 1 3 6 8 2
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 This table shows the values when the fan is not installed.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.

Performance test standard

Engine SAA6D140E-5
Machine models D275A-5R
Test item Rated horsepower Max. torque High idle speed Low idle speed
Specification value 337 kW/2,000 rpm 2,030 Nm/1,400 rpm
— 2,200 ± 50 rpm 700 ± 50 rpm
(Gross value) {451.6 HP/2,000 rpm} {207 kgm/1,400 rpm}
Speed rpm 2,000 1,400 2,200 ± 50 700 ± 50
N 2,177 to 2,314 2,753 to 2,917
Dynamometer load — —
{kg} {222.0 to 236.0} {280.7 to 297.5}
Output kW 327 to 347
— — —
(Gross value) {HP} {438 to 465}
Nm 1,970 to 2,087
Torque (Gross value) — — —
{kgm} {201 to 213}
Fuel consumption sec/300cc Min. 12.8 — — —
Coolant temperature °C 70 to 90 70 to 90 70 to 90 70 to 90
Lubricating oil
°C 90 to 110 90 to 110 90 to 110 90 to 110
temperature
Lubricating oil kPa 340 to 490 340 to 490 340 to 490 Min. 120
pressure {kg/cm2} {3.5 to 5.0} {3.5 to 5.0} {3.5 to 5.0} {Min. 1.2}
Exhaust temperature °C Max. 670 Max. 670 — —

a This table shows the standard values obtained by using the JIS correction coefficients.
a Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.
a This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
a Use ASTM No.1 or No. 2 diesel fuel as fuel.
a Use SAE15W-40 as lubricating oil.

22 140E-5 Series
20 Standard value table SEN00147-07

Running-in standard

Engine SAA6D140E-5
PC600-8, PC600LC-8, PC600-8E0, PC600LC-8E0
Machine models
PC700-8E0, PC700LC-8E0
Procedure
Item
1 2 3 4 5
Running time min. 1 3 6 8 2
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 This table shows the values when the fan is not installed.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.

Performance test standard

Engine SAA6D140E-5
PC600-8, PC600LC-8, PC600-8E0, PC600LC-8E0
Machine models
PC700-8E0, PC700LC-8E0
Test item Rated horsepower Max. torque High idle speed Low idle speed
323 kW/1,800 rpm 1,944Nm/1,400rpm
Specification value
— {433.3 HP/ {198.4 kgm/ 1,950 ± 50 rpm 800 ± 25 rpm
(Gross value)
1,800 rpm} 1,400 rpm}
Speed rpm 1,800 1,400 1,950 ± 50 800 ± 25
N 2,323 to 2,470 2,626 to 2,793
Dynamometer load — —
{kg} {237 to 252} {268 to 285}
kW 313 to 333
Output (Gross value) — — —
{HP} {420 to 447}
Nm 1,882 to 1,999
Torque (Gross value) — — —
{kgm} {192 to 204}
Fuel consumption sec/300cc Min. 13.8 — — —
Coolant temperature °C 70 to 90 70 to 90 70 to 90 70 to 90
Lubricating oil
°C 90 to 110 90 to 110 90 to 110 80 to 110
temperature
Lubricating oil kPa 340 to 490 340 to 490 340 to 490 Min. 120
pressure {kg/cm2} {3.5 to 5.0} {3.5 to 5.0} {3.5 to 5.0} {Min. 1.2}
Exhaust temperature °C Max. 650 Max. 650 — —

a This table shows the standard values obtained by using the JIS correction coefficients.
a Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.
a This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
a Use ASTM No.1 or No. 2 diesel fuel as fuel.
a Use SAE15W-40 as lubricating oil.

140E-5 Series 23
SEN00147-07 20 Standard value table

Running-in standard

Engine SAA6D140E-5
PC600-8R, PC600LC-8R,
Machine models PC600-8R1, PC600LC-8R1,
PC700-8R, PC700LC-8R, PC700LC-8R1
Procedure
Item
1 2 3 4 5
Running time min. 1 3 6 8 2
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 This table shows the values when the fan is not installed.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.

Performance test standard

Engine SAA6D140E-5
PC600-8R, PC600LC-8R,
Machine models PC600-8R1, PC600LC-8R1,
PC700-8R, PC700LC-8R, PC700LC-8R1
Test item Rated horsepower Max. torque High idle speed Low idle speed
323 kW/1,800 rpm 1,944Nm/1,400rpm
Specification value
— {433.3 HP/ {198.4 kgm/ 1,950 ± 50 rpm 800 ± 25 rpm
(Gross value)
1,800 rpm} 1,400 rpm}
Speed rpm 1,800 1,400 1,950 ± 50 800 ± 25
N 2,323 to 2,470 2,626 to 2,793
Dynamometer load — —
{kg} {237 to 252} {268 to 285}
kW 313 to 333
Output (Gross value) — — —
{HP} {420 to 447}
Nm 1,882 to 1,999
Torque (Gross value) — — —
{kgm} {192 to 204}
Fuel consumption sec/300cc Min. 13.8 — — —
Coolant temperature °C 70 to 90 70 to 90 70 to 90 70 to 90
Lubricating oil
°C 90 to 110 90 to 110 90 to 110 80 to 110
temperature
Lubricating oil kPa 340 to 490 340 to 490 340 to 490 Min. 120
pressure {kg/cm2} {3.5 to 5.0} {3.5 to 5.0} {3.5 to 5.0} {Min. 1.2}
Exhaust temperature °C Max. 700 Max. 700 — —

a This table shows the standard values obtained by using the JIS correction coefficients.
a Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.
a This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
a Use ASTM No.1 or No. 2 diesel fuel as fuel.
a Use SAE15W-40 as lubricating oil.

24 140E-5 Series
20 Standard value table SEN00147-07

Running-in standard

Engine SAA6D140E-5
PC800-8, PC800SE-8, PC800LC-8, PC850-8, PC850SE-8
Machine models
PC800-8E0, PC800SE-8E0, PC800LC-8E0, PC850-8E0, PC850SE-8E0
Procedure
Item
1 2 3 4 5
Running time min. 1 3 6 8 2
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 This table shows the values when the fan is not installed.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.

Performance test standard

Engine SAA6D140E-5
PC800-8, PC800SE-8, PC800LC-8, PC850-8, PC850SE-8
Machine models
PC800-8E0, PC800SE-8E0, PC800LC-8E0, PC850-8E0, PC850SE-8E0
Test item Rated horsepower Max. torque High idle speed Low idle speed
370 kW/1,800 rpm 2,195 Nm/1,350 rpm
Specification value
— {496.4 HP/ {223.8 kgm/ 1,980 ± 50 rpm 825 ± 25 rpm
(Gross value)
1,800 rpm} 1,350 rpm}
Speed rpm 1,800 1,350 1,980 ± 50 825 ± 25
N 2,550 to 2,690 2,930 to 3,100
Dynamometer load — —
{kg} {260 to 274} {299 to 316}
kW 359 to 381
Output (Gross value) — — —
{HP} {481 to 512}
Nm 2,126 to 2,264
Torque (Gross value) — — —
{kgm} {217 to 231}
Fuel consumption sec/300cc Min. 12.3 — — —
Coolant temperature °C 70 to 90 70 to 90 70 to 90 70 to 90
Lubricating oil
°C 90 to 110 90 to 110 90 to 110 80 to 110
temperature
Lubricating oil kPa 340 to 490 340 to 490 340 to 490 Min. 120
pressure {kg/cm2} {3.5 to 5.0} {3.5 to 5.0} {3.5 to 5.0} {Min. 1.2}
Exhaust temperature °C Max. 650 Max. 650 — —

a This table shows the standard values obtained by using the JIS correction coefficients.
a Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.
a This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
a Use ASTM No.1 or No. 2 diesel fuel as fuel.
a Use SAE15W-40 as lubricating oil.

140E-5 Series 25
SEN00147-07 20 Standard value table

Running-in standard

Engine SAA6D140E-5
PC800-8R, PC800SE-8R, PC800LC-8R, PC850-8R, PC850SE-8R
Machine models
PC800-8R1, PC800SE-8R1, PC800LC-8R1, PC850-8R1, PC850SE-8R1
Procedure
Item
1 2 3 4 5
Running time min. 1 3 6 8 2
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 This table shows the values when the fan is not installed.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.

Performance test standard

Engine SAA6D140E-5
PC800-8R, PC800SE-8R, PC800LC-8R, PC850-8R, PC850SE-8R
Machine models
PC800-8R1, PC800SE-8R1, PC800LC-8R1, PC850-8R1, PC850SE-8R1
Test item Rated horsepower Max. torque High idle speed Low idle speed
370 kW/1,800 rpm 2,195 Nm/1,350 rpm
Specification value
— {496.4 HP/ {223.8 kgm/ 1,980 ± 50 rpm 825 ± 25 rpm
(Gross value)
1,800 rpm} 1,350 rpm}
Speed rpm 1,800 1,350 1,980 ± 50 825 ± 25
N 2,550 to 2,690 2,969 to 3,162
Dynamometer load — —
{kg} {260 to 274} {303 to 323}
kW 359 to 381
Output (Gross value) — — —
{HP} {481 to 512}
Nm 2,126 to 2,264
Torque (Gross value) — — —
{kgm} {217 to 231}
Fuel consumption sec/300cc Min. 12.3 — — —
Coolant temperature °C 70 to 90 70 to 90 70 to 90 70 to 90
Lubricating oil
°C 90 to 110 90 to 110 90 to 110 80 to 110
temperature
Lubricating oil kPa 340 to 490 340 to 490 340 to 490 Min. 120
pressure {kg/cm2} {3.5 to 5.0} {3.5 to 5.0} {3.5 to 5.0} {Min. 1.2}
Exhaust temperature °C Max. 700 Max. 700 — —

a This table shows the standard values obtained by using the JIS correction coefficients.
a Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.
a This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
a Use ASTM No.1 or No. 2 diesel fuel as fuel.
a Use SAE15W-40 as lubricating oil.

26 140E-5 Series
20 Standard value table SEN00147-07

Running-in standard

Engine SAA6D140E-5
Machine models WA500-6
Procedure
Item
1 2 3 4 5
Running time min. 1 3 6 8 2
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 This table shows the values when the fan is not installed.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.

Performance test standard

Engine SAA6D140E-5
Machine models WA500-6
Test item Rated horsepower Max. torque High idle speed Low idle speed
Specification value 266 kW/1,900 rpm 1,803 Nm/1,250 rpm
— 2,150 ± 50 rpm 700 ± 25 rpm
(Gross value) {357 HP/1,900 rpm} {184 kgm/1,250 rpm}
Speed rpm 1,900 1,250 2,150 ± 50 700 ± 25
N 1,744 to 1,852 2,440 to 2,597
Dynamometer load — —
{kg} {178 to 189} {249 to 265}
kW 248 to 263
Output (Gross value) — — —
{HP} {333 to 353}
Nm 1,744 to 1,862
Torque (Gross value) — — —
{kgm} {178 to 190}
Fuel consumption sec/300cc Min. 16.8 — — —
Coolant temperature °C 70 to 90 70 to 90 70 to 90 70 to 90
Lubricating oil
°C 90 to 110 90 to 110 90 to 110 80 to 110
temperature
Lubricating oil kPa 340 to 490 340 to 490 340 to 490 Min. 120
pressure {kg/cm2} {3.5 to 5.0} {3.5 to 5.0} {3.5 to 5.0} {Min. 1.2}
Exhaust temperature °C Max. 650 Max. 650 — —

a This table shows the standard values obtained by using the JIS correction coefficients.
a Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.
a This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
a Use ASTM No.1 or No. 2 diesel fuel as fuel.
a Use SAE15W-40 as lubricating oil.

140E-5 Series 27
SEN00147-07 20 Standard value table

Running-in standard

Engine SAA6D140E-5
Machine models WA500-6R
Procedure
Item
1 2 3 4 5
Running time min. 1 3 6 8 2
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 This table shows the values when the fan is not installed.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.

Performance test standard

Engine SAA6D140E-5
Machine models WA500-6R
Test item Rated horsepower Max. torque High idle speed Low idle speed
Specification value 266 kW/1,900 rpm 1,803 Nm/1,250 rpm
— 2,150 ± 50 rpm 700 ± 25 rpm
(Gross value) {357 HP/1,900 rpm} {184 kgm/1,250 rpm}
Speed rpm 1,900 1,250 2,150 ± 50 700 ± 25
N 1,814 to 1,922 2,440 to 2,597
Dynamometer load — —
{kg} {185 to 196} {249 to 265}
kW 258 to 274
Output (Gross value) — — —
{HP} {346 to 368}
Nm 1,744 to 1,862
Torque (Gross value) — — —
{kgm} {178 to 190}
Fuel consumption sec/300cc Min. 16.8 — — —
Coolant temperature °C 70 to 90 70 to 90 70 to 90 70 to 90
Lubricating oil
°C 90 to 110 90 to 110 90 to 110 80 to 110
temperature
Lubricating oil kPa 340 to 490 340 to 490 340 to 490 Min. 120
pressure {kg/cm2} {3.5 to 5.0} {3.5 to 5.0} {3.5 to 5.0} {Min. 1.2}
Exhaust temperature °C Max. 670 Max. 670 — —

a This table shows the standard values obtained by using the JIS correction coefficients.
a Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.
a This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
a Use ASTM No.1 or No. 2 diesel fuel as fuel.
a Use SAE15W-40 as lubricating oil.

28 140E-5 Series
20 Standard value table SEN00147-07

Running-in standard

Engine SAA6D140E-5
HD325-7
Machine models
HD405-7
Procedure
Item
1 2 3 4 5
Running time min. 1 3 6 8 2
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 This table shows the values when the fan is not installed.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.

Performance test standard

Engine SAA6D140E-5
HD325-7
Machine models
HD405-7
Test item Rated horsepower Max. torque High idle speed Low idle speed
Specification value 386 kW/2,000 rpm 2,170 Nm/1,400 rpm
— 2,300 ± 25 rpm 725 ± 25 rpm
(Gross value) {517.7 HP/2,000 rpm} {221.3 kgm/1,400 rpm}
Speed rpm 2,000 1,400 2,300 ± 25 725 ± 25
N 2,499 to 2,646 2,930 to 3,120
Dynamometer load — —
{kg} {255 to 270} {299 to 318}
kW 374 to 398
Output (Gross value) — — —
{HP} {502 to 533}
Nm 2,100 to 2,230
Torque (Gross value) — — —
{kgm} {214 to 228}
Fuel consumption sec/300cc Min. 11.4 — — —
Coolant temperature °C 70 to 90 70 to 90 70 to 90 70 to 90
Lubricating oil
°C 90 to 110 90 to 110 90 to 110 80 to 110
temperature
Lubricating oil kPa 340 to 490 340 to 490 340 to 490 Min. 120
pressure {kg/cm2} {3.5 to 5.0} {3.5 to 5.0} {3.5 to 5.0} {Min. 1.2}
Exhaust temperature °C Max. 650 Max. 650 — —

a This table shows the standard values obtained by using the JIS correction coefficients.
a Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.
a This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
a Use ASTM No.1 or No. 2 diesel fuel as fuel.

140E-5 Series 29
SEN00147-07 20 Standard value table

Running-in standard

Engine SAA6D140E-5
HD325-7R
Machine models
HD405-7R
Procedure
Item
1 2 3 4 5
Running time min. 1 3 6 8 2
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 This table shows the values when the fan is not installed.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.

Performance test standard

Engine SAA6D140E-5
HD325-7R
Machine models
HD405-7R
Test item Rated horsepower Max. torque High idle speed Low idle speed
Specification value 386 kW/2,000 rpm 2,170 Nm/1,400 rpm
— 2,300 ± 25 rpm 725 ± 25 rpm
(Gross value) {517.7 HP/2,000 rpm} {221.3 kgm/1,400 rpm}
Speed rpm 2,000 1,400 2,300 ± 25 725 ± 25
N 2,499 to 2,646 2,930 to 3,120
Dynamometer load — —
{kg} {255 to 270} {299 to 318}
kW 374 to 398
Output (Gross value) — — —
{HP} {502 to 533}
Nm 2,100 to 2,230
Torque (Gross value) — — —
{kgm} {214 to 228}
Fuel consumption sec/300cc Min. 11.4 — — —
Coolant temperature °C 70 to 90 70 to 90 70 to 90 70 to 90
Lubricating oil
°C 90 to 110 90 to 110 90 to 110 80 to 110
temperature
Lubricating oil kPa 340 to 490 340 to 490 340 to 490 Min. 120
pressure {kg/cm2} {3.5 to 5.0} {3.5 to 5.0} {3.5 to 5.0} {Min. 1.2}
Exhaust temperature °C Max. 680 Max. 680 — —

a This table shows the standard values obtained by using the JIS correction coefficients.
a Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.
a This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
a Use ASTM No.1 or No. 2 diesel fuel as fuel.
a Use SAE15W-40 as lubricating oil.

30 140E-5 Series
20 Standard value table SEN00147-07

Running-in standard

Engine SAA6D140E-5
Machine models HM350-2
Procedure
Item
1 2 3 4 5
Running time min. 1 3 6 8 2
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 This table shows the values when the fan is not installed.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.

Performance test standard

Engine SAA6D140E-5
Machine models HM350-2
Test item Rated horsepower Max. torque High idle speed Low idle speed
Specification value 304 kW/2,000 rpm 1,990 Nm/1,400 rpm
— 2,200(+50/0) rpm 725 ± 25 rpm
(Gross value) {407.2 HP/2,000 rpm} {203 kgm/1,400 rpm}
Speed rpm 2,000 1,400 2,200(+50/0) 725 ± 25
N 1,960 to 2,087 2,695 to 2,862
Dynamometer load — —
{kg} {200 to 213} {275 to 292}
kW 295 to 315
Output (Gross value) — — —
{HP} {395 to 419}
Nm 1,931 to 2,048
Torque (Gross value) — — —
{kgm} {197 to 209}
Fuel consumption sec/300cc Min. 13.8 — — —
Coolant temperature °C 70 to 90 70 to 90 70 to 90 70 to 90
Lubricating oil tem-
°C 90 to 110 90 to 110 90 to 110 80 to 110
perature
Lubricating oil pres- kPa 340 to 490 340 to 490 340 to 490 Min. 120
sure {kg/cm2} {3.5 to 5.0} {3.5 to 5.0} {3.5 to 5.0} {Min. 1.2}
Exhaust temperature °C Max. 650 Max. 650 — —

a This table shows the standard values obtained by using the JIS correction coefficients.
a Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.
a This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
a Use ASTM No.1 or No. 2 diesel fuel as fuel.
a Use SAE15W-40 as lubricating oil.

140E-5 Series 31
SEN00147-07 20 Standard value table

Running-in standard

Engine SAA6D140E-5
Machine models HM350-2R
Procedure
Item
1 2 3 4 5
Running time min. 1 3 6 8 2
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 This table shows the values when the fan is not installed.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.

Performance test standard

Engine SAA6D140E-5
Machine models HM350-2R
Test item Rated horsepower Max. torque High idle speed Low idle speed
Specification value 304 kW/2,000 rpm 1,991 Nm/1,400 rpm
— 2,200(+50/0) rpm 725 ± 25 rpm
(Gross value) {407.2 HP/2,000 rpm} {203 kgm/1,400 rpm}
Speed rpm 2,000 1,400 2,200(+50/0) 725 ± 25
N 1,960 to 2,087 2,695 to 2,862
Dynamometer load — —
{kg} {200 to 213} {275 to 292}
kW 295 to 315
Output (Gross value) — — —
{HP} {395 to 419}
Nm 1,931 to 2,048
Torque (Gross value) — — —
{kgm} {197 to 209}
Fuel consumption sec/300cc Min. 13.8 — — —
Coolant temperature °C 70 to 90 70 to 90 70 to 90 70 to 90
Lubricating oil tem-
°C 90 to 110 90 to 110 90 to 110 80 to 110
perature
Lubricating oil pres- kPa 340 to 490 340 to 490 340 to 490 Min. 120
sure {kg/cm2} {3.5 to 5.0} {3.5 to 5.0} {3.5 to 5.0} {Min. 1.2}
Exhaust temperature °C Max. 670 Max. 670 — —

a This table shows the standard values obtained by using the JIS correction coefficients.
a Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.
a This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
a Use ASTM No.1 or No. 2 diesel fuel as fuel.
a Use SAE15W-40 as lubricating oil.

32 140E-5 Series
20 Standard value table SEN00147-07

Running-in standard

Engine SAA6D140E-5
Machine models HM400-2, HM400-3M0
Procedure
Item
1 2 3 4 5
Running time min. 1 3 6 8 2
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 This table shows the values when the fan is not installed.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.

Performance test standard

Engine SAA6D140E-5
Machine models HM400-2, HM400-3M0
Test item Rated horsepower Max. torque High idle speed Low idle speed
Specification value 338 kW/2,000 rpm 2,090 Nm/1,400 rpm
— 2,200(+50/0) rpm 725 ± 25 rpm
(Gross value) {452.6 HP/2,000 rpm} {213 kgm/1,400 rpm}
Speed rpm 2,000 1,400 2,200(+50/0) 725 ± 25
N 2,185 to 2,313 2,832 to 2,999
Dynamometer load — —
{kg} {223 to 236} {289 to 306}
kW 327 to 348
Output (Gross value) — — —
{HP} {439 to 466}
Nm 2,029 to 2,146
Torque (Gross value) — — —
{kgm} {207 to 219}
Fuel consumption sec/300cc Min. 13.0 — — —
Coolant temperature °C 70 to 90 70 to 90 70 to 90 70 to 90
Lubricating oil
°C 90 to 110 90 to 110 90 to 110 80 to 110
temperature
Lubricating oil kPa 340 to 490 340 to 490 340 to 490 Min. 120
pressure {kg/cm2} {3.5 to 5.0} {3.5 to 5.0} {3.5 to 5.0} {Min. 1.2}
Exhaust temperature °C Max. 650 Max. 650 — —

a This table shows the standard values obtained by using the JIS correction coefficients.
a Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.
a This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
a Use ASTM No.1 or No. 2 diesel fuel as fuel.
a Use SAE15W-40 as lubricating oil.

140E-5 Series 33
SEN00147-07 20 Standard value table

Running-in standard

Engine SAA6D140E-5
Machine models HM400-2R, HM400-3R
Procedure
Item
1 2 3 4 5
Running time min. 1 3 6 8 2
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 This table shows the values when the fan is not installed.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.

Performance test standard

Engine SAA6D140E-5
Machine models HM400-2R, HM400-3R
Test item Rated horsepower Max. torque High idle speed Low idle speed
Specification value 338 kW/2,000 rpm 2,090 Nm/1,400 rpm
— 2,200(+50/0) rpm 725 ± 25 rpm
(Gross value) {452.6 HP/2,000 rpm} {213 kgm/1,400 rpm}
Speed rpm 2,000 1,400 2,200(+50/0) 725 ± 25
N 2,185 to 2,313 2,832 to 2,999
Dynamometer load — —
{kg} {223 to 236} {289 to 306}
kW 327 to 348
Output (Gross value) — — —
{HP} {439 to 466}
Nm 2,029 to 2,146
Torque (Gross value) — — —
{kgm} {207 to 219}
Fuel consumption sec/300cc Min. 13.0 — — —
Coolant temperature °C 70 to 90 70 to 90 70 to 90 70 to 90
Lubricating oil
°C 90 to 110 90 to 110 90 to 110 80 to 110
temperature
Lubricating oil kPa 340 to 490 340 to 490 340 to 490 Min. 120
pressure {kg/cm2} {3.5 to 5.0} {3.5 to 5.0} {3.5 to 5.0} {Min. 1.2}
Exhaust temperature °C Max. 670 Max. 670 — —

a This table shows the standard values obtained by using the JIS correction coefficients.
a Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.
a This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
a Use ASTM No.1 or No. 2 diesel fuel as fuel.
a Use SAE15W-40 as lubricating oil.

34 140E-5 Series
20 Standard value table SEN00147-07

Running-in standard

Engine SAA6D140E-5
Machine models SDG400S-6B1 (HOKUETSU INDUSTRIES GENERATOR)
Procedure
Item
1 2 3 4 5
Running time min. 1 3 6 8 2
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 This table shows the values when the fan is not installed.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.

Performance test standard

Engine SAA6D140E-5
Machine models SDG400S-6B1 (HOKUETSU INDUSTRIES GENERATOR)
Test item Rated horsepower Max. torque High idle speed Low idle speed
Specification value 371 kW/1,800 rpm —
— 1,890 ± 50 rpm 875 ± 25 rpm
(Gross value) {498 HP/1,800 rpm} —
Speed rpm 1,800 — 1,890 ± 50 875 ± 25
N 2,695 to 2,813 —
Dynamometer load — —
{kg} {275 to 287} —
kW 360 to 382
Output (Gross value) — — —
{HP} {483 to 512}
Nm
Torque (Gross value) — — — —
{kgm}
Fuel consumption sec/300cc Min. 10.8 — — —
Coolant temperature °C 70 to 90 — 70 to 90 70 to 90
Lubricating oil
°C 90 to 110 — 90 to 110 80 to 110
temperature
Lubricating oil kPa 340 to 490 — 340 to 490 Min. 120
pressure {kg/cm2} {3.5 to 5.0} {—} {3.5 to 5.0} {Min. 1.2}
Exhaust temperature °C Max. 670 — — —

a This table shows the standard values obtained by using the JIS correction coefficients.
a Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.
a This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
a Use ASTM No.1 or No. 2 diesel fuel as fuel.
a Use SAE15W-40 as lubricating oil.

140E-5 Series 35
SEN00147-07

KOMATSU 140E-5 Series engine

Form No. SEN00147-07

© 2012 KOMATSU
All Rights Reserved
Printed in Japan 12-12 (01)

36
SEN00149-05

ENGINE 1SHOP MANUAL

140E-5 Series

30 Testing and adjusting 1


Testing and adjusting
Testing and adjusting (with EGR).................................................................................................................... 3
Testing and adjusting tools list ............................................................................................................. 3
Sketches of special tools...................................................................................................................... 5
Testing air boost pressure .................................................................................................................... 6
Testing exhaust temperature................................................................................................................ 7
Adjusting valve clearance .................................................................................................................... 8
Testing compression pressure ............................................................................................................. 9
Testing blow-by pressure ....................................................................................................................11
Testing engine oil pressure ................................................................................................................ 12
Testing EGR valve and bypass valve drive oil pressure .................................................................... 13
Handling fuel system parts ................................................................................................................. 14
Releasing residual pressure in fuel system........................................................................................ 14
Testing fuel pressure .......................................................................................................................... 15
Reduced cylinder mode operation ..................................................................................................... 16
No-injection cranking.......................................................................................................................... 16
Testing fuel return rate and leakage................................................................................................... 17

140E-5 Series 1
SEN00149-05 30 Testing and adjusting

Bleeding air from fuel circuit ............................................................................................................... 20


Testing fuel system for leakage .......................................................................................................... 22
Testing and adjusting alternator belt tension ...................................................................................... 23
Testing and adjusting fan belt tension ................................................................................................ 24
Handling controller high-voltage circuit .............................................................................................. 25
Testing and adjusting (EGR-less).................................................................................................................. 26
Testing and adjusting tools list............................................................................................................ 26
Sketches of special tools.................................................................................................................... 28
Testing air boost pressure .................................................................................................................. 29
Testing exhaust temperature .............................................................................................................. 30
Adjusting valve clearance................................................................................................................... 31
Testing compression pressure............................................................................................................ 32
Testing blow-by pressure.................................................................................................................... 34
Testing engine oil pressure................................................................................................................. 35
Handling fuel system parts ................................................................................................................. 36
Releasing residual pressure in fuel system........................................................................................ 36
Testing fuel pressure .......................................................................................................................... 37
Reduced cylinder mode operation...................................................................................................... 38
No-injection cranking.......................................................................................................................... 38
Testing fuel return rate and leakage ................................................................................................... 39
Bleeding air from fuel circuit ............................................................................................................... 42
Testing fuel system for leakage .......................................................................................................... 44
Testing and adjusting alternator belt tension ...................................................................................... 45
Testing and adjusting fan belt tension ................................................................................................ 46
Handling controller high-voltage circuit .............................................................................................. 47

2 140E-5 Series
30 Testing and adjusting SEN00149-05

Testing and adjusting (with EGR) 1


Testing and adjusting tools list 1

Testing and Sym-


Part No. Part name Q'ty Remarks
adjusting item bol
Testing air boost 799-201-2202 Boost gauge kit 1 –101 – 200 kPa {–760 – 1,500 mmHg}
A
pressure 799-401-2220 Hose 1 I-coupler type (if necessary)
Testing exhaust
B 799-101-1502 Digital thermometer 1 –99.9 – 1,299°C
temperature
Adjusting valve Commercially Intake: 0.35 mm
C Clearance gauge 1
clearance available Exhaust: 0.57 mm
1 795-502-1590 Compression gauge 1 0 – 7 MPa {0 – 70 kg/cm2}
Testing compression
D 795-471-1330 Adapter 1
pressure 2 For 140E-5
6261-71-6150 Gasket 1
Testing blow-by
E 799-201-1504 Blow-by checker 1 0 – 5 kPa {0 – 500 mmH2O}
pressure
Pressure gauge:
Testing engine oil pres-
799-101-5002 Hydraulic tester 1 2.5, 6, 40, 60 MPa
sure 1 {25, 60, 400, 600 kg/cm2}
Testing EGR valve and F
bypass valve drive oil 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
pressure
2 799-401-2320 Hydraulic tester 1 Pressure gauge: 1 MPa {10 kg/cm2}
Pressure gauge:
799-101-5002 Hydraulic tester 1 2.5, 6, 40, 60 MPa
1 {25, 60, 400, 600 kg/cm2}

Testing fuel pressure G 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
2 799-401-2320 Gauge 1 Pressure gauge: 1 MPa {10 kg/cm2}
795-471-1450 Adapter 1 8 × 1.25 mm o R1/8
3
07005-00812 Gasket 1
1 6151-51-8490 Spacer 1 Inside diameter: 14 mm
2 6206-71-1770 Joint 1 Inside diameter of joint: 10 mm
Commercially
3 Hose 1 ∅5mm × 2 – 3 m
available
Testing fuel return rate Commercially
and leakage
H 4 Hose 1 ∅15mm × 2 – 3 m
available
Commercially
5 Measuring cylinder 1
available
Commercially
6 Stopwatch 1
available

140E-5 Series 3
SEN00149-05 30 Testing and adjusting

Testing and Sym-


Part No. Part name Q'ty Remarks
adjusting item bol
799-601-4130 T-adapter — For Ne sensor
799-601-4330 Socket — For Bkup sensor
799-601-4240 Socket — For atmospheric pressure sensor
799-601-4250 Socket — For boost pressure sensor
799-601-4180 T-adapter — For EGR gas sensor
799-601-9420 T-adapter — For common rail pressure
799-601-4150 T-adapter — For oil pressure sensor
795-799-5540 T-adapter — For boost temperature sensor
For coolant temperature sensor
795-799-5530 T-adapter —
For fuel temperature sensor
Troubleshooting for
For EGR valve solenoid
controllers, sensors, J 799-601-9020 T-adapter —
For bypass valve solenoid
and actuators
For EGR valve stroke sensor
799-601-9030 T-adapter —
For bypass valve stroke sensor
799-601-9430 T-adapter — For supply pump PCV
799-601-9020 T-adapter — For injector
799-601-4260 T-adapter — For controller (4-pole)
799-601-4210 T-adapter — For controller (50-pole)
799-601-4220 T-adapter — For controller (60-pole)
799-601-9320 T-box —
For 24-pole type
799-601-9310 Plate —
799-601-4350 T-box — For 60-pole type
Checking coolant tem-
perature and oil temper- — 799-101-1502 Digital thermometer 1 –99.9 – 1,299°C
ature
Checking voltage and Commercially
— Tester 1
resistance available
21 mm deep socket
Commercially (MITOLOY 4ML 21 or equivalent)
Socket 1
available Applicable engine serial No.:
Removal and installa- 530056-534132
tion of engine coolant —
temperature sensor 19 mm deep socket
(MITOLOY 4ML 19 or equivalent)
795T-981-1010 Socket 1
Applicable engine serial No.:
534133 and up

4 140E-5 Series
30 Testing and adjusting SEN00149-05

Sketches of special tools 1


Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.

Socket

140E-5 Series 5
SEN00149-05 30 Testing and adjusting

Testing air boost pressure 1

a Testing tools for air boost pressure


Symbol Part No. Part name
799-201-2202 Boost gauge kit
A
799-401-2220 Hose

k Be careful not to touch any hot part when


removing or installing the testing tools.
a The test point is subject to machine models.

1. Remove air boost pressure pickup plug (1)


from the bottom of the air intake connector.

4. After finishing testing, remove the testing tools


and return the removed parts.
q Remove the gasket sealant remaining on
the threads of the removed plug with a
wire brush and apply new adhesive or
gasket sealant to the plug before install-
ing.
2 Plug: Adhesive (LT2) or gasket
sealant (LG-5)
3 Plug:
6.9 – 14.7 Nm {0.7 – 1.5 kgm} (*1)
9.8 – 19.6 Nm {1.0 – 2.0 kgm} (*2)
(*1): When air intake connector is made of
2. Install nipple [1] of boost gauge kit A and con- iron.
nect it to gauge [2]. (*2): When air intake connector is made of
aluminum.

3. Run the engine at the rated output and test the


air boost pressure.
a When testing with the engine mounted on
the machine, test on the condition
described in the shop manual for the
machine.

6 140E-5 Series
30 Testing and adjusting SEN00149-05

Testing exhaust temperature 1

a Testing tool for exhaust temperature


Symbol Part No. Part name
B 799-101-1502 Digital thermometer

k Remove and install the testing tools after


the exhaust manifold temperature has low-
ered.
a The test point is subject to machine models.

1. Remove exhaust temperature pickup plug (1)


from the bottom of the exhaust manifold.
a You may measure at either front or rear
plug.
4. After finishing testing, remove the testing tools
and return the removed parts.
q Clean the thread of the removed plug and
apply seizure prevention compound to the
plug before installing.
2 Plug: Seizure prevention com-
pound (LC-G)
(NEVER-SEEZ (NEVER-SEEZ COM-
POUND CO, LTD) or equivalent).
3 Plug: 2.9 – 5.9 Nm {0.3 – 0.6 kgm}

2. Install sensor [1] of digital thermometer B and


connect it to thermometer [2].

3. Run the engine and test the exhaust tempera-


ture in the whole speed range.
a When testing with the engine mounted on
the machine, test on the condition
described in the shop manual for the
machine.

140E-5 Series 7
SEN00149-05 30 Testing and adjusting

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

5. While fixing adjustment screw (3), tighten lock-


nut (4).
3 Locknut: 45.1 – 51.0 Nm {4.6 – 5.2 kgm}
a After tightening the locknut, check the
valve clearance again.

2. Rotate the crankshaft forward to bring the


stamped “1.6TOP” line (a) of the damper to
pointer (2) and set the No. 1 cylinder to the
compression top dead center.
a Rotate the crankshaft with the hexagonal
part at the end of the water pump drive
shaft.
a When the No. 1 cylinder is at the compres-
sion top dead center, the rocker arm of the
No. 1 cylinder can be moved by the valve
clearance with the hand. If the rocker arm
cannot be moved, rotate the crankshaft
one more turn. 6. After adjusting the No. 1 cylinder, rotate the
crankshaft forward by 120° and adjust the
clearance of each cylinder according the firing
order.
a Firing order: 1 – 5 – 3 – 6 – 2 – 4

7. After finishing adjustment, return the removed


parts.
3 Cylinder head cover mounting bolt:
29.4 – 34.3 Nm {3.0 – 3.5 kgm}

8 140E-5 Series
30 Testing and adjusting SEN00149-05

Testing compression pressure 1

a Testing tools for compression pressure


Symbol Part No. Part name
1 795-502-1590 Compression gauge
D 795-471-1330 Adapter
2
6261-71-6150 Gasket

k When measuring the compression pres-


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

a Measure the compression pressure after the


engine is warmed up (Engine oil temperature: 4. Install adapter D2 to the mounting hole on the
40 – 60°C). injector and the compression gauge D1.
a Fit the gasket to the adapter end without
1. Remove cylinder head cover (1) of the cylinder fail.
to be tested for compression pressure. a Fix the adapter with the injector holder.
3 Holder mounting bolt:
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
a Apply a little amount of engine oil to the
connecting parts of the adapter and gauge
so that air will not leak easily.

5. Install rocker arm assembly (2) and adjust the


valve clearance.
3 Rocker arm mounting bolt:
93 – 103 Nm {9.5 – 10.5 kgm}
a See “Adjusting valve clearance.”

2. Bring the cylinder to be tested to the compres-


sion top dead center and remove rocker arm
assembly (2).
a See “Adjusting valve clearance.”

3. Disconnect fuel high-pressure tube (3) and


injector wiring harness and remove injector (4).
a Disconnect the terminal of the injector wir-
ing harness on the injector side and the
bracket on the rocker housing side and
r e m o v e t h e i n j e c t o r w ir i n g h a r n e s s 6. Connect the INSITE (bench test tool) to the
(Loosen the 2 terminal nuts alternately). engine and set the engine in the no-injection
a Pass a wire, etc. under the fuel path pro- cranking mode.
jected sideways and pull up the injector a When inspecting with the engine mounted
(Do not pry the injector top up). on the machine, set the engine in the no-
injection cranking mode by operating the
monitor panel.
k If the engine is not set in the no-injec-
tion cranking mode, it will start and will
be dangerous. Accordingly, be sure to
set the engine in this mode.

140E-5 Series 9
SEN00149-05 30 Testing and adjusting

7. Rotate the engine with the starting motor and


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

8. After finishing testing, remove the testing tools


and return the removed parts.
a Install the injector and fuel high-pressure
tube according to the following procedure.
1) Push in injector (11) with the hand to
assemble holder (12) temporarily.
a Change the copper gasket and the O-ring
for a new part.
2) Tighten bolt (13) and washer (14) tempo-
rarily.
2 Spherical part of washer: Engine oil
3) Tighten sleeve nut (15) of the fuel high-
pressure tube temporarily.
4) Tighten bolt (13) permanently.
3 Bolt: 58.8 – 73.5 Nm {6.0 – 7.5 kgm}
5) Tighten sleeve nut (15) permanently.
3 Sleeve nut: 39.2 – 49.0 Nm {4 – 5 kgm}

a Install the injector wiring harness accord-


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

3 Rocker arm assembly mounting bolt:


93 – 103 Nm {9.5 – 10.5 kgm}

a Adjust the valve clearance. For details, see


“Adjusting valve clearance.”

3 Cylinder head cover mounting bolt:


29.4 – 34.3 Nm {3.0 – 3.5 kgm}

10 140E-5 Series
30 Testing and adjusting SEN00149-05

Testing blow-by pressure 1

a Testing tool for blow-by pressure


Symbol Part No. Part name
E 799-201-1504 Blow-by checker

a The test point is subject to machine models.

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. Run the engine at the rated output and test the


blow-by pressure.
a When testing with the engine mounted on
the machine, test on the condition
described in the shop manual for the
machine.

4. After finishing testing, remove the testing tools


and return the removed parts.

140E-5 Series 11
SEN00149-05 30 Testing and adjusting

Testing engine oil pressure 1

a Testing tools for engine oil pressure


Symbol Part No. Part name
799-101-5002 Hydraulic tester
1
F 790-261-1204 Digital hydraulic tester
2 799-401-2320 Hydraulic tester

a The test point is subject to machine models.

1. Remove oil pressure pickup plug (1) from the


cylinder block.

4. After finishing testing, remove the testing tools


and return the removed parts.
q Remove the gasket sealant remaining on
the threads of the removed plug with a
wire brush and apply new adhesive or
gasket sealant to the plug before install-
ing.
2 Plug: Adhesive (LT2) or gasket
sealant (LG-5)
3 Plug:
16.7 – 37.2 Nm {1.7 – 3.8 kgm}

2. Install nipples [1] and [2] of hydraulic tester F1


and connect them to hydraulic tester F2.
a Since the size of the plug hole is R1/4,
quick nipple (799-101-5210) may be used.

3. Run the engine at the rated output and low idle


and test the oil pressure.
a When testing with the engine mounted on
the machine, test on the condition
described in the shop manual for the
machine.

12 140E-5 Series
30 Testing and adjusting SEN00149-05

Testing EGR valve and bypass 3. Connect hydraulic tester [2] (Component part
valve drive oil pressure 1 of tool F1) to the nipple.

4. Start the engine and measure the oil pressure


a Testing instrument for EGR valve and bypass at low idle and high idle.
valve drive oil pressure
Symbol Part No. Part name
799-101-5002 Hydraulic tester
F 1
790-261-1204 Digital hydraulic tester

a The measuring point may be different from the


following explanation, depending on each
applicable machine.

1. Remove oil pressure pickup plug (2) from the


left side of timing gear cover (1).

2. Install nipple [1] (Component part of tool F1:


PT 1/8) to the hole from which the oil pressure
pickup plug was removed. 5. After finishing measurement, remove the mea-
suring instruments and return the removed
parts.
q Remove the gasket sealant remaining on the
threads of the removed plug with a wire brush
and apply new adhesive or gasket sealant to
the plug before installing.
2 Plug: Adhesive (LT2) or gasket seal-
ant (LG-5)
3 Plug: 9.8 – 19.6 Nm {1.0 – 2.0 kgm}

140E-5 Series 13
SEN00149-05 30 Testing and adjusting

Handling fuel system parts 1 Releasing residual pressure in


fuel system 1
a Precautions for testing and maintaining fuel
system a Pressure is generated in the low-pressure cir-
The common rail fuel injection system (CRI) cuit and high-pressure circuit of the fuel sys-
consists of more precise parts than the con- tem while the engine is running.
ventional fuel injection pump and nozzle. If for- Low-pressure circuit:
eign matter enters this system, it can cause a Feed pump – Fuel filter – Supply pump
trouble. High-pressure circuit:
When testing and maintaining the fuel system, Supply pump – Common rail – Injector
take care more than the past. If dust, etc. a The pressure in both low-pressure circuit and
sticks to any part, wash that part thoroughly high-pressure circuit lowers to a safety level
with clean fuel. automatically 30 seconds after the engine is
a Precautions for replacing fuel filter cartridge stopped.
Be sure to use the Komatsu genuine fuel filter a Before the fuel circuit is tested and its parts are
cartridge. removed, the residual pressure in the fuel cir-
Since the common rail fuel injection system cuit must be released completely. Accordingly,
(CRI) consists of more precise parts than the observe the following.
conventional fuel injection pump and nozzle, it k Before testing the fuel system or removing
employs a high-efficiency special filter to pre- its parts, wait at least 30 seconds after stop-
vent foreign matter from entering it. If a filter ping the engine until the residual pressure
other than the genuine one is used, the fuel in the fuel circuit is released. (Do not start
system may have a trouble. Accordingly, the work just after stopping the engine
never use such a filter. since there is residual pressure.)

14 140E-5 Series
30 Testing and adjusting SEN00149-05

Testing fuel pressure 1 3. Run the engine at high idle and measure the
fuel pressure.
a If the fuel pressure is in the following
a Testing tools for fuel pressure range, it is normal.
Symbol Part No. Part name
799-101-5002 Hydraulic tester Engine speed Fuel pressure
1
790-261-1204 Digital hydraulic tester 0.15 – 0.3 MPa
High idle
G 2 799-401-2320 Gauge {1.5 – 3 kg/cm2}

795-471-1450 Adapter
3
07005-00812 Gasket

a Check the fuel pressure in only the low-pres-


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

1. Remove fuel pressure pickup plug (1) from the


fuel filter head.

4. After finishing testing, remove the testing tools


and return the removed parts.
3 Plug: 7.8 – 9.8 Nm {0.8 – 1.0 kgm}

2. Install adapter G3, 90° elbow [1] of hydraulic


tester G1, and nipple [2] and connect them to
gauge G2.

140E-5 Series 15
SEN00149-05 30 Testing and adjusting

Reduced cylinder mode No-injection cranking 1


operation 1
a No-injection cranking means to crank the
a Reduced cylinder mode operation means to engine with the starting motor while all the
run the engine with the fuel injectors of 1 or injections are stopped electrically. The pur-
more cylinders disabled electrically to reduce pose and effect of this operation are as follows.
the number of effective cylinders. The pur- q Before the engine is started after it or the
poses and effects of this operation are as fol- machine has been stored for a long period, the
lows. no-injection cranking is performed to lubricate
1. This operation is used to find out a cylinder the engine parts and protect them from sei-
which does not output power normally (or, zure.
combustion in it is abnormal). a Perform the no-injection operation with the
2. When a cylinder is selected for the reduced engine mounted on the machine or connected
cylinder mode operation, if the engine speed to INSITE (bench test tool). Before perform-
and output do not change from the normal ing, see Testing method in the shop manual for