Komatsu SAA6D140E-5, 140E-5 Series SEN00074-16 (Preview)
COVER
00 Index and foreword
Index
Composition of shop manual
Table of contents
Foreword and general information
Safety notice
How to read the shop manual
Explanation of terms for maintenance standard
Handling of electric equipment and hydraulic component
Handling of connectors newly used for engines
How to read electric wire code
Precautions when carrying out operation
Method of disassembling and connecting push-pull type coupler
Standard tightening torque table
Conversion table
01 Specification
Specification and technical data
Outline
Specifications
General view
Weight table
Engine performance curves
10 Structure, function and maintenance standard
Structure, function and maintenance standard, Part 1
Air intake and exhaust unit
Air cleaner
Turbocharger
Aftercooler
Muffler
EGR system
Cylinder head
Cylinder block
Cylinder liner
Main moving parts
Crankshaft
Camshaft
Cam follower and push rod
Piston, piston ring and piston pin
Connecting rod
Flywheel and flywheel housing
Vibration damper
Timing gear
Valve system
Valve and valve guide
Rocker arm and shaft
Crosshead and guide
Structure, function and maintenance standard, Part 2
Lubrication system
Lubrication system diagram
Oil pump
EGR oil pump
Oil filter
Oil cooler
Fuel system
CRI system diagram
Outline of CRI system
Fuel piping
Fuel cooler
Fuel filter
Priming pump
Electric priming pump
Engine controller cooler
Cooling system
Cooling system diagram
Water pump
Thermostat
Corrosion resistor
Cooling fan drive
Accessories
Front PTO
Electrical equipment
Alternator
Starting motor
Starting aid
Engine controller
20 Standard value table
Standard service value table
Standard service value table for testing, adjusting, and troubleshooting
Running-in standard and performance test standard
30 Testing and adjusting
Testing and adjusting
Testing and adjusting (with EGR)
Testing and adjusting tools list
Sketches of special tools
Testing air boost pressure
Testing exhaust temperature
Adjusting valve clearance
Testing compression pressure
Testing blow-by pressure
Testing engine oil pressure
Testing EGR valve and bypass valve drive oil pressure
Handling fuel system parts
Releasing residual pressure in fuel system
Testing fuel pressure
Reduced cylinder mode operation
No-injection cranking
Testing fuel return rate and leakage
Bleeding air from fuel circuit
Testing fuel system for leakage
Testing and adjusting alternator belt tension
Testing and adjusting fan belt tension
Handling controller high-voltage circuit
Testing and adjusting (EGR-less)
Testing and adjusting tools list
Sketches of special tools
Testing air boost pressure
Testing exhaust temperature
Adjusting valve clearance
Testing compression pressure
Testing blow-by pressure
Testing engine oil pressure
Handling fuel system parts
Releasing residual pressure in fuel system
Testing fuel pressure
Reduced cylinder mode operation
No-injection cranking
Testing fuel return rate and leakage
Bleeding air from fuel circuit
Testing fuel system for leakage
Testing and adjusting alternator belt tension
Testing and adjusting fan belt tension
Handling controller high-voltage circuit
40 Troubleshooting
General information on troubleshooting
Points to remember when troubleshooting
Method of displaying trouble diagnosis lamps (Method of displaying error code)
Error codes and failure codes list
Information in troubleshooting table
Connection table for connector pin numbers
T- branch box and T- branch adapter table
Troubleshooting of mechanical system (S-mode)
Troubleshooting of mechanical system (S-mode)
Method of using troubleshooting charts
S-1 Starting performance is poor
S-2 Engine does not start
S-3 Engine does not pick up smoothly
S-4 Engine stops during operations
S-5 Engine does not rotate smoothly
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 coolant (or coolant spurts back or coolant level goes down)
S-12 Oil pressure drops
S-13 Oil level rises (Entry of coolant/fuel)
S-14 Coolant temperature becomes too high (overheating)
S-15 Abnormal noise is made
S-16 Vibration is excessive
Troubleshooting of electrical system (E-mode), Part 1
Troubleshooting of electrical system (E-mode), Part 1
Troubleshooting method for disconnecting wiring harness of pressure sensor system
E-1 Code [111/CA111] Engine Controller Internal Failure
E-2 Code [115/CA115] Eng. Ne and Bkup Speed Sensor Error
E-3 Code [122/CA122] Charge (boost) Air Press Sensor High Error
E-4 Code [123/CA123] Charge (boost) Air Press Sensor Low Error
E-5 Code [131/CA131] Throttle Sensor High Error
E-6 Code [132/CA132] Throttle Sensor Low Error
E-7 Code [135/CA135] Oil Press. Sensor High Error
E-8 Code [141/CA141] Oil Press. Sensor Low Error
E-9 Code [144/CA144] Coolant Temp. Sensor High Error
E-10 Code [145/CA145] Coolant Temp. Sensor Low Error
E-11 Code [153/CA153] Charge (boost) Air Temp. Sensor High Error
E-12 Code [154/CA154] Charge (boost) Air Temp. Sensor Low Error
E-13 Code [187/CA187] Sensor Sup. 2 Volt. Low Error
E-14 Code [221/CA221] Ambient Air Press. Sensor High Error
E-15 Code [222/CA222] Ambient Air Press. Sensor Low Error
E-16 Code [227/CA227] Sensor Sup. 2 Volt. High Error
E-17 Code [234/CA234] Eng. Overspeed
E-18 Code [238/CA238] Ne Speed Sensor Sup. Volt. Error
E-19 Code [263/CA263] Fuel Temp. Sensor High Error
E-20 Code [265/CA265] Fuel Temp. Sensor Low Error
E-21 Code [271/CA271] PCV1 Short Error
E-22 Code [272/CA272] PCV1 Open Error
E-23 Code [273/CA273] PCV2 Short Error
E-24 Code [274/CA274] PCV2 Open Error
E-25 Code [322/CA322] Injector #1 System Open/Short Error
E-26 Code [323/CA323] Injector #5 System Open/Short Error
E-27 Code [324/CA324] Injector #3 System Open/Short Error
E-28 Code [325/CA325] Injector #6 System Open/Short Error
E-29 Code [331/CA331] Injector #2 System Open/Short Error
E-30 Code [332/CA332] Injector #4 System Open/Short Error
E-31 Code [342/CA342] Engine Controller Data Matching Error
E-32 Code [351/CA351] INJ. Drive Circuit Error
E-33 Code [352/CA352] Sensor Sup. 1 Volt. Low Error
E-34 Code [386/CA386] Sensor Sup. 1 Volt. High Error
E-35 Code [431/CA431] Idle Validation Switch Error
E-36 Code [432/CA432] Idle Validation Process Error
E-37 Code [441/CA441] Supply Voltage Low Error
E-38 Code [442/CA442] Supply Voltage High Error
Troubleshooting of electrical system (E-mode), Part 2
Troubleshooting of electrical system (E-mode), Part 2
E-39 Code [449/CA449] Rail Press. High Error 2
E-40 Code [451/CA451] Rail Press. Sensor High Error
E-41 Code [452/CA452] Rail Press. Sensor Low Error
E-42 Code [553/CA553] Rail Press. High Error 1
E-43 Code [554/CA554] Rail Press Sensor In Range Error
E-44 Code [559/CA559] No-pressure Feed By Supply pump 1
E-45 Code [689/CA689] Eng. Ne Speed Sensor Error
E-46 Code [731/CA731] Eng. Bkup Speed Sensor Phase Error
E-47 Code [757/CA757] All Engine Controller Data Lost Error
E-48 Code [778/CA778] Eng. Bkup Speed Sensor Error
E-49 Code [1228/CA1228] EGR Valve Servo Error 1
E-50 Code [1625/CA1625] EGR Valve Servo Error 2
E-51 Code [1626/CA1626] Bypass Valve Solenoid Drive Short Circuit Error
E-52 Code [1627/CA1627] Bypass Valve Solenoid Drive Open Error
E-53 Code [1628/CA1628] Bypass Valve Servo Error 1
E-54 Code [1629/CA1629] Bypass Valve Servo Error 2
E-55 Code [1631/CA1631] Bypass Valve Lift Sensor High Error
E-56 Code [1632/CA1632] Bypass Valve Lift Sensor Low Error
E-57 Code [1633/CA1633] KOMNET Error
E-58 Code [1642/CA1642] EGR Inlet Press Sensor Low Error
E-59 Code [1653/CA1653] EGR Inlet Press Sensor High Error
E-60 Code [2185/CA2185] Throttle Sens. Sup. Volt. High Error
E-61 Code [2186/CA2186] Throttle Sens. Sup. Volt. Low Error
E-62 Code [2249/CA2249] No-pressure Feed By Supply pump 2
E-63 Code [2271/CA2271] EGR Valve Lift Sensor High Error
E-64 Code [2272/CA2272] EGR Valve Lift Sensor Low Error
E-65 Code [2351/CA2351] EGR Valve Solenoid Drive Short Error
E-66 Code [2352/CA2352] EGR Valve Solenoid Drive Open Error
E-67 Code [2555/CA2555] Intake Air Heater Relay Open Error
E-68 Code [2556/CA2556] Intake Air Heater Relay Short Error
E-69 Code [(143)/B@BAZG] Eng. Oil Press Low Torque Derate
E-70 Code [(146)/B@BCNS] Eng. Overheat
E-71 Code [(415)/B@BAZG] Eng. Oil Press. Low Speed Derate
50 Disassembly and assembly
General information on disassembly and assembly
General information on disassembly and assembly
How to read this manual
Coating materials list
Special tools list
Sketches of special tools
Disassembly and assembly, Part 1 (with EGR)
Disassembly and assembly, Part 1 (with EGR)
General disassembly of engine
General assembly of engine
Disassembly and assembly, Part 2 (EGR-less)
Disassembly and assembly, Part 2 (EGR-less)
General disassembly of engine
General assembly of engine
Disassembly and assembly, Part 3
Disassembly and assembly, Part 3
Removal and installation of fuel supply pump unit (with EGR)
Removal and installation of fuel supply pump unit (EGR-less)
Replacement of oil seal of engine mounted on machine
90 Repair and replacement of parts
Information related to repair and replacement
Flowchart
Special tool table
Special tool sketch
Cylinder head
Part names related to cylinder head
Testing and inspection of cylinder head
Pressure test of cylinder head
Replacement of valve guide
Replacement of valve seat insert
Replacement of crosshead guide
Repair of cylinder head mounting face by grinding
Repair of valve by grinding
Cylinder block
Part names related to cylinder block
Testing and inspection of cylinder block
Method of checking main bearing metal inside diameter with alignment bar
Part names related to crankshaft
Testing and inspection of crankshaft
Part names related to connecting rod
Testing and inspection of connecting rod
Replacement of flywheel ring gear
Replacement of crankshaft gear
Replacement of camshaft gear
Replacement of main bearing metal cap
Replacement of connecting rod small end bushing
Replacement of cam bushing
Repair of cylinder block top by grinding
Repair of counterbore by grinding
Check and identification after repair by grinding
Gasket sealant application procedure
Repair standard for cylinder liner O-ring
Replacement of engine rear seal
Replacement of wear sleeve (when sleeve is installed)
Repair of crankshaft by grinding
Improvement of surface roughness of crankshaft journal
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