Komatsu 140E, 12V140, 12V140E, 6D140, SA12V140Z Series Engine Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu 140E, 12V140, 12V140E, 6D140, SA12V140Z Series Engine, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu 140E, 12V140, 12V140E, 6D140, SA12V140Z Series Engine workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 5,897 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
CEBM002601 - SA12V140Z-1 Series Engine Shop Manual.pdf
CEBM002602 - SA12V140Z-1 Series Diesel Engine Shop Manual.pdf
CEBM002603 - SA12V140Z-1, SAA12V140ZE-2 Series Diesel Engine Shop Manual.pdf
SEBE62120112 - 6D140-1 Series Diesel Engine Shop Manual.pdf
SEBM008611 - 6D140-2 Series Diesel Engine Shop Manual.pdf
SEBM008612 - 6D140-2 Series Diesel Engine Shop Manual.pdf
SEBM022209 - 140-3 Series Diesel Engine (SA6D140E-3, SAA6D140E-3, SDA6D140E-3) Shop Manual.pdf
SEBM022213 - 140-3 Series Diesel Engine Shop Manual.pdf
SEBM028318 - 12V140-1 Series Diesel Engine (SA12V140-1, SDA12V140-1, SAA12V140-1) Shop Manual.pdf
SEN00074-16 - 140E-5 Series Engine Shop Manual.pdf
SEN00291-04 - 12V140E-3 Series Engine Shop Manual.pdf
SEN00291-13 - 12V140E-3 Series Engine (SAA12V140E-3) Shop Manual.pdf
SEN00291-14 - 12V140E-3 Series Engine Shop Manual.pdf
SEN05641-02 - 140E-6 Series Engine Shop Manual.pdf
MAIN SECTIONS
COVER...1
00 Index and foreword...0
Index...3
Composition of shop manual...4
Table of contents...5
Foreword and general information...13
Safety notice...14
How to read the shop manual...19
Explanation of terms for maintenance standard...21
Handling of electric equipment and hydraulic component...23
Handling of connectors newly used for engines...32
How to read electric wire code...35
Precautions when carrying out operation...38
Method of disassembling and connecting push-pull type coupler...41
Standard tightening torque table...44
Conversion table...48
01 Specification...0
Specification and technical data...55
Outline...56
Specifications...60
General view...78
Weight table...115
Engine performance curves...119
10 Structure, function and maintenance standard...0
Structure, function and maintenance standard, Part 1...129
Air intake and exhaust unit...131
Air cleaner...133
Turbocharger...136
Aftercooler...147
Muffler...148
EGR system...153
Cylinder head...160
Cylinder block...164
Cylinder liner...167
Main moving parts...168
Crankshaft...170
Camshaft...171
Cam follower and push rod...172
Piston, piston ring and piston pin...174
Connecting rod...176
Flywheel and flywheel housing...177
Vibration damper...180
Timing gear...182
Valve system...186
Valve and valve guide...188
Rocker arm and shaft...190
Crosshead and guide...191
Structure, function and maintenance standard, Part 2...193
Lubrication system...196
Lubrication system diagram...196
Oil pump...200
EGR oil pump...201
Oil filter...202
Oil cooler...204
Fuel system...206
CRI system diagram...206
Outline of CRI system...208
Fuel piping...230
Fuel cooler...234
Fuel filter...235
Priming pump...238
Electric priming pump...239
Engine controller cooler...240
Cooling system...241
Cooling system diagram...241
Water pump...246
Thermostat...249
Corrosion resistor...250
Cooling fan drive...252
Accessories...255
Front PTO...255
Electrical equipment...257
Alternator...257
Starting motor...268
Starting aid...270
Engine controller...271
20 Standard value table...0
Standard service value table...273
Standard service value table for testing, adjusting, and troubleshooting...274
Running-in standard and performance test standard...291
30 Testing and adjusting...0
Testing and adjusting...309
Testing and adjusting (with EGR)...311
Testing and adjusting tools list...311
Sketches of special tools...313
Testing air boost pressure...314
Testing exhaust temperature...315
Adjusting valve clearance...316
Testing compression pressure...317
Testing blow-by pressure...319
Testing engine oil pressure...320
Testing EGR valve and bypass valve drive oil pressure...321
Handling fuel system parts...322
Releasing residual pressure in fuel system...322
Testing fuel pressure...323
Reduced cylinder mode operation...324
No-injection cranking...324
Testing fuel return rate and leakage...325
Bleeding air from fuel circuit...328
Testing fuel system for leakage...330
Testing and adjusting alternator belt tension...331
Testing and adjusting fan belt tension...332
Handling controller high-voltage circuit...333
Testing and adjusting (EGR-less)...334
Testing and adjusting tools list...334
Sketches of special tools...336
Testing air boost pressure...337
Testing exhaust temperature...338
Adjusting valve clearance...339
Testing compression pressure...340
Testing blow-by pressure...342
Testing engine oil pressure...343
Handling fuel system parts...344
Releasing residual pressure in fuel system...344
Testing fuel pressure...345
Reduced cylinder mode operation...346
No-injection cranking...346
Testing fuel return rate and leakage...347
Bleeding air from fuel circuit...350
Testing fuel system for leakage...352
Testing and adjusting alternator belt tension...353
Testing and adjusting fan belt tension...354
Handling controller high-voltage circuit...355
40 Troubleshooting...0
General information on troubleshooting...357
Points to remember when troubleshooting...358
Method of displaying trouble diagnosis lamps (Method of displaying error code)...359
Error codes and failure codes list...361
Information in troubleshooting table...366
Connection table for connector pin numbers...368
T- branch box and T- branch adapter table...404
Troubleshooting of mechanical system (S-mode)...409
Troubleshooting of mechanical system (S-mode)...412
Method of using troubleshooting charts...412
S-1 Starting performance is poor...416
S-2 Engine does not start...418
S-3 Engine does not pick up smoothly...422
S-4 Engine stops during operations...423
S-5 Engine does not rotate smoothly...424
S-6 Engine lacks output (or lacks power)...425
S-7 Exhaust smoke is black (incomplete combustion)...426
S-8 Oil consumption is excessive (or exhaust smoke is blue)...428
S-9 Oil becomes contaminated quickly...429
S-10 Fuel consumption is excessive...430
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)...431
S-12 Oil pressure drops...432
S-13 Oil level rises (Entry of coolant/fuel)...433
S-14 Coolant temperature becomes too high (overheating)...435
S-15 Abnormal noise is made...436
S-16 Vibration is excessive...437
Troubleshooting of electrical system (E-mode), Part 1...439
Troubleshooting of electrical system (E-mode), Part 1...441
Troubleshooting method for disconnecting wiring harness of pressure sensor system...441
E-1 Code [111/CA111] Engine Controller Internal Failure...444
E-2 Code [115/CA115] Eng. Ne and Bkup Speed Sensor Error...445
E-3 Code [122/CA122] Charge (boost) Air Press Sensor High Error...446
E-4 Code [123/CA123] Charge (boost) Air Press Sensor Low Error...450
E-5 Code [131/CA131] Throttle Sensor High Error...454
E-6 Code [132/CA132] Throttle Sensor Low Error...458
E-7 Code [135/CA135] Oil Press. Sensor High Error...460
E-8 Code [141/CA141] Oil Press. Sensor Low Error...462
E-9 Code [144/CA144] Coolant Temp. Sensor High Error...464
E-10 Code [145/CA145] Coolant Temp. Sensor Low Error...466
E-11 Code [153/CA153] Charge (boost) Air Temp. Sensor High Error...468
E-12 Code [154/CA154] Charge (boost) Air Temp. Sensor Low Error...470
E-13 Code [187/CA187] Sensor Sup. 2 Volt. Low Error...472
E-14 Code [221/CA221] Ambient Air Press. Sensor High Error...476
E-15 Code [222/CA222] Ambient Air Press. Sensor Low Error...478
E-16 Code [227/CA227] Sensor Sup. 2 Volt. High Error...480
E-17 Code [234/CA234] Eng. Overspeed...480
E-18 Code [238/CA238] Ne Speed Sensor Sup. Volt. Error...482
E-19 Code [263/CA263] Fuel Temp. Sensor High Error...484
E-20 Code [265/CA265] Fuel Temp. Sensor Low Error...486
E-21 Code [271/CA271] PCV1 Short Error...488
E-22 Code [272/CA272] PCV1 Open Error...490
E-23 Code [273/CA273] PCV2 Short Error...492
E-24 Code [274/CA274] PCV2 Open Error...494
E-25 Code [322/CA322] Injector #1 System Open/Short Error...496
E-26 Code [323/CA323] Injector #5 System Open/Short Error...498
E-27 Code [324/CA324] Injector #3 System Open/Short Error...500
E-28 Code [325/CA325] Injector #6 System Open/Short Error...502
E-29 Code [331/CA331] Injector #2 System Open/Short Error...504
E-30 Code [332/CA332] Injector #4 System Open/Short Error...506
E-31 Code [342/CA342] Engine Controller Data Matching Error...508
E-32 Code [351/CA351] INJ. Drive Circuit Error...510
E-33 Code [352/CA352] Sensor Sup. 1 Volt. Low Error...512
E-34 Code [386/CA386] Sensor Sup. 1 Volt. High Error...513
E-35 Code [431/CA431] Idle Validation Switch Error...516
E-36 Code [432/CA432] Idle Validation Process Error...518
E-37 Code [441/CA441] Supply Voltage Low Error...519
E-38 Code [442/CA442] Supply Voltage High Error...519
Troubleshooting of electrical system (E-mode), Part 2...521
Troubleshooting of electrical system (E-mode), Part 2...523
E-39 Code [449/CA449] Rail Press. High Error 2...523
E-40 Code [451/CA451] Rail Press. Sensor High Error...524
E-41 Code [452/CA452] Rail Press. Sensor Low Error...527
E-42 Code [553/CA553] Rail Press. High Error 1...528
E-43 Code [554/CA554] Rail Press Sensor In Range Error...529
E-44 Code [559/CA559] No-pressure Feed By Supply pump 1...530
E-45 Code [689/CA689] Eng. Ne Speed Sensor Error...534
E-46 Code [731/CA731] Eng. Bkup Speed Sensor Phase Error...536
E-47 Code [757/CA757] All Engine Controller Data Lost Error...536
E-48 Code [778/CA778] Eng. Bkup Speed Sensor Error...538
E-49 Code [1228/CA1228] EGR Valve Servo Error 1...541
E-50 Code [1625/CA1625] EGR Valve Servo Error 2...542
E-51 Code [1626/CA1626] Bypass Valve Solenoid Drive Short Circuit Error...543
E-52 Code [1627/CA1627] Bypass Valve Solenoid Drive Open Error...545
E-53 Code [1628/CA1628] Bypass Valve Servo Error 1...546
E-54 Code [1629/CA1629] Bypass Valve Servo Error 2...547
E-55 Code [1631/CA1631] Bypass Valve Lift Sensor High Error...548
E-56 Code [1632/CA1632] Bypass Valve Lift Sensor Low Error...550
E-57 Code [1633/CA1633] KOMNET Error...550
E-58 Code [1642/CA1642] EGR Inlet Press Sensor Low Error...551
E-59 Code [1653/CA1653] EGR Inlet Press Sensor High Error...552
E-60 Code [2185/CA2185] Throttle Sens. Sup. Volt. High Error...554
E-61 Code [2186/CA2186] Throttle Sens. Sup. Volt. Low Error...558
E-62 Code [2249/CA2249] No-pressure Feed By Supply pump 2...558
E-63 Code [2271/CA2271] EGR Valve Lift Sensor High Error...559
E-64 Code [2272/CA2272] EGR Valve Lift Sensor Low Error...561
E-65 Code [2351/CA2351] EGR Valve Solenoid Drive Short Error...562
E-66 Code [2352/CA2352] EGR Valve Solenoid Drive Open Error...564
E-67 Code [2555/CA2555] Intake Air Heater Relay Open Error...565
E-68 Code [2556/CA2556] Intake Air Heater Relay Short Error...566
E-69 Code [(143)/B@BAZG] Eng. Oil Press Low Torque Derate...568
E-70 Code [(146)/B@BCNS] Eng. Overheat...568
E-71 Code [(415)/B@BAZG] Eng. Oil Press. Low Speed Derate...569
50 Disassembly and assembly...0
General information on disassembly and assembly...571
General information on disassembly and assembly...572
How to read this manual...572
Coating materials list...574
Special tools list...577
Sketches of special tools...578
Disassembly and assembly, Part 1 (with EGR)...583
Disassembly and assembly, Part 1 (with EGR)...584
General disassembly of engine...584
General assembly of engine...602
Disassembly and assembly, Part 2 (EGR-less)...637
Disassembly and assembly, Part 2 (EGR-less)...638
General disassembly of engine...638
General assembly of engine...654
Disassembly and assembly, Part 3...687
Disassembly and assembly, Part 3...688
Removal and installation of fuel supply pump unit (with EGR)...688
Removal and installation of fuel supply pump unit (EGR-less)...690
Replacement of oil seal of engine mounted on machine...693
90 Repair and replacement of parts...0
Information related to repair and replacement...699
Flowchart...700
Special tool table...702
Special tool sketch...704
Cylinder head...709
Part names related to cylinder head...710
Testing and inspection of cylinder head...711
Pressure test of cylinder head...713
Replacement of valve guide...713
Replacement of valve seat insert...714
Replacement of crosshead guide...721
Repair of cylinder head mounting face by grinding...722
Repair of valve by grinding...723
Cylinder block...725
Part names related to cylinder block...727
Testing and inspection of cylinder block...728
Method of checking main bearing metal inside diameter with alignment bar...730
Part names related to crankshaft...731
Testing and inspection of crankshaft...732
Part names related to connecting rod...733
Testing and inspection of connecting rod...734
Replacement of flywheel ring gear...735
Replacement of crankshaft gear...736
Replacement of camshaft gear...737
Replacement of main bearing metal cap...738
Replacement of connecting rod small end bushing...740
Replacement of cam bushing...741
Repair of cylinder block top by grinding...743
Repair of counterbore by grinding...744
Check and identification after repair by grinding...746
Gasket sealant application procedure...747
Repair standard for cylinder liner O-ring...749
Replacement of engine rear seal...750
Replacement of wear sleeve (when sleeve is installed)...754
Repair of crankshaft by grinding...755
Improvement of surface roughness of crankshaft journal...760
