Komatsu 140-3 Series - Repair, Service and Maintenance Manual

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KOMATSU 140-3 SERIES - DIESEL ENGINE SERVICE MANUAL

- English Workshop Manual, to Engines Diesel Komatsu 140-3 Series.
 

CONTENTS:

MAIN MENU
COVER
CONTENTS
00 FOREWARD
- SAFETY
- FOREWARD
- HOW TO READ THIS MANUAL
- HOISTING INSTRUCTIONS
- METHOD OF DISASSEMBLING, CONNECTING, PUSH-PULL TYPE COUPLER
- COATING MATERIALS
- STANDARD TIGHTENING TORQUE
- ELECTRIC WIRE CODE
- COVERSION TABLE
- UNITS
01 GENERAL
- OUTLINE
- SPECIFICATIONS
- OVERALL DRAWING
- WEIGHT TABLE
- ENGINE PERFORMANCE CURVE
11 STRUCTURE AND FUNCTION, MAINTENANCE STANDARD
- INTAKE, EXHAUST SYSTEM
--- INTAKE, EXHAUST EQUIPMENT
--- AIR CLEANER
--- TURBOCHARGER
--- AFTERCOOLER
- ENGINE
--- CYLINDER HEAD
--- CYLINDER BLOCK
--- CYLINDER LINER
--- MAIN MOVING PARTS
--- CRANKSHAFT
--- CAMSHAFT
--- CAM FOLLOWER AND PUSH ROD
--- PISTON PISTON RING PISTON PIN
--- CONNECTING ROD
--- FLYWHEEL, FLYWHEEL HOUSING
--- VIBRATION DAMPER
--- TIMING GEAR
--- VALVE SYSTEM
--- VALVE, VALVE GUIDE
--- ROCKER ARM AND SHAFT
--- CROSSHEAD AND GUIDE
- LUBRICATION SYSTEM
--- LUBRICATION SYSTEM DIAGRAM
--- OIL PUMP
--- OIL FILTER
--- OIL COOLER
- FUEL SYSTEM
--- FUEL SYSTEM DIAGRAM
--- OUTLINE OF CRI SYSTEM
--- FUEL PIPING
--- FUEL COOLER
--- FUEL FILTER
- COOLANT SYSTEM
--- COOLING SYSTEM DIAGRAM
--- WATER PUMP
--- THERMOSTAT
--- CORROSION RESISTOR
--- COOLING FAN DRIVE
- ACCESSORIES
--- FRONT PRO
--- AIR COMPRESSOR
--- EXHAUST BRAKE
- ELECTRICAL COMPONENTS
--- ALTERNATOR
--- STARTING MOTOR
--- STARTING AID
12 TESTING AND ADJUSTING
- STANDARD VALUE TABLE FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
- STANDARD VALUE TABLE FOR ELECTRICAL RELATED PARTS
- TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
- MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)
- MEASURING EXHAUST TEMPERATURE
- ADJUSTING VALVE CLEARENCE
- MEASURING COMPRESSION PRESSURE
- MEASURING BLOW-BY PRESSURE
- MEASURING OIL PRESSURE
- HANDLING EQUIPMENT IN FUEL CIRCUIT
- RELEASING REMAINING PRESSURE IN FUEL SYSTEM
- MEASURING FUEL PRESSURE
- REDUCED CYLINDER MODE OPERATION
- BLEEDING AIR FROM FUEL SYSTEM
- CHECK FOR LEAKAGE IN FUEL SYSTEM
- ADJUSTING SPEED SENSOR
- TESTING AND ADJUSTING ALTERNATOR BELT TENSION
- TESTING AND ADJUSTING FAN BELT TENSION
- HANDLING CONTROLLER HIGH VOLTAGE CIRCUIT
- RUN-IN STANDARD
- PERFORMANCE TEST STANDARDS
- TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)
--- POINTS TO REMEMBER WHEN TROUBLESHOOTING
--- METHOD OF USING TROUBLESHOOTING CHARTS
--- S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)
--- S-2 ENGINE DOES NOT START
--- S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)
--- S-4 ENGINE STOPS DURING OPERATIONS
--- S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)
--- S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)
--- S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)
--- S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)
--- S-9 OIL BECOMES CONTAMINATED QUICKLY
--- S-10 FUEL CONSUMPTION IS EXCESSIVE
--- S-11 OIL IS IN COOLING WATER (OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN)
--- S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)
--- S-13 OIL LEVEL RISES (WATER, FUEL IN OIL)
--- S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)
--- S-15 ABNORMAL NOISE IS MADE
--- S-16 VIBRATION IS EXCESSIVE
- TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)
--- POINTS TO REMEMBER WHEN TROUBLESHOOTING
--- METHOD OF USING TROUBLESHOOTING FLOWCHART
--- ERROR CODE DISPLAYS AND POINTS TO REMEMBER WHEN TROUBLESHOOTING
--- ACTION TAKEN BY CONTROLLER AND CONDITION OF MACHINE WHEN ERROR CODE IS DISPLAYED
--- E-1 ERROR CODE [E-1B] [ABNORMALITY IN NE REVOLUTION SENOR SYSTEM]
--- E-2 ERROR CODE [E-1C] [ABNORMALITY IN G REVOLUTION SENOR SYSTEM]
--- E-3 ERROR CODE [E-20] [ABNORMALITY IN MODEL SELECTION SYSTEM]
--- E-4 ERROR CODE [E-22] [OVERRUN]
--- E-5 ERROR CODE [E-23] [OVERHEAT]
--- E-6 ERROR CODE [E-24] [DROP IN OIL PRESSURE]
--- E-7 ERROR CODE [E-30] [ABNORMALITY IN IDLING VALIDATION SIGNAL SYSTEM]
--- E-8 ERROR CODE [E-31B] [ABNORMALITY IN NE REVOLUTION SENOR SYSTEM]
--- E-9 ERROR CODE [E-34] [ABNORMALITY IN WATER TEMPERATURE HIGH-TEMPERATURE SENSOR SYSTEM]
--- E-10 ERROR CODE [E-36] [ABNORMALITY IN OIL PRESSURE SYSTEM
--- E-11 ERROR CODE [E-3C] [ABNORMALITY IN BOOST PRESSURE SENSOR SYSTEM
--- E-12 ERROR CODE [E-3D] [ABNORMALITY IN FUEL TEMPERATURE SENSOR SYSTEM]
--- E-13 ERROR CODE [E-50] [ABNORMALITY IN PREHEATING RELAY CONNECTING POINT SYSTEM]
--- E-14 ERROR CODE [E-51] [ABNORMALITY IN PREHEAT RELY COIL SYSTEM]
--- E-15 ERROR CODE [E-54] [ SHORT CURCUIT IN STARTING SWITCH C SYSTEM
--- E-16 ERROR CODE [E-56] [POWER SOURCE SYSTEM ABNORMALITY 1]
--- E-17 ERROR CODE [E-57] [POWER SOURCE SYSTEM ABNORMALITY 2]
--- E-18 ERROR CODE [E-5A] ABNORMALITY IN FUEL INJECTION QUANTITY CONTROL SWITCH SIGNAL]
--- E-19 ERROR CODE [E-6A] [ABNORMALITY IN WATER TEMPERATURE LOW-TEMPERATURE SENSOR SYSTEM]
--- E-20 ERROR CODE [E-70] [EXCESS CURRENT IN FUEL SUPPLY PUMP PCV1 SYSTEM
--- E-21 ERROR CODE [E-71] EXCESS CURRENT IN FUEL SUPPLY PUMP PCV2 SYSTEM
--- E-22 ERROR CODE [E-71] DISCONNECTION CURRENT IN FUEL SUPPLY PUMP PCV1 SYSTEM
--- E-23 ERROR CODE [E-71] DISCONNECTION CURRENT IN FUEL SUPPLY PUMP PCV2 SYSTEM
--- E-24 ERROR CODE [E-77] [ABNORMALITY IN COMMON RAIL FUEL PRESSURE SENSOR SYSTEM
--- E-25 ERROR CODE [E-79] [COMMON RAIL FUEL HIGH PRESSURE ABNORMALITY 1]
--- ERROR CODE [E-7A] [COMMON RAIL FUEL HIGH PRESSURE ABNORMALITY 2]
--- E-26 ERROR CODE [E-7B] [FUEL SUPPLY PUMP NON-FORCE FEED 1]
--- ERROR CODE [E-7C] [FUEL SUPPLY PUMP NON-FORCE FEED 2]
--- E-27 ERROR CODE [E-7D] [ABNORMALITY IN COMMON RAIL FUEL PRESSURE]
--- E-28 ERROR CODE [E-80] [DEFECTIVE CONTROLLER]
--- E-29 ERROR CODE [E-81] [DISCONNECTION IN NO. 1 FUEL INJECTOR SYSTEM]
--- E-30 ERROR CODE [E-82] [DISCONNECTION IN NO.2 FUEL INJECTOR SYSTEM]
--- E-31 ERROR CODE [E-83] [DISCONNECTION IN NO. 3 FUEL INJECTOR SYSTEM]
--- E-32 ERROR CODE [E-84] [DISCONNECTION IN NO. 4 FUEL INJECTOR SYSTEM]
--- E-33 ERROR CODE [E-85] [DISCONNECTION IN NO. 5 FUEL INJECTOR SYSTEM]
--- E-34 ERROR CODE [E-86] [DISCONNECTION IN NO.6 FUEL INJECTOR SYSTEM]
--- E-35 ERROR CODE [E-8A] [SHORT CIRCUIT IN NO. 1, NO.2, NO.3 FUEL INJECTOR SYSTEM]
--- E-36 ERROR CODE [E-8B] [SHORT CIRCUIT IN NO.3, NO.4, NO.5 FUEL INJECTOR SYSTEM]
13 DIASSEMBLY AND ASSEMBLY
- METHOD OF USING MANUAL
- PRECAUTIONS WHEN CARRYING OUT OPERATION
- SPECIAL TOOL LIST
- GENERAL DISASSEMBLY OF ENGINE
- GENERAL ASSEMBLY OF ENGINE
- PROCEDURE FOR REMOVING AND INSTALLING FUEL SUPPLY PUMP UNIT