140e-6 Series PDF

SEN05641-02
ENGINE 140E -6 SERIES

SHOP MANUAL
ENGINE
140E-6 SERIES
Model Serial Number
140E-6
SERIES
00 Index and foreword

1 00 Index and foreword
140E-6 SERIES 00-1

Index
Index (ALL-0310-001-A-00-A)
00 Index and foreword ....................................................................................................................... 00-1
Index ......................................................................................................................................... 00-2
Foreword, safety and general information ..................................................................................... 00-5
Important safety notice ......................................................................................................... 00-5
How to read the shop manual.............................................................................................. 00-12
Explanation of terms for maintenance standard .................................................................... 00-13
Handling equipment of fuel system devices .......................................................................... 00-15
Handling of intake system parts........................................................................................... 00-16
Handling of hydraulic equipment.......................................................................................... 00-17
Method of disconnecting and connecting of push-pull type coupler ......................................... 00-19
Handling of electrical equipment.......................................................................................... 00-22
How to read electric wire code............................................................................................. 00-30
Precautions when performing operation ............................................................................... 00-33
Standard tightening torque table.......................................................................................... 00-37
List of abbreviation ............................................................................................................. 00-41
Conversion table ................................................................................................................ 00-46
01 Specification................................................................................................................................. 01-1
Table of contents ........................................................................................................................ 01-2
General information .................................................................................................................... 01-3
Exhaust gas regulation ......................................................................................................... 01-3
Specifications............................................................................................................................. 01-6
Machine model .................................................................................................................... 01-6
Specifications ...................................................................................................................... 01-7
General view ..................................................................................................................... 01-10
Weight table ...................................................................................................................... 01-23
Engine performance curve .................................................................................................. 01-24
10 Structure and function ................................................................................................................... 10-1
Components layout..................................................................................................................... 10-4
Components layout drawing.................................................................................................. 10-4
Intake and exhaust system parts .................................................................................................. 10-7
Intake and exhaust system layout drawing ............................................................................. 10-7
Intake and exhaust system circuit diagram ............................................................................. 10-9
Air cleaner ......................................................................................................................... 10-11
KVGT................................................................................................................................ 10-12
Aftercooler......................................................................................................................... 10-18
EGR system piping drawing ................................................................................................ 10-19
EGR system circuit diagram ................................................................................................ 10-21
EGR valve......................................................................................................................... 10-22
EGR cooler........................................................................................................................ 10-24
Mixing connector................................................................................................................ 10-26
KCCV layout drawing ......................................................................................................... 10-27
KCCV ventilator ................................................................................................................. 10-29
KDPF................................................................................................................................ 10-33
Engine main body parts............................................................................................................. 10-37
Cylinder head .................................................................................................................... 10-37
Cylinder block .................................................................................................................... 10-39
Main moving parts.............................................................................................................. 10-41
Timing gear ....................................................................................................................... 10-44
Front cover ........................................................................................................................ 10-45
Valve system ..................................................................................................................... 10-46
Flywheel and flywheel housing ............................................................................................ 10-48
Lubrication system.................................................................................................................... 10-49
Lubrication system parts layout drawing ............................................................................... 10-49
Lubrication system diagram ................................................................................................ 10-50
Oil pump ........................................................................................................................... 10-51
Boost oil pump ................................................................................................................... 10-53
Oil filter.............................................................................................................................. 10-55
00-2 140E-6 SERIES

Index
Oil cooler........................................................................................................................... 10-56

Oil cooler thermo-valve....................................................................................................... 10-58
Oil pan .............................................................................................................................. 10-59
Fuel system ............................................................................................................................. 10-60
Fuel system parts layout drawing......................................................................................... 10-60
Fuel system circuit diagram................................................................................................. 10-62
Outline of CRI system ............................................................................................................... 10-65
Fuel system ....................................................................................................................... 10-65
Various controls ................................................................................................................. 10-66
Structure and operation of CRI system................................................................................. 10-68
Structure and operation of component parts ......................................................................... 10-69
Fuel dozing .............................................................................................................................. 10-79
Dozing piping drawing ........................................................................................................ 10-79
Pre-filter ............................................................................................................................ 10-82
Main filter .......................................................................................................................... 10-83
Cooling system......................................................................................................................... 10-84
Cooling system parts layout drawing.................................................................................... 10-84
Cooling system circuit diagram............................................................................................ 10-85
Water pump....................................................................................................................... 10-86
Thermostat ........................................................................................................................ 10-88
Electrical equipment.................................................................................................................. 10-90
Alternator .......................................................................................................................... 10-90
Alternator mounting ............................................................................................................ 10-93
Starting motor .................................................................................................................... 10-94
Fuel feed pump.................................................................................................................. 10-96
Fuel feed pump switch........................................................................................................ 10-97
Engine wiring harness ........................................................................................................ 10-98
Engine controller .............................................................................................................. 10-100
Sensor ............................................................................................................................ 10-106
20 Standard value table ..................................................................................................................... 20-1
Standard service value table........................................................................................................ 20-3
Standard value table for engine ............................................................................................. 20-3
Running-in standard and performance test standard ............................................................... 20-9
50 Disassembly and assembly ........................................................................................................... 50-1
General information on disassembly and assembly........................................................................ 50-3
How to read this manual ....................................................................................................... 50-3
Coating materials list ............................................................................................................ 50-5
Special tools list ................................................................................................................... 50-9
Sketches of special tools .................................................................................................... 50-11
Disassembly and assembly ....................................................................................................... 50-14
General disassembly of engine ........................................................................................... 50-14
General assembly of engine................................................................................................ 50-29
Removal and installation of supply pump.............................................................................. 50-61
Procedures for replacing engine front oil seal ....................................................................... 50-65
Procedures for replacing engine rear oil seal ........................................................................ 50-68
60 Maintenance standard................................................................................................................... 60-1
KVGT.................................................................................................................................. 60-3
Engine main body parts............................................................................................................... 60-4
Cylinder head ...................................................................................................................... 60-4
Cylinder block ...................................................................................................................... 60-5
Cylinder liner ....................................................................................................................... 60-7
Crankshaft........................................................................................................................... 60-8
Cam follower and push rod ................................................................................................... 60-9
Piston ............................................................................................................................... 60-10
Connecting rod .................................................................................................................. 60-12
140E-6 SERIES 00-3

Index
Timing gear ....................................................................................................................... 60-14

Camshaft .......................................................................................................................... 60-16
Valve and valve guide......................................................................................................... 60-17
Rocker arm........................................................................................................................ 60-19
Crosshead and guide ......................................................................................................... 60-20
Flywheel............................................................................................................................ 60-21
Cooling system......................................................................................................................... 60-23
Oil cooler........................................................................................................................... 60-23
Water pump....................................................................................................................... 60-25
Index.................................................................................................................................................................... 1
00-4 140E-6 SERIES

Foreword, safety and general information
Foreword, safety and general information (ALL-0370-001-A-00-A)
Important safety notice (ALL-1120-012-A-01-A)
(Rev. 2012/01)
• Appropriate servicing and repair are extremely important to ensure safe operation of the machine. The
shop manual describes the effective and safe servicing and repair methods recommended by Komatsu.
Some of these methods require the use of the special tools designed by Komatsu for the specific purpose.
• The symbol mark k is used for such matters that require special cautions during the work. The work
indicated by the caution mark should be performed according to the instructions with special attention to
the cautions. Should hazardous situation occur or be anticipated during such work, be sure to keep safe
first and take every necessary measure.
General precautions knowledge of welding perform the work. When

performing welding work, always wear welding
k Inappropriate handling causes an extreme gloves, apron, shielding goggles, cap, etc.
danger. Read and understand what is • Before starting work, warm up your body
described in the operation and maintenance thoroughly to start work under good condition.
manual before operating the machine. Read • Avoid continuing work for long hours and take
and understand what is described in this rests with proper intervals to keep your body in
manual before starting the work. good condition. Take a rest in a specified safe
place.
• Before performing any greasing or repairs, read
all the safety labels stuck to the machine. For Safety points
the locations of the safety labels and detailed 1 Good arrangement
explanation of precautions, see the operation 2 Correct work clothes
and maintenance manual.
3 Observance of work standard
• Locate a place in the repair workshop to keep
4 Practice of making and checking signals
the tools and removed parts. Always keep the
Prohibition of operation and handling by
tools and parts in their correct places. Always 5
unlicensed workers
keep the work area clean and make sure that Safety check before starting work
6
there is no dirt, water or oil on the floor. Smoke
Wearing protective goggles (for cleaning or
only in the areas provided for smoking. Never 7 grinding work)
smoke while working.
Wearing shielding goggles and protectors (for
• When performing any work, always wear the 8 welding work)
safety shoes and helmet. Do not wear loose
9 Good physical condition and preparation
work cloths, or clothes with buttons missing.
Precautions against work which you are not
1. Always wear the protective eyeglasses when 10 used to or you are used to too much
hitting parts with a hammer.
2. Always wear the protective eyeglasses when Preparation
grinding parts with a grinder, etc. • Before adding oil or making any repairs, place
• When performing any work with two or more the machine on a firm and level ground, and
workers, always agree on the working procedure apply the parking brake and chock the wheels or
before starting. While working, always keep tracks to prevent the machine from moving.
conversations of the work between your fellow • Before starting work, lower the work equipment
workers and your self on any step of the work. (blade, ripper, bucket, etc.) to the ground. If it is
During the work, hang the warning tag of not possible to lower the equipment to the
"UNDER WORKING" in the operator's ground, insert the lock pin or use blocks to
compartment. prevent the work equipment from falling. And be
• Only qualified workers must perform the work sure to lock all the work equipment control levers
and operation which require license or and hang a warning tag on them.
qualification. • When performing the disassembling or
• Keep the tools in good condition. And learn the assembling work, support the machine securely
correct way to use the tools, and use the proper with blocks, jacks, or stands before starting the
ones among them. Before starting the work, work.
thoroughly check the tools, forklift truck, service • Remove all of mud and oil from the steps or
car, etc. other places used to get on and off the machine
• If welding repairs is required, always have a completely. Always use the handrails, ladders of
trained and experienced welder with good
140E-6 SERIES 00-5

steps when getting on or off the machine. Never • When removing piping, prevent the fuel or oil
jump on or off the machine. When the scaffold is from spilling out. If any fuel or oil drips onto the
not provided, use steps or stepladder to secure floor, wipe it off immediately. Fuel or oil on the
your footing. floor can cause you to slip and can even cause
fires.
Precautions during work • As a general rule, do not use gasoline to wash
• For the machine equipped with the battery parts. Do not use gasoline to clean the electrical
disconnect switch, check that the system parts, in particular.
operating lamp is turned off before starting the • Reinstall the parts removed to their original
work. Then, turn the battery disconnect switch to places. Replace the damaged parts and the
the OFF (Q) position and remove the switch key. parts which must not be used with new ones.
For the machine not equipped with the battery When installing the hoses and wiring harnesses,
disconnect switch, remove the cable from the be careful that they are not damaged by
battery before starting the work. Be sure to contacting with other parts when the machine is
remove the negative end (-) of the battery cable operated.
first. • When connecting the high pressure hoses and
• Release the remaining pressure in the circuits tubes, make sure that they are not twisted. The
completely before the work when the parts in the damaged high pressure hoses and tubes are
circuits of oil, fuel, coolant and air are very dangerous when they are installed. So, be
disconnected or removed. When the cap of the extremely careful when connecting the high
oil filter, drain plug or oil pressure pickup plug is pressure pipings. In addition, check that their
removed, loose them slowly to prevent the oil connections are correct.
from spurting out. • When assembling or installing the parts, be sure
• When removing or installing the checking plug or to tighten the bolts to the specified torque. When
the piping in the fuel circuit, wait 30 seconds or installing the protective parts such as guards, or
longer after the engine is shut down and start the parts which vibrate violently or rotate at high
the work after the remaining pressure is speeds, be sure to check that they are installed
released from the fuel circuit. correctly.
• Immediately after the engine is shut down, the • When aligning two holes, never insert your
coolant and oil in the circuits are hot. Be careful fingers or hand into the holes. Align the holes
not to get scalded by the hot coolant and oil. with care so that your fingers are not caught in
Start the work after checking that the coolant the hole.
and oil are cooled down sufficiently. • When measuring hydraulic pressure, check that
• Start the work after the engine is shut down. Be the measuring tools are correctly installed.
sure to shut down the engine when working on • Pay attention to safety when removing and
or around the rotating parts in particular. When installing the tracks of the track type machines.
checking the machine without shutting down the When removing the track, it separates suddenly.
engine (measuring oil pressure, engine speed, The workers should not stand at either end of
oil or coolant temperature), take extreme care the track.
not to get caught in the rotating parts or the • If the engine is operated for a long time in a
working equipment. closed place which is not ventilated well, you
• The hoist or crane must be used to sling the may suffer from gas poisoning. Accordingly,
components weighing 25 kg or heavier. Check open the windows and doors to ventilate the
the slings (wire rope, nylon sling, chain and place well.
hook) for damage before the work. Use the
slings with ample capacity and install them to Precautions for slinging work and making
the proper places. Operate the hoist or crane signals
slowly to prevent the component from hitting any • Only one appointed worker must make signals
other part. Do not work with any part still raised and co-worker must communicate with each
by the hoist or crane. other frequently. The appointed signaler must
• When removing the part which is under internal make specified signals clearly at the place
pressure or reaction force of the spring, always where the signaler is well seen from the
leave two bolts in diagonal positions. Loosen operator's seat and where the signaler can see
those two bolts gradually and alternately and the working condition easily. The signaler must
release the pressure, then, remove the part. always stand in front of the load and guide the
• When removing the part, be careful not to break operator safely.
or damage the electrical wiring. The damaged 1. Do not stand under the load.
wiring may cause electrical fires. 2. Do not step on the load.
• Check the slings before starting sling work.
00-6 140E-6 SERIES

• Keep putting on the gloves during sling work. • Use the specified eye bolts and fix wire ropes,
(Put on the leather gloves, if available.) chains, etc. to them with shackles, etc.
• Measure the weight of the load by the eye and • Apply wire ropes to the middle portion of the
check its center of gravity. hook.
• Use the proper sling according to the weight of
a Slinging near the tip of the hook may cause
the load and method of slinging. If too thick wire
the rope to slip off the hook during hoisting.
ropes are used to sling a light load, the load may
The hook has the maximum strength at the
slip and fall.
middle part.
• Do not sling a load with one wire rope only. If do
so, the load may rotate or the sling gets loose
and the sling may slip off. Install two or more
wire ropes symmetrically.
k Slinging with one rope may cause turning

of the load during hoisting, untwisting of
the rope, or slipping of the rope from its
original slinging position on the load,
which can result in a dangerous accident.
• Hanging angle must be 60 degrees or smaller as
a rule.
• When hanging a heavy load (25kg or heavier),
the hanging angle of the rope must be narrower • Do not use twisted or kinked wire ropes.
than that of the hook. • When slinging up a load, observe the following.
a When slinging a load with two ropes or more, 1. Wind up the rope slowly until the wire rope
the larger the hanging angle is, the larger the tensions. When putting your hands on the
tension of each rope. The figure bellow wire ropes, do not grasp them but press them
shows the variation of allowable load in kN down from above. If you grasp them, your
{kg} when hoisting is made with two ropes, fingers may be caught.
each of which is allowed to sling up to 9.8 kN 2. After the wire ropes are stretched, stop the
{1000kg} a load vertically, at various hanging crane and check the condition of the slung
angles. When the two ropes sling a load load, wire ropes, and pads.
vertically, up to19.6 kN {2000 kg} of total 3. If the load is unstable or the wire rope or
weight can be suspended. This weight is chains are twisted, lower the load and lift it
reduced to 9.8 kN {1000 kg} when the two up again.
ropes make a hanging angle of 120 degrees. 4. Do not lift up the load at an angle.
If the two ropes sling a 19.6 kN {2000 kg} • When lowering a load, pay attention to the
load at a hanging angle of 150 degrees, each following.
rope is subjected to a force as large as 39.2 1. When lifting down a load, stop it temporarily
kN {4000 kg}. at 30 cm above the floor, and then lower it
slowly.
2. Check that the load is stable, and then
remove the sling.
3. Remove kinks and dirt from the wire ropes
and chains used for the sling work, and put
them in the specified place.
Precautions for using mobile crane

a Read the Operation and Maintenance Manual of
the crane carefully in advance and operate the
crane safely.
• When installing wire ropes to an angular load,

apply pads to protect the wire ropes. If the load
is slippery, apply proper material to prevent the
wire rope from slipping.
140E-6 SERIES 00-7

Precautions for using overhead traveling crane Nominal

diameter of rope Allowable load
k The hoist or crane must be used to sling the mm kN ton
components weighing 25 kg or heavier. A
12 12.7 1.3
part weighing 25 kg or heavier in
14 17.3 1.7
"disassembly and assembly" section is
16 22.6 2.3
indicated with the symbol of 4 . 18 28.6 2.9
20 35.3 3.6
• Before starting work, check the wire ropes,
25 55.3 5.6
brake, clutch, controller, rails, over winding
prevention device, ground fault circuit interrupter 30 79.6 8.1
for electric shock prevention, crane collision 40 141.6 14.4
prevention device, and energizing warning lamp, 50 221.6 22.6
and check the following safety items. 60 318.3 32.4
• Observe the signals for sling work.
• Operate the hoist at a safe place. a The allowable load is calculated as one sixth of
• Be sure to check the directions of the direction the breaking load of the rope to be used (safety
indication plate (north, south, east and west) and coefficient: 6).
the operating button. Precautions for disconnecting and connecting
• Do not sling a load at an angle. Do not move the hoses and tubes in air conditioner circuit
crane while the slung load is swinging.
• Do not raise or lower a load while the crane is Disconnection
moving longitudinally or laterally. k When replacing the air conditioner unit, air
• Do not drag a sling. conditioner compressor, condenser or
• When lifting up a load, stop it just after it leaves receiver drier, etc., collect the refrigerant (air
the ground and check safety, and then lift it up. conditioner gas: R134a) from the air
• Consider the travel route in advance and lift up a conditioner circuit before disconnecting the
load to a safe height. air conditioner hoses.
• Place the control switch in a position where it will
not be an obstacle to work and passage. a Ask a qualified person for collecting, adding and
• After operating the hoist, do not swing the filling operations of the refrigerant (air
control switch. conditioner gas: R134a).
• Remember the position of the main switch so
that you can turn off the power immediately in an a Never release the refrigerant (air conditioner
emergency. gas: R134a) to the atmosphere.
• Shut down the main switch when the hoist stops k If refrigerant gas (air conditioner gas: R134a)
because of a blackout. When turning on a switch gets in your eyes, you may lose your sight.
which is turned OFF by the ground fault circuit And if it touches your skin, you may suffer
interrupter for electric shock prevention, check from frostbite. Put on protective eyeglasses,
that the devices related to that switch are not in gloves and working cloth with long sleeves
operating condition. while collecting the refrigerant or filling the
• If you find an obstacle around the hoist, stop the air conditioner circuit with the refrigerant.
operation.
• After finishing the work, stop the hoist at the • When loosening the nuts fixing air conditioner
specified position and raise the hook to at least hoses and tubes, be sure to use two wrenches;
two meters above the floor. Do not leave the use one wrench to fix and use the other one to
sling attached to the hook. loosen the nut.
Selecting wire ropes Connection
• Select adequate ropes depending on the weight • When installing the hose for the air conditioner
of the parts to be hoisted, referring to the table circuit, take care not to allow invasion of dirt,
below dusts and water into the hose.
Wire ropes (standard "Z" twist ropes without • Check that the O-rings are fitted to the joints
galvanizing) (JIS G3525, Type 6x37-A) when connecting the air conditioner piping.
Nominal • Once an O-ring is used, it is deformed and
diameter of rope Allowable load deteriorated. Accordingly, do not reuse it.
mm • When removing the O-rings, use a soft tool so
kN ton
that the piping is not damaged.
10 8.8 0.9
00-8 140E-6 SERIES

• Check that the O-ring is not damaged or

deteriorated.
• Apply compressor oil for refrigerant (R134a) to
the O-ring.
a However, do not apply oil to the threaded
portion of a bolt, nut or union.
Manufacturer Part name
DENSO ND-OIL8
VALEO THERMAL ZXL100PG (equivalent to
SYSTEMS PAG46)
SANDEN SP-10
• When tightening nuts of the air conditioner
hoses and tubes, be sure to use two wrenches.
Use one wrench to fix and tighten the nut with
the other wrench to the specified torque (Use a
torque wrench for tightening).
a Example of fitting of O-ring
• An O-ring is fitted to every joint of the air
conditioner piping.
For tightening torques, see "Others",

"Precautions for disconnection and connection
of air conditioner piping".
140E-6 SERIES 00-9

Fire prevention (ALL-0000-001-K-27-A)
Action if fire occurs (ALL-0000-17A-K-01-A)

• Turn the starting switch to the OFF position to
shutdown the engine.
• Use the handrails and steps to get off the
machine.
• Do not jump off the machine. You may fall or
suffer serious injury.
• The fume generated by a fire contains harmful 9 J D 0 1 7 2 0
materials which have a bad influence on a
human body when they are sucked.
Don't breathe a fume.
• After a fire, there may be harmful compounds
left. If it touches your skin it may have a bad
influence on your body.
Be sure to wear rubber gloves when handle the
materials left after the fire.
The material of the gloves, which is
recommended is polychloroprene (Neoprene) or
polyvinyl chloride (in the lower temperature 9 J D 0 1 7 2 1
environment).
When wearing cotton-work-gloves, wear rubber • Fire caused by accumulation or attachment
gloves under them. of flammable material
• Remove any dry leaves, chips, pieces of
Prevent fire (ALL-0000-17B-K-03-A) paper, coal dust, or any other flammable
• Fire caused by fuel, oil, coolant or window materials accumulated or attached to or
washer fluid around the engine exhaust manifold, muffler,
Do not bring any flame or fire close to flammable or battery, or on the undercovers.
substances such as fuel, oil, coolant or window • To prevent fires from being caught, remove
washer fluid.There is danger that they may catch any flammable materials such as dry leaves,
fire. Always observe the following. chips, pieces of paper, coal dust, or any
• Do not smoke or use any flame near fuel or other flammable materials accumulated
other flammable substances. around the cooling system (radiator, oil
• Shut down the engine before adding fuel. cooler) or on the undercover.
• Do not leave the machine when adding fuel • Fire coming from electric wiring
or oil. Short circuits in the electrical system can cause
• Tighten all the fuel and oil caps securely. fire. Always observe the following.
• Be careful not to spill fuel on overheated • Keep all the electric wiring connections clean
surfaces or on parts of the electrical system. and securely tightened.
• After adding fuel or oil, wipe up any spilled • Check the wiring every day for looseness or
fuel or oil. damage. Reconnect any loose connectors or
• Put greasy rags and other flammable refasten wiring clamps. Repair or replace any
materials into a safe container to maintain damaged wiring.
safety at the workplace. • Fire caused by piping
• When washing parts with oil, use a non- Check that all the clamps for the hoses and
flammable oil. Do not use diesel oil or tubes, guards, and cushions are securely fixed
gasoline.There is danger that they may catch in position.
fire. If they are loose, they may vibrate during
• Do not weld or use a cutting torch to cut any operation and rub against other parts.There is
pipes or tubes that contain flammable liquids. danger that this may lead to damage to the
• Determine well-ventilated areas for storing oil hoses and cause high-pressure oil to spurt out,
and fuel. Keep the oil and fuel in the leading to fire and serious personal injury or
specified place and do not allow death.
unauthorized persons to enter. • Fire around the machine due to highly heated
• When performing grinding or welding work exhaust gas
on the machine, move any flammable This machine is equipped with KDPF (Komatsu
materials to a safe place before starting. Diesel Particulate Filter).
00-10 140E-6 SERIES

KDPF is a system for purifying soot in exhaust

gas. The exhaust gas discharged during the
purification process (regeneration) can be higher
temperature than that of existing models. Do not
bring any flammable material close to the outlet
of the exhaust pipe.
• If there are thatched houses, dry leaves or
pieces of paper around the job site, set the
system to the "Regeneration Disable" before
starting operation to prevent fire hazard of
highly heated exhaust gas caused by KDPF
regeneration.
See the operation and maintenance manual
for the setting procedure.
• Explosion caused by lighting equipment
• When checking fuel, oil, battery electrolyte,
or coolant, always use lighting equipment
with anti-explosion specifications.
• When taking the electrical power for the
lighting equipment from the machine itself,
follow the instructions in the operation and
maintenance manual.
DISPOSE OF WASTE
MATERIALS (ALL-0000-99A-K-02-A)
To prevent pollution, pay full attention to the way to
dispose of waste materials.
• Always put the oil and coolant drained from the
machine in containers. Never drain the oil and
coolant directly onto the ground or dump into the
sewage system, rivers, the sea, or lakes.
• Observe the related laws and regulations when
disposing of harmful objects such as oil, fuel,
coolant, solvent, filters, and batteries.
Some kinds of rubber and plastics may produce

poisonous gas harmful to human body when they
are burned.
• As for rubber, plastics, or parts (hoses, cables,
and wiring harnesses, etc.) which contain those
materials, ask the industrial waste treatment
firms for their disposals in accordance with the
local regulations.
140E-6 SERIES 00-11

How to read the shop manual (ALL-0320-010-A-03-A)
(Rev. 2012/01)
• Some attachments and optional parts described in this shop manual may not be arranged for certain
areas. Contact your Komatsu distributor if one or some of them are required.
• Materials and specifications are subject to change without notice.
• The shop manuals are available for "Machine part" and "Engine part". For the engine, see the shop
manual for the same model of the engine as the one which is mounted on the machine.
Composition of shop manual

• This shop manual describes the technical information required for the services performed in a workshop.
The shop manual is divided into the following chapters for the convenience of use.
00. Index and foreword
• This section includes the index, foreword, safety and basic information.
01. Specification
• This section explains the specifications of the machine.
10. Structure and function
• This section explains the structure and function of the machine. The section of "Structure and function"
serves not only to give an understanding for the structure of each component, but also serves as
reference material for troubleshooting.
20. Standard value table
• The standard values for a new machine and trouble shooting are described. This standard value table is
used for testing and adjusting, and determining a failure at troubleshooting.
50. Disassembly and assembly
• This section explains the procedures for removing, installing, disassembling, and assembling each part or
component and the special tools for the works as well as precautions for doing them safely. In addition,
tightening torque, and quantity and weight of coating material, oil, grease, and coolant required for the
works are also explained.
60. Maintenance standard
• This section describes the maintenance standard values for each component. This section gives the
criterion values for each component and required remedy at disassembly or maintenance.
Symbol
Important safety and quality portions are marked with the following symbols so that the shop manual is used
practically.
Symbol Item Remarks
Safety The special safety precautions required for performing work are
k described.
The special technical precautions or other precautions for preserving
a Caution standards required when performing work are described
The weight of part or component and the cautions required when
4 Weight selecting hoisting wire or when working posture is important are
described.
Tightening The tightening torques that require special attention during assembly
3 torque work are described.
The places to be coated with adhesives, etc. during assembling are
2 Coat
indicated.
Oil, coolant The places to which oil is supplied and the quantity of the oil are
5 indicated.
6 Drain The places from which oil is drained and quantity of the oil are indicated.
Unit
• In this shop manual, the units are indicated with International System of units (SI).
• For reference, Gravitational System of units which is used to be used is indicated in parentheses of { }.
00-12 140E-6 SERIES

Explanation of terms for maintenance standard (ALL-0330-006-A-01-A)
(Rev. 2012/01)
• The chapter of maintenance standard shows judgement criteria to determine the products to be replaced
or to be reused. The judgement criteria are described by using the following terms.
Standard dimension and tolerance

• To be accurate, the finished dimension of a part
is slightly different from one to another.
• To specify the finished dimension of a part, a
certain dimension is set for the part and an
allowable difference from that dimension is
indicated.
• The above dimension set is called the "standard
dimension" and the range of difference from the
standard dimension is called the "tolerance".
• The standard dimension and tolerance are
indicated by attaching the symbols of + or - and
a number on the right side of the standard
dimension.
Example:
Standard dimension Tolerance
-0.022
120
-0.126
• The tolerance may be indicated in the text and a
table as "standard dimension (upper limit of
tolerance/lower limit of tolerance)."
Example: 120(-0.022/-0.126)
• Usually, the dimension of a hole and the
dimension of a shaft to be inserted into the hole
are indicated by the same standard dimension
and different tolerances of the hole and shaft.
The tightness of fit is decided by the tolerance. Standard interference
• Indication of dimension of rotating shaft and hole • When the diameter of a hole of a part shown in
and their related drawing. the given standard dimension and tolerance
Example: table is smaller than that of the shaft to be
inserted, the difference between those
Standard Tolerance diameters is called the "interference".
dimension Shaft Hole • Subtract the maximum dimension of the hole
-0.030 +0.046 from the minimum dimension of the shaft and
60
-0.076 0 call it (A). Subtract the minimum dimension of
the hole from the maximum dimension of the
Standard clearance and standard value shaft and call it (B). The range between (A) and
• The clearance made when new parts are (B) is the "standard interference".
assembled is called the standard clearance, • After repairing or replacing some parts, measure
which is indicated by the range from the the dimension of their hole and shaft and check
minimum clearance to the maximum clearance. that the interference is in the standard range.
• When some parts are repaired, the clearance is
generally adjusted to the standard clearance. Repair limit and allowable value or allowable
• The values indicating performance and function dimension
of new products or equivalent are called the • The dimensions of parts change because of the
"standard value", which is indicated by a range wear or deformation while they are used. When
or a target value. the dimension changes exceeding certain value,
• When some parts are repaired, the value of the parts can not be used any longer. This value
performance/function is set to the standard is called "repair limit".
value. • If a part is worn to the repair limit, it must be
replaced or repaired.
140E-6 SERIES 00-13

• The performance and function of the products

lower while they are used. When the value of the
performance and function lowers exceeding a
certain limit and it influences the operation etc.,
this value is called the allowable value or
allowable dimension.
• A product whose dimension is out of the
allowable value, must be repaired. However,
since the allowable values are generally
estimated through various tests or experiences
in most cases, the judgement must be made in
consideration of the operating condition and
customer's requirement.
Allowable clearance
• Parts can be used until the clearance between
them is increased to a certain limit. The limit at
which those parts cannot be used is called the
"allowable clearance".
• If the clearance between the parts exceeds the
allowable clearance, they must be replaced or
repaired.
Allowable interference
• The allowable maximum interference between
the hole of a part and the shaft of another part to
be assembled is called the "allowable
interference".
• The allowable interference shows the repair limit
of the part of smaller tolerance.
• The parts whose interferences are out of the
allowable interference must be replaced or
repaired.
00-14 140E-6 SERIES

Handling equipment of fuel system devices (PC-AD00-2A4-K-00-A)
(Rev. 2012/01)
• The common rail fuel injection system (CRI)
consists of more precise parts than the parts
used in the conventional fuel injection pump and
nozzle. If foreign material enters this system, it
may cause a failure. Use special care to prevent
entry of the foreign material when servicing the
fuel system.
Use care for working environment

• Avoid filter change or repairing the machine in
rain or high winds, or at places where there is a
lot of dust.
Sealing openings
• Plug the pipes and the openings of the
components which are removed with the caps,
tapes, vinyl bags, etc. to prevent foreign material
from entering. Never perform repair works under
the condition that the openings are left as they
are or plugged with cloths as foreign material
may enter or environment may be polluted by
the oil leaked. Do not discard the waste oil
somewhere or other. Hand it over to your
customer for disposal, or dispose it by yourself.
How to clean parts when dirt is stuck

• If any dirt or dust sticks the parts of the fuel
system, clean it off thoroughly with clean fuel.
Precautions for replacing fuel filter cartridge

• Be sure to use the Komatsu genuine fuel filter
cartridge.
• The common rail fuel injection system (CRI)
consists of more precise parts than the parts
used in the conventional fuel injection pump and
nozzle. In order to prevent foreign material from
entering this system, the filter employs a
specially high performance of filter element. If a
filter element other than the genuine one is used,
the fuel system may have a failure. Accordingly,
never use such a filter element.
140E-6 SERIES 00-15

Handling of intake system parts (PC220-A900-2A4-K-00-A)
(Rev.2012/01)
• The Komatsu Variable Geometry Turbocharger
(KVGT) consists of more precise parts (variable
mechanism) than the parts used in the
conventional turbocharger. If foreign material
enters this system, it may cause a failure. Use
special care to prevent entry of the foreign
material when servicing the air intake system.
Be careful of working environment

• Avoid the repair work of the machine in rain or
strong wind or at the places where there is a lot
of dust.
Sealing openings
components which are removed, with the caps,
from entering. Never perform repair works under
the condition that the openings are left open or
plugged with rag since foreign material may
enter.
00-16 140E-6 SERIES

Handling of hydraulic equipment (ALL-C000-2A4-P-01-A)
(Rev. 2012/01)
• With the increase in pressure and precision of the hydraulic components, the most common cause of a
failure is dirt (foreign material) in the hydraulic circuit. Therefore, the special care must be taken when
adding hydraulic oil,or when disassembling or assembling the hydraulic components.
Be careful of working environment

• Avoid adding hydraulic oil, replacing filters, or
repairing the machine in rain or high winds, or at
places where there is a lot of dust.
Disassembly and maintenance work in the field

• When disassembly or maintenance work of the
hydraulic is performed in the field, there is
danger of dust entering the components. It is
also difficult to check the performance of the
components after repairs, so it is desirable to
use the component exchange service. The
disassembly and assembly of the hydraulic
components must be performed in the specially
arranged dustproof workshop and the Preventing intrusion of foreign materials during
performance test of the components must be refilling operations.
performed with the special testing equipment. • Care must be taken when adding hydraulic oil so
that foreign material does not enter. Keep the oil
filler port and the area around it, oil supply pump
and oil container clean. If an oil cleaning device
is used, it is possible to remove the dirt that is
collected during storage. It is a surer means.
Sealing openings
components which are removed with the caps,
from entering. Never leave the openings of the
pipes and hoses without being covered or Replacing hydraulic oil while its temperature is
high
plugged with cloth as foreign material may enter
• When the hydraulic oil is warm, it flows easily. In
them or environment may be polluted by the oil
addition, sludge can also be drained from the
leaked. Do not discard the waste oil somewhere
circuit together with the oil. So, it is better to
or other. Hand it over to your customer for
change the hydraulic oil while it is warm. When
disposal, or dispose it by yourself.
changing the hydraulic oil, the old oil must be
drained as much as possible. (Drain the oil not
only from the hydraulic tank, but also from the
filter housing and the drain plug hole in the
circuit.) If the old oil is left in the system, the
contaminant and sludge in the oil mix with the
new oil and shorten the life of the new hydraulic
oil.
140E-6 SERIES 00-17

Flushing operations
• After disassembling the equipment or when
changing the hydraulic oil with new one, flush
the system to remove the contaminant and
sludge left in the hydraulic circuit as well as the
oil which includes them. Normally, flushing is
performed twice. Primary flushing is performed
by use of the flushing oil and the secondary
flushing is performed by use of the specified
hydraulic oil.
Cleaning operations
• After repairing the hydraulic equipment (pump,
control valve, etc.) or when the machine is in
operation, perform oil cleaning to remove the
sludge or contaminant in the hydraulic oil circuit.
The oil cleaning equipment can remove the ultra
fine (approximately 3 μm) particles that the filter
built in the hydraulic equipment can not remove.
So, it is an extremely effective device.
00-18 140E-6 SERIES

Method of disconnecting and connecting of push-pull type coupler (ALL-

C930-001-P-00-A)
(Rev. 2012/01)
k Loosen the oil filler cap of the hydraulic tank slowly to release the remaining pressure in the
hydraulic tank.
k Even if the remaining pressure is released from the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly, prepare an oil container.
Type 1 (ALL-C930-925-P-01-A)
Disconnection Connection
1. Hold adapter (1) and push hose joint (2) into 1. Hold hose adapter (1) or hose (5) and insert it in
mating adapter (3). (Fig. 1) mating adapter (3) aligning them with each other.
(Fig. 4)
a It can be pushed in by approximately 3.5mm.
a Do not hold rubber cap part (4).
a Do not hold rubber cap portion (4).
2. After inserting the hose fitting in the adapter on
2. While pushing hose joint (2) into adapter (3),
the other side perfectly, pull it back to check the
push rubber cap (4) against adapter (3) until
connecting condition. (Fig. 4)
"click" is heard. (Fig. 2)
3. Hold hose adapter (1) or hose (5) and pull it out. a When the hose fitting is pulled back, the
(Fig. 3) rubber cap will move toward the hose,
however, it is not a problem.
a Since some hydraulic oil flows out, prepare
an oil container.
140E-6 SERIES 00-19

Type 2 (ALL-C930-925-P-02-A)
1. While holding the fitting, push body (7) in straight 1. While holding the fitting, push body (7) in straight
until sliding prevention ring (6) hits contact until sliding prevention ring (6) hits contact
surface (a) at the hexagonal part on the male surface (a) at the hexagonal part on the male
side. (Fig. 6) side to connect it. (Fig. 9)
2. While keeping the condition of Step 1, turn lever
(8) to the right (clockwise). (Fig. 7)
3. While keeping the conditions of Steps 1 and 2,
pull out whole body (7) to disconnect it. (Fig. 8)
00-20 140E-6 SERIES

Type 3 (ALL-C930-925-P-03-A)
1. While holding the fitting, push body (9) in straight 1. While holding the fitting, push body (9) in straight
until sliding prevention ring (8) hits contact until sliding prevention ring (8) hits contact
surface (b) at the hexagonal portion on the male surface (a) at the hexagonal portion on the male
side. (Fig. 10) side to connect them. (Fig. 13)
2. While keeping the condition of Step 1, push
cover (10) straight until it hits contact surface (b)
of the hexagonal portion on the male side. (Fig.
11)
3. While keeping the conditions of Steps 1 and 2,
pull out whole body (9) to disconnect it. (Fig. 12)
140E-6 SERIES 00-21

Handling of electrical equipment (ALL-E000-2A4-P-01-A)
(Rev. 2012/01)
• To maintain the performance of the machine over a long period, and to prevent failures or troubles before
they occur, correct "operation", "maintenance and inspection" "troubleshooting", and "repairs" must be
performed. This section deals particularly with correct repair procedures for mechatronics components
and is aimed at improving the quality of repairs. For this purpose, it describes the working procedures in
"Handling of electrical equipment".
Precautions for handling electric equipment
Handling wiring harnesses and connectors

• Wiring harnesses consist of wires connecting
one component to another component,
connectors used for connecting and
disconnecting one wire from another wire, and
protectors or tubes used for protecting the wires.
• Compared with other electrical components
fitted in boxes or cases, wiring harnesses are
more likely to be affected by the direct effects of
rain water, heat, or vibration. Furthermore,
during inspection and repair operations, they are
frequently removed and installed again, so they Defective crimping or soldering of connectors
are likely to suffer deformation or damage. For
this reason, it is necessary to be extremely • The pins of the male and female connectors are
careful when handling the wiring harnesses. attached to wires by crimping or soldering. If
excessive force is applied to the wire, the joining
area may become loose, which may result in a
defective connection or breakage.
Main failures occurring in wiring harness

Defective contact of connectors (defective
contact between male and female connectors) Disconnections in wiring
• Problems with defective contact are likely to • If the wiring harness is pulled to disconnect the
occur because the male connector is not connector, or the components are lifted with a
properly inserted into the female connector,or crane while the wiring harness is still connected,
because one or both of connectors are or a heavy object hits the wiring harness, the
deformed or the position is not correctly aligned, crimping of the connector may separate, or the
or because there is corrosion or oxidization of soldering may be damaged, or the wiring
the contact surfaces. The corroded or oxidized harness may be broken.
contact surfaces may become shiny again (and
contact may become normal) by connecting and
disconnecting the connectors approximately ten
times.
00-22 140E-6 SERIES

blow it with compressed air and spray it with

electrical contact restorer.
a When wiping the joint portion of the
connector, be careful not to apply excessive
force or deform the pins.
a If there is oil or water in the compressed air, it
causes the contacts to become dirtier. So,
remove the oil and water from the
compressed air completely before cleaning
the connector with the compressed air.
High-pressure water entering connector

• The connector is designed to make it difficult for
water to enter (drip-proof structure), but if high-
pressure water is sprayed directly on the
connector, water may enter the connector,
depending on the direction of the water jet.
Accordingly, take care not to spray water over
the connector.
The connector is designed to prevent water from
entering, but once water does enter, it is difficult
to drain it. If water should get into the connector,
the pins will be short-circuited by the water. So if
any water gets in, immediately dry the connector Removing, installing, and drying connectors
and wiring harnesses
or take other appropriate action before passing
Disconnecting connectors
electricity through it.
1. Hold the connectors when disconnecting.
• Disconnect connectors by holding the
connector bodies. For the connectors held by
a screw, loosen the screw fully, then hold the
male and female connectors with each hand
respectively and pull them apart horizontally.
For the connectors with lock stopper, press
down the stopper with your thumb and pull
the connectors apart.
a Never pull the connector with one hand.
Entry of water, mud or dirt when disconnecting a

connector
• If any water, mud or dirt is stuck to the outside
surface of a connector, it can enter inside the
connector when the connector is disconnected.
Before disconnecting the connector, wipe off any
stuck water or dirt by using a piece of dry cloth
or blow it with compressed air.
Oil, mud or dirt stuck to connector
• If any oil or grease is stuck to the connector and
an oil film is formed on the mating surface of the 2. When removing from clips
male and female pins, the oil prevents electricity • Both of the connector and clip have stoppers,
from passing through, resulting in defective which are engaged with each other when the
contact. If any oil or grease, mud or dirt is stuck connector is connected.
to the connector, wipe it off with a dry cloth or
140E-6 SERIES 00-23

• Check that there is no oil, dirt or water stick

to the connector pins (joint portion).
• Check that the connector pins are free from
deformation, defective contact, corrosion, or
damage.
• Check that external surfaces of the
connectors are free from damage or
breakage.
a If any oil, water or dirt is stuck to the
connector, wipe it off with a dry cloth. If any
water is inside the connector, warm the
connector and the inside of the wiring
• When removing a connector from a clip, pull harness with a dryer. But be careful not to
the connector in a parallel direction to the clip make it too hot as it causes short circuit.
for removing stoppers. a If there is any damage or breakage, replace
a If the connector is pried up and down or the connector.
to the right and left, the housing may 2. Fix the connector securely.
break. • Align the connectors correctly, and fit them
securely. For the connectors with the lock
stopper, push in the connectors until "click" is
heard.
3. Action to take after removing connectors

• After removing the connector, cover it with
the vinyl bag to prevent entry of dust, dirt,oil
or water in the contact portion. 3. Correct the protrusion of the boot and
misalignment of the wiring harness
a If the machine is left disassembled for a • For connectors fitted with the boot, correct
long time, it is particularly easy for any extrusion of the boot. In addition, if the
improper contact to occur, so always wiring harness or the clamp is out of the
cover the connector. position, put it in its original position.
a If the connector cannot be corrected
easily, remove the clamp and adjust the
position.
Connecting connectors
1. Check the connector visually.
00-24 140E-6 SERIES

• If the connector clamp is removed, be sure to • If there is any oil or dirt on the wiring harness,
return it to its original position. And check wipe it off with a dry cloth. Avoid washing by
that it is securely installed. using steam. If the wire harness must be
washed in water, do not apply high pressure
water or steam directly to the wiring harness. If
water gets directly on the connector, do as
follows.
1. Disconnect the connector and wipe off the water
with a dry cloth.
a If the connector is to be blown with dry
compressed air, there is a risk that oil in the
air may cause defective contact of the
conditioner, remove oil and water in the air
before starting air blow.
Deutsch connector (DT8-pin, DT12-pin)

Disconnection
1. While pressing locks (a) and (b) from each side
respectively, pull out female connector (2).
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 to use hot air in order to
prevent the connector or related parts from
Connection becoming too hot, as it causes deformation
1. Push in female connector (2) horizontally until or damage to the connector.
the lock clicks. (Arrow: x)
2. Since locks (a) and (b) may not be set
completely, push in female connector (2) with
curving movement until the locks are set
normally. (Arrow: x, y, and z)
a Lock (a) in the figure is pulled down (not set
completely), and lock (b) is set completely.
3. Perform a continuity test on the connector.

After drying, leave the wiring harness
disconnected and perform a continuity test to
check for any short circuits between pins caused
by water.
a After the connector is completely dried, blow
the contact restorer and reassemble them.
Drying wiring harness
140E-6 SERIES 00-25

2. While pressing lock (L2), pull out connector (1).

Handling of connectors used on engine
Slide, lock type (Type 1) (FRAMATOME-3,

FRAMATOME-2)
Disconnection
1. Slide lock (L1) to the right.
2. While pressing lock (L2), pull out connector (1)
toward you.
a In the case that even if lock (L2) is pressed,
connector (1) cannot be pulled out toward
you unless part A floats, float part A with a
small flat-head screwdriver while pressing
lock (L2), and then pull out connector (1)
toward you.
a Lock (L2) is located in the back of connector
(1).
Connection
1. Insert the connector securely until a click is
heard. Connection
Slide, lock type (Type 2) (FRAMATOME-24) heard.
Disconnection
1. Slide down lock (red) (L1). Pull lock type (PACKARD-2)
Disconnection
1. Disconnect the connector (2) by pulling lock (B)
(on the wiring harness side) of connector (2)
outward.
00-26 140E-6 SERIES

Connection Connection
1. Insert the connector securely until a click is 1. Insert the connector securely until a click is
heard. heard.
Push lock type (1) (BOSCH-3) Push lock type (2) (SUMITOMO-4)
Disconnection Disconnection
1. While pressing lock (C), pull out connector (3) in 1. While pressing lock (C), pull out connector (4) in
the direction of the arrow. the direction of the arrow.
• 114 series Connection
heard.
• 107 series
Push lock type (3) (AMP-3)

Disconnection
1. While pressing lock (E), pull out connector (5) in
the direction of the arrow.
Example) Fuel pressure sensor in common rail:
PFUEL etc (AMP-3)
a If the lock is located on the underside, use

flat-head screwdriver [1] since you cannot
insert your fingers.
While pushing up lock (C) of the connector
with flat-head screwdriver [1], pull out
connector (3) in the direction of the arrow.
140E-6 SERIES 00-27

Example) Injection pressure control valve of

supply pump: PCV (SUMITOMO-2)
Connection
1. Insert the connector to the end while aligning its
Example) Speed sensor of supply pump: G grove to the other.
(SUMITOMO-3) 2. Turn housing (H1) in the direction of the arrow
until it "clicks".
a Pull the connector straight up.
Connection Handling controller

• The electronic circuits for control including the
microcomputers are assembled in the controller.
heard.
These electronic circuits in the controller must
Turn-housing type (Round green connector) be handled with care as they control the
(CANNON-4) machine.
Disconnection • Do not place objects on top of the controller.
1. Turn housing (H1) in the direction of the arrow.
a Unlock the connector by turning housing (H1).
When the lock is release the housing is felt
tight to turn.
2. Pull out housing (H1) in the direction of the
arrow.
a Housing (H1) is left on the wiring harness
side.
• Cover the control connectors with tape or a vinyl

bag. Never touch the connector contacts.
• During rainy weather, do not leave the controller
in a place where it is exposed to rain.
• Do not place the controller on oil, water, or soil,
or in a place that can be heated to a high
00-28 140E-6 SERIES

temperature even for a short period of time.

(Place it on a suitable dry stand.)
• Precautions when performing arc welding

When performing arc welding on the machine
body, disconnect all the wiring harness
connectors connected to the controller. Put the
arc welding ground to the place close to the
welding point.
Precautions for troubleshooting electrical

circuits
• Be sure to turn the starting switch to the "OFF"
position before disconnecting or connecting the
connectors.
• Before performing troubleshooting, check all the
related connectors for loose connection.
a Check the related connectors for their
performance by disconnecting and
connecting them several times.
• Be sure to connect all the disconnected
connectors before proceeding to the next step.
a If the starting switch is turned to the "ON"
position with the connectors disconnected,
the failure which is not related to the part
which is actually failed.
• When performing the troubleshooting for the
circuit (measurement of voltage, resistance,
continuity, current, etc.), shake the related wiring
harnesses and connectors several times and
check that the multimeter reading does not
change.
a If there is any value change on the
multimeter, there may be a defective contact
in the circuit.
140E-6 SERIES 00-29

How to read electric wire code (ALL-E500-030-P-00-A)

(Rev. 2012/01)
• In the electrical circuit diagram, material, thickness and color of each electric wire are indicated by
symbols. The wire code is helpful in understanding the electrical circuit diagram.
Example) AEX 0.85 L: Indicates blue, heat-resistant, low-voltage wire for automobile, having nominal No. of
0.85
Indicates type of wire by symbol.
Type, symbol, and material of wire are shown in Table 1.
AEX
(Since the use of AV and AVS wires depends on size (nominal No.), their symbols are not
indicated on the diagram.)
Indicates size of wire by nominal No.
0.85
Size (Nominal No.) is shown in Table 2.
Indicates color of wire by color code.
L
Color codes are shown in Table 3.
Type, symbol, and material

• AV and AVS are different in thickness and outside diameter of the coating. CAVC has a circular
compressed conductor. It differs from AV and AVS in the outside diameter of conductor and thickness of
the coating. And AEX is similar to AV in thickness and outside diameter of the coating but different from AV
and AVS in material of the coating.
(Table 1)
Temperature
Type Sym- Conductor Example of use
Insulator material range (°C) in
bol material
use
Low-voltage For large current wiring
wire for AV
automobile (nominal No. 5 and above)
Thin-cover
low-voltage
General wiring
wire for AVS
automobile (nominal No. 3 and lower)
Soft polyvinyl chloride -30 to +60
(Type 1) Annealed
Thin-cover copper for
low-voltage electric For mid- to small-size
wire for CAVS appliance excavators
automobile (nominal No. 1.25 and lower)
Type 2
Heat-
resistant low- (Safety factor:
Heat-resistant cross
voltage wire AEX linked polyethylene -50 to +110 Wiring at high-temperature
for place
automobile
00-30 140E-6 SERIES

Dimension
(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5
Number of
strands/ 20/ 30/ 11/ 50/ 16/ 37/ 26/ 58/ 41/ 65/
7/0.32
Diameter of 0.18 0.18 0.32 0.18 0.32 0.26 0.32 0.26 0.32 0.32
strand
Conductor Cross-
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 —
Coating D
AV Standard — — — — — — — 4.6
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/ 108/ 127/ 169/ 217/
50/0.45 84/0.45 41/0.80 70/0.80 85/0.80
Diameter of 0.80 0.80 0.80 0.80
strand
Conductor Cross-
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 — — — — — — — — —
Coating D
AV Standard 5.5 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
AEX Standard 5.3 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
Nominal No. 0.5f 0.5 0.75f 0.85 1.25f 1.25

Number of
strands/ 7/round 11/round 16/round
— — —
Diameter of compression compression compression
strand
Conductor Cross-
sectional — 0.56 — 0.88 — 1.29
area (mm2)
d (approx.) — 0.9 — 1.1 — 1.4
Coating D
CAVS Standard — 1.6 — 1.8 — 2.1
a "f" of nominal No. denotes "flexible".
140E-6 SERIES 00-31

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
a Remarks: In a color code consisting of two colors, the first color is the color of the background and the
second color is the color of the marking.
Examples)
GW means that the background is "Green" and marking is "White".
Types of circuits and color codes

Type of wire AVS, AV, CAVS 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 — — — — — — —
Appendix Gr — — — — — — —
P — — — — — — —
Sb — — — — — — —
Dg — — — — — — —
Ch — — — — — — —
00-32 140E-6 SERIES

Precautions when performing operation (ALL-1160-927-A-00-A)
(Rev. 2012/01)
• When performing "removal or installation" and "disassembly or assembly" of the components, observe the
following general cautions.
Precautions for removal work

• If the coolant contains antifreeze, dispose of it correctly as chemicals. Do not drain the coolant to the
sewage rashly.
• After disconnecting the hoses or tubes, plug them to prevent dirt or dust from entering.
• When draining oil, prepare a container with sufficient capacity.
• Check the match marks which indicate the installing position, and put match marks on the places where
they seem necessary before removal of the components to prevent any mistake when assembling.
• To prevent any excessive force from being applied to the wiring, always hold the connectors when
disconnecting the connectors. Do not pull the wires.
• Attach the tags to wires and hoses to show their installing positions to prevent any mistake when
installing.
• Check the number and thickness of the shims, and keep them in a safe place.
• When hoisting the components, prepare the slings with sufficient strength.
• When using forcing screws to remove any component, tighten the forcing screws uniformly and
alternately.
• Before removing any component, clean the surrounding area and cover the component to prevent any
foreign material from entering after removal.
a Precautions when handling piping during disassembly
Use the plugs indicated below for the pipes disconnected at the disassembly.
Face seal type hoses and tubes
Nominal No. Plug (nut end) Nut (elbow end)
02 07376-70210 02789-00210
03 07376-70315 02789-00315
04 07376-70422 02789-00422
05 07376-70522 02789-00522
06 07376-70628 02789-00628
Split flange type hoses and tubes
Nominal No. Flange (hose end) Sleeve head (tube end) Split flange
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500
140E-6 SERIES 00-33

If the part is not under hydraulic pressure, the following corks can be used.
Dimensions
Nominal No. Part No.
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
Precautions for installation work

• Tighten all of the bolts and nuts (sleeve nuts) to the specified torque (KES).
• Install the hoses without twist and interference, and securely fasten the clamps located in-between if they
are.
• Replace all of the gaskets, O-rings, cotter pins, and lock plates with new parts.
• Bend the cotter pins and lock plates securely.
• When applying adhesive, clean and degrease the part, and apply two to three drops of adhesive to the
threaded portion.
• When applying liquid gasket, clean and degrease the surface, and apply it uniformly after making sure that
the surface is free from dirt or damage.
• Clean all of the parts, and correct any damage, dents, burrs, or rust found on them.
• Coat the rotating parts and sliding parts with engine oil.
• Coat the surfaces of the press-fitting parts with molybdenum disulfide lubricant (LM-P).
• After installing the snap ring, check that the snap ring is settled in the ring groove completely.
• When connecting wiring harness connectors, clean the connectors to remove oil, dirt, or water, then
connect them securely.
• Use the eye bolts with no fatigue and deformation and screw them in securely. Match the directions of the
eyes and the hook.
• When installing split flanges, tighten the bolts uniformly and alternately to prevent excessive tightening on
one side.
a When the hydraulic cylinder is used for the first time after reassembly of the hydraulic equipment such as
the hydraulic cylinder, pump, etc. and piping after removing them for repair, be sure to perform air bleeding
of the hydraulic circuit according to the following procedure.
1. Start and run the engine at low idle.
2. Repeat the operation to extend and retract each cylinder of the work equipment to approximately 100
mm before the stroke end four to five times.
3. Operate the hydraulic cylinder three to four times to the end of its stroke.
00-34 140E-6 SERIES

a After the completion of repair and when operating the machine which is stored long term, perform the air
bleeding with the same procedure as the one described above.
140E-6 SERIES 00-35

Precautions at the time of completing work

Refilling of coolant, oil and grease
• When the coolant is drained, tighten the drain valve securely, then refill the coolant reservoir with the
coolant Komatsu recommends to the specified level. Start the engine to circulate the coolant in the piping,
and add the coolant to the specified level again.
• When the hydraulic components are removed and installed, refill the oil reservoir with the oil Komatsu
recommends to the specified level. Start the engine to circulate the oil in the piping, and add the oil to the
specified level again.
• If the hydraulic piping or hydraulic equipment is removed, be sure to bleed air from the system after
rebuilding the parts, by referring to "Testing and adjusting".
• Supply the specified amount of grease to the work equipment parts.
Check of installed condition of cylinder heads and manifolds
• Check the cylinder head and intake and exhaust manifold mountings for looseness.
• If any bolt is loose, retighten it.
a For the tightening torques, see the "Disassembly and assembly".
Check of engine piping for damage and looseness
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints
Intake and exhaust for air suction and exhaust gas leakage.
system
If any part is loosely installed or damaged, retighten the bolts or repair the part.
Cooling system for water leakage.
If any part is loosely installed or damaged, retighten the bolts or repair the part.
Fuel system for fuel leakage.
If any part is loosely installed or damaged, retighten the bolts or repair the parts.
Check of KDPF or muffler and exhaust pipe for damage and looseness
• Visually check the KDPF or muffler, exhaust pipe and their mounting parts for a crack and damage. If any
part is damaged, replace it.
• Check the mounting bolts, nuts, and clamps of the KDPF or muffler, exhaust pipe and their mounting parts
for looseness.
If any part is loosely installed, retighten the bolts.
Check of KDPF or muffler function
• Check the KDPF or the muffler for unusual noise comparing to the noise when they are new.
If any unusual noise is heard, repair KDPF or muffler, referring to "Troubleshooting" and "Disassembly and
assembly".
00-36 140E-6 SERIES

Standard tightening torque table (ALL-M140-03B-P-01-A)
(Rev. 2012/01)
Table of tightening torque for bolts and nuts

Unless otherwise specified, tighten the metric bolts and nuts to the torque shown in the table below.
1. The following table applies to the bolts in Fig. A.
Thread Width Tightening torque
diameter across flats
(mm) (mm) (Nm) (kgm)
6 10 (10) 11.8 to 14.7 1.2 to 1.5
8 13 (12) 27 to 34 2.8 to 3.5
10 17 (14) 59 to 74 6.0 to 7.5
12 19 (17) 98 to 123 10.0 to 12.5
14 22 157 to 196 16 to 20
16 24 245 to 309 25 to 31.5
18 27 343 to 427 35 to 43.5
20 30 490 to 608 50 to 62
22 32 662 to 829 67.5 to 84.5
24 36 824 to 1,030 84 to 105
27 41 1,180 to 1,470 120 to 150
30 46 1,520 to 1,910 155 to 195
33 50 1,960 to 2,450 200 to 250
36 55 2,450 to 3,040 250 to 310
39 60 2,890 to 3,630 295 to 370
a Values with ( ) in the "Width across flats" column are for (*) marked bolt (flange bolt) shown in Fig. A.
2. The following table applies to the bolts in Fig. B.
6 10 5.9 to 9.8 0.6 to 1.0
8 12 13.7 to 23.5 1.4 to 2.4
10 14 34.3 to 46.1 3.5 to 4.7
12 17 74.5 to 90.2 7.6 to 9.2
Fig. A Fig. B
a Values with parentheses are applied to the width across flats of (*) marked bolts (flanged bolts)
140E-6 SERIES 00-37

Table of tightening torque for split flanged bolts

a Unless otherwise specified, tighten the split flange bolt to the torque shown in the table below.
10 14 59 to 74 6.0 to 7.5
12 17 98 to 123 10.0 to 12.5
16 22 245 to 309 25 to 31.5
Table of tightening torque for O-ring boss piping joints

a Unless otherwise specified, tighten the pipe joint for O-ring boss to the torque shown in the table below.
Thread Width Tightening torque (Nm {kgm})
Nominal No. diameter across flats
(mm) mm Range Target
02 14 35 to 63 {3.5 to 6.5} 44 {4.5}
— 18 Varies 59 to 98 {6.0 to 10.0} 78 {8.0}
03, 04 20 depending 84 to 132 {8.5 to 13.5} 103 {10.5}
05, 06 24 on type of 128 to 186 {13.0 to 19.0} 157 {16.0}
10, 12 33 connector. 363 to 480 {37.0 to 49.0} 422 {43.0}
14 42 746 to 1,010 {76.0 to 103} 883 {90.0}
Table of tightening torque for O-ring boss plugs

a Unless otherwise specified, tighten the plug for O-ring boss to the torque shown in the table below.
Thread Width Tightening torque (Nm {kgm})
Nominal No. diameter across flats
(mm) mm Range Target
08 8 14 5.88 to 8.82 {0.6 to 0.9} 7.35 {0.75}
10 10 17 9.8 to 12.74 {1.0 to 1.3} 11.27 {1.15}
12 12 19 14.7 to 19.6 {1.5 to 2.0} 17.64 {1.8}
14 14 22 19.6 to 24.5 {2.0 to 2.5} 22.54 {2.3}
16 16 24 24.5 to 34.3 {2.5 to 3.5} 29.4 {3.0}
18 18 27 34.3 to 44.1 {3.5 to 4.5} 39.2 {4.0}
20 20 30 44.1 to 53.9 {4.5 to 5.5} 49.0 {5.0}
24 24 32 58.8 to 78.4 {6.0 to 8.0} 68.6 {7.0}
30 30 32 93.1 to 122.5 {9.5 to 12.5} 107.8 {11.0}
33 33 — 107.8 to 147.0 {11.0 to 15.0} 127.4 {13.0}
36 36 36 127.4 to 176.4 {13.0 to 18.0} 151.9 {15.5}
42 42 — 181.3 to 240.1 {18.5 to 24.5} 210.7 {21.5}
52 52 — 274.4 to 367.5 {28.0 to 37.5} 323.4 {33.0}
00-38 140E-6 SERIES

Table of tightening torque for hose (taper seal type and face seal type)
a Unless otherwise specified, tighten the hose fittings (taper seal type and face seal type) to the torque
shown in the following table.
a The table is applied to the threads coated with engine oil (wet threads)
Tightening torque (Nm {kgm}) Taper seal Face seal
Width
Nominal across Nominal No. - Thread root
No. of Thread size threads per
flats Range Target diameter
hose (mm) (mm) inch, type of (reference)
thread
34 to 54 {3.5 to 5.5} 44 {4.5} — 9/16 -18UN 14.3
02 19
34 to 63 {3.5 to 6.5} 44 {4.5} 14 — —
22 54 to 93 {5.5 to 9.5} 74 {7.5} — 11/16 -16UN 17.5
03
24 59 to 98 {6.0 to 10.0} 78 {8.0} 18 — —
04 27 84 to 132 {8.5 to 13.5} 103 {10.5} 22 13/16 -16UN 20.6
05 32 128 to 186 {13.0 to 19.0} 157 {16.0} 24 1 -14UNS 25.4
06 36 177 to 245 {18.0 to 25.0} 216 {22.0} 30 1-3/16 -12UN 30.2
(10) 41 177 to 245 {18.0 to 25.0} 216 {22.0} 33 — —
(12) 46 197 to 294 {20.0 to 30.0} 245 {25.0} 36 — —
(14) 55 246 to 343 {25.0 to 35.0} 294 {30.0} 42 — —
Table of tightening torque for face seal joints

a The tightening torque table below applies to the seal joint (sleeve nut type)
a The table is applied to the threads coated with engine oil (wet threads).
Outer Tightening torque (Nm {kgm}) Face seal
Width
diameter of Nominal No. - Thread root
across flats
pipe Range Target threads per inch, diameter
(mm)
(mm) type of thread (Reference)
8 19 14 to 16 {1.4 to 1.6} 15 {1.5} 9/16 -18UN 14.3
10 22 24 to 27 {2.4 to 2.7} 25.5 {2.6} 11/16 -16UN 17.5
12 24 {27} 43 to 47 {4.4 to 4.8} 45 {4.6} 13/16 -16UN 20.6
15 {16} 30 {32} 60 to 68 {6.1 to 6.8} 64 {6.5} 1 -14UNS 25.4
22 {20} 36 90 to 95 {9.2 to 9.7} 92.5 {9.4} 1-3/16 -12UN 30.2
Reference: The face seal joint of the dimension in ( ) is also used, depending on the specification.
140E-6 SERIES 00-39

Tightening torque table for bolts and nuts on 102,107 and 114 series engines
a Unless otherwise specified, tighten the metric threads bolts and nuts used on the 102, 107 and 114 series
engines to the torques shown in the following table.
Thread diameter Tightening torque
(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 — —
Tightening torque table for I-joints on 102,107 and 114 series engines
a Unless otherwise specified, tighten the metric I-joints used on the 102, 107 and 114 series engines to the
torque shown in the following table.
Thread diameter 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
Tightening torque table for tapered screws on 102,107 and 114 series engines
a Unless otherwise specified, tighten the tapered inch thread screws used on the 102, 107 and 114 series
engines to the torques shown in the following table.
Material In cast iron or steel In aluminum
Tightening torque Tightening torque
Thread diameter (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
00-40 140E-6 SERIES

List of abbreviation (ALL-0360-005-A-00-A)

(Rev. 2012/01)
• This list of abbreviations includes the abbreviations used in the text of the shop manual for parts,
components, and functions whose meaning is not immediately clear. The spelling is given in full with an
outline of the meaning.
• Abbreviations that are used in general society may not be included.
• Special abbreviations which appear infrequently are noted in the text(marked witha).
• This list of abbreviations consists of two parts. The first part is a list of the abbreviations used in the text of
the manual, and the second part is a list of the abbreviations used in the circuit diagrams.
List of abbreviations used in the shop manual

Purpose of use (major
Abbrevia- Full Spelling applicable machine (*), or Explanation
tion equipment/device)
Function with which when the tires skid
Anti-skid Brake Travel and brake (wheels stop rotating), the brakes are
ABS System released, and when the wheels start to rotate,
(HD, HM)
the brakes are applied again.
Automatic Idling
AISS Engine Automatic setting function of idling speed
Setting System
Function that a lever can perform the steering
Advanced Joystick Steering operations, shifting gear speed operation and
AJSS Steering System changing direction operation instead of a
(WA)
steering wheel.
Function that the retarder works automatically
Automatic Retarder Travel and brake with a certain braking force when the
ARAC
Accelerator Control (HD, HM) accelerator pedal is released while the
machine travels downhill.
Function that the retarder works automatically
with a certain braking force so that the
Automatic Retarder Travel and brake machine travels with the speed not exceeding
ARSC Speed Control (HD, HM) the speed set by the operator when the
accelerator pedal is released while the
machine travels downhill.
Function with which, when the rear wheels
Automatic Spin Travel and brake spin on soft ground surfaces, this function
ASR Regulator (HD, HM) automatically uses the optimum braking force
to drive both wheels.
A device that can be fixed onto a machine in
ATT Attachment Work equipment
order to enable it to do different jobs.
Brake Valve that bypasses part of the brake cooling
Brake cooling oil oil to reduce the load on the hydraulic pump
BCV
control valve (HD) when the retarder is not being used.
Controller Area Communication and One of communication standards that is used
CAN
Network electronic control in the network on the machine
Crankcase Depression Regulator valve that is installed to the KCCV
CDR Engine ventilator It is not used independently and
Regulator
described CDR valve.
System that can simultaneously actuate
Closed-center Load multiple actuators regardless of the load
CLSS Oil pressure
Sensing System (provides better combined operation
comparing to OLSS).
Function to maintain optimum fuel injection
amount and fuel injection timing by using
CRI Common Rail Injection Engine
engine controller to perform electronic control
of supply pump, common rail, and injector.
Electronic control device that uses the signals
Electronic Control from the sensors on the machine to indicate
ECM Electronic control system
Module the optimum actuation to the actuators .
(Same as ECU)
140E-6 SERIES 00-41


Transmission Proportional electromagnetic valve that
Electronic Control
ECMV gradually increases oil pressure to engage
Modulation Valve (D, HD, WA, etc.)
clutch and reduces transmission shock.
System that ensures smooth high-speed
Electronically Travel travel by using hydraulic spring effect of
ECSS Controlled Suspension
(WA) accumulator to absorb vibration of machine
System
during travel
Electronic control device that uses the signals
from the sensors on the machine to indicate
ECU Electronic Control Unit Electronic control system the optimum actuation to the actuators .
(Same as ECM)
Function to recirculate part of exhaust gas to
Exhaust Gas Engine combustion chamber in order to reduce
EGR
Recirculation combustion temperature and to control
emission of NOx.
Equipment System that allows data (filter, oil replacement
Management interval, malfunctions on machine, failure
EMMS Machine monitor
Monitoring System code, and failure history) from each sensor on
the machine to be checked on monitor.
Electromagnetic Electromagnetic proportional control
EPC Oil pressure Mechanism that actuator works in proportion
Proportional Control
to current
Structure that protects operator's head from
Falling Object Cab and canopy falling objects. (Structure to protect operator)
FOPS
Protective Structure
Performance standardized in ISO 3449
Forward-Neutral- Operation
F-N-R Forward - NEUTRAL - REVERSE
Reverse
Communication Global Positioning System Satellite
Global Positioning
GPS System (KOMTRAX ､KOMTRAX positioning system that is used to determine
Plus) the current location on the earth
Steering function that uses a combination of
Hydrostatic Steering Steering hydraulic motor and bevel shaft to control
HSS System difference in travel speed of right and left
(D) tracks to turn machine without using steering
clutch.
Hydraulic transmission system that uses a
Hydro Static Transmission combination of hydraulic pump and hydraulic
HST motor to shift gear steplessly without using
Transmission (D, WA)
gears.
Valve that adjusts fuel intake amount at inlet
Inlet Metering Actuator Engine port of pump in order to control fuel discharge
IMA
amount of supply pump. Same meaning as
IMV
Valve adjusting fuel intake amount at inlet port
IMV Inlet Metering Valve Engine of pump in order to control fuel discharge
amount of supply pump. Described IMV (IMA)
This mechanism separates oil in blowby gas
Komatsu Closed Engine and returns it to the intake side to afterburn it
KCCV
Crankcase Ventilation there. It primarily consists of filters.
This filter is used to capture soot in exhaust
Komatsu Catalyzed Engine gas.
KCSF
Soot Filter
It is built in to KDPF.
The catalyst used for purifying exhaust gas.
Komatsu Diesel
KDOC Engine It is built in to KDPF.
Oxidation Catalyst
00-42 140E-6 SERIES


This component with built-in KDOC (catalyst)
and KCSF purifies exhaust gas.
Komatsu Diesel Engine
KDPF Part building in (soot-capturing filter)
Particulate Filter
It is installed in place of the currently used
muffler.
Function that recovers the drive force of the
wheels by braking automatically with the
Komatsu Traction Travel and brake optimum force and at the same time activates
KTCS Control System the inter-axle differential lock when the wheels
(HM system)
idle while the machine travels on the soft
ground road.
Komatsu Variable
The turbocharger on which the cross-section
KVGT Geometry Engine
area of the exhaust passage is made variable.
Turbocharger
Liquid Display Image display equipment such
LCD Liquid Crystal Display Machine monitor as the monitor which assembles in the liquid
crystal element.
Light Emitting Diode Semi-conductor element
LED Light Emitting Diode Electronic parts that emits light when the voltage is applied in
the normal direction.
Local Interconnect Communication and One of communication standards that is used
LIN
Network electronic control in the network on the machine
Function that detects differential pressure of
LS Load Sensing Oil pressure pump and controls discharge amount
according to load.
Low Voltage Communication and One of communication standards that is used
LVDS Differential Signaling electronic control in the network on the machine
It means the intake air flow of the engine. It is
Engine not used independently but used together with
MAF Mass Air Flow
the sensor. The mass air flow sensor may be
called MAF sensor.
Service that allows transmission and
Multimedia Messaging reception of short messages consisting of
MMS Communication characters or voice or images between cell
Service
phones.
Device actuated to open electric or hydraulic
NC Normally Closed Electric and hydraulic circuits that are normally closed if not
actuated.
Device actuated to close electric or hydraulic
NO Normally Open Electric and hydraulic
circuits that are normally open if not actuated.
Open-center Load Hydraulic system that can operate multiple
OLSS Oil pressure actuators at the same time, regardless of the
Sensing System
load.
Pressure
PC Oil pressure A function used to correct oil pressure.
Compensation
System in which a controller instantly
Palm command control Steering analyses data from each lever, pedal, and
PCCS system dial, and performs optimum electronic control
(D)
of the engine and transmission.
Valve installed at inlet port of pump to adjust
Pre-stroke Control Engine fuel intake amount in order to control fuel
PCV
Valve discharge amount of supply pump.
Proportional pressure control Mechanism that
Proportional Pressure Oil pressure actuator works in proportion to hydraulic
PPC
Control pressure
Piston Pump and Oil pressure
PPM Piston pump and motor.
Motor (D, PC, etc.)
PTO Power Take Off Power transmission Power take-off mechanism
140E-6 SERIES 00-43

Power Tilt and power Work equipment Function that performs hydraulic control of the
PTP tilt and pitch of the bulldozer blade.
Pitch dozer (D)
Structure that protects operator fastening seat
belt from being crushed when machine tips
Roll-Over Protective Cab and canopy over (Structure to protect operator when
ROPS
Structure machine tips over)
Performance standardized in ISO 3471
Abbreviation for "International system of units"
International unit
SI Unit Unit system that is employed worldwide, and
system
"one unit against one factor"
Actuator that moves a part with a movable iron
SOL Solenoid Electric core in the coil (solenoid), which is moved by
energizing the coil.
Two Way Valve Hydraulic and electric Solenoid valve that switches the direction of
TWV
flow.
*1: Code for applicable machine family
D: Bulldozer
HD: Dump truck
HM: Articulated dump truck
PC: Power shovel
WA: Wheel loader
List of abbreviations used in the circuit diagrams
Abbreviation Actual word spelled out
A/C Air Conditioner
A/D Analogue-to-Digital
A/M Air Mix Damper
ACC Accessory
ADD Additional
AUX Auxiliary
BR Battery Relay
CW Clockwise
CCW Counter Clockwise
ECU Electronic Control Unit
ECM Electronic Control Module
ENG Engine
EXGND External Ground
F.G. Frame Ground
GND Ground
IMA Inlet Metering Actuator
NC No Connection
S/T
Steering
STRG
SIG Signal
SOL Solenoid
STD Standard
OPT
Option
OP
PRESS Pressure
SPEC Specification
SW Switch
TEMP Temperature
00-44 140E-6 SERIES

Abbreviation Actual word spelled out

T/C Torque Converter
T/M Transmission
140E-6 SERIES 00-45

Conversion table (ALL-2150-931-A-00-A)

(Rev. 2012/01)
Method of using the conversion table

• The unit conversion table enables the simple conversion in the figures between the different units. For
further details of the method of use of the conversion table, see the examples given below.
Example: Method of using the conversion table to convert a unit from millimeters to inches
Conversion of 55 mm into inches
1. Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a horizontal
line from (A).
2. Locate the number 5 in the row across the top, take this as (B), then draw a vertical line down from (B).
3. Take the point where the two lines cross as (C). This point (C) gives the value when converting the unit
from millimeters to inches. Therefore, 55 mm = 2.165 in.
Conversion of 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 get 55 mm.
2. Then convert 55 mm to 2.165 in by the same procedure as above.
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 get the original value. This gives 550 mm = 21.65 in. Therefore, 550 mm = 21.65
in.
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 2.017 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 2.847 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
00-46 140E-6 SERIES

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 2.847 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
Kilograms to pounds
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
l 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-6 SERIES 00-47

l to U.K. Gallons
1 l＝ 0.21997 U.S.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
00-48 140E-6 SERIES

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-6 SERIES 00-49

Temperature
Conversion of Fahrenheit to Celsius
• A simple way to convert a Fahrenheit temperature reading into a Celsius temperature reading or vice
versa is to see the number in the center column of the following table. The figures on the following table
show the temperatures in both Fahrenheit and Celsius.
• When converting from Fahrenheit to Celsius degrees, consider the center column to be a table of
Fahrenheit temperatures and read the corresponding Celsius temperature in the column at the left.
• When converting from Celsius to Fahrenheit degrees, consider the center column to be a table of Celsius
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
00-50 140E-6 SERIES

SHOP MANUAL
ENGINE
140E-6 SERIES
Model Serial Number
140E-6
SERIES
01 Specification
2 01 Specification
140E-6 SERIES 01-1

01 Specification
Table of contents
Table of contents (ALL-0310-002-A-00-A)

01 Specification................................................................................................................................. 01-1
General information .................................................................................................................... 01-3
Exhaust gas regulation ......................................................................................................... 01-3
Specifications............................................................................................................................. 01-6
Machine model .................................................................................................................... 01-6
Specifications ...................................................................................................................... 01-7
General view ..................................................................................................................... 01-10
Weight table ...................................................................................................................... 01-23
Engine performance curve .................................................................................................. 01-24
01-2 140E-6 SERIES

01 Specification
Exhaust gas regulation
General information (ALL-0000-001-A-00-A)
Exhaust gas regulation (ENG125-A000-017-K-00-A)
• The three main diesel engine emissions that adversely impact the human body and the environment are
the following:
1. NOx (nitrogen oxides): causes breathing problems and acid rain
2. HC (hydrocarbons): causes photochemical smog
3. PM (particulates in air such as soot): causes cancer and breathing problems
• NOx are produced when the nitrogen (N2) in air reacts with oxygen (O2) at high temperatures. These
substances are produced when a diesel engine combustion takes place with too much air (nitrogen). To
reduce NOx, it is necessary to lower the combustion temperature in the cylinder to suppress the oxidation
of N (nitrogen). Therefore, an air-cooled aftercooler (2) exhaust gas recirculation (EGR) is used for
lowering the temperature of the air from turbocharger (1).
• HC is the main component of fuel. HC in the blowby gas holds the most part of hazardous materials
emitted from a diesel engine, however, this has been released into the air.
• Like HC, PM is generated from imperfect combustion of fuel. It is a particle (solid substance) adhered to
soot and the like. Generally speaking, reduction of NOx and reduction of PM are in paradoxical
relationship, namely trying to reduce one results in increasing the other. In order to reduce PM despite this
difficulty, we have employed common rail (3) so that the electronically controlled high-pressure fuel
injection system can atomize the fuel sprayed, cut the injection time and optimize injection timing.
• Emission regulations are established in Japan, US, and various regions in Europe. The history of the USA
regulations from the 1st (Tier 1) to 4th (Tier 4) is traced in the following table. (Transition of USA EPA(*1)
emission regulations, for engine rated horsepower 130 kW to 560 kW) The horizontal axis shows the NOx
+ NMHC(*2) level, and the vertical axis shows the PM level.
In the 4th (Tier 4) regulation, both the NOx + NMHC and PM standards are tightened to levels approx.1/7
of the 3rd (Tier 3) regulation. This 4th regulation is referred to as "Tier 4 regulation"
(* 3).
*1: United States Environmental Protection Agency
*2: General term for hydrocarbons (HC) that have a high photochemical reactivity.
*3: There are two stages in Tier 4. The 1st stage is referred to as "Tier 4 Interim", for which actions are
taken this time. The 2nd stage is referred to as "Tier 4 Final".
140E-6 SERIES 01-3

01 Specification
Actions taken to meet the Tier 4 regulation (ENG125-A000-018-K-00-A)
1. Engine
2. Air cleaner
3. Air cooled aftercooler
4. EGR cooler
dP: KDPF differencial pressure and outlet pressure sensor
DOSER: Fuel doser
ECU(CM2250): Engine controller
EGRSOL: EPC valve (for EGR)
01-4 140E-6 SERIES

01 Specification
EGRV: EGR valve

MAF: Mass air flow and temperature sensor
PAMB: Ambient pressure sensor
PCCV: Crankcase pressure sensor
PIM: Charge pressure sensor
REV: KVGT speed sensor
SEGR: EGR valve lift sensor
SVGT: KVGT position sensor
T: KDPF inside temperature sensor
TIM: Charge temperature sensor
VGTSOL: EPC valve (for KVGT)
• The following describes our major improvements done in Tier 4 over Tier 3.
1. Efficiency of EGR (Exhaust Gas Recirculation) cooler (4) has been increased (NOx reduced).
2. Intake air flow at low engine speeds is increased by utilizing variable speed operation of the turbocharger
(KVGT) (PM reduced).
3. Employment of the high-precision EGR valve Oxygen density control is optimized for each driving
condition by using a high precision EGR valve (EGRV), mass air flow (MAF) and temperature sensor,
engine controller, and by monitoring each part of the EGR circuit (NOx and PM reduced).
4. Common rail pressure is raised to increase fuel injection pressure and microparticulate the fuel spray (PM
reduced).
5. Blowby gas reduction system (KCCV) is introduced to perform internal circulation of blowby gas (HC
reduced).
6. Soot collecting filter (KCSF) is introduced (PM reduced).
7. Variations between injectors are averaged by engine controller (CM2250).
8. Combustion chamber is improved (NOx and PM reduced)
9. Fuel injection and KVGT are automatically controlled by recognition of high altitude with ambient pressure
sensor (PAMB) (NOx and PM reduced at a high altitude).
10.KVGT speed (REV) is monitored (to protect the KVGT).
11.When clogging of the soot collecting filter (KCSF) is detected by the differential pressure (dP) across the
KDPF, the engine controller performs automatic regeneration(*), or prompts the operator to perform
manual stationary regeneration on the machine monitor (to maintain the KDPF function).
*: A new feature to clean (oxidize) the soot accumulated in the soot collecting filter (KCSF) inside the KDPF.
140E-6 SERIES 01-5

01 Specification
Machine model
Specifications (ALL-2111-001-A-00-A)
Machine model (ENG140-A000-00V-K-00-A)

Engine Engine serial No. Machine model
HM400-3 Articulated dump truck
SAA6D140E-6 D155AX-7 Bulldozer
WA500–7 Wheel loader
01-6 140E-6 SERIES

01 Specification
Specifications
Specifications (ENG107-2110-001-A-00-A)
<Applicable machine> HM400-3 (ENG140-2110-030-A-00-A)
Engine name SAA6D140E-6

Number of cylinders – bore x stroke mm 6 – 140 × 165
Total displacement l {cc} 15.2 {15,230}
Firing order – 1–5–3–6–2–4
Overall length mm 1,498
Overall width mm 1,091
Dimension Overall height (excluding
mm 1,527
exhaust pipe)
Overall height (including
mm –
exhaust pipe)
Rated horsepower kW {HP}/rpm 353 {473}/ 2,000
Max. torque Nm {kgm}/rpm 2,275 {232}/ 1,400
Max. speed with no load
rpm 2,200 (+ 50 / 0)
(High idle speed)
Performance
Min. speed with no load
rpm 725 ± 25
(Low idle speed)
Fuel consumption ratio at
g/kWh {g/HPh} 218 {163}
rated point
Dry weight kg 1,890
Fuel injection system – High-pressure common rail type
Fuel injection system control – Electronic control type
Quantity of lubricating oil (Refill capacity) l 58 (50)
Quantity of coolant l 27 (Engine only)
Alternator – 24 V,60 A,90 A
Starting motor – 24 V,11kW
Turbocharger – Komatsu KTR95V
140E-6 SERIES 01-7

01 Specification
Specifications
<Applicable machine> D155AX-7 (ENG140-2110-030-A-01-A)

No. of cylinders - bore x stroke mm 6 - 140 x 165
Piston displacement l {cc} 15.2 {15,230}
mm 1,672
exhaust pipe)
mm 1,769
exhaust pipe)
At rated horsepower kW {HP}/rpm 268 {360}/ 1,900
rpm 2,100 (0 / - 50)
(High idle speed)
Performance
rpm 740 (+ 25 / 0)
(Low idle speed)
Fuel consumption rate at
g/kWh {g/HPh} 219 {163}
rated horsepower
Dry weight kg 2,118
Fuel injection system control – Electronic control system
Lubricating oil amount (refill capacity) l 58 {50}
Coolant amount l 27 (engine only)
Alternator – 24 V, 60 A, 90 A
Starting motor – 24 V, 11 kW
01-8 140E-6 SERIES

01 Specification
Specifications
<Applicable machine> WA500-7 (ENG140-2110-030-A-02-A)

Number of cylinders – bore x stroke mm 6 – 140 × 165
Total displacement l {cc} 15.2 {15,230}
mm 1,694
exhaust pipe)
mm 1,793
exhaust pipe)
Rated horsepower kW {HP}/rpm 266 {357}/ 1,900
rpm 2,150 (± 50)
(High idle speed)
Performance
rpm 700 ± 25
(Low idle speed)
Fuel consumption ratio at
g/kWh {g/HPh} 221 {162}
rated point
Dry weight kg 2,096 (With KDPF)
Fuel injection system control – Electronic control type
Quantity of lubricating oil (Refill capacity) l 45 (37)
Quantity of coolant l 27 (Engine only)
Alternator – 24 V、90 A
Starting motor – 24 V、11kW
140E-6 SERIES 01-9

01 Specification
General view
General view (ENG107-2180-001-A-00-A)
<Applicable machine> HM400-3 (ENG140-2180-041-A-00-A)

Left side
a The shape is subject to machine models.
1. Center of crankshaft
2. Rear face of flywheel housing
01-10 140E-6 SERIES

01 Specification
General view
Right side
2. Rear face of flywheel housing
140E-6 SERIES 01-11

01 Specification
General view
Front side
2. Cylinder center
01-12 140E-6 SERIES

01 Specification
General view
Back side
2. Cylinder center
140E-6 SERIES 01-13

01 Specification
General view
<Applicable machine> D155AX-7 (ENG140-2180-041-A-01-A)

Left side
2. Rear side of flywheel housing
01-14 140E-6 SERIES

01 Specification
General view
Right side
140E-6 SERIES 01-15

01 Specification
General view
Front side
2. Center of cylinder
01-16 140E-6 SERIES

01 Specification
General view
Rear side
140E-6 SERIES 01-17

01 Specification
General view
<Applicable machine> WA500-7 (ENG140-2180-041-A-02-A)

Left side
01-18 140E-6 SERIES

01 Specification
General view
Right side
140E-6 SERIES 01-19

01 Specification
General view
Front side
01-20 140E-6 SERIES

01 Specification
General view
Rear side
140E-6 SERIES 01-21

01 Specification
General view
Dimensions table (ENG140-2110-2A4-A-00-A)
a These dimensions are given for reference when the engine is set on a test bench.
Unit: mm
Dimension of each part
Engine Machine model
A B C D
HM400-3 1,498 1,527 542 1,091
SAA6D140E-6 D155AX-7 1,513 1,838 420 1,193
WA500–7 1,572 1,793 407 1,105
01-22 140E-6 SERIES

01 Specification
Weight table
Weight table (ENG140-2120-931-A-00-A)
Unit: kg
No. Item Component part SAA6D140E-6
1 Turbocharger (KVGT) Komatsu VGT 33
2 Cylinder head assembly Cylinder head, valve, and valve spring 23 x 6
3 Cylinder block assembly Cylinder block, bearing, and cap 480
4 Front cover 56
HM400-3 28
5 Oil pan D155AX-7 26
WA500–7 26
HM400-3 58
6 Flywheel assembly Flywheel and ring gear D155AX-7 60
WA500–7 60
7 Flywheel housing assembly 65
8 Crankshaft assembly Crankshaft and crank gear 136
9 Camshaft assembly Camshaft, cam gear, and thrust plate 20
Piston and connecting rod Piston, piston ring, piston pin, and
10 assembly connecting rod 11 x 6
11 Oil pump 7
12 Supply pump 15
13 Water pump 18
24 V, 60 A 11
14 Alternator
24 V, 90 A 19
15 Starting motor 24 V, 11 kW 18
16 EGR oil pump 6
17 EGR valve 11
18 EGR cooler 11 x 2
12 in. 81
19 KDPF
14 in. 107
20 KCCV ventilator 3
21 Air intake manifold 39
22 Exhaust manifold 18
23 EGR cooler mount bracket 27
140E-6 SERIES 01-23

01 Specification
Engine performance curve
Engine performance curve (ENG140-2170-00V-A-00-A)
Reference document
Engine Engine serial No. Machine model page
HM400-3 01-25
SAA6D140E-6 D155AX-7 01-26
WA500-7 01 - 27
01-24 140E-6 SERIES

01 Specification
Performance curve (ENG107-2170-001-A-01-A)

<Applicable machine> HM400-3 (ENG140-2170-34E-A-00-A)
Rated horsepower: 353 ± 10.5 kW {473 ± 14.1 HP}/2,000 rpm (GROSS)
Maximum torque: 2,275 ± 68 Nm {232 ± 6.9 kgm}/1,400 rpm (GROSS)
140E-6 SERIES 01-25

01 Specification
<Applicable machine> D155AX-7 (ENG140-2170-34E-A-01-A)
Rated horsepower: 268 ± 8.4 kW {360 ± 11.3 HP} / 1,900 rpm (GROSS)
Maximum torque: 1,834 ± 55.0 Nm {187 ± 5.6 kgm} / 1,300 rpm (GROSS)
01-26 140E-6 SERIES

01 Specification
<Applicable machine> WA500-7 (ENG140-2170-34E-A-02-A)
Rated horsepower: 266 ± 8.0 kW {357 ± 10.7 HP}/1,900 rpm (GROSS)

Maximum torque: 1,805 ± 54 Nm {184 ± 5.5 kgm}/1,250 rpm (GROSS)
140E-6 SERIES 01-27

01 Specification
01-28 140E-6 SERIES

SHOP MANUAL
ENGINE
140E-6 SERIES
Model Serial Number
140E-6
SERIES
10 Structure and function

3 10 Structure and function
140E-6 SERIES 10-1

Table of contents

10 Structure and function ................................................................................................................... 10-1
Components layout..................................................................................................................... 10-4
Components layout drawing.................................................................................................. 10-4
Intake and exhaust system layout drawing ............................................................................. 10-7
Intake and exhaust system circuit diagram ............................................................................. 10-9
Air cleaner ......................................................................................................................... 10-11
KVGT................................................................................................................................ 10-12
Aftercooler......................................................................................................................... 10-18
EGR system piping drawing ................................................................................................ 10-19
EGR system circuit diagram ................................................................................................ 10-21
EGR valve......................................................................................................................... 10-22
EGR cooler........................................................................................................................ 10-24
Mixing connector................................................................................................................ 10-26
KCCV layout drawing ......................................................................................................... 10-27
KCCV ventilator ................................................................................................................. 10-29
KDPF................................................................................................................................ 10-33
Engine main body parts............................................................................................................. 10-37
Cylinder head .................................................................................................................... 10-37
Cylinder block .................................................................................................................... 10-39
Main moving parts.............................................................................................................. 10-41
Timing gear ....................................................................................................................... 10-44
Front cover ........................................................................................................................ 10-45
Valve system ..................................................................................................................... 10-46
Flywheel and flywheel housing ............................................................................................ 10-48
Lubrication system.................................................................................................................... 10-49
Lubrication system parts layout drawing ............................................................................... 10-49
Lubrication system diagram ................................................................................................ 10-50
Oil pump ........................................................................................................................... 10-51
Boost oil pump ................................................................................................................... 10-53
Oil filter.............................................................................................................................. 10-55
Oil cooler........................................................................................................................... 10-56
Oil cooler thermo-valve....................................................................................................... 10-58
Oil pan .............................................................................................................................. 10-59
Fuel system ............................................................................................................................. 10-60
Fuel system parts layout drawing......................................................................................... 10-60
Fuel system circuit diagram................................................................................................. 10-62
Outline of CRI system ............................................................................................................... 10-65
Fuel system ....................................................................................................................... 10-65
Various controls ................................................................................................................. 10-66
Structure and operation of CRI system................................................................................. 10-68
Structure and operation of component parts ......................................................................... 10-69
Fuel dozing .............................................................................................................................. 10-79
Dozing piping drawing ........................................................................................................ 10-79
Pre-filter ............................................................................................................................ 10-82
Main filter .......................................................................................................................... 10-83
Cooling system......................................................................................................................... 10-84
Cooling system parts layout drawing.................................................................................... 10-84
Cooling system circuit diagram............................................................................................ 10-85
Water pump....................................................................................................................... 10-86
Thermostat ........................................................................................................................ 10-88
Electrical equipment.................................................................................................................. 10-90
Alternator .......................................................................................................................... 10-90
Alternator mounting ............................................................................................................ 10-93
Starting motor .................................................................................................................... 10-94
Fuel feed pump.................................................................................................................. 10-96
10-2 140E-6 SERIES

Table of contents
Fuel feed pump switch........................................................................................................ 10-97

Engine wiring harness ........................................................................................................ 10-98
Engine controller .............................................................................................................. 10-100
Sensor ............................................................................................................................ 10-106
140E-6 SERIES 10-3

Components layout drawing
Components layout (ALL-A000-001-K-04-A)
Components layout drawing (ENG140-A000-04D-K-00-A)
1. Cylinder block
2. Cylinder liner
3. Piston
4. Connecting rod
5. Piston pin
6. Intake valve
7. Exhaust valve
8. Crosshead
9. Injector
10. Cylinder head cover
11. Flywheel housing
12. Rear oil seal
13. Flywheel
14. Ring gear
15. Crankshaft
16. Main bearing cap
10-4 140E-6 SERIES

17. Oil pan

18. Oil strainer
19. Crankshaft gear
20. Front cover
21. Front seal
22. Vibration damper
23. Crankshaft pulley
24. Exhaust manifold

25. Turbocharger
26. Cylinder head
27. Rocker arm
28. Rocker arm shaft
29. Push rod
30. Intake manifold
31. Cam follower
140E-6 SERIES 10-5

32. Camshaft
33. Common rail
34. Supply pump
35. Connecting rod cap
Engine
Name: SAA6D140E-6 (with turbocharger and air cooled aftercooler)
Type: In-line 6-cylinder, water-cooled, direct injection type, 4-cycle diesel engine
10-6 140E-6 SERIES

Intake and exhaust system layout drawing
Intake and exhaust system parts (ENG107-A900-001-K-00-A)
Intake and exhaust system layout drawing (ENG140-A900-04D-K-00-A)
1. KVGT
2. Mixing connector
3. EGR valve
4. Intake connector
5. EGR cooler
140E-6 SERIES 10-7

Intake and exhaust system layout drawing
6. Exhaust manifold
A: To KDPF
B: From aftercooler
C: To intake manifold
D: From air cleaner
E: To aftercooler
10-8 140E-6 SERIES

Intake and exhaust system circuit diagram
Intake and exhaust system circuit diagram (ENG125-A900-052-K-00-A)
A: From atmosphere
B: To atmosphere
1. Air cleaner
2. KVGT
3. Air cooled aftercooler
4. Intake air heater
5. Intake manifold
6. Exhaust manifold
7. EGR valve
8. KCCV ventilator
9. KDPF
10. EGR cooler
11. Flywheel housing
12. Engine oil pan
13. Engine
14. Mixing connector
Function (ENG125-A900-042-K-00-A)
• A variable displacement turbocharger KVGT (KOMATSU Variable Geometry Turbocharger), EGR system
(EGR valve and EGR cooler) which sends a part of exhaust gas back to the combustion chamber in order
to suppress generation of NOx, KDPF (KOMATSU Diesel Particulate Filter) which purify the exhaust gas,
and a blowby gas recirculation system KCCV (KOMATSU Closed Crankcase Ventilation) are introduced
for this engine.
• Clean air is necessary to maintain the engine performance. If dirt or dust enters, the engine can get
damaged and the performance may be degraded.
• Air flows through air cleaner (1), KVGT (2), and air cooled aftercooler (3) into the engine.
140E-6 SERIES 10-9

Intake and exhaust system circuit diagram
• The KVGT has a variable geometry mechanism not found in conventional turbochargers. The KVGT can
get seriously damaged if foreign material enters the KVGT. Therefore, a high quality air cleaner is
essential for the engine. Follow the procedures in the Operation and Maintenance Manual to clean or
replace the air cleaner element, and be careful not to let foreign material enter the system during
replacement work.
• Intake air flows from air cleaner (1) into the compressor side of KVGT (2). The air charged at KVGT (2) is
cooled at air cooled aftercooler (3). The air then flows through mixing connector (14), air intake manifold
(5) and then into the cylinders for combustion.
• Exhaust gas is sent from exhaust manifold (6) to the turbine side of KVGT (2). Thus the turbine wheel is
driven by the energy of the exhaust gas.
• The engine controller outputs signals to the EGR system for opening EGR valve (7) most properly
according to the load on the engine to attain both clean exhaust gas and low fuel consumption.
• When EGR valve (7) opens, part of the exhaust gas (EGR gas) flows from exhaust manifold (6) through
EGR piping to EGR cooler.
• The exhaust gas cooled by EGR cooler (10) flows through EGR valve (7) and mixes with the intake air in
mixing connector (14), then flows into intake manifold (5).
• KDPF (9) is installed to meet the new exhaust gas regulations. The KDPF consists of KDOC (oxidation
catalyzer) and KCSF (soot collecting filter).
• Particulate soot in the exhaust gas are collected to purify the exhaust gas.
10-10 140E-6 SERIES

Air cleaner
Air cleaner (ENG140-A910-041-K-00-A)
1. Vacuator valve
2. Inlet
3. Outlet
4. Mass air flow and temperature sensor mounting part
5. Rectifier wire net
6. Outer element
7. Inner element
8. Air cleaner clogging sensor or dust indicator mounting
Specifications (ENG140-A910-030-K-00-A)
• Type: Cyclopac type

• Filtering area (outer element): 14.7 m2
• Filtering area (inner element): 1.85 m2
Operation (ENG140-A910-044-K-00-A)
• Since inlet (2) is placed tangentially, the intake air is sucked in while swirling along the body and a
centrifugal force is generated by the swirl flow.
• The dust contained in the intake air is separated by the centrifugal separation effect.
• More than 99.9% of the dust is removed by outer element (6) and only clean air is sucked into the engine
through outer element (6), rectifier wire net (5), and outlet (3).
• Rectifier wire net (5) rectifies the air flow to the mass air flow sensor (4) which is important to the engine
control.
• The dust separated while the air is sucked in is discharged out automatically through vacuator valve (1)
when the engine is stopped.
140E-6 SERIES 10-11

KVGT
KVGT (ENG125-AA10-041-K-00-A)
KVGT: Abbreviation for KOMATSU Variable Geometry Turbocharger and denotes the variable displacement
turbocharger.
10-12 140E-6 SERIES

KVGT
1. Blower housing
2. KVGT speed sensor
3. Hydraulic actuator
4. Turbine housing
5. Plate
6. Vane
7. Nozzle ring
8. Push rod
9. Shaft
10. Blower impeller
11. Turbine wheel
12. Piston
A: Air intake inlet
B: Air intake outlet
C: Exhaust inlet
D: Exhaust outlet
Operation (ENG140-AA10-044-K-00-A)
1. Air cleaner
2. KVGT
3. KDPF
4. EGR cooler
5. EGR valve
C: Blower impeller
T: Turbine impeller
• The new exhaust gas regulation not only requires to control emissions at high engine speeds but also at
low engine speeds. To meet the requirements, the EGR ratio is increased. (EGR ratio = volume of EGR/
intake air flow)
• To obtain a high EGR ratio especially at low engine speeds, the turbine inlet pressure (P3) must be higher
than the boost pressure (P2). A variable displacement turbocharger (KVGT), in which the exhaust gas
pressure hitting the turbine impeller (T) can be adjusted, is introduced.
• The charged pressure rises faster, also contributing to suppress the generation of PM (particles) due to
insufficient oxygen at low engine speeds.
• The turbine impeller (T) drives the blower impeller (C) via a shaft. In turn the blower impeller (C) sends a
large amount of air to the cylinders for combustion. When the air flow from KVGT (2) increases, more fuel
can be injected, and the engine output increases.
• Since the density of the air and the amount of oxygen increases when the air is cooled, more fuel can be
injected, and the engine output increases.
140E-6 SERIES 10-13

KVGT
a Adequate amount of clean high quality oil is required to maintain the KVGT performance. Be sure to use
Komatsu genuine high quality oil. Follow the procedures in the Operation and Maintenance Manual when
replacing oil or oil filter.
• Exhaust gas enters from (C) of turbine housing (4), flows through section (P) and out from (D). Section (P)
is surrounded by plate (5) and nozzle ring (7) fixed on turbine housing (4), and vane (6).
• The passage area changes when nozzle ring (7) slides right or left.
• The hydraulic actuator (3) moves piston (12) in the actuator up/down by using the oil pressure controlled
at the EPC valve installed to the EGR valve, and also controls the right/left slide of push rod (8).
• Exhaust gas hits vane (6), and then turbine impeller (11) drives blower impeller (10) via shaft (9). This
works as a compressor and the air entered from (A) is compressed and sent out from (B).
• When the exhaust gas pressure at the inlet (C) of turbine housing (4) is low (at low engine speeds), push
rod (8) slides to the right to narrow section (P).
• Then the exhaust gas pressure to turbine impeller (11) increases, the turbocharger speed also increases,
and more air (oxygen) is inhaled.
• The turbocharger speed is sensed by KVGT speed sensor (2).
When nozzle ring is closed

• At low engine speeds, exhaust gas inlet passage (P) is narrowed (L1). (Not completely closed)
• When the turbine inlet pressure increases while the nozzle ring is closed, the flow speed to the turbine
increases and the turbocharger speed increases.
10-14 140E-6 SERIES

KVGT
When nozzle ring is open

• At high engine speeds, exhaust gas inlet passage (P) is widened (L2).
• As the engine speed and the turbine inlet pressure (exhaust gas pressure) increases, exhaust gas inlet
passage (P) widens (L2) to effectively apply the exhaust gas pressure to turbine impeller (11).
a Nozzle ring (7), vane (6) and rod (8) are integrated and slide together but do not rotate.
a KVGT position sensor is installed to hydraulic actuator (3). The KVGT position sensor is calibrated
together with the variable mechanism in the KVGT, and values are stored in the memory inside the KVGT
position sensor. If any of the hydraulic actuator (3), KVGT position sensor, or KVGT body fails, replace the
whole KVGT.
Hydraulic actuator operation
• Hydraulic actuator (6) is moved by the oil pressure controlled by EPC valve (8) installed to EGR valve
(10).
• The force for the movement is the oil pressure supplied from boost pump (12).
140E-6 SERIES 10-15

KVGT
• Position of hydraulic actuator (6) is sensed by KVGT position sensor (5) and the signals are fed back to
engine controller (7).
1. Air cleaner
2. Mass air flow and temperature sensor
10-16 140E-6 SERIES

KVGT
3. KVGT
5. KVGT position sensor
6. Hydraulic actuator
7. Engine controller
8. EPC valve (for KVGT)
9. KDPF
10. EGR system (EGR cooler and EGR valve)
C. Blower impeller
T. Turbine impeller
KVGT control system

• Based on information from KVGT position sensor (5), mass air flow and temperature sensor (2), and
KVGT speed sensor (4), etc., the engine controller (7) moves hydraulic actuator (6) by using the oil
pressure controlled by EPC valve (8), to move the piston.
• A good response at high altitudes is maintained by sensing high elevations with the ambient pressure
sensor, and automatically controlling the fuel injection and the KVGT.
Lubrication
• Cooled oil from the engine oil cooler is sent through the supply pipe to the KVGT for lubrication.
• Oil is sent to the bearing housing to lubricate the shaft bearing and thrust bearing.
• Return oil is drained from the return pipe connected to the bottom of the bearing housing and falls to the oil
pan.
Cooling
• Coolant from the cylinder block enters the center housing to cool the KVGT.
• Coolant return flows from the center housing and joins the flow at the EGR cooler air bent piping.
140E-6 SERIES 10-17

Aftercooler
Aftercooler (ENG140-A9A0-041-K-00-A)
1. Core
2. Tank
3. Tube
4. Fin
A: Intake air outlet
B: Intake air inlet
Specifications (ENG140-A9A0-030-K-00-A)
• Cooling method:
• Core type: Triangle slate
• Fin pitch: 4.0/2
• Total heat dissipation area: 29.98 m2
10-18 140E-6 SERIES

EGR system piping drawing
EGR system piping drawing (ENG140-A9J0-04D-K-00-A)
EGR: Abbreviation for Exhaust Gas Recirculation

1. KVGT
2. Intake manifold
3. Mixing connector
4. EGR valve
5. Air intake connector
6. EGR cooler
140E-6 SERIES 10-19

EGR system piping drawing
7. Exhaust manifold
Function (ENG140-A9J0-042-K-00-A)
• EGR valve (driven hydraulically)

Controls the gas flow from the exhaust system to the air intake system. Since the exhaust pressure is
higher than the boost pressure, the exhaust gas flows to the air intake side.
• EGR cooler
Cools the exhaust gas.
Engine coolant is used for cooling.
• Mixing connector
Mix the air from the air-cooled aftercooler and exhaust gas from the EGR valve to the air intake side.
• Controls each part of the EGR circuit and controls the EGR rate according to the operating condition to
ensure clean exhaust at all times.
• Since the EGR circuit is monitored and troubleshooted, a serious trouble is prevented.
10-20 140E-6 SERIES

EGR system circuit diagram
EGR system circuit diagram (ENG125-A9J0-052-K-00-A)
1. Air cleaner
2. KDPF
3. Ambient pressure sensor
4. Aftercooler
5. EGR cooler
6. EGR valve
7. Hydraulic actuator (power piston)
8. EPC valve (for EGR valve)
9. EGR valve lift sensor
10. Exhaust manifold
11. Boost pump
12. Intake manifold
13. Charge (boost) pressure and temperature sensors
15. Mixing connector
C: Blower impeller
T: Turbine impeller
Operation (ENG125-A9J0-044-K-00-A)
• The engine controller outputs signals for opening EGR valve (6) most properly according to the load on
the engine to attain both clean exhaust gas and low fuel consumption.
• When EGR valve (6) opens, a part of the exhaust gas (EGR gas) flows from exhaust manifold (10)
through EGR piping to EGR cooler (5).
• The exhaust gas cooled by EGR cooler (5) flows through EGR valve (6) and mixes with the intake air in
mixing connector (15), and then flows into intake manifold (12).
140E-6 SERIES 10-21

EGR valve
EGR valve (ENG107-A9K1-041-K-00-A)
1. Valve
2. Spring
3. Power piston
4. Spool
5. Spring
A: EGR gas inlet (from EGR cooler)
B: EGR gas outlet (to intake manifold)
C: Servo drive oil inlet
D: Servo drive oil outlet
E: KVGT control oil pressure outlet
F: KVGT drive oil pressure outlet
Structure
• The EGR valve consists of the EGR gas flow control mechanism and the EPC valves.
• There are two EPC valves, one for the EGR valves control and one for the KVGT control.
10-22 140E-6 SERIES

EGR valve
Operation (ENG107-A9K1-044-K-00-A)
• Oil from the boost oil pump flows into the EGR valve from port (C). Control pressure from the EPC valve
flows into port (E).
• Spool (4) is pressed to the right by the force of spring (5), and EGR valve (1) is closed by the force of
spring (2). Therefore, exhaust gas from the EGR cooler does not flow to the intake side.
• To open EGR valve (1), first the control pressure from the EPC valve enters port (E). Spool (4) moves to a
position whereat this control pressure and the force of spring (5) are balanced.
• The hydraulic circuit in power piston (3) opens, and then the oil from the boost oil pump entering from port
(C) pushes power piston (3) to the left.
• Oil from the boost oil pump acts on power piston (3) and generates force (Fp).
• When force (Fp) becomes larger than force (Fs) of spring (2), EGR valve (1) opens and then exhaust gas
will flow to the intake side.
• Since the hydraulic circuit to spool (4) is closed by movement of power piston (3), power piston (3) stops at
a position determined by spool (4). The valve position is controlled by the engine controller by controlling
the spool position with the control pressure of the EPC valve.
• A servo mechanism prevents external force applied to valve (1) from acting on spool (4), which is in
contact with power piston (3).
• Position of spool (4) is sensed by the EGR valve lift sensor.
140E-6 SERIES 10-23

EGR cooler
EGR cooler (ENG125-A9L0-041-K-00-A)
1. Header plate
4. Shell
A: EGR gas inlet
B: EGR gas outlet (to EGR valve)
C: Coolant inlet
D: Coolant outlet
E: Air vent
F: Air vent
2. Flat tube
3. Inner fin
Operation (ENG125-A9L0-044-K-00-A)
• The EGR gas enters from (A) and flows through 11 flat tubes (2).
10-24 140E-6 SERIES

EGR cooler
• Coolant enters from (C) and flows around flat tube (2) in shell (4) and then goes out from (D).
• The EGR gas is effectively cooled by flat tubes (2) with inner fins (3) and flows out from EGR gas outlet
(B).
140E-6 SERIES 10-25

Mixing connector
Mixing connector (ENG140-A9Q5-041-K-00-A)
A: Air inlet
B: EGR gas inlet
C: To cylinder head (intake gas)
1. Intake connector
2. Mixing connector
3. Intake manifold
4. Electric air heater
Function (ENG125-A9Q5-042-K-00-A)
Mixes EGR gas with air.
10-26 140E-6 SERIES

KCCV layout drawing
KCCV layout drawing (ENG140-A180-04D-K-00-A)
KCCV: Abbreviation for KOMATSU Closed Crankcase Ventilation

1. KCCV ventilator
2. KVGT
3. Check valve
4. CDR valve
A: Blowby gas
B: Engine oil-free blowby gas (to KVGT intake side)
C: Engine oil mist separated from the blowby gas by the ventilator KCCV (to oil pan)
• Formerly blowby gas (A) was discharged to the atmosphere as is. However, the tightened exhaust gas
regulation no longer permits releasing blowby gas to the atmosphere.
• Since blowby gas (A) contains engine oil components, which may cause the following problems when
recirculated to KVGT (2), a filter is provided at KCCV ventilator (1) to remove the oil.
1. Degraded performance of turbocharger and aftercooler due to adherence of engine oil
2. Abnormal engine combustion
3. Malfunction of sensors due to adherence of engine oil
140E-6 SERIES 10-27

KCCV layout drawing
Operation (ENG125-A180-044-K-00-A)
a The figure on the left shows the traditional flow of blowby gas that has been discharged to the atmosphere.
The figure on the right shows the flow of blowby gas recirculated to the intake system by the KCCV
ventilator.
1: Air cleaner
2: KVGT
3: After cooler
4: Cylinder block (crankcase)
5: Breather
6: KCCV ventilator
7: Oil pan
• Engine oil is removed from blowby gas (A) in engine (4) by the filter in KCCV ventilator (6), and then the
cleaned gas (B) is recirculated to the intake side of the KVGT.
• Removed engine oil (C) flows through a check valve and falls to the oil pan.
10-28 140E-6 SERIES

KCCV ventilator
KCCV ventilator (ENG140-A18H-041-K-00-A)
1. Heater tube
2. Crankcase pressure sensor
3. Case
4. CDR valve
5. Filter
6. Relief valve
7. Impactor
A: Blowby gas inlet (from engine breather)
B: Blowby gas outlet (to KVGT intake side)
C: Oil drain port (to oil pan)
D: Coolant inlet
E: Coolant outlet
Function (ENG125-A18H-042-K-00-A)
• When blowby gas is recirculated to the intake side of the KVGT, the pressure inside the crankcase
becomes negative, and dust may be sucked in through the crankshaft seals. Therefore, CDR valve
(regulator valve) controls the pressure inside the crankcase.
• If the filter in the KCCV ventilator clogs, pressure inside the crankcase increases and oil may leak, so clog
of filter is detected by crankcase pressure sensor.
• There are two types of filters that differ by the filter replacement method; the top load type (removed
upward) and the bottom load type (removed downward).
• Warmed engine coolant is conducted to the locations that pose potential problem of freezing to prevent it
from happening.
140E-6 SERIES 10-29

KCCV ventilator
Operation (ENG140-A18H-044-K-00-A)
• Blowby gas enters from (A). The larger drops of oil mist are removed from the blowby gas when it flows
through the impactor (7) holes in filter (5).
• Smaller drops of oil mist are removed by filter (5).
• Removed oil flows down along in the filter to oil drain port (C) and then flows to the oil pan.
• The CDR valve is operated by the negative intake pressure of the KGVT to prevent excessive negative
pressure in the crankcase.
• Crankcase pressure sensor (2) senses the blowby gas pressure (crankcase pressure).
• When the engine controller determines that the filter is clogged from crankcase pressure sensor (2)
signals, failure code CA555 is issued. If the pressure increases further, failure code CA556 is issued.
• Relief valve (6) is installed in case (3). It operates to protect the KCCV ventilator and engine when filter (5)
is blocked.
CDR valve (ENG107-A18A-041-K-00-A)
CDR: Abbreviation for Crankcase Depression Regulator
1. Diaphragm
2. Spring
A: Crankcase side
B: KVGT side (intake side)
• The CDR valve is a regulator valve which prevents excessive negative crankcase pressure (P1).
• Normally, diaphragm (1) is pushed up by spring (2) and blowby gas flows from crankcase side (A) to
KVGT side (intake side) (B).
• When intake air flow at KVGT side (intake side) (B) increases and crankcase pressure (P1) decreases,
force of spring (2) yields to ambient pressure (P2). The diaphragm shuts the passage and temporarily
blocks the flow.
• Then, when blowby gas accumulates in the crankcase and pressure (P1) recovers, the diaphragm is
pushed up again and blowby gas starts to flow again.
10-30 140E-6 SERIES

KCCV ventilator
Forming of condensed water and emulsion (ENG125-A18H-14H-K-00-A)
1. Air cleaner
2. KVGT
3. Aftercooler
4. Engine
5. Breather
6. KCCV ventilator
7. Oil pan
Outline
• If the machine is continuously operated in a low load condition at low ambient temperatures, the moisture
in the blowby gas may condense instead of evaporating away. The water will flow through KCCV ventilator
(6) to oil pan (7). The following occurs:
1. Moisture in the blowby gas condenses inside KCCV piping (A).
2. The condensed water flows through the drain circuit to the oil pan.
3. The water in the oil pan evaporates.
4. When the vapor condenses again at a relatively cool place inside the engine, it mixes with oil and forms
a milky mixture. This mixture is so-called "mayonnaise sludge"(*).
* : A mixture of oil and water, emulsified like mayonnaise (emulsion)
5. Mayonnaise sludge will deposit during low load operation when various parts in the engine are not
warmed up enough.
• Mayonnaise sludge is formed at low temperature areas that cause condensation, such as inside of
breather (B), back side of head cover (C), and dipstick (D).
140E-6 SERIES 10-31

KCCV ventilator
• Mayonnaise sludge will evaporate away as the engine is operated under load and the engine oil
temperature increases.
• Condensation water of the blowby gas in oil is harmless. However, if any engine coolant is in oil, the
engine must be checked for coolant leakage.
10-32 140E-6 SERIES

KDPF
KDPF (ENG140-A9H0-041-K-00-A)
KDPF: Abbreviation for KOMATSU Diesel Particulate Filter

1. KCSF unit
2. Aggregate connector box
3. Inlet unit
4. KDOC inlet temperature sensor
5. KDOC unit
6. KDPF differencial pressure sensor port
7. KDOC outlet temperature sensor
8. KDPF differencial pressure sensor
9. KDPF differencial pressure sensor port
10. Outlet unit
11. KDPF outlet temperature sensor
12. Hanger bracket
13. Sensor bracket
14. Sensor bracket band
15. Water drain port
A: From KVGT
B: Exhaust
C: Water drain
• The KDPF consists of the following components: inlet unit (3) to introduce exhaust gas, KDOC unit (5) that
houses an oxidation catalyst, KCSF unit (1) that houses a soot collecting filter with a catalyzer, and outlet
unit (10) that sends out exhaust gas and has a "dam" to prevent rain water from entering KCSF unit (1).
• KDOC unit (5) consists of a ceramic honeycomb coated with oxidation catalyst material. By using this
ceramic honeycomb, it performs two functions properly; One is to oxidize NO (nitrogen monoxide) in the
140E-6 SERIES 10-33

KDPF
exhaust gas into NO2 (nitrogen dioxide) and the other is to burn the fuel injected during automatic
regeneration and manual stationary regeneration (*1).
• The ceramic honeycomb is guarded by a mat made of special fiber to prevent damage caused by engine
and machine vibrations.
• The mat also prevents overheating of the KDPF outer periphery by insulating the heat generated at the
ceramic honeycomb during operation.
• The KCSF unit (1) also consists of a ceramic honeycomb coated with oxidation catalyst material, like the
KDOC unit (5). This ceramic honeycomb collects soot.
• Three temperature sensors and one differential pressure sensor (an integrated KDPF differential pressure
and KDPF outlet pressure sensor) are installed to the KDPF.
• Temperature signals from these three temperature sensors are used in combination to monitor the KDOC
and KCSF operations and to perform various troubleshootings.
• The differential pressure sensor detects the amount of soot deposited in the KCSF by sensing the
pressure difference across the KCSF. Like the temperature sensors, this sensor is also used for various
troubleshootings.
*1: Denotes to purification (oxidation) processing of soot.
k While engine is running and for some time after engine is stopped, the surface of KDPF and
nearby piping are extremely hot. Be careful not to get burned when working near the KDPF.
Function (ENG125-A9H0-042-K-00-A)
A: Flow of exhaust gas

1. KDOC(oxidation catalyzer)
2. KCSF
3. Sealing (made of ceramics)
4. Cell
5. Ceramics honeycomb
• The KDPF purifies the exhaust gas by catching most of the granulous or chain-like soot formed by the PM
(particulates in air such as soot) included in the exhaust from the engine.
• KCSF (2) is made of ceramic.
10-34 140E-6 SERIES

KDPF
• Inside the KCSF, there are many cells partitioned by ceramic walls. Cells plugged at the inlet side and
cells plugged at the outlet side are alternately arranged.
• The soot deposited in KCSF (2) are naturally oxidized and burned away by the effect of KDOC (1), in
operating conditions with relatively high exhaust gas temperatures. (This is referred to as "passive
regeneration".)
• On the other hand, when the exhaust temperature is relatively low, in conditions such as continued low
load operations, the deposit of soot in KCSF (2) increases.
• The engine controller continuously monitors the amount of deposited soot by estimating from the
operating conditions and calculating based on the KCSF differential pressure sensor signals.
• When the soot deposit exceeds a certain level, and the engine is operated with the exhaust gas
temperature exceeding a certain level, the engine controller executes "automatic regeneration" to burn
(oxidize) the soot.
• During automatic regeneration, the engine controller automatically controls the fuel injection timing and
the KVGT to raise the exhaust temperature. (This operation is called "exhaust temperature-raising
control")
• As the exhaust temperature increases, the engine controller automatically performs calculations based on
the exhaust temperature at the KDOC inlet and flow of the exhaust gas, so that KCSF (2) can efficiently
burn (oxidize) the soot.
• Fuel is injected from (fuel doser) installed to the outlet portion of turbocharger. (Fuel dosing) Fuel that is
injected into this piping mixes with exhaust gas and combusts (oxidizes) soot by the action of KDOC.
• Automatic regeneration is not performed when regeneration is executed from the machine monitor, or
when the outside air temperature is extremely low, and when the exhaust gas temperature is not high
enough to burn soot because the engine has been operated at low loads for a while. Thus, soot deposit in
the KCSF will increase.
• If the soot deposit in the KCSF exceeds a certain level, it will be necessary to perform "manual stationary
regeneration" to burn away (oxidize) the soot.
• If the soot deposit exceeds the acceptable level, the exhaust gas flow will be restricted. This can increase
fuel consumption, degrade engine combustion, or cause other problems.
• If the soot deposit exceeds the limit to safely perform "manual stationary regeneration", the KDPF fails and
replacement becomes unavoidable. Make sure to follow the procedures in the Operation and
Maintenance Manual when performing "manual stationary regeneration".
Types of soot regeneration functions (ENG125-A9H0-042-K-01-A)
a Regeneration refers to a new function used for purifying (oxidizing) soot accumulated in the soot collection
filter (KCSF) inside the KDPF.
1. Passive regeneration
When the engine exhaust temperature is relatively high, the catalyst effect of the KDOC to oxidize soot will
be stronger and the soot deposit in the KCSF will be naturally burned away.
2. Active regeneration (increase of engine exhaust temperature + fuel dosing)
1) Automatic regeneration
This is the regeneration process started automatically when the soot deposit exceeds a certain level.
At this time, the engine controller performs the exhaust temperature-raising control mode (*1) and fuel
dosing (*2). Another type of automatic regeneration is performed by the engine controller at certain
intervals, regardless of the amount of soot deposited in the KCSF. (= time-dependent regeneration)
*1: The fuel injection timing and the KVGT are controlled to raise the exhaust temperature.
*2: Fuel is injected to increase the exhaust temperature and accelerate the regeneration process. No.
1, 2, and 3 injectors are used for fuel dosing to increase exhaust gas temperature by approx. 100 deg.
by applying the load to KVGT. This is called "thermal mode".
2) Manual stationary regeneration (*3)
When the exhaust temperature does not reach a certain level due to the machine operating condition,
or when regeneration is disabled by the operator, automatic regeneration will not be performed and the
soot deposit in the KCSF may increase. In such conditions, the machine monitor displays a manual
stationary regeneration request, action level [L01], on the screen. The operator must perform
regeneration by operating the machine monitor on its screen. A regeneration feature is also provided
for the technician who should use this feature from the machine monitor menu after engine controller
replacement, KDPF replacement, and KCSF ash cleaning. (=Regeneration for service (*2)
• A KDPF drying feature is provided to prevent excessive accumulation of unburned fuel in the KDPF
when the machine is operated for a long time with low exhaust temperature.
140E-6 SERIES 10-35

KDPF
• When certain conditions are met, the engine controller automatically switches control to increase
the exhaust temperature to dry the KCSF. If some of the conditions for automatic drying are not met,
manual stationary regeneration may be requested.
a Follow the procedures in the Operation and Maintenance Manual when starting and stopping
KDPF regeneration.
a Be sure to use ultra-low-sulfur diesel fuel. Non-specified fuels may cause KDPF failure.
a Be sure to use the specified Komatsu genuine oil for the KDPF. Non-specified oils may cause
KDPF clogging in a short time, resulting in increased fuel consumption or KDPF failure.
a Do not modify the KDPF itself or exhaust pipes. Modifications disturb normal operation of the
KDPF, leading to a failure.
a Do not apply impacts to the KDPF by stepping on, dropping, or striking it. The KDPF contains a
ceramic honeycomb, which can be damaged by strong impacts.
a The engine controller performs automatic regeneration even when the amount of soot deposit is
low. Since this is programmed to maintain the KDPF performance, this is normal.
a During automatic regeneration and manual stationary regeneration, the KVGT automatically
operates and the engine sound changes. The flow of exhaust gas through the KDPF changes
and the exhaust sound changes, but this is normal.
a During automatic regeneration and manual stationary regeneration, especially at low
temperatures, white smoke may come out from the exhaust pipe for a short time, but this is
normal. Be sure to perform regeneration at a well ventilated place since carbon monoxide can
be produced.
a During automatic regeneration and manual stationary regeneration, a strange odor may be
smelled from the exhaust pipe, but this is normal.
a During automatic regeneration and manual stationary regeneration, the exhaust temperature at
the exhaust pipe can exceed 650 °C. Make sure that there is no flammable material near the
exhaust system to prevent fire. Make sure that nobody is standing in front of the exhaust pipe,
and pay sufficient attention to safety of the environment.
a KDPF temperature values are shown below for reference.
KDOC_Out (KDOC
KDOC_In (KDOC inlet KDPF_Out (KDPF outlet
outlet temperature
temperature sensor) temperature sensor)
sensor)
Not regenerating (idling) 100 to 250 °C
Regenerating (under
exhaust temperature-raising 100 to 250 °C 400 to 550 °C
control: 1,000 rpm)
10-36 140E-6 SERIES

Cylinder head
Engine main body parts (ENG107-R402-001-K-00-A)
Cylinder head (ENG140-A100-041-K-00-A)
The shape is subject to change depending the machine model.
1. Cylinder head bolt

2. Air bleeding pipe from coolant
3. Fuel spill pipe
4. Cylinder head
5. Cylinder head cover
6. Valve guide
7. Valve seat insert
8. Injector
A: Intake air
B: Exhaust gas
C: To fuel tank
140E-6 SERIES 10-37

Cylinder head
D: To radiator
Cylinder head
• Direct injection type
• 4-valve type
• Split-type 1-cylinder, 1-head
• Centralized cooling system for valve bridge and injector
• Cylinder head bolt: Plastic-region tightening
Valve seat
• Valve seat inserts are press fitted to both intake and exhaust valves
Rocker cover
• O-ring seal
Injector
• Dry type (without sleeve)
10-38 140E-6 SERIES

Cylinder block
Cylinder block (ENG140-A300-041-K-00-A)
1. Cylinder block
2. Cylinder liner
3. Thrust bearing metal
4. Main bearing metal
5. Main bearing metal cap
6. Main bearing metal cap bolt
7. Front cover
8. Front oil seal
9. Liner ring (Silicon rubber)
10. Liner ring (Ethylene-propylene rubber)
11. Clevis seal
12. Piston cooling nozzle
140E-6 SERIES 10-39

Cylinder block
Cylinder block
• Crankshaft section: 7 bearings
• Camshaft section: 7 bearings
• Main cap bolt: Plastic-region tightening
Front oil seal

• Single lip with dust seal
(Lay-down seal)
Piston cooling
• With piston cooling nozzle (1 pieces for each cylinder)
Cylinder liner
• Wet type
• Machining on inside: Plateau honing soft nitriding process
Liner ring
• Upper: Clevis seal
• Middle: O-ring (Ethylene-propylene rubber)
• Lower: O-ring (Silicone rubber)
10-40 140E-6 SERIES

Main moving parts
Main moving parts (ENG140-R403-001-K-00-A)
1. Piston (FCD piston)

2. Connecting rod bushing
3. Piston pin
4. Crankshaft
5. Crank gear (Number of teeth: 36)
6. Connecting rod cap
7. Connecting rod bearing metal
8. Connecting rod
9. Connecting rod cap bolt
10. Top ring
11. Second ring
12. Oil ring
140E-6 SERIES 10-41

Main moving parts
Specifications (ENG140-R403-030-K-00-A)
Crankshaft
• Closed die forging
• Journal, fillet induction hardening
Piston
• Special thin ductile cast iron (FCD piston)
Connecting rod lubricating oil hole: Made
Piston cooling from connecting rod end: Applied
Features of FCD piston
• The FCD piston has high heat resistance.
• The FCD piston has low thermal expansion factor and the clearance between the liner and it can be
reduced.
• Since the FCD piston has high strength, the top ring can be installed to a higher place, and the loss area
of the combustion chamber can be reduced.
• The exhaust sound is low and the exhaust gas color is better.
• The output can be heightened.
Piston ring
10-42 140E-6 SERIES

Main moving parts
Top ring (1): Double-side keystone, inner cut, barrel face, nitrided
Second ring (2): Keystone, inner cut, taper face, hard chromium-plated
Oil ring (3): With coil expander and nitrided surface
140E-6 SERIES 10-43

Timing gear
Timing gear (ENG140-A5A0-041-K-00-A)
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. Fuel supply pump drive gear (Number of teeth: 48)
7. EGR oil pump drive gear (Number of teeth: 22)
8. Crank gear (Number of teeth: 36)
9. Oil pump drive gear (Number of teeth: 20)
A,B,C: Timing mark
10-44 140E-6 SERIES

Front cover
Front cover (ENG140-A5B2-041-K-00-A)
1. Water pump mounting hole

2. Front cover
140E-6 SERIES 10-45

Valve system
Valve system (ENG140-A700-041-K-00-A)
A: Lubricating oil inlet

1. Cam gear (Number of teeth: 48)
2. Thrust plate
10-46 140E-6 SERIES

Valve system
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
Valve timing
Camshaft: Drawn steel bar (Turning)

Journal and cam sections: Induction hardening
140E-6 SERIES 10-47

Flywheel and flywheel housing
Flywheel and flywheel housing (ENG140-A560-041-K-00-A)

1. Rear seal
2. Ring gear
3. Flywheel
4. Flywheel housing
5. Engine speed sensor (NE sensor for engine control)
Number of teeth of ring gear Number of internal teeth of flywheel

148 –
10-48 140E-6 SERIES

Lubrication system parts layout drawing
Lubrication system (ENG107-AB00-001-K-00-A)
Lubrication system parts layout drawing (ENG140-AB00-04D-K-00-A)
1. EGR valve
2. Engine oil pan
3. KVGT
4. Engine oil filter
5. Boost pump
140E-6 SERIES 10-49

Lubrication system diagram
Lubrication system diagram (ENG140-AB00-052-K-00-A)
1. Strainer
2. Oil pump
3. Relief valve
4. Oil cooler
5. Oil filter
6. Safety valve
7. Lubrication of KVGT
8. Lubrication of main gallery
9. Lubrication of each bearing
10. Boost pump
11. Regulator valve
12. KVGT
13. EGR valve
16. Piston cooling gallery
17. Lubrication of piston
18. Oil pan
10-50 140E-6 SERIES

Oil pump
Oil pump (ENG140-AB50-041-K-00-A)

A: From oil pan
B: To oil cooler
C: Rotation direction
D: Pump mounting face
1. Pump cover
2. Drive gear
3. Pump body
4. Pump drive gear (Number of teeth: 20)
5. Driven gear
6. Main relief valve
7. Main valve spring
8. Sub relief valve
140E-6 SERIES 10-51

Oil pump
9. Sub valve spring

Specifications (ENG140-AB50-030-K-00-A)
Oil pump
• Type: Gear pump
• Speed: Engine speed × 1.8
Main relief valve

• Cracking pressure: 600 ± 50 kPa {6.0 ± 0.5 kg/cm2 }
Sub-relief valve
• Cracking pressure: 1,000 ± 50 kPa {10.0 ± 0.5 kg/cm2 }
Function (ENG140-AB50-042-K-00-A)
• The oil pump feeds engine oil which lubricates the inside of the engine.
10-52 140E-6 SERIES

Boost oil pump
Boost oil pump (ENG140-A9N0-041-K-00-A)

A: From main gallery
B: To EGR valve and bypass valve
1. Pump cover
2. Drive gear
3. Pump body
4. Driven gear
5. Pump drive gear (Number of teeth: 22)
6. Main relief valve
7. Main valve spring
140E-6 SERIES 10-53

Boost oil pump
Specifications (ENG140-A9N0-030-K-00-A)
Oil pump
• Type: Gear pump
• Speed: Engine speed × 1.09
Main relief valve

• Cracking pressure: 1,430 ± 100 kPa {14.6 ± 1.0 kg/cm2 }
Function (ENG140-A9N0-042-K-00-A)
• The boost oil pump feeds engine oil which drives the EGR valve and the KVGT.
• The pump is installed between the main gallery to EGR valve and KVGT circuit.
• The pump feeds oil pressure to the EGR valve drive, EGR valve control, KVGT drive, and KVGT control
circuits.
10-54 140E-6 SERIES

Oil filter
Oil filter (ENG140-ABC0-041-K-00-A)

A: Oil inlet
B: Oil outlet
1. Safety valve
2. Filter head
3. Cartridge
Specifications (ENG140-ABC0-030-K-00-A)
Oil filter
Filtration area: 0.44 m2 (Full flow)
Safety valve
Cracking pressure: 343 ± 19.6 kPa {3.5 ± 0.2 kg/cm2 }
140E-6 SERIES 10-55

Oil cooler
Oil cooler (ENG140-B810-041-K-00-A)

A: Oil inlet
B: Oil outlet
C: Coolant inlet
1. Oil cooler cover
2. Cooler element (SAA6D140E-6: 15 layers)
3. Thermo-valve
4. Thermo-valve spring
10-56 140E-6 SERIES

Oil cooler
5. Thermo-valve cover
Specifications (ENG140-B810-030-K-00-A)
Oil cooler
• Heat dissipation surface area
SAA6D140E-6: 1.23 m2
• Heat exchange rate
SAA6D140E-6: Min. 39,800 kcal/h
140E-6 SERIES 10-57

Oil cooler thermo-valve
Oil cooler thermo-valve (ENG140-B810-041-K-01-A)
1. Pellet
2. Piston
3. Valve
4. Spring
5. Case
6. Washer
7. Ring
Specifications (ENG140-B810-030-K-01-A)
Cracking temperature: 85 ± 2 °C
Full opening temperature: 91 ± 2 °C
Full opening lift: Min. 7 mm
Function (ENG125-B810-042-K-00-A)
This valve is installed in oil cooler. It opens when oil reaches a specified temperature to bypass oil.
10-58 140E-6 SERIES

Oil pan
Oil pan (ENG140-AB20-041-K-00-A)
1. Oil pan
2. Oil level sensor
3. Dipstick
140E-6 SERIES 10-59

Fuel system parts layout drawing
Fuel system (ENG107-AD00-001-K-00-A)
Fuel system parts layout drawing (ENG140-AD00-04D-K-00-A)
10-60 140E-6 SERIES

Fuel system parts layout drawing
1. Injector
2. Pressure limiter valve
3. Common rail
4. High-pressure pipe
5. Pre-fuel filter
6. Main filter
7. Feed pump
8. Supply pump
140E-6 SERIES 10-61

Fuel system circuit diagram
Fuel system circuit diagram (ENG140-AD00-052-K-00-A)
1. NE speed sensor
3. Injector
4. Fuel tank
5. Pre-fuel filter
6. Main fuel filter
7. Overflow valve
8. Supply pump
8A. PCV
8B. High-pressure pump
8C. Priming pump (sub)
8D. Feed pump
8E. Relief valve
10-62 140E-6 SERIES

8F. Bkup speed sensor (G sensor)

9. Common rail
10. High-pressure injection pipe
11. Flow damper
12. Pressure limiter
13. Fuel feed pump
14. Engine controller cooler
15. Fuel doser solenoid valve assembly
15A. Fuel doser solenoid valve 1
15B. Fuel doser solenoid valve 2
15C. Doser fuel pressure sensor
16. Fuel doser
17. Relief valve
Operation (ENG125-AD00-044-K-00-A)
• The fuel system is of an electronically controlled high pressure common rail type. The high-pressure
common rail system consists of four main components.
• They are feed pump (low-pressure fuel pump), supply pump (high-pressure fuel pump) (2), common rail
(4) and injector (3).
• The fuel system uses injectors (3) driven by solenoids.
• The engine controller (EC) controls the solenoid in each injector (3) to control the fuel supply and timing to
the injector (3).
• By controlling the solenoids electronically, the flow and timing are precisely controlled.
2. Supply pump
3. Injector
4. Common rail
EC: Engine controller
PS: Common rail pressure sensor
• Supply pump (2) feeds high-pressure fuel to common rail (4). High-pressure fuel is stored in common rail
(4).
• Engine controller (EC) controls the solenoid in each injector (3) to control the fuel supply and timing to the
injector (3).
• Fuel flows to fuel feed pump through pre-filter with water separator.
• Fuel is discharged from fuel feed pump, filtrated at main filter and then enters supply pump (2).
• Fuel in supply pump (2) is pressurized to a high pressure by two plungers.
• Common rail (4) accumulates fuel and works as a fuel manifold when distributing fuel to supply line of
each injector (3).
• By using common rail pressure sensor (PS) in common rail (4), engine controller (EC) monitors pressure
supplied from supply pump (2) to common rail (4).
• The pressure detected by common rail pressure sensor (PS) is used by engine controller (EC) to regulate
the fuel pressure from supply pump (2).
140E-6 SERIES 10-63

• Pressure limiter (common rail pressure relief) is installed in common rail (4).
• Pressure limiter is a safety valve that relieves common rail pressure if it exceeds the predetermined
threshold value.
• Fuel that is relieved by pressure limiter returns to fuel tank through fuel return circuit connected to
common rail (4).
• High-pressure fuel flows to the side of injector (3) and is injected when solenoid is energized and internal
needle is raised.
• In active regeneration by KDPF, fuel doser supplies fuel to piping to increase exhaust gas temperature at
KDOC.
10-64 140E-6 SERIES

Fuel system
Outline of CRI system (ENG125-AD00-04A-K-00-A)
Outline
• The CRI system detects the condition of the engine (engine speed, accelerator throttle position, coolant
temperature, etc.) with sensors.
• 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.
• The CRI system has a self-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.
• In addition, the CRI system has a fail-safe function which stops the engine when a certain parts fail and a
backup function which continues the operation by changing the control method in such a case.
Configuration
• The CRI system is divided by the function into the fuel system and control system.
Fuel system (ENG125-AD00-042-K-00-A)
• The fuel system distributes the high-pressure fuel supplied by the supply pump to the cylinders through
the common rail.
• The solenoid valve in the injector opens and closes the nozzle needle valve to start and finish injection.
140E-6 SERIES 10-65

Various controls
Various controls (ENG125-AP00-042-K-01-A)
• The CRI system controls the fuel injection rate and fuel injection timing more properly than the mechanical
governor or timer of the conventional fuel injection pump.
• For the control of the system, calculations necessary to the engine controller are performed from the
signals sent from the sensors installed to the engine and machine.
• The energizing timing and duration of the injector are so controlled that the optimum quantity of fuel will be
injected in the optimum timing.
10-66 140E-6 SERIES

Various controls
1. Fuel injection rate control function (ENG125-AG12-042-K-00-A)
• The fuel injection rate control function, which replaces the function of the conventional governor, controls
the fuel injection rate to an optimum one according to the signals of engine speed and accelerator throttle
position.
2. Fuel injection timing control function (ENG125-AG13-042-K-00-A)
• The fuel injection timing control function, which replaces the conventional timer function, controls the fuel
injection timing to an optimum one according to the signals of engine speed and fuel injection rate.
3. Fuel injection pressure control function (ENG125-AG14-042-K-00-A)
(Common rail fuel pressure control function)
• The fuel injection control function (common rail fuel pressure control function) controls the fuel delivery
rate of the supply pump by measuring the fuel pressure using the common rail fuel pressure sensor and
feeding it back to the engine controller.
• This function performs pressure feedback control so that the fuel injection pressure will be the same as the
optimum value (command value) set according to the engine speed and fuel injection rate.
140E-6 SERIES 10-67

Structure and operation of CRI system
Structure and operation of CRI system (ENG125-AD00-040-K-00-A)
• The CRI system consists of the fuel supply pump, common rail, injector, engine controller to control them,
and sensors.
• The fuel supply pump generates common rail fuel pressure. The fuel pressure is controlled by the fuel
delivery rate of the supply pump.
• The delivery rate is controlled by turning on and off the PCV (pressure control valve) of the fuel supply
pump according to the electric signals from the engine controller.
• The common rail receives the pressurized fuel from the fuel supply pump and distributes it to the cylinders.
• The fuel pressure is sensed by the common rail fuel pressure sensor installed to the common rail.
• A feedback control is applied so that the actual fuel pressure will match to the command pressure set
according to the engine speed and the load on the engine.
• The fuel pressure in the common rail is applied to the nozzle side of the injector and to the control
chamber through the fuel injection pipe of each cylinder.
• The injector controls the fuel injection rate and fuel injection timing by turning ON and OFF the TWV (2-
way solenoid valve).
• When the TWV is turned ON (energized), the fuel circuit is so changed that the high-pressure fuel in the
control chamber will flow through the orifice. As a result, the needle valve is raised to start fuel injection by
the nozzle cracking pressure of the high-pressure fuel on the nozzle side.
• When the TWV is turned OFF (de-energized), the fuel circuit is so changed that the high-pressure fuel will
be applied to the control chamber through the orifice. As a result, the needle valve lowers and finishes fuel
injection.
• Accordingly, the fuel injection timing and fuel injection rate are controlled respectively by the timing to turn
ON the TWV and the length of the turn-on time of the TWV.
10-68 140E-6 SERIES

Structure and operation of component parts
Structure and operation of component parts (ENG125-AD00-001-K-01-A)
Supply pump (ENG140-AD70-041-K-00-A)
1. 3-head cam
2. Overflow valve
3. Drive gear
4. No.1 high-pressure pump
5. PCV (pressure control valve)
6. No.2 high-pressure pump
7. Priming pump
8. Feed pump
9. Gear for Bkup speed sensor (G sensor)
Function (ENG125-AD70-042-K-00-A)
Outline
• The supply pump consists of priming pump (7), feed pump (8) and high-pressure pumps (4) and (6).
• The function of the supply pump is to generate common rail fuel pressure by controlling the fuel delivery.
Structure
• High-pressure pumps (4) and (6) have the pressure feed systems similar to those of the conventional in-
line fuel injection pump and the PCVs (pressure control valves) for each cylinder to control the fuel
delivery.
• By employing the 3-head cam (1), the necessary number of the cylinders of high-pressure pumps (4) and
(6) is reduced to 1/3 of the engine cylinders.
• Since the frequency of feeding fuel to the common rail is the same as that of fuel injection, the common rail
fuel pressure is smooth and stable.
• The fuel fed by high-pressure pumps (4) and (6) to the common rail is categorized as follows.
• No.1 high-pressure pump (on the drive gear side) (4) compensates for drop in the common rail fuel
pressure caused by fuel injection into the No.1, 3 and 5 cylinders.
140E-6 SERIES 10-69

• No.2 high-pressure pump (on the feed pump side) (6) compensates for drop in the common rail fuel
pressure caused by fuel injection into the No.2, 4 and 6 cylinders.
Operation (ENG125-AD70-044-K-00-A)
• (A): During the lowering stroke of the plunger, the PCV is open and the low-pressure fuel is sucked in the
plunger chamber through the PCV.
• (B): While the PCV is not energized and is open after the plunger starts the rising stroke, the sucked fuel is
returned through the PCV without being pressurized.
• (C): If the PCV is energized and closed in the timing for the necessary delivery, the return passage is
closed and the pressure in the plunger chamber rises. Accordingly, the fuel is fed through the delivery
valve (check valve) to the common rail. That is, the quantity of the fuel corresponding to the plunger lift
after the PCV is closed is the delivery. The delivery is changed and the common rail fuel pressure is
controlled by changing the opening timing (pre-stroke of plunger) of the PCV.
• (D): After the cam passes the maximum lift point, the plunger starts the lowering stroke and the pressure in
it decreases. 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, namely the state of (A) starts again.
PCV (pre-stroke control valve)

• The PCV adjusts the fuel delivery from the supply pump to adjust the common rail fuel pressure. The
delivery from the supply pump to the common rail is decided by the timing of energizing the PCV.
10-70 140E-6 SERIES

Feed pump
• The feed pump built in the supply pump assembly sucks up the fuel from the fuel tank and sends it to the
high-pressure pump chamber through the fuel filter.
• The feed pump is driven by the camshaft. Its outer and inner rotors start rotating when driven.
• 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-6 SERIES 10-71

Common rail (ENG125-AE21-041-K-00-A)

Structure
• Common rail (4) distributes the high-pressure fuel generated on high-pressure pump to the injectors of the
cylinders.
• Common rail (4) is equipped with common rail fuel pressure sensor (2), flow damper (1) and pressure
limiter (3).
• The fuel injection pipes are connected to flow dampers (1) to send the high-pressure fuel to the injectors.
• The piping of pressure limiter (3) is returned to the fuel tank.
Flow damper (ENG125-AE23-042-K-00-A)

Function
• The flow dampers reduce the pressure pulses in the high-pressure piping and supply the fuel to the
injectors with stable pressure.
• If excessive fuel flows out, the flow dampers block the fuel passage to prevent abnormal outflow of the
fuel.
• 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 flow of fuel.
10-72 140E-6 SERIES

Operation (ENG140-AE23-044-K-00-A)
When fuel is not injected

• Piston (2) is in contact with stopper (1). (Initial position)
• The fuel for static leakage is supplied through the clearance between orifice (a) of piston (2) and sliding
portion.
When fuel is injected

• Piston (2) compresses spring (3) with pressure of fuel and moves to the right.
• The fuel for dynamic leakage is supplied through the clearance between orifice (a) of piston (2) and sliding
portion.
When fuel is stopped

• If the fuel flows out abnormally because of a burst of the piping, etc., piston (2) moves to the right stroke
end.
• The end of piston (2) touches seat (b) to stop the flow of fuel.
• Once the fuel is stopped, piston (2) does not return to the initial position until the engine is stopped.
Pressure limiter
• If abnormally high pressure is generated, the pressure limiter opens to release that pressure.
• If the common rail fuel pressure reaches about 241 MPa {2,458 kg/cm 2} the pressure limiter operates
(opens).
• If the common rail fuel pressure lowers to 30 MPa {310 kg/cm 2}, the pressure limiter resets itself (closes)
to maintain the pressure.
• Under the normal condition, the pressure limiter does not reset itself (close) until the engine is stopped.
140E-6 SERIES 10-73

1. Ball
2. Housing
3. Spring
4. Body
5. Guide
Common rail fuel pressure sensor
• The common rail fuel pressure sensor is installed to the common rail to sense the fuel pressure.
• This sensor is a semiconductor pressure sensor, which utilizes the phenomenon that the electric
resistance of silicon changes according to pressure applied to it.
10-74 140E-6 SERIES

Injector (ENG125-AE60-04A-K-00-A)
Function (ENG125-AE60-042-K-00-A)
• 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 optimum timing, by the optimum quantity, at the optimum injection rate, and
under the optimum spray condition while referencing signals from engine controller.
• The TWV (2-way solenoid valve) controls the start and finish of fuel injection by controlling the pressure in
the control chamber.
• The orifice restricts the nozzle valve opening speed to control the fuel injection rate.
• The hydraulic piston transmits the force generated by the pressure in the control chamber to the needle
valve of the nozzle.
• The nozzle has the function of atomizing fuel.
140E-6 SERIES 10-75

Structure (ENG125-AE60-041-K-00-A)
1. Inlet connector
2. Terminal
3. Upper body
4. Solenoid
5. Valve body
6. Orifice (OUT)
7. Orifice (IN)
8. Pressure control chamber
9. Control piston
10. Spring
11. Pressure pin
12. Nozzle assembly
13. QR code tab
10-76 140E-6 SERIES

• The injector consists of the traditional nozzle section, orifice to control the fuel injection rate, hydraulic
piston, and 2-way solenoid valve.
A: When fuel is not injected

B: When fuel injection is started
C: When fuel injection is finished
D: From common rail
1. Nozzle
2. Control piston
3. Orifice (IN)
4. Orifice (OUT)
5. Valve body
6. Solenoid
7. Spring
8. Pressure control chamber
Operation (ENG125-AE60-044-K-00-A)
1) When fuel is not injected (A)

• When solenoid (6) is not energized, valve body (5) is pushed down by spring (7).
• Since the high-pressure fuel is applied from the common rail to pressure control chamber (8), nozzle (1) is
closed and the fuel is not injected.
2) When fuel injection is started (B)

• When solenoid (6) is energized, valve body (5) is pulled up by the electromagnetic force and the fuel
passage opens.
• Since the fuel in pressure control chamber (8) flows out through orifices (3) and (4), nozzle (1) rises and
fuel injection pump starts.
• The fuel injection rate is gradually increased by the function of orifices (3) and (4).
• If energization of solenoid (6) is continued, injection rate is set to the maximum.
140E-6 SERIES 10-77

3) When fuel injection is finished (C)

• When solenoid (6) is de-energized, valve body (5) is lowered by spring (7) and the fuel passage is closed.
• At this time, the high-pressure fuel in the common rail is applied to pressure control chamber (8) suddenly
and nozzle (1) is closed quickly, fuel injection is finished sharply.
10-78 140E-6 SERIES

Dozing piping drawing
Fuel dozing (ENG125-A9H6-001-K-00-A)
Dozing piping drawing (ENG140-A9H6-04D-K-00-A)
1. Fuel doser solenoid valve 2

2. Fuel doser
3. Doser fuel pressure sensor
5. Fuel feed pump
Outline (ENG125-A9H6-04A-K-00-A)
• In active regeneration by KDPF, the fuel doser supplies exhaust piping to increase the exhaust gas
temperature at KDOC.
• The fuel, which is pressurized by the electrical fuel feed pump, is fed to the fuel doser since fuel doser
solenoid valve 1 opens during active regeneration.
• When active regeneration is finished, fuel doser solenoid valve 1 closes, stopping fuel supply. And at the
same time, the remaining pressure is discharged because the fuel doser solenoid valve 2 opens at this
point.
140E-6 SERIES 10-79

Fuel doser (ENG125-A9H6-042-K-00-A)
1. Fuel doser
A: Fuel inlet
B: Coolant inlet
C: Coolant outlet
• The engine controller calculates volume of the fuel to be injected by fuel doser (1) necessary to procure
appropriate KDOC outlet temperature.
• The engine controller drives fuel doser (1) in order to have injection of the calculated volume of fuel by
controlling PWM according to the pressure detected by the doser fuel pressure sensor.
Fuel doser solenoid valve and doser fuel pressure sensor (ENG125-A9JE-042-K-00-A)

3. Doser fuel pressure sensor
A: Fuel inlet
B: Fuel outlet (to fuel doser)
10-80 140E-6 SERIES

C: Fuel outlet (drain)

• The fuel doser solenoid valves (1) and (2) are assembled with doser fuel pressure sensor (3) as fuel doser
solenoid valve.
• Mesh filter is installed to fuel inlet (A) of the fuel doser solenoid valve assembly.
• Doser fuel pressure sensor (3) measures pressure of fuel supplied to the fuel doser.
• When active regeneration is finished, fuel doser solenoid valve (1) closes, stopping fuel supply. And at the
same time, the remaining pressure is drained because the fuel doser solenoid valve (2) opens at this
point.
140E-6 SERIES 10-81

Pre-filter
Pre-filter (ENG125-AEA0-041-K-00-A)

A: Fuel inlet
B: Fuel outlet
1. Air bleeding plug
2. Filter head
3. Cartridge
Specifications (ENG125-AEA0-030-K-00-A)
Filtration area: 1.0 m2
10-82 140E-6 SERIES

Main filter
Main filter (ENG125-AED0-041-K-00-A)

A: Fuel inlet
B: Fuel outlet
1. Air bleeding plug
2. Filter head
3. Cartridge
Specifications (ENG125-AED0-030-K-00-A)
Filtration area: 1.0 m2
140E-6 SERIES 10-83

Cooling system parts layout drawing
Cooling system (ENG107-B110-001-K-00-A)
Cooling system parts layout drawing (ENG140-B110-04D-K-00-A)
1. KVGT
2. EGR cooler
3. Water pump
4. Oil cooler
A: From radiator
B: To radiator
10-84 140E-6 SERIES

Cooling system circuit diagram
Cooling system circuit diagram (ENG140-B110-052-K-00-A)
1. Radiator
2. Thermostat
3. Cylinder head
4. KVGT
5. EGR cooler
6. Cylinder block
7. Engine oil cooler
8. Water pump
9. Water manifold
10. Coolant temperature sensor
11. Fuel dozer
12. KCCV
a: Flow when thermostat is open
b: Flow when thermostat is closed
140E-6 SERIES 10-85

Water pump
Water pump (ENG140-BA10-041-K-00-A)

A: From radiator
B: To oil cooler
D: Pump mounting face
1. Oil seal
2. Ball bearing
3. Pump shaft
10-86 140E-6 SERIES

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

5. Pump body
6. Water seal
7. Impeller
8. Pump cover
Specifications (ENG140-BA10-030-K-00-A)
Type: Centrifugal type driven with gear

Speed: Engine speed × 1.56
Delivery: 785 l/min
Total head : Min. 18.5 m
140E-6 SERIES 10-87

Thermostat
Thermostat (ENG140-BA30-041-K-00-A)
1. Thermostat
2. Thermostat housing
a: To radiator
b: To water pump
Specifications (ENG125-BA30-030-K-00-A)
• Cracking temperature: 76.5 ± 2 ℃

• Full opening temperature: 90 °C
• Valve lift: Min. 9 mm
Operation (ENG125-BA30-044-K-00-A)
When coolant is cool (when valve is closed)
When the coolant temperature is lower than the valve opening temperature of the thermostat, valve (1) is
closed. As a result, coolant (C) from cylinder block and cylinder head flows to water pump (A) without flowing
to radiator.
10-88 140E-6 SERIES

Thermostat
When coolant is warm (when valve is open)

As the coolant temperature reaches valve opening temperature, expansion action of heat sensing part (2)
opens valve (1) and coolant (C) flows to radiator (B).
140E-6 SERIES 10-89

Alternator
Electrical equipment (ENG107-AK50-001-K-00-A)
Alternator (ENG125-AKK0-041-K-00-A)
Alternator with built-in regulator (Open type, 60 A) (ENG125-AKK0-041-K-02-A)

1. Alternator
2. Alternator pulley
3. Terminal B
4. Terminal R
5. Terminal E
6. Internal electrical circuit diagram
6A. Initial energizing resistor
6B. Regulator
6C. Field coil
10-90 140E-6 SERIES

Alternator
Specifications (ENG140-AKK0-030-K-00-A)
Pulley
Specifica- Num- Outside Weight
Engine Machine model Type
tions ber of diameter (kg)
stage (mm)
Open type (brushless),
SAA6D140- HM400-3, D155AX-7 manufactured by Nikko 24 V, 60
8 80 11
E-6 Electric Industry A
Alternator with built-in regulator (Open type, 90 A) (ENG140-AKK0-041-K-00-A)

1. Alternator
2. Alternator pulley
3. Terminal B
4. Terminal E
5. Terminal R
6. Internal electrical circuit diagram
6A. Initial energizing resistor
6B. Regulator
6C. Field coil
140E-6 SERIES 10-91

Alternator
Specifications (ENG140-AKK0-030-K-01-A)
Pulley
Specifica- Num- Outside Weight
Engine Machine model Type
tions ber of diameter (kg)
stage (mm)
Open type (brushless),
SAA6D140- HM400-3, D155AX-7, manufactured by Nikko 24 V, 90A 8 85 19
E-6 WA500-7 Electric Industry
10-92 140E-6 SERIES

Alternator mounting
Alternator mounting (ENG140-AKN0-041-K-00-A)

1. Tensioner
2. Alternator
3. Compressor
4. Alternator drive belt
5. Crankshaft pulley
140E-6 SERIES 10-93

Starting motor
Starting motor (ENG-AK70-001-K-00-A)
With built-in safety relay (11 kW) (ENG125-AK70-041-K-01-A)

1. Pinion gear
2. Starting motor (body)
3. Magnetic switch
4. External electrical circuit diagram
4A. Safety relay
10-94 140E-6 SERIES

Starting motor
4B. Starting motor

5. Connector specifications
Type A: 2P connector (male)
B, C, R, S, E: Each terminal
Specifications (ENG140-AK70-030-K-00-A)
Machine Specifica- Number of Connector

Engine Type Weight (kg)
model tions pinion teeth type
HM400-3, Water-proof, oil-proof
SAA6D140E- type, manufactured by 24 V,11 kW
D155A-7, 12 18 A
6 Nikko Electric Industry
WA500-7
140E-6 SERIES 10-95

Fuel feed pump
Fuel feed pump (PC400-AEH0-041-K-00-A)
1. Body
2. Rubber
3. Bracket
4. Connector
A. Fuel inlet
B. Fuel outlet
Function (PC400-AEH0-042-K-00-A)
Operates according to the control by the engine controller or timer of the fuel feed pump switch for the
following purposes.
• Increases the fuel pressure in the fuel dosing process. (Control by engine controller)
• Bleed air from the fuel route (engine side). (Control by timer of fuel feed pump switch)
10-96 140E-6 SERIES

Fuel feed pump switch
Fuel feed pump switch (PC400-AEH5-041-K-00-A)
1. Body
2. Toggle switch
3. LED lamp
4. Connector
Function (PC400-AEH5-042-K-00-A)
• Receives signals from the engine controller and drives the fuel feed pump.
• Drives the fuel pump by operating the toggle switch to bleed air from the fuel route after replacement of the
fuel filter etc.
• The air in the fuel route is bled by driving the fuel feed pump according to the setting of the built-in timer.
• Drive pattern of fuel feed pump:
Perform the cycle of “Drive pump (30 sec) o Stop pump (10 sec)” 10 times, and then stop automatically
140E-6 SERIES 10-97

Engine wiring harness
Engine wiring harness (ENG140-AK51-041-K-00-A)
1. Crankcase pressure sensor

2. KVGT position sensor
4. Fuel dosing pressure sensor
6. Ambient pressure sensor
7. Charge temperature sensor
8. Charge pressure sensor
9. Coolant temperature sensor
10. Ne sensor
12. Common rail pressure sensor
10-98 140E-6 SERIES

Engine wiring harness
13. Engine oil pressure sensor

14. Supply pump
15. Bkup speed sensor (G sensor)
140E-6 SERIES 10-99

Engine controller
Engine controller (PC220-AP70-041-K-00-A)
Function (ENG107-AP70-042-K-00-A)
• The engine controller CM2250, co-developed by Komatsu and Cummins, is adopted.

• It performs calculations based on input signals from various sensors to output signals for optimized engine
control.
• The engine controller shares information with other controllers on the machine through the network (CAN)
and optimally controls the engine according to the machine conditions.
• By mounting the controller on the engine, serviceability in the field is improved.
• The controller is mounted with rubber vibration isolators to reduce the effect of vibration.
10-100 140E-6 SERIES

Engine controller
Engine controller system diagram (ENG140-AP70-052-K-00-A)
Input and output signals (ENG140-AP70-03C-K-00-A)
• The following is the list of the symbols used for signal category in the input/output signal table.
A: Electric power supply
B: Input
C: Ground/Shield/Return
D: Output
E: Communication
DRC26–60P(1)[ECM J1(CN-CE01)]
Pin No. Signal name Signal category
1 (*1) –
2 Engine oil pressure sensor B
3 Crankcase pressure sensor B
4 (*1) –
5 Charge temperature sensor B
6 Intake temperature sensor B
7 CAN_C(+) E
8 CAN_B(+)(KOMNET/r) E
9 Bkup speed sensor (+) B
10 (*1) –
140E-6 SERIES 10-101

Engine controller

11 (*1) –
12 (*1) –
13 Coolant temperature sensor (-) C
14 Coolant temperature sensor (+) B
15 Charge pressure sensor B
16 Ambient pressure sensor B
17 CAN_C(-) E
18 CAN_B(-)(KOMNET/r) E
19 (*1) –
20 (*1) –
21 Sensor power supply (12 V) A
22 Mass air flow and temperature sensor (-) C
23 Mass air flow and temperature sensor (+) B
24 (*1) –
25 (*1) –
26 Ne (crankshaft) speed sensor (+) B
27 (*1) –
28 (*1) –
29 (*1) –
30 (*1) –
31 (*1) –
32 GND C
33 (*1) –
34 (*1) –
35 (*1) –
37 Ne (crankshaft) speed sensor (-) C
38 (*1) –
39 (*1) –
40 (*1) –
41 (*1) –
42 (*1) –
43 Injector #4 (+) D
49 (*1) –
50 (*1) –
51 (*1) –
52 (*1) –
53 Injector #4 (–) C
59 GND C
*1: Never connect these pins. Malfunctions or failures may occur.
10-102 140E-6 SERIES

Engine controller
DRC26–60P(2)[ECM J2(CN-CE02)]
1 Supply pump PCV2 (-) C
2 Supply pump PCV2 (+) D
3 (*1) –
4 Supply pump PCV1 (-) C
6 EGR actuator (+) D
7 (*1) –
10 KVGT actuator (+) D
11 (*1) –
12 (*1) –
13 (*1) –
14 (*1) –
15 (*1) –
16 EGR actuator (-) C
17 (*1) –
18 Fuel doser solenoid valve 1, 2 (-) C
19 (*1) –
20 KVGT actuator (-) C
21 Common rail pressure sensor (-) C
22 (*1) –
23 (*1) –
24 CAN_B (+) E
25 CAN_B (-) E
26 (*1) –
27 (*1) –
28 (*1) –
29 (*1) –
32 KVGT speed sensor (+) B
33 KVGT speed sensor (-) C
34 (*1) –
35 (*1) –
36 Doser fuel pressure sensor B
37 (*1) –
38 KVGT position sensor B
39 (*1) –
40 (*1) –
41 (*1) –
42 (*1) –
43 (*1) –
44 (*1) –
45 (*1) –
46 GND C
Dosing fuel pressure sensor, KVGT position sensor, EGR valve lift
47 sensor (-) C
48 (*1) –
49 (*1) –
50 Fuel doser (+) D
140E-6 SERIES 10-103

Engine controller

51 (*1) –
52 (*1) –
53 (*1) –
54 (*1) –
55 Common rail pressure sensor (+) B
56 (*1) –
57 (*1) –
58 (*1) –
59 EGR valve lift sensor (+) B
60 Fuel doser (-) C
DRC26–60P(3)[CN-CE03]
1 continuous power supply (24 V) A
2 continuous power supply (24 V) A
3 Starting switch ACC signal B
4 Intake air heater relay (+) D
5 (*1) –
6 (*1) –
7 (*1) –
8 (*1) –
9 System operating lamp D
10 (*1) –
11 Continuous power supply (24 V) A
12 Continuous power supply (24 V) A
13 GND C
14 Electrical fuel feed pump D
15 (*1) –
16 (*1) –
17 CAN_A (+) (KOMNET/c) E
18 CAN_A (-) (KOMNET/c) E
19 GND C
20 (*1) –
21 GND C
22 GND C
23 (*1) –
24 (*1) –
25 (*1) –
26 (*1) –
27 (*1) –
28 (*1) –
29 (*1) –
30 (*1) –
31 GND C
32 GND C
33 (*1) –
34 (*1) –
35 (*1) –
36 (*1) –
37 (*1) –
38 (*1) –
10-104 140E-6 SERIES

Engine controller

39 (*1) –
40 (*1) –
41 GND C
43 GND C
44 (*1) –
45 KDOC inlet temperature sensor B
46 (*1) –
47 (*1) –
48 KDOC outlet temperature sensor B
49 Idle validation signal 1 B
50 Idle validation signal 2 B
51 Throttle signal B
53 (*1) –
54 KDPF outlet temperature sensor B
55 KDPF differential pressure sensor B
56 (*1) –
57 (*1) –
58 KDPF outlet pressure sensor B
59 (*1) –
60 (*1) –
140E-6 SERIES 10-105

Sensor
Sensor (ALL-E700-001-P-00-A)
Sensors layout drawing (ENG140-AK50-04D-K-00-A)
List of sensors (ENG140-AK50-056-K-00-A)
No. Sensor Connector label name

1 KVGT speed sensor VGT_REV
2 KVGT position sensor SVGT
3 KDOC inlet temperature sensor TEMP1
4 KDPF differential pressure and outlet pressure sensor E25
5 Crankcase pressure sensor PCCV
10-106 140E-6 SERIES

Sensor
6 Coolant temperature sensor TWTR

7 Engine oil level sensor P44
8 Air cleaner clogging sensor E26[TOUT]
9 KDOC outlet temperature sensor TEMP2
10 KDPF outlet temperature sensor TEMP3
11 Common rail pressure sensor PFUEL
12 Ambient pressure sensor PAMB
13 Ne (crankshaft) speed sensor NE
14 Bkup (camshaft) speed sensor G
15 Engine oil pressure switch POIL
16 Mass air flow and temperature sensor MAF
17 EGR valve lift sensor SEGR
18 Charge temperature sensor TIM
19 Doser fuel pressure sensor HC
Engine oil pressure sensor (PC400-ABK5-041-K-00-A)
1. Connector
2. Sensor
3. O-ring
Function (PC400-ABK5-042-K-00-A)
• This oil pressure sensor, installed in the cylinder block, detects engine oil pressure to output variable
voltage.
KVGT speed sensor (ENG125-AAQ4-041-K-00-A)
KVGT: Abbreviation for KOMATSU Variable Geometry Turbocharger
140E-6 SERIES 10-107

Sensor
1. Sensor
2. O-ring
3. Connector
Function (ENG125-AAQ4-042-K-00-A)
• This sensor, installed to KVGT in the engine, outputs the pulse voltage by means of the rotation of KVGT
turbine.
KVGT position sensor (ENG-AAQ3-041-K-00-A)
1. O-ring (small)
2. O-ring (large)
3. Sensor
4. Connector
Function (ENG-AAQ3-042-K-00-A)
• This sensor, installed to KVGT in the engine, detects the location of the nozzle ring which is built in KVGT
to output the corresponding variable voltage.
Output characteristics
• The relation between stroke and output voltage is as shown in the following graph.
10-108 140E-6 SERIES

Sensor
Ambient pressure sensor (ENG-AAP2-041-K-00-A)
1. Connector
2. Sensor
Function (ENG-AAP2-042-K-00-A)
• This sensor, installed to the air intake cover at the engine top side, detects the ambient pressure to output
the corresponding variable voltage.
140E-6 SERIES 10-109

Sensor
Charge temperature sensor (ENG125-AAM4-041-K-00-A)
Function (ENG125-AAM4-042-K-00-A)
• The charge temperature sensor detects the intake air temperature (boost temperature) and sends it to the
engine controller.
• The thermistor is used as a sensor of which resistance changes according to the temperature. The engine
controller applies voltage to the thermistor and senses the temperature by using the voltage divided by the
resistance in the computer and the resistance of the thermistor.
Coolant temperature sensor (ENG-BA87-041-K-00-A)
1. Connector
2. Sensor
3. O-ring
Function (ENG140-BA87-042-K-00-A)
• This sensor, installed on the cylinder block of the engine, converts the temperature variation into the
resistance variation, and outputs the corresponding signals.
10-110 140E-6 SERIES

Sensor
Ne (crankshaft) speed sensor (ENG-AG42-041-K-00-A)
1. O-ring
2. Sensor
3. Connector
Function (ENG140-AG42-042-K-00-A)
• This sensor, installed to the flywheel housing, outputs the pulse voltage due to the gear rotation.
Bkup speed sensor (G sensor) (ENG125-AG62-041-K-00-A)
(cylinder sensor)
140E-6 SERIES 10-111

Sensor
Function (ENG125-AG62-042-K-00-A)
• Like the NE speed sensor, it utilizes 0 to 5 V pulses that result from the change in the magnetic lines
passing through the sensor.
• 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 deg.
• In addition to the above teeth, one more tooth is installed. Accordingly, seven pulses are generated every
two revolutions of the engine.
• The standard pulse of No. 1 cylinder is recognized by the combination of the NE speed sensor pulse and
Bkup speed sensor pulse.
Common rail pressure sensor (ENG-AE28-041-K-00-A)
1. Connector
2. Sensor
Function (ENG-AE28-042-K-00-A)
• This sensor, installed to the common rail in the engine, detects the fuel pressure to output the
corresponding variable voltage.
10-112 140E-6 SERIES

Sensor
EGR valve lift sensor (ENG125-A9S2-041-K-00-A)
1. O-ring (small)
2. O-ring (large)
3. Sensor
4. Connector
Function (ENG125-A9S2-042-K-00-A)
• This sensor, installed to EGR valve in the engine, detects the EGR valve opening to output the
• The relation between stroke and output voltage is as shown in the graph below.
140E-6 SERIES 10-113

Sensor
Mass air flow and temperature sensor (ENG-A96H-041-K-00-A)
1. Connector
2. O-ring
3. Sensor
Function (ENG-A96H-042-K-00-A)
• This sensor, installed to the outlet side of air cleaner, converts the variations of intake air flow and
temperature into the resistance variation, and outputs the corresponding signals.
a The “MAF (Mass Air Flow)“ means the “intake air flow“.
KDPF differential pressure and outlet pressure sensor (ENG-A9HL-041-K-00-A)
1. High-pressure port
2. Low-pressure port
3. Connector
4. Sensor
Function (ENG-A9HL-042-K-00-A)
• This sensor, installed to KDPF, detects the inlet pressure and outlet pressure of KDPF to output the
• The outputted pressure difference is the difference between the KDPF inlet pressure which is detected at
high-pressure port (1) and the KDPF outlet pressure which is detected at low-pressure port (2).
• The KDPF outlet pressure is outputted as a pressure which is detected at low-pressure port (2).
10-114 140E-6 SERIES

Sensor
KDOC inlet temperature sensor (ENG-A9HG-041-K-00-A)
KDOC: Abbreviation for KOMATSU Diesel Oxidation Catalyst
1. Sensor
2. Connector
Function (ENG-A9HG-042-K-00-A)
• This sensor, installed to the inlet side of KDOC which is built in KDPF, converts the temperature variation
into the resistance variation, and outputs the corresponding signals.
KDOC outlet temperature sensor (ENG-A9HH-041-K-00-A)
KDOC: Abbreviation for KOMATSU Diesel Oxidation Catalyst
1. Sensor
2. Connector
Function (ENG-A9HH-042-K-00-A)
• This sensor, installed to the outlet side of KDOC which is built in KDPF, converts the temperature variation
into the resistance variation, and outputs the corresponding signals.
KDPF outlet temperature sensor (ENG-A9HJ-041-K-00-A)
140E-6 SERIES 10-115

Sensor
1. Sensor
2. Connector
Function (ENG-A9HJ-042-K-00-A)
• This sensor, installed to the outlet side of KDPF, converts the temperature variation into the resistance
variation, and outputs the corresponding signals.
Crankcase pressure sensor (ENG-A18C-041-K-00-A)
1. Connector
2. Sensor
3. O-ring
Function (ENG-A18C-042-K-00-A)
• This sensor, installed to the inlet side of KCCV head portion, detects the crankcase pressure (blowby
pressure) to output the corresponding variable voltage.
10-116 140E-6 SERIES

Sensor
Engine oil level sensor (ENG-AB45-041-K-00-A)
1. Connector
2. Bracket
3. Float
4. Switch
Function (ENG-AB45-042-K-00-A)
• This sensor, installed on the side face of the oil pan, turns “OFF“ by the lowered float, if the oil level
becomes lower than specified.
Air cleaner clogging sensor (PC-A968-041-K-01-A)
1. Adapter
2. Hood
3. Indicator
4. Connector
Function (PC-A968-042-K-00-A)
• The sensor is installed on the air cleaner outlet side. The switch is turned to “ON“ position, if the air
cleaner is clogged and the pressure level drops to the specified level (negative pressure).
140E-6 SERIES 10-117

Sensor
Dosing fuel pressure sensor (PC400-A9JC-041-K-00-A)
1. O-ring
2. Sensor
3. Connector
Function (PC400-A9JC-042-K-00-A)
• The sensor, which is installed to the dosing fuel solenoid valve assembly, detects the pressure of the fuel
supplied to output the corresponding variable voltage.
10-118 140E-6 SERIES

SHOP MANUAL
ENGINE
140E-6 SERIES
Model Serial Number
140E-6
SERIES
20 Standard value table

4 20 Standard value table
140E-6 SERIES 20-1

Table of contents

20 Standard value table ..................................................................................................................... 20-1
Standard service value table........................................................................................................ 20-3
Standard value table for engine ............................................................................................. 20-3
Running-in standard and performance test standard ............................................................... 20-9
20-2 140E-6 SERIES

Standard value table for engine
Standard service value table (ALL-A000-001-K-00-A)
Standard value table for engine (ENG125-A000-033-K-00-A)
<Applicable machines> HM400–3 (ENG140-A000-033-K-00-A)
Performance
Engine SAA6D140E-6
Standard value
Item Measurement condition Unit for new Repair limit
machine
• Engine coolant High idle 2,200(+50 / 0) 2,200(+50 / 0)
Engine speed temperature: within rpm
operating range Low idle 725 ± 25 725 ± 25
Air intake and exhaust system

Engine SAA6D140E-6
Standard value Repair limit
Item Measurement condition Unit
for new machine
kPa
Air intake resistance Whole speed range {mmH2O}
Max. 3.73 {380} Min. 7.47 {762}
Min. 145
Boost pressure At rated horsepower (2,000 rpm) kPa {mmHg} Min. 163 {1,220}
{1,090}
Exhaust
Whole speed range (20°C) °C Max. 670 700
temperature
Engine outlet
• Engine coolant (Between
temperature: within turbocharger Bosch index – Max. 3.0
operating range and KDPF
Exhaust gas color • At torque converter inlet)
stall
KDPF outlet
• After kept for 5 sec.
at normal condition (Exhaust pipe Bosch index – Max. 0.5
outlet)
Intake valve 0.35 –
Valve clearance mm
Exhaust valve 0.57 –
EGR valve and At high idle MPa Min. 1.43 {14.6} Min. 1.43 {14.6}
KVGT drive
pressure At low idle {kg/cm2} Min. 1.18 {12.0} Min. 1.18 {12.0}
Engine itself
Engine itself SAA6D140E-6
Standard value
machine
Compression Engine oil temperature: 40 to 60°C MPa
Min. 4.1 {42} Min. 2.8 {29}
pressure Engine speed: 250 to 280 rpm {kg/cm2}
At rated horsepower kPa

Blowby pressure Max. 2.94 {300} Max. 3.92 {400}
(when KCCV is disconnected) {mmH2O}
140E-6 SERIES 20-3

Lubrication system
Engine SAA6D140E-6
Standard value
machine
At rated horsepower
Engine oil SAE5W-30LA
Min. 0.34 {3.5} Min. 0.21 {2.1}
temperature: Min. 80° SAE5W-40LA
C SAE10W- MPa
Oil pressure
At low idle 30LA {kg/cm2}
Engine oil SAE15W- Min. 0.10 {1.0} Min. 0.08 {0.8}
temperature: Min. 80° 40LA
C
Oil temperature Whole speed range (inside oil pan) °C 90 to110 120
At continuous rated horsepower
Oil consumption % Max. 0.15 0.3
(Ratio to fuel consumption)
Cooling system
Engine SAA6D140E-6
Standard value
machine
Auto-tensioner Auto-tensioner
Fan and alternator Deflection when pressed with finger
mm (automatic (automatic
belt tension force of 98 N {10 kg}
adjustment) adjustment)
20-4 140E-6 SERIES

<Applicable machines> D155AX-7 (ENG140-A000-033-K-01-A)
Performance
Engine SAA6D140E-6
Standard value
machine
• Coolant High idle 2,100 (0 / -50) 2,100 (0 / -50)
Engine speed temperature: Within rpm
operating range Low idle 740 (+25 / 0) 740 (+25 / 0)

Engine SAA6D140E-6
Standard value
machine
kPa
Max. 3.73 {380} Max. 7.47 {762}
Boost pressure
(aftercooler inlet At rated horsepower (2,000 rpm) kPa {mmHg} 118 {890} or 105 {790} or
pressure) above above
Exhaust
temperature (turbine Whole speed range (20°C) °C Max. 670 700
outlet )
• Coolant Engine outlet
temperature: Within (between
operating range turbocharger Bosch index - Max. 3.0
• When torque and KDPF
Exhaust gas color inlet)
converter is stalling
• After kept for 5 KDPF outlet
seconds at normal (exhaust pipe Bosch index - Max. 0.5
condition outlet)
Intake valve 0.35 -
Valve clearance mm
Exhaust valve 0.57 -
EGR valve and At high idle 1.43 {14.6} or 1.43 {14.6} or
MPa above above
KVGT drive oil
pressure {kg/cm2} 1.18 {12.0} or 1.18 {12.0} or
At low idle
above above
Main body
Engine SAA6D140E-6
Standard value
machine
Compression Engine oil temperature: 40 to 60 °C MPa 4.1 {42} or 2.8 {29} or
pressure Engine speed: 200 to 280 rpm {kg/cm2} above above
140E-6 SERIES 20-5

Lubrication system
Engine SAA6D140E-6
Standard value
machine
At rated horsepower
Engine oil SAE5W-30LA 0.34 {3.5} or 0.21 {2.1} or
temperature: Min. 80 ° SAE5W-40LA above above
C SAE10W- MPa
Hydraulic
Engine oil SAE15W- 0.10 {1.0} or 0.08 {0.8} or
temperature: Min. 80 ° 40LA above above
C
Engine oil
Whole speed range (inside oil pan) °C 90 to 110 120
temperature
Ratio to fuel consumption
Cooling system
Engine SAA6D140E-6
Standard value
machine
Automatic Automatic
Tension of alternator Deflection when pressed with finger mm adjustment adjustment
belt and fan force of 98 N {10 kg}
(auto-tensioner) (auto-tensioner)
20-6 140E-6 SERIES

<Applicable machines> WA500-7 (ENG140-A000-033-K-02-A)
Performance
Engine SAA6D140E-6
Standard value
machine
• Coolant High idle 2,150 ± 50 2,150 ± 50
Engine speed temperature: Within rpm
operating range Low idle 700 ± 25 700 ± 25

Engine SAA6D140E-6
Standard value
machine
kPa
Max. 3.73 {380} Max. 7.47 {762}
Boost pressure
(aftercooler inlet At rated horsepower (1,900 rpm) kPa {mmHg} 119 {890} or 105 {790} or
pressure) above above
Exhaust
temperature (turbine Whole speed range (20°C) °C Max. 670 700
outlet )
• Coolant Engine outlet
temperature: Within (between
operating range turbocharger Bosch index - Max. 3.0
• When torque and KDPF
Exhaust gas color inlet)
converter is stalling
• After kept for 5 KDPF outlet
seconds at normal (exhaust pipe Bosch index - Max. 0.5
condition outlet)
Intake valve 0.35 -
Valve clearance mm
Exhaust valve 0.57 -
EGR valve and At high idle 1.43 {14.6} or 1.43 {14.6} or
MPa above above
KVGT drive oil
pressure {kg/cm2} 1.18 {12.0} or 1.18 {12.0} or
At low idle
above above
Main body
Engine SAA6D140E-6
Standard value
machine
Compression Engine oil temperature: 40 to 60 °C MPa 4.1 {42} or 2.8 {29} or
pressure Engine speed: 200 to 280 rpm {kg/cm2} above above
140E-6 SERIES 20-7

Lubrication system
Engine SAA6D140E-6
Standard value
machine
At rated horsepower
Engine oil SAE5W-30LA 0.34 {3.5} or 0.21 {2.1} or
temperature: Min. 80 ° SAE5W-40LA above above
C SAE10W- MPa
Hydraulic
Engine oil SAE15W- 0.10 {1.0} or 0.08 {0.8} or
temperature: Min. 80 ° 40LA above above
C
Engine oil
Whole speed range (inside oil pan) °C 90 to 110 120
temperature
Ratio to fuel consumption
Cooling system
Engine SAA6D140E-6
Standard value
machine
Automatic Automatic
Tension of alternator Deflection when pressed with finger mm adjustment adjustment
belt and fan force of 98 N {10 kg}
(auto-tensioner) (auto-tensioner)
20-8 140E-6 SERIES

Running-in standard and performance test standard
Running-in standard and performance test standard (ENG125-A000-034-K-00-A)
<Applicable machines> HM400–3 (ENG140-A000-034-K-00-A)
Running-in standard
Engine SAA6D140E-6
Procedure
Item
1 2 3 4 5
Running time min. 1 3 6 8 2
Engine speed rpm 725 1,260 1,580 1,820 2,000
Dynamometer N {kg} 0 {0} 934 {95} 1,490 {152} 1,940 {198} 2,354 {240}
load
Output kW {HP} 0 {0} 88 {118} 177 {237} 265 {355} 353 {473}
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Performance test standard
Engine SAA6D140E-6
Rated horsepower Max. torque Max. speed with Min. speed with
Test item
no load no load
2,275Nm /
Specification 353kW / 2,000rpm
1,400rpm
value – {473 HP / 2,200(+50 / 0)rpm 725±25rpm
{232kgm /
(Gross) 2,000rpm}
1,400rpm}
Engine speed rpm 2,000 1,400 2,200(+50 / 0) 725±25
Dynamometer N 2,283 to 2,424 3,082 to 3,273
– –
load {kg} {233 to 247} {314 to 334}
Output kW 343 to 363
– – –
(Gross) {HP} {460 to 487}
Torque Nm 2,206 to 2,343
– – –
(Gross) {kgm} {225 to 239}
Fuel
– – –
consumption sec/300 cc 27.5
Coolant
temperature °C 70 to90 70 to 90 70 to 90 70 to 90
Lubricating oil
temperature °C 90 to 110 90 to 110 90 to 110 80 to 110
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
°C Max. 620 Max. 670 – –
temperature
a This table shows the standard values obtained by using the JIS correction coefficients.
a This table shows the standard values when the air cleaner and the KDPF are installed and no load is
applied to the alternator.
a Use JIS No.2 diesel fuel for the fuel.
a Use SAE15W-40LA as lubricating oil.
140E-6 SERIES 20-9

<Applicable machines> D155AX-7 (ENG140-A000-034-K-01-A)
Running-in standard
Engine SAA6D140E-6
Procedure
Item
1 2 3 4 5
Engine speed rpm 740 1,197 1,501 1,729 1,900
Dynamometer N {kg} 0 {0} 747 {76} 1,192 {122} 1,552 {158} 1,883 {192}
load
Output kW {HP} 0 {0} 67 {90} 134 {180} 201 {269} 268 {360}
Engine SAA6D140E-6
Flywheel Max. speed Min. speed
Test item Max. torque
horsepower with no load with no load
1,834Nm /
Specification 268 kW / 1,900rpm
1,300rpm
value – {360 HP / 2,100 (0 / -50) rpm 740 (+25 / 0)
{187kgm /
(Gross value) 1,900rpm}
1,300rpm}
Engine speed rpm 2,000 1,400 2,100 (0 / -50) rpm 740 (+25 / 0)
– –
load {kg} {186 to 198} {254 to 269}
– – –
(Gross value) {HP} {349 to 371}
– – –
(Gross value) {kgm} {181.4 to 192.6}
Ratio to fuel
cc/sec Max. 21.0 – – –
consumption
Coolant
temperature: °C 70 to 90 70 to 90 70 to 90 70 to 90
Lubricating oil
Exhaust gas
°C Max. 620 Max. 670 – –
temperature
20-10 140E-6 SERIES

<Applicable machines> WA500-7 (ENG140-A000-034-K-02-A)
Running-in standard
Engine SAA6D140E-6
Procedure
Item
1 2 3 4 5
Engine speed rpm 700 1,197 1,501 1,729 1,900
Dynamometer N {kg} 0 {0} 745 {76} 1,187 {121} 1,540 {157} 18,68 {190}
load
Output kW {HP} 0 {0} 67 {91} 133 {181} 200 {271.5} 266 {357}
Engine SAA6D140E-6
Rated horsepower Max. torque Max. speed with Min. speed with
Test item
no load no load
1,805Nm /
Specification 266kW / 1,900rpm
1,250rpm
value – {357 HP / 2,150 ± 50 rpm 700 rpm
{184kgm /
(Gross) 1,900rpm}
1,250rpm}
Engine speed rpm 1,900 1,250 2,150 ± 50 rpm 700
– –
load {kg} {185 to 196} {249 to 265}
– – –
(Gross) {HP} {346 to 367}
– – –
(Gross) {kgm} {178 to 190}
Fuel
– – –
consumption sec/300 cc 21
Coolant
temperature °C 70 to90 70 to 90 70 to 90 70 to 90
Lubricating oil
Exhaust
°C Max. 620 Max. 670 – –
temperature
140E-6 SERIES 20-11

20-12 140E-6 SERIES

SHOP MANUAL
ENGINE
140E-6 SERIES
Model Serial Number
140E-6
SERIES
50 Disassembly and assembly

5 50 Disassembly and assembly
140E-6 SERIES 50-1

Table of contents

50 Disassembly and assembly ........................................................................................................... 50-1
General information on disassembly and assembly........................................................................ 50-3
How to read this manual ....................................................................................................... 50-3
Coating materials list ............................................................................................................ 50-5
Special tools list ................................................................................................................... 50-9
Sketches of special tools .................................................................................................... 50-11
Disassembly and assembly ....................................................................................................... 50-14
General disassembly of engine ........................................................................................... 50-14
General assembly of engine................................................................................................ 50-29
Removal and installation of supply pump.............................................................................. 50-61
Procedures for replacing engine front oil seal ....................................................................... 50-65
Procedures for replacing engine rear oil seal ........................................................................ 50-68
50-2 140E-6 SERIES

General information on disassembly and assembly
General information on disassembly and assembly (ALL-3851-001-A-00-A)
How to read this manual (ALL-0320-011-A-00-A)

(Rev.2010.10)
Removal and installation of TTTT assembly • Common tools that are necessary for installation
Special tools are described as [1], [2] ... etc. and their part
• Special tools which are necessary for removal or numbers, part names and quantities are not
installation of assemblies are described as described.
A1•••X1 etc. and their part numbers, part names, • Marks shown in the installation section are
necessities, and quantities are described in the explained below.
special tool list. k: This mark indicates safety-related
• Marks used in the column of necessity are precautions which must be followed when
explained below. performing the work.
t: Tools are not substituted, must always be
equipped (used). a : This marks gives guidance or precautions
q: Tools extremely useful if available or tools when performing the work.
that can be substituted with commercially
available tool. 4 : This mark shows the weight of a part or
• For details and the sketches of the special tools, the assembled parts for a device.
see "special tool list" and "sketches of special
tools". 2 : This mark indicates a specific coating
Removal agent to be used.
• In the removal section, the work procedures, 3 : This mark indicates the specified
precautions and know-how to do the work and tightening torque.
the amount of oil and coolant to be drained are
described. 5 : This mark indicates the amount of oil or
• Common tools that are necessary for the coolant to be added.
removal work are indicated as [1], [2] ... etc. and
their part numbers, part names and quantities Disassembly and assembly of TTTT assembly
are not described. Special tools
• Marks used in the removal section are explained • Special tools which are necessary for
below. disassembly and assembly of assemblies are
described as A1•••X1 etc. and their part
k: This mark indicates safety-related numbers, part names, necessities, and
precautions which must be followed when quantities are described in the special tool list.
performing the work. • Marks used in the column of necessity are
explained below.
a : This mark gives guidance or precautions when t: Tools are not substituted, must always be
performing the work. equipped (used).
[*1]: This mark indicates that instructions or q: Tools extremely useful if available or tools
precautions for the assembly installation work are that can be substituted with commercially
given in the installation section. available tool.
• For details and the sketches of the special tools,
6 : This mark shows the amount of oil or see "special tool list" and "sketches of special
coolant to be drained. tools".
Disassembly
4 : This mark shows the weight of a part or • In the disassembly section, the work
the assembled parts for a device. procedures, precautions and know-how to do
Installation the work, and the amount of oil and coolant to be
• Unless otherwise instructed the installation of drained are described.
assemblies is to be made in the reverse order to • Common tools that are necessary for the
removal. disassembly work are indicated as [1], [2] ... etc.
• Instructions and precautions for assembly and their part numbers, part names, and
installation are shown with [*1] mark in the quantities are not described.
removal section, identifying which step the • Marks used in the disassembly section are
instructions are intended for. explained below.
140E-6 SERIES 50-3

k: This mark indicates safety-related

precautions which must be followed when
performing the work.
a : This marks gives guidance or precautions

when performing the work.
6 : This mark shows the amount of oil or

coolant to be drained.
4 : This mark shows the weight of a part or

the assembled parts for a device.
Assembly
• In the assembly section, the work procedures,
precautions and the know-how to do the work,
and the amount of oil or coolant to be added are
described.
• Common tools that are necessary for the
disassembly work are indicated as [1],[2] ... etc.
and their part numbers, part names, and
quantities are not described.
• Marks used in the assembly section are
explained below.
k This mark indicates safety-related
precautions which must be followed when
a : This mark gives guidance or precautions when

4 : This mark shows the weight of a part or

the assembled parts for a device.
2 : This mark indicates a specific coating
agent to be used.
3 : This mark indicates the specified
tightening torque.
5 : This mark indicates the amount of oil or

coolant to be added.
50-4 140E-6 SERIES

Coating materials list (ALL-3540-071-A-00-A)

(Rev.2011.07)
a The recommended coating materials such as adhesives, gasket sealants, and greases used for
disassembly and assembly are listed below.
a For coating materials not listed below, use the equivalent of products shown in this manual.
Adhesive
Komatsu code Part No. Capacity Container Main features and applications
• Use to prevent rubber gaskets, rubber
LT-1A 790-129-9030 150 g Tube cushions, and cork plugs from coming out.
• Use for plastic (except polyethylene,
20g Polyethy- polypropylene, tetrafluoroethylene, and
LT-1B 790-129-9050 (2 pcs. lene vinyl chloride), rubber, metal, and non-
contained) container metal parts which require immediate and
strong adhesion.
Polyethy- • Features: Resistance to heat and
LT-2 790–129–9180 50 g lene chemicals
container • Use to fix and seal bolts and plugs.
790-129-9060 Adhesive:
(Set of 1 kg • Use to bond and seal metal, glass and
LT-3 Can plastics.
adhesive and Hardener:
hardener) 500 g
Polyethy-
LT-4 790-129-9040 250 g lene • Use to seal plugs for blank holes.
container
Holtz
790-129-9120 75 g Tube • Heat-resistant seal used to repair engines
MH705
• Instantaneous adhesive
Polyethy- • Curing time: From 5 sec. to 3 min.
Three- 50 g
790-129-9140 lene • Use mainly to bond metals, rubbers,
Bond1735
container plastics, and woods.
• Instantaneous adhesive
Polyethy- • Quick-curing type (max. strength is
Aron Alpha 2g
790-129-9130 lene obtained after 30 minutes)
201
container • Use mainly to bond rubbers, plastics, and
metals.
• General-purpose instantaneous adhesive
with excellent resistance to heat and
Loctite 499 428–99–80070 20 g Tube impact
• Use on the bushing mounting faces of axle
supports.
• Features: Resistance to heat and
Polyethy- chemicals
Loctite 648-50 79A-129-9110 50 cc lene • Use for fitted portions used at high
container temperatures.
140E-6 SERIES 50-5

Liquid gasket
• Use to seal various thread portions, pipe
Polyethy- joints, and flanges.
LG-5 790-129-9080 1 kg lene • Use to seal taper plugs, elbows, and
container nipples for hydraulic piping.
• Features: Silicon-based heat and cold-
resistant sealant
LG-6 790-129-9160 200 g Tube • Use to seal thread portions and flange
surface.
• Use to seal oil pan, final drive case, etc.
• Features: Silicon-based quick-curing
sealant
LG-7 790-129-9170 1 kg Tube • Use to seal flywheel housing, intake
manifold, old, oil pan, thermostat housing,
etc.
LG-8 • Features: Silicon-based, heat and cold-
resistant, vibration-resistant, impact-
ThreeBond 419-15-18131 100 g Tube resistant sealant
1207B • Use to seal transfer case, etc.
• Use for rough surfaces such as the circle
LG-9 gear top seal which is not clamped by
ThreeBond 790-129-9310 200 g Tube bolts, gaps in the weld which must be
1206D caulked, etc.
• Can be coated with paint.
LG-10 • Use as lubricant or sealant when the
ThreeBond 790-129-9320 200 g Tube radiator hoses are put on.
1206E • Can be coated with paint.
LG-11 • Feature: Can be used together with solid
gaskets.
ThreeBond 790-129-9330 200 g Tube • Use for covers of the transmission case
1121 and steering case etc.
ThreeBond
790-129-9090 100 g Tube • Liquid gasket used to repair engine
1211
Molybdenum disulfide lubricant
• Use to prevent galling and seizure of
press-fitted portions, shrinkage-fitted
LM-P 09940-00040 200 g Tube portions, and thread portions.
• Use to lubricate linkages, bearings, etc.
• Spray type
• Thin molybdenum disulfide films are made
on metal surfaces to prevent the metals
— 09995-00250 190 g Can from galling.
• Use for the drive shaft splines, needle
bearings, pins and bolts of various links,
etc.
50-6 140E-6 SERIES

Seizure prevention compound
• Feature: Seizure and galling prevention
compound with metallic super-fine-grain,
LC-G etc.
— — Can
NEVER-SEEZ • Use for the mounting bolt in the high
temperature area of the exhaust manifold
and the turbocharger, etc.
Grease
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
G2-LI SYG2-160LI
• Lithium grease with extreme pressure
G0-LI (*) SYGA- Various Various lubrication performance, general purpose
*: For cold 160CNLI type
regions SYG0-400LI-A
(*)
SYG0-16CNLI
(*)
• Use for parts under heavy load.
Caution:
Molybdenum 400 g x 10 Bellows- • Do not use this grease for rolling
SYG2-400M
disulfide type bearings like swing circle bearings, etc.
grease SYG2-400M-A 400 g x 20 container and splines.
LM-G (G2-M) SYGA-16CNM 16 kg Can • Use this grease for work equipment
pins only when installing them, but do
not use it afterward.
Hyper White SYG2-400T-A
Grease SYG2-16CNT Bellows- • Higher seizure resistant, heat resistant and
G2-T 400 g type water resistant than molybdenum disulfide
SYG0-400T-A grease.
G0-T (*) (*) 16 kg container
• Not conspicuous on machine since color is
*: For cold SYG0-16CNT Can white.
regions (*)
Bio grease
G2-B SYG2-400B
G2-BT (*) SYGA-16CNB Bellows-
400 g type • Since this grease is biodegradable in short
*: For use at SYG2-400BT period, it has less impact on
(*) 16 kg container
high microorganisms, animals, and plants.
temperature SYGA- Can
and under high 16CNBT(*)
load
• Silicone grease with wide usable
G2-S temperature range, high resistance to
thermal-oxidative degradation and
ThreeBond — 200 g Tube performance to prevent deterioration of
1855 rubber and plastic parts
• Use for oil seals of the transmission, etc.
• Urea (organic system) grease with heat
resistance and long life. Enclosed type.
G2-U-SENS
427-12-11871 2 kg Can • Use for rubber, bearing and oil seal in
grease
damper.
Caution: Do not mix it with lithium grease.
140E-6 SERIES 50-7

Primer
Glass • Use to accelerate hardening of
Loctite 712 428–99–80080 100 ml
container instantaneous adhesive.
• Use as primer for painted cab sheet
Sunstar Paint
Glass metal surface.
Primer 580 20 ml
container (Effective period: 4 months after
Super
417-926-3910 manufacture)
Sunstar Glass • Use as primer for cab glass surface.
Primer 580 Glass (Effective period: 4 months after
20 ml
For adhering cab glass

Super container manufacture)
• Use as primer for painted cab sheet
Sunstar Paint Glass metal surface.
22M-54-27230 20 ml (Effective period: 4 months after
Primer 435-95 container
manufacture)
• Use as primer for black ceramic-coated
glass surface and for hard
Sunstar Glass polycarbonate-coated surface.
22M-54-27240 150 ml Steel can
Primer 435-41 (Effective period: 4 months after
manufacture)
• Use as primer for sash (Almite)
Sunstar Sash Glass (Effective period: 4 months after
22M-54-27250 20 ml
Primer GP-402 container manufacture)
Adhesive
• Use "S" in high temperature season
Sunstar and "W" in low temperature season as
Polyethy-
Penguin Seal adhesive for glass.

417-926-3910 320 ml lene
580 Super "S" (Effective period: 4 months after
container
or "W" manufacture)
Sika Japan, Polyethy- • Use as adhesive for glass.
Sikaflex 20Y-54-39850 310 ml lene (Effective period: 6 months after
256HV container manufacture)
Sunstar Ecocart • Use as adhesive for glass.
Penguin Super 22M-54-27210 320 ml (Special (Effective period: 6 months after
560 container) manufacture)
Caulking material
Sunstar Polyethy- • Use to seal joints of glass parts.
Penguin Seal 417-926-3920 320 ml lene (Effective period: 4 months after

No.2505 container manufacture)
Sekisui Polyethy- • Use to seal front window.
Silicone 20Y-54-55130 333 ml lene (Effective period: 6 months after
Sealant container manufacture)
• Use to seal glass-to-glass joint.
GE Toshiba Translucent white seal.
Silicones 22M-54-27220 333 ml Cartridge
(Effective period: 12 months after
TOSSEAL 381 manufacture)
50-8 140E-6 SERIES

Special tools list (ENG140-3530-061-A-00-A)
• Part Nos. of special tools starting with 79*T-***-**** mean that they are not available from Komatsu Ltd. (i.e.
tools to be made locally).
• Mark used in the column of "Necessity" are explained below.
t: Tools are not substituted, must always be equipped (used).
q: Tools extremely useful if available or tools that can be substituted with commercially available tool.
• Mark used in the column of "New/Redesign" are explained below.
N: Tools with new part numbers, newly developed for this model.
R: Tools, with advanced part numbers, developed by improving existing tools for other models.
Blank: Tools already available for other models that can be used without any modification
• Tools marked with Q in the sketch column have the sketches. (See "Sketches of special tools")
New/redesign
Necessity
Sketch
Sym- Contents of work and
Q'ty
Work Part No. Part name
bol remarks
Disassembly and 790-501- Engine repair stand t 1

1
assembly of engine 2001
A
assembly 790-901-
2 Bracket t 1
1261
Removal and
installation of cylinder 795-102- Spring pusher
C t 1
head valve spring 2103
Removal and
installation of piston D 795-100-1191 Piston ring tool t 1
ring
Removal of cylinder 795-236- Liner puller t 1
E
liner 1000
Press fitting of cylinder 795-230- t 1
F Liner driver
liner 5472
Insertion of piston
G 795-921-1100 Piston holder t 1
assembly
Measurement of
protrusion of cylinder H 795-502-1121 Gauge holder t 1
liner
Adjusting valve 795-125- Feeler gauge
I q 1
clearance 1210
Torque plus angle
J 790-331-1110 Wrench q 1
method for bolt
L 795-931-1100 Seal puller t 1 Pulling-out of oil seal
795T-521- t 1
Push tool Q
1111 Press-fitting of engine front
1 01050-31655 Bolt t 3 seal (standard type)
M 01050-31635 Bolt t 3
795T-521-
Push tool t 1 Q Press-fitting of engine front
2 1150
seal (sleeve type)
Removal and 01050-31635 Bolt t 3
installation of engine 795T-421-
Push tool t 1 Q
front seal and rear 1260 Press-fitting of engine rear
seal 1 01050-31640 Bolt t 4 seal (standard type)
01643-31645 Washer t 8
795T-421- t 1
N Push tool Q
1240
2 01050-31645 Bolt t 4 Press-fitting of engine rear
01643-31645 Washer t 4 seal (sleeve type)
795T-421- t 1
3 Push tool Q
1231
140E-6 SERIES 50-9

New/redesign
Necessity
Sketch
Sym- Contents of work and
Q'ty
Work Part No. Part name
bol remarks
02050-31645 Bolt t 4
01643-31645 Washer t 4
Press-fitting of valve 795-130- t 1
Q Push tool
stem seal 1720
50-10 140E-6 SERIES

Sketches of special tools (ENG140-3531-066-A-00-A)
Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
M1 Push tool
M2 Push tool
　 Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
N1 Push tool
140E-6 SERIES 50-11

N2 Push tool
　 Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
N3 Push tool
50-12 140E-6 SERIES

140E-6 SERIES 50-13

Disassembly and assembly
Disassembly and assembly (ENG107-A000-001-K-00-A)
General disassembly of engine (ENG140-A000-530-K-00-A)
a Since the shapes, quantity, locations, etc. of the

parts may be different from the actual machine,
check them before starting the work.
1. Preparatory work
Before disassembling the engine, check its parts
for crack and damage, and then wash it
thoroughly and carefully for accurate parts
inspection and rapid disassembly and assembly.
a Before washing the engine, perfectly seal
each opening, electrical parts, and wiring
connectors or remove them so that water
does not enter them.
2. Engine assembly 3) Lower engine assembly (1) onto blocks [2]
and stabilize it.
1) Place engine assembly (1) on blocks [1].
4) Remove the mounting bolt and suction tube
a The weight of engine assembly (1) (3).
depends on the applicable machine. 5) Remove the mounting bolts to remove
underframe (4).
4 Engine assembly (1):
a The number of underframes (4) depends
2,000 kg on the applicable machine.
2) Drain the coolant and engine oil. 6) Set engine assembly (1) again on blocks [2]
a The quantity of the oil depends on the to stabilize it.
applicable machine.
6 Engine oil:
58 l
3. Engine oil pan and suction tube
1) Using lifting tool [1], sling engine assembly
(1).
4 Engine assembly (1):

2,000 kg
a The KDPF bracket and air cleaner
bracket are installed to some applicable 4. Starting motor assembly
machines.
1) Remove clips (1).
For removal, see the shop manual for the 2) Remove mounting bolts (2) to remove
machine body. starting motor assembly (3).
2) Remove the mounting bolt, sling engine
assembly (1), and remove engine oil pan (2).
50-14 140E-6 SERIES

5. KVGT assembly 6) Remove exhaust elbow mounting bracket

1) Disconnect connector DOSER (1). (9).
2) Remove bolts (2), which are also securing
the clamp, and remove bracket (3).
7) Remove heat insulation plates (10), (11), and

(14) and brackets (12), (13), (15), (16), and
3) Disconnect coolant tubes (4) and (6) and fuel (17).
doser tube (5).
4) Remove the mounting bolts to remove
bracket (7).
8) Remove cover (18).
5) Remove the doser connector and exhaust

elbow (8).
140E-6 SERIES 50-15

9) Remove KVGT coolant tube (19) and oil

4 KVGT assembly (26):
drain tube (20).
45 kg
10)Disconnect the following connectors.

(23): PIM 6. EGR cooler
(24): TIM 1) Remove EGR coolant tubes (1), (2), (3), (8),
(25): TWTR and (9).
11)Remove KVGT lubrication tube (21). 2) Remove EGR air vent tubes (4), (5), (6), and
12)Disconnect tube (22). (7).
3) Disconnect EGR coolant tubes (11) and (12).
13)Sling and remove KVGT assembly (26).

4) Sling and remove the EGR cooler and
bracket (10).
50-16 140E-6 SERIES

4 EGR cooler (10): 4 Oil cooler (1):

80 kg 40 kg
7. Thermostat housing and water pump tube 10.Water pump

1) Remove thermostat pipe (1). Remove the mounting bolts to remove water
2) Remove EGR cooler mounting bracket (2). pump (1).
3) Remove water pump tube (3).
4) Remove thermostat housing (4).
11.KCCV
1) Disconnect connector PCCV (1).
8. Exhaust manifold
a To disconnect locked connector (1), move
Sling and remove exhaust manifold (1).
lock [1] of the housing in the direction of
the arrow and push down lock [2] and pull
4 Exhaust manifold (1):
out.
25 kg
2) Disconnect drain hose (2).

9. Oil cooler
3) Remove KCCV (3).
1) Using guide bolts [1] and eyebolts [2], sling
oil cooler (1).
2) Remove the mounting bolts to remove oil
cooler (1).
140E-6 SERIES 50-17

(10) SOV1
(11) CAN-C
a The installed position of KCCV depends

on the applicable machine.
12.Oil filter (12) VGT-REV
1) Remove head tube (1). (13) SEGR
2) Remove the mounting bolts on the oil filter (14) SOV2
head side to remove the oil filter and head (15) EGR
assembly (2). (16) VGT-SOL
13.Harness assembly (17) PCV1

(18) PCV2
1) Remove the mounting bolts and remove
(19) G
engine controller cover (1).
2) Disconnect the following connectors.
(2) PFUEL
(3) POIL
(4) J1 and J2
(5) BREAKOUT
(6) NE
14.Engine controller
Remove the mounting bolts to remove engine
controller (1).
(7) INJ
(8) PAMB
(9) PDOSER
50-18 140E-6 SERIES

15.Fuel pre-filter 17.Fuel filter

1) Remove head tube (1). 1) Remove the mounting bolts to remove
2) Remove fuel pre-filter (2) together with the electric fuel feed pump cover (1).
head.
2) Remove fuel tubes (2) and (3).

16.EGR valve 3) Remove the mounting bolts to remove fuel
1) Remove the mounting bolts to remove fuel filter head and cartridge (4).
doser cover (1).
2) Remove EGR oil tube (2), EGR oil drain tube
(3), and then remove EGR valve (4).
3) Disconnect fuel filter head tube (5).
18.Alternator, belt, and air conditioner compressor

1) Tighten adjustment bolt (1) to release the
tension of the tensioner from the auxiliary
belt.
4) Disconnect fuel doser relief valve tube (6). 2) Remove the auxiliary belt.
5) Remove the mounting bolts to remove 3) Install the stopper bolt to the position of
harness bracket (7). tensioner (6).
6) Remove fuel doser relief valve (8).
7) Remove the mounting bolts to remove fuel
doser block (9).
8) Remove block (10).
9) Remove oil tube mounting bracket (11).
140E-6 SERIES 50-19

a Use the stopper bolt of M10 x 1.5 with

4 Air intake manifold connector and
stem length of 90 mm.
joint (4):
Do not remove the stopper bolt until the
45 kg
tensioner is installed again.
3) Sling and remove air intake manifold (5).

4) Remove the mounting bolts to remove
alternator (3).
4 Air intake manifold (5):
5) Remove the mounting bolts to remove air
compressor (4). 45 kg
6) Remove cover (5). 4) Remove oil level gauge (6).
19.Air intake manifold 5) Remove the mounting bolts to remove fuel

tube (7).
1) Remove brackets (1) and (2) and oil filler
pipe (3).
20.Fuel cooling plate

2) Sling and remove air intake manifold 1) Disconnect fuel hose (1) and remove fuel
connector and joint (4) together. cooling plate (2).
50-20 140E-6 SERIES

2) Remove the mounting bolts to remove fuel 3) Remove the mounting bolts to remove
cooling plate mounting bracket (3). bracket (6).
3) Remove electric fuel feed pump harness 4) Remove cylinder head covers (7).
mounting clip (4). 5) Remove fuel spray prevention caps (3).
4) Remove bracket (5). 6) Remove high-pressure tube (5).
7) Remove high-pressure tube (4).
21.Common rail
1) Remove clamps (1). 8) Remove fuel tubes (8) and (9) and oil tubes
(10), (11), and (12).
a Disconnect injector connectors according 9) Remove fuel tubes (13) and (14).
to the following procedure.
(1) Apply flat-head screwdriver to stepped
portion (part a).
(2) While pressing stopper (2a), move
flat-head screwdriver [1] in direction (X) to
disconnect the connector.
10)Remove the special bolts to remove

common rail (15).
11)Remove fuel feed pump (16).
2) Remove harnesses CN1 to CN6 (2).
140E-6 SERIES 50-21

22.Supply pump and EGR oil pump 24.Push rod

1) Remove the mounting bolts to remove Remove push rod (1).
supply pump (1).
25.Cam follower cover

2) Remove the mounting bolts to remove oil Remove cam follower cover (1).
junction block (2) and EGR oil pump (3).
26.Cam follower
23.Rocker arm and shaft assembly Remove mounting bolts (1) to remove cam
follower (2).
1) Remove three mounting bolts (3) to remove
rocker arm and shaft assembly (4).
2) Loosen locknut (2) and loosen adjustment
screw (1) sufficiently so that an excessive
force will not be applied to the mounting bolt
when removing and installing.
50-22 140E-6 SERIES

27.Damper assembly 30.Camshaft

Sling damper assembly (1), remove the 1) Match mounting bolts (1) to the holes of cam
mounting bolts, and remove the damper gear (2) and remove bolts (1).
assembly.
4 Damper assembly (1):

45 kg
2) Sling camshaft (3) and pull it out, while

rotating it so that it does not damage the cam
bushing.
28.Tension pulley 4 Camshaft (3):

Remove the mounting bolts to remove tension 20 kg
pulley (1).
31.Injection drive gear

29.Front cover
1) Loosen nut (2).
1) Using eyebolts [1], sling front cover (1). 2) Using gear puller [1], remove injection drive
2) Remove the mounting bolts, and sling and gear (1).
remove front cover (1).
a Injection drive gear (1) can be removed
4 Front cover (1): safely by tightening the gear puller without
removing nut (2).
65 kg
3) Remove front oil seal (2) from the front cover.
32.Idler gear and engine oil pump
140E-6 SERIES 50-23

1) Remove mounting bolt (1) to remove plate 2) Remove upper seat (2), outer spring (3), and
(2) and idler gear (3). inner spring (4).
2) Remove three mounting bolts (4) to remove
engine oil pump (5).
3) Remove mounting bolt (6) to remove shaft
(7) and main idler gear (8).
3) Remove valve stem seal (5) and lower seat

(6).
4) Raise the cylinder head and remove valve
(7).
33.Cylinder head assembly (removal)
1) Remove coolant tube (1) and bracket (2).
35.Flywheel
1) Install eyebolt [1].
2) Remove five mounting bolts (3) of cylinder
head assembly (4). Using eyebolt [1], sling
flywheel (1) using the guide bolts.
and remove cylinder head assembly (4).
4 Flywheel (1):
4 Cylinder head assembly (4):
60 kg
25 kg
36.Flywheel housing
34.Cylinder head (disassembly)
1) Using tool C, compress the valve spring and
remove cotter (1).
flywheel housing (1).
50-24 140E-6 SERIES

4 Flywheel housing (1):

70 kg
2) Remove the carbon from the upper wall of

the cylinder liner with fine sandpaper.
3) Rotate the crankshaft to set the piston to be
37.Setting to engine repair stand removed to the bottom dead center.
4) Check that there are identification stamps (a)
1) Install tool A2 to the cylinder block. Sling and
on the connecting rod and camshaft side of
set the engine to tool A1.
the cap.
a The stamps on the connecting rod and
cap must be the same.
a If there is no stamp, put stamps before
disassembling.
38.Piston cooling nozzle

Remove the mounting bolts to remove piston
cooling nozzles (1) and (2).
5) Remove two mounting bolts (1) of the

connecting rod cap.
6) While hitting lightly with a plastic hammer,
remove connecting rod cap (2) and
connecting rod bearing together.
39.Piston and connecting rod assembly (removal)

1) Before removing the piston and connecting
rod assembly, measure the end play of the
connecting rod with dial gauge [1].
140E-6 SERIES 50-25

a When hitting with the plastic hammer,

take care not to damage the threads of
mounting bolts (1).
7) Push in the connecting rod end with a

wooden rod etc. from the engine oil pan side
to remove piston and connecting rod
assembly (3).
a When removing, take care not to damage
the inside wall of the cylinder liner with
the corners of the connecting rod.
8) Similarly, remove the other piston and
connecting rod assemblies.
3) Using tool D, remove piston ring (5).
a Store the removed parts so that the
sliding surfaces of the pistons, bearings, a Store the parts (piston, connecting rod,
etc. are not damaged. connecting rod bearing, piston rings, and
piston pin) by the cylinder No.
a Assemble each connecting rod and cap
loosely so that they can be assembled
easily and store them together with the
bearing.
41.Crankshaft
40.Piston and connecting rod (disassembly)

1) Using tool [1], remove two snap rings (1).
2) Support connecting rod (2) with the hand and
pull out piston pin (3) to separate piston (4)
and connecting rod (2).
50-26 140E-6 SERIES

a Before removing crankshaft (1), measure its

end play with dial gauge [1].
5) Using bolts [2], sling and remove crankshaft

(1).
1) Remove two each of the main cap mounting a When removing crankshaft (1), take care
bolts (2) to remove main caps (3) to (9). not to damage its journal portions.
2) Insert mounting bolts (2) into the bolt holes of
the main cap, and shake and remove the 4 Crankshaft (1):
main cap. 140 kg
6) Remove upper thrust bearing (12). (Only

journal No. 7)
a Check and record the mounting position
of upper thrust bearing (12).
7) Remove upper main bearing (13) from each
main journal.
a Identify the locations of the parts (main
cap, main bearing, and thrust bearing)
and store them by the cylinder No.
3) Remove lower thrust bearing (10). (Only

main cap No. 7 (9))
a Check and record the mounting position
of lower thrust bearing (10).
4) Remove lower main bearing (11) from each
main cap.
42.Cylinder liner
140E-6 SERIES 50-27

a Before removing cylinder liner (1), measure

its protrusion with tool H.
1) Using tool E, take out cylinder liner (1).
50-28 140E-6 SERIES

General assembly of engine (ENG140-A000-710-K-00-A)
a Since the shapes, quantity, locations, etc. of the If part (R) is sharp or has burrs, polish it
parts may be different from the actual machine, with scrapers or sandpaper. Finish this
check them before starting the work. face specially smoothly so that it does not
damage the O-ring.
a Clean each part, and check for dents, damage,
3] If face (B) is so pitted that it cannot be
blowhole, etc. Before assembling, check that oil
repaired, replace the cylinder block.
and coolant passages are through.
4] If the faces and portions (R) are pitted,
Tightening of bolts by torque plus angle method finish them smoothly.
a Bolts to be tightened by torque plus angle 5] Check the counterbore portions and
method remove burrs, if any. Remove all chips
and dirt on face (C) since they cause
• Cylinder head mounting bolt
imperfect fitting of the cylinder liner and
• Main cap mounting bolt
accordingly cause water leakage and
• Connecting rod mounting bolt
improper protrusion of the cylinder liner.
• Flywheel mounting bolt
a If any counterbore portions are drooped,
a Since a bolt tightened by the toque plus angle
corroded, or pitted, repair them.
method has permanent strain, the number of its
repeated use is limited. Accordingly, take care of
the following points.
• Measure the stem length of each bolt and
check that it is less than the using limit. If a
bolt is longer than the using limit, do not
reuse it but replace it.
• Count the number of punch mark on the bolt
head. If it exceeds the specified number, do
not use the bolt but replace it.
1. Cylinder block
1) Install tool A2 to cylinder block (1).
2) Sling cylinder block (1) and set tool A2 to tool
A1. 2. Cylinder liner
1) Check the O-ring grooves and outside of the
4 Cylinder block (1):
cylinder liner for rust and pitting. If there are
420 kg any defects, replace the cylinder liner.
2) Install brand-new clevis seal (1) and O-rings
(2) and (3) to the cylinder liner.
a Check that the grooves of the liner are
free of burrs, damage, and dirt.
a Set the clevis seal with the chamfered
side down and press up its all periphery
into the seal groove so that it is not
twisted when installed.
a While referring to the following, install O-
rings (2) and (3).
• O-ring (2): There is yellow
3) Prepare the cylinder block according to the identification point.
following procedure. • O-ring (3): Whole body is red.
a Be sure to perform this preparation work 2 Clevis seal and O-ring:
before inserting the cylinder liner. Rubber lubricant (RF-1)
1] Using sandpaper etc., remove rust and
a RF-1: If RF-1 manufactured by DAIDO
scales form faces (A) and (B) until the
CHEMICAL INDUSTRY is not available,
machines surfaces appear.
apply clean engine oil SAE No. 30.
2] Using sandpaper (No. 240 or equivalent),
polish part (R) until it is smooth.
140E-6 SERIES 50-29

a Since the clevis seal and O-ring swell and a If the liquid gasket is left for a long time,
deteriorate with oil, apply the oil a little its surface hardens. Complete the
with a brush just before installing. installation of the cylinder liner to the
cylinder block within 50 minutes.
5) Insert cylinder liner (1) into the cylinder block.

Insert the liner slowly into the cylinder block
so that the O-rings are not damaged.
6) Push in cylinder liner (1) further with both
hands.
a If the liner does not go in smoothly, the O-
rings may be damaged. Check the
cylinder block for burrs.
7) Using tool F, press fit cylinder liner (1) into
the cylinder block.
3) After installing the liner O-rings, check them

for twist. If they are twisted, correct them with
a smooth rod (approximately –f10).
8) To prevent the liquid gasket from being

forced out from between the block and liner
after the cylinder head is tightened, tighten
the cylinder head temporarily with the used
head gasket inserted.
4) Apply liquid gasket to the counterbore fitting a Tighten the bolts in the following order.
portions of the cylinder block and cylinder
liner.
a Remove dirt, oil, etc. from the liner flange
contact face of the counterbore portion.
2 Cylinder block:
Liquid gasket (LG-6)
• Liquid gasket: f2 to 3 mm
• Overlap of liquid gasket (a): 6 ± 6 mm
50-30 140E-6 SERIES

3 Temporary tightening torque: 2 Inside wall of bearing:

137 to 157 Nm {14 to 16 kgm} Engine oil (EO30)
9) Remove the cylinder head and wipe off the 2) Drive the dowel pin so that its protrusion from
excessive liquid gasket forced out of the the end face of the cylinder block is 2.7 to 3.4
counterbore portion. mm and install thrust bearing (2) on the
a Be sure to perform steps 8) and 9) since upper side to journal No. 7.
the liquid gasket forced out can deform a Match the protrusion to the notch of the
the grommet of the head gasket. cylinder block and take care of its
10)Using tool H, measure the protrusion of the direction.
cylinder liner.
a Protrusion of cylinder liner:
0.07 to 0.15 mm
a If any liquid gasket is forced out onto the
cylinder block top from the fitting portion
of the cylinder block and cylinder liner,
wipe it off.
3) Sling crankshaft (3) and install it to the

cylinder block.
a When replacing the crank gear, heat it
with bearing heater (30 A) (set
temperature: 150 °C) and fit it
immediately after heated.
a When installing the crankshaft, take care
3. Crankshaft not to hit its sliding surface against the
1) Install upper main bearing (1) to the cylinder cylinder block.
block, while matching its protrusion to the
notch of the cylinder block. 4 Crankshaft (3):
140 kg
a The oil hole is made on the upper main
bearing.
a Before installing the bearing, check that
its reverse side is free from foreign
matter.
140E-6 SERIES 50-31

2 Cylinder block journal:

Engine oil (EO30)
8) Tighten main cap mounting bolts (6)

according to the following procedure.
4) Install the lower main bearing to the main cap, a Tighten the bolts from the center to both
while matching its protrusion to the notch of ends in order.
the main cap.
2 Threaded portion of bolt and
a Before installing the bearing, check that washer:
its back side is free from foreign matter.
Engine oil (EO30)
5) Drive the dowel pin so that its protrusion from
the end face of cap No. 7 is 2.7 to 3.4 mm 3 Mounting bolt
and install thrust bearings (4) on both sides. 1st time: 108 to 128 Nm {11 to 13
a Match the protrusion to the notch of the kgm}
main cap and take care of its direction. 2nd time: 230 to 240 Nm {23.5 to
24.5 kgm}
3rd time: By using tool J, tighten
bolt by 90 deg. (+30 deg. /0).
6) Check that the stamped journal No. at the

center of main cap (5) is the same as the
journal No. of the cylinder block, and then
install the main cap.
a Install the main cap with embossed letter a When not using tool J, make marks (b) on
"F" directed toward front of the engine. the main cap and bolt with paint etc. and
7) Check the following items of each main cap then tighten the bolt by 90 deg. (+30 deg.
mounting bolt. If any of them is out of the /0).
standard, do not reuse the bolt but replace it. 9) Put one punch mark (c) on the mounting bolt
head.
• The number of tightening times reaches
six (five punch marks).
• Stem length of bolt (a): Min. 176.3 mm
50-32 140E-6 SERIES

a When a new bolt is used, do not put a a Take out the expander and fit it to the
punch mark on its head. piston, and then install the oil ring. At this
time, check that the expander is fitted to
the ring groove perfectly.
10)Rotate the crankshaft to check for smooth

rotation.
11)Measure the end play of the crankshaft with 2) Set the abutment joints of the piston rings as
dial gauge [1]. shown below.
a End play: 0.140 to 0.315 mm a Adjust the the abutment joint of the oil
ring expander at 180 degrees to that of
a If a measured value is out of the standard the oil ring.
value, correct it, referring to "Maintenance
standard".
3) Set the piston and connecting rod.

4. Piston and connecting rod assembly a Set the cylinder No. at the piston head
a The piston and cylinder liner are selective and the embossed part No. of the
fitted parts, and the spare parts are so connecting rod in the same direction and
designed that clearance is secured. insert piston pin (3) to install piston (2) to
connecting rod (4).
1) Using tool D, install piston rings (1) to the
4) Install snap rings (5) on both sides to secure
piston.
the piston pin.
a Install the top ring and second ring to the
piston with the stamp side up.
• Stamp of top ring: 1H
• Stamp of second ring: 2RX
140E-6 SERIES 50-33

5) Install upper bearing (6) of the connecting 8) Using tool G, compress the piston rings, and
rod to the connecting rod, while matching its push the piston head with an wooden rod etc.
protrusion to the notch of the connecting rod. into the cylinder block.
9) Check the following items of each connecting

rod cap mounting bolt. If any of them is out of
the standard, do not reuse the mounting bolt
6) Set the crankshaft of the cylinder to be
but replace it.
installed to the bottom dead center.
7) Set the embossed part No. of the connecting • The number of tightening times reaches
rod toward the front of the engine (the six times (five punch marks) or less
cylinder No. stamp is on the camshaft side) • Stem length of bolt (a): Min. 95.0 mm
and insert the piston and connecting rod
assembly (7) in the cylinder block.
a Referring to step 2), adjust the abutment
joints of the piston rings again.
2 Inside wall of connecting rod
bearing and cylinder:
Engine oil (EO30)
10)Install lower bearing (8) to the connecting

rod cap, while matching its protrusion to the
notch of the connecting rod cap.
11)Install connecting rod cap (9) to connecting

rod (4), while matching their a's to each
other.
50-34 140E-6 SERIES

2 Inside wall of connecting rod cap a When a new bolt is used, do not put a
bearing: punch mark on its head.
Engine oil (EO30)
14)Rotate the crankshaft to check for smooth

rotation.
15)Measure the side clearance of the
connecting rod with dial gauge [1].
a Side clearance: 0.100 to 0.274 mm
a If a measured value is out of the standard
standard".
12)Tighten connecting rod cap mounting bolts

(10) according to the following procedure.
3 Mounting bolt
1st time: 127 ± 4.9 Nm {13 ± 0.5
kgm}
2nd time: By using tool J, tighten
5. Piston cooling nozzle
1) Rotate the crankshaft to set pistons No. 1 to
No. 3 according to the mounting position.
• No. 1 is at top: No. 1 and No. 6 can be
installed
installed
installed
2) Install piston cooling nozzle (1) and plate (2)
to each cylinder in order.
a Install the piston cooling nozzle toward
the front of the engine and the plate
a When not using tool J, make marks (b) on toward the rear.
the connecting rod cap and bolt with paint
etc. and then tighten the bolt by 90 deg.
(+30 deg. /0).
13)After tightening, put one punch mark (c) on
the mounting bolt head.
140E-6 SERIES 50-35

a After assembling the pistons and

4 Flywheel housing (1):
connecting rods, check that the nozzle is
at the center of the shaker hole of each 70 kg
piston. In addition, check that each piston
does not interfere with the piston cooling
nozzle.
a Tighten the flywheel housing mounting

bolts in the numerical order shown in the
figure below in two times.
6. Flywheel housing
1) Apply liquid gasket lines 1 mm in diameter to a When tightening first time, tighten
positions (a) shown below. mounting bolts 1 and 4, and 2 and 9
twice.
2 Mating face:
3 Mounting bolt
1st time: 147 to 235 Nm {15 to 24
2 Threaded part and seat surface of kgm}
bolt: 2nd time: 245 to 309 Nm {25 to 31.5
Engine oil (EO30) kgm}
2) Using eyebolt [1], sling and install flywheel 3) Measurement of facial runout and radial
housing (1) to the cylinder block. runout of flywheel housing
1] Install the magnet stand of dial gauge [1]
to the end face of the crankshaft.
2] Set dial gauge [1] so that its probe is at a
right angle to the end face of the flywheel
housing.
3] Rotate the crankshaft by one turn on the
damper side and obtain the difference
between the maximum and minimum
readings of the gauge.
a Measure at least eight places equally
spaced on the periphery of the end face
of the flywheel housing.
50-36 140E-6 SERIES

a Move the crankshaft to either front or rear a Check the wear of the shaft and select either
end to eliminate error caused by the end a "standard seal" or a "sleeved seal". If the
play. wear condition of the shaft is glossy and no
scratch (when touched by a finger, wear
a After rotating the crankshaft by one turn,
depth is 10 m or less), install a "standard
check that the pointer of the dial gauge
seal A". Otherwise, install a "sleeved seal B".
reads the value at the start of rotation.
a (8): Shows the inner plastic tube/installation
a Since the gauge pointer moves to both
guide.
right and left, take care not to mistake the
runout direction when the gauge point is a (7): Shows the sleeve.
at the top, bottom, right, or left.
a Do not remove installation guide (8) from rear
a Facial runout: Max. 0.30 mm seal (4) before installing it.
a Left: standard seal, Right: sleeved seal
4) Measurement of radial runout of flywheel

housing
Similarly to the measurement of the facial a Clean, degrease, and dry the contacting
runout, set dial gauge [1] so that its probe is surface against the flywheel housing.
at right angle to the spigot joint portion of the
flywheel housing. a Clean, degrease, and dry the seal lip sliding
surface (peripheral surface of the
a No error is caused by the end play of the crankshaft).
crankshaft in measurement of the radial
runout. However, observe other a Check that the housing, the end corner of the
precautions for measurement of the facial crankshaft and lip sliding surface are free
runout. from flaw, burr, sharp edge, rust, etc.
a Radial runout: Max. 0.30 mm
1) Procedure for installing standard seal

7. Rear oil seal a When installing rear seal (4), do not apply
oil or grease to the shaft and seal lip.
1] Put the large inside diameter side (b) of
installation guide (8) of rear seal (4) to the
end face of crankshaft (6).
140E-6 SERIES 50-37

a Take extreme care not to put the a After press fitting the seal, remove the
wrong end. red sealant layer from its periphery.
2] Push in rear seal (4) until its metal ring 2) Procedure for installing sleeved seal
passes over the large inside diameter
a When installing the rear seal, do not
side of the inner plastic tube.
apply oil or grease to the crankshaft or
a Lightly tap with a plastic hammer to the contact face and seal lip face of
install while taking care not to deform sleeve (7).
the metal ring. 1] Set sleeve and rear seal assembly (9) to
3] After pushing in the rear seal, remove tool N2.
installation guide (8).
2 Contact face of sleeve (7):
a When removing the installation guide,
take care not to damage the seal lip.
2] Set sleeve (7) of the rear seal to the end

4] Tighten the four bolts evenly to press fit
of crankshaft (6). Press fit sleeve and rear
rear seal (4) until the end of tool N1
seal assembly (9) by tightening the four
reaches the end of crankshaft (6).
bolts evenly until the end face of tool N2
a First tighten the bolts for tool N1 reaches the end face of crankshaft (6).
without washers until they reach the
bottom, and then tighten the bolts
using two washers per bolt.
a Take extreme care not to damage the
lip when setting the tools for press
fitting the seal.
50-38 140E-6 SERIES

a Tighten tool N2 with the bolts and

4 Flywheel:
washers.
60 kg
3] Remove N2 and install N3.

2) Tighten the mounting bolts according to the
4] Tighten the four bolts evenly to press fit
following procedure.
the sleeve and rear seal assembly (9)
until the end of tool N3 reaches the end of 3 Flywheel mounting bolt:
crankshaft (6). 1st time: 118 ± 4.9 Nm {12 ± 0.5
a First tighten the bolts for tool N3 kgm}
without washers until they reach the 2nd time: By using tool J, tighten
bottom, and then tighten the bolts the bolts by 90 deg. (30 deg. /0) in
using two washers per bolt. the order of (1) to (8).
a After press-fitting the seal, remove the
red sealant layer from its periphery.
a Press fitting depth of rear seal:
13.2 ± 0.2 mm from end of crankshaft
a When not using tool J, make marks (f) on

the bolts and flywheel with paint etc. and
then tighten the bolts by 90 deg. (+30 deg.
/0) in the order of (1) to (8).
8. Flywheel a After tightening, put a punch mark (g) on
1) Using eyebolt [1], sling and install flywheel each bolt head to indicate the number of
(1) to the crankshaft and tighten the bolts. tightening.
a Install the flywheel while aligning the a When a new bolt is used, do not put a
dowel pin of the crankshaft with the dowel punch mark on its head.
hole of flywheel.
a Take care that the flywheel does not
touch the speed sensor.
2 Threaded part and seat surface of
bolt:
Engine oil (EO30)
140E-6 SERIES 50-39

a The bolt which has five punch marks 3 Mounting bolt:

must be replaced without being reused. 784 ± 44.1 Nm {80 ± 4.5 kgm}
3) After installing the flywheel, measure the

facial runout and radial runout with dial
gauge [1].
a Facial runout: Max. 0.20 mm
a Radial runout: Max. 0.13 mm
10.Sub idler gear and oil pump assembly

1) Install oil pump assembly (1).
3 Mounting bolt:
98 to 123 Nm {10 to 12.5 kgm}
2) Install sub idler gear (2) together with shaft

9. Main idler gear (4) and plate (3).
1) Install bearing (3) and shaft (2) to the outside
of main idler gear (1) and install bearing (3) a Install shaft (4) with stamp "TOP" at top
and plate (4) to the inside. and install plate (3) with the inside
chamfered portion directed toward the
a Direct the inside chamfered portion of gear.
plate (4) toward the gear.
2) While matching stamps "A" of the crankshaft 3 Mounting bolt:
gear and main idler gear (1) with each other, 377.6 to 426.6 Nm {38.5 to 43.5
tighten mounting bolt (5). kgm}
50-40 140E-6 SERIES

3 Mounting bolt:
98 to 123 Nm {10 to 12.5 kgm}
12.Cam follower assembly

1) Install two lever assemblies (5) to shaft (6).
a Insert the cam follower so that the side on
which the ball is driven in the shaft is
directed toward the rear of the engine.
2) Install snap ring (4).
11.Camshaft
1) Install camshaft (1) to the cylinder block,
while rotating it so that it does not damage
the cam bushing.
a If the cam gear was replaced, put it in an
electric oven etc. and heat it at 220 to
240°C for 30 to 60 minutes, and then
install it by shrink-fit.
2 Journal face of camshaft:
3) Install cam follower assembly (1), matching
Engine oil (EO30) with the dowel pin, and tighten mounting
bolts (2).
4 Camshaft (1):
3 Mounting bolt:
20 kg
44.1 to 58.8 Nm {4.5 to 6.0 kgm}
2) While matching stamps (c) of camshaft gear

(1) and the main idler gear with each other, 4) Install cover (3) together with the O-ring.
tighten mounting bolts (2). 3 Mounting bolt:
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
140E-6 SERIES 50-41

a When installing fuel supply pump drive

gear (7) to the fuel supply pump shaft,
match its stamp (B) with stamp (B) of the
main idler gear (portion of Q in the figure).
3 Mounting bolt:
245 to 274 Nm {25 to 28 kgm}
13.Fuel supply pump assembly, EGR oil pump, and

drive gear
1) Install oil junction block (1) and oil tube (2).
2) Install EGR oil pump (3).
3) Lightly tighten fuel supply pump drive
housing (4) with bolts [1].
4) Install fuel supply pump assembly (5).
14.Measurement of backlash and end play
2 Fuel supply pump mounting bolt:
Liquid gasket (LT-2) a Measure the backlash and end play of each
gear with dial gauge [1].
a Install the supply pump so that its
coupling is matched with omitted tooth a When measuring the water pump drive gear
(A) of the drive housing. portion and EGR oil pump drive gear portion,
keep them installed lightly.
5) Remove bolts [1] that are lightly tightening

fuel supply pump drive housing (4). • Standard backlash values of each gear
Point Range (mm)
A 0.141 to 0.425
B 0.129 to 0.391
C 0.129 to 0.391
D 0.141 to 0.425
E 0.080 to 0.417
F 0.095 to 0.346
G 0.118 to 0.369
• Standard end play values of each gear
Point Range (mm)
1 0.1 to 0.25
2 0.05 to 0.17
6) Install fuel supply pump drive gear (7) to the
3 0.014 to 0.315
fuel supply pump shaft and tighten mounting
nut (6). 4 0.07 to 0.20
50-42 140E-6 SERIES

a If a measured value is out of the standard

standard".
15.Front cover
1) Install the gasket and install front cover (1),
using eyebolts [1].
4 Front cover (1):

65 kg
2) Put both of your hands to the metal ring of

seal (1) and push the seal evenly to pass
over the large diameter side of the plastic
inner tube.
a Lightly tap with a plastic hammer to install
while taking care not to deform the metal
ring.
3) After pushing in the seal, remove plastic
inner tube (2).
16.Front oil seal
Install front oil seal (1) according to the following a When removing the plastic inner tube,
procedure. take care not to damage the seal lip.
a Before installing the seal, check that the end

corner and lip sliding contact surface of the
crankshaft and the front cover are free from
flaw, burr, and rust.
a When installing the seal, do not apply oil or
grease to the crankshaft and seal lip. Also,
wipe away oil or grease thoroughly from the
shaft.
a Never remove the inner plastic tube (2) of the
supply part seal just before installation.
1) Set large inside diameter side a of inner
plastic tube (2) to the end of crankshaft (3).
a Take care not to put the wrong end. 4) Using tool M1, tighten the three bolts evenly
until the end of tool M1 reaches the end of
crankshaft (5).
140E-6 SERIES 50-43

a First use 55 mm bolts and tighten until

they bottom. Then replace them with 35
mm bolts and tighten.
a Seal driving distance from crankshaft (a):
9.1 to 10.1 mm
a Take care not to damage the seal lip
when setting the tools for press fitting.
a After press fitting the seal, remove the red
sealant layer from its periphery.
4) Install inner spring (4) and outer spring (3),

and then install upper seat (2).
5) Using tool C, compress the valve spring and
install valve cotter (1).
a Check that the cotter is fitted securely to
the groove of the valve stem by hitting the
valve stem lightly with a plastic hammer.
17.Damper assembly
Sling damper assembly (1), match it with the
dowel pin, and tighten 6 mounting bolts (2).

45 kg
3 Mounting bolt (2):
245 to 309 Nm {25 to 31.5 kgm}
6) Check that the cylinder head mounting face
and inside of the cylinders are free from dirt
and foreign matter, and then set cylinder
head gasket (8).
a When installing the gasket, check that the
grommets are not fall off or lost.
18.Cylinder head assembly

1) Using tool Q, press fit valve stem seal (5)
until it reaches the valve guide.
2) Install valve (7).
2 Valve stem:
Engine oil (EO30)
3) Install lower seat (6). 7) Check the following items of each cylinder
head mounting bolt. If any of them is out of
the standard, do not reuse the mounting bolt
but replace it.
50-44 140E-6 SERIES

• The number of tightening times reaches

six times (five punch marks) or less
• Stem length of bolt (a)
Short bolt: Min. 170.8 mm
Long bolt: Min. 205.8 mm
8) Using eyebolts [1], sling and install cylinder

head assembly (9) and tighten the mounting
bolts and auxiliary bolts.
2 Mounting bolt:
Molybdenum disulfide lubricant
(LM-P)
or engine oil (EO30)
a When not using tool J, make marks (a)
3 Cylinder head assembly (9): and (b) on the bolt and head with paint
25 kg etc. and then tighten the bolt by 90 deg.
(+30 deg. /0).
a After tightening bolts (1) to (6), tighten
bolt (7).
3 Bolt (7):
66.6 ± 7.4 Nm {6.8 ± 0.8 kgm}
3 Mounting bolt
1st time: 137 to 157 Nm {14 to 16
kgm}
2nd time: 284 to 294 Nm {29.0 to
30.0 kgm}
3rd time: By using tool J, tighten
19.Crosshead
1) Install crosshead (1).
2) Adjust the crosshead according to the
following procedure.
1] Loosen the locknut and return the
adjustment screw.
2] While pressing the top of crosshead
lightly, tighten the adjustment screw.
140E-6 SERIES 50-45

3] After the adjustment screw touches the

valve stem, tighten it further by 20
degrees.
4] At this position, tighten the locknut.
5] Remove the crosshead to insert the fuel
injector.
3 Lock nut:
58.7 ± 5.9 Nm {6.0 ± 0.6 kgm}
2) Insert fuel injector (2) into holder (3), and

then insert injector connector (4) while facing
it to the high-pressure pipe insertion hole.
20.Fuel injector, common rail, and high-pressure

pipe
a Check that the inside of the injector sleeve is
free from dirt.
k Before installing the high-pressure pipe,

check it for the following. If the high- 3) Apply engine oil to portion (a) of the valve
pressure fuel pipe has any defect, replace cotter and portion (b) of crosshead (5), and
it with a new one since fuel may leak. then install the crosshead.
• Visually check that the taper seal
2 Valve cotter (a) and crosshead (b):
portion of the connection (portion (a):
2 mm area from the tip-end) is free Engine oil (EO30)
from longitudinal slits (b) or dents (c).
• Make sure that there are no steps or
wear which your fingernail can feel on
the portion (d) (end of taper seal:
portion at the area of 2 mm from the
tip). (Namely, this portion must be free
from fatigue.)
4) Install the spherical washer to bolt (6) and

lightly tighten holder (3).
2 Spherical washer:
Engine oil (EO30)
5) Fit the O-ring, insert high-pressure pipe
sleeve (7) through the high-pressure pipe
insertion portion, and tighten it lightly while
matching it with injector connector (4).
1) Install common rail (1) lightly.
Tighten sleeve nut (8) on the common rail
side as well and take care that the high-
50-46 140E-6 SERIES

pressure pipe does not lean. (Lightly tighten

in the order of No. 1, No. 6, No. 5, No. 4, No.
3, and No. 2.)
2 O-ring:
Engine oil (EO30)
6) Lightly tighten sleeve nuts (10) and (11) on
the common rail side and fuel supply pump
side.
7) Tighten holder (3) to the specified torque.
a While taking care that the high-pressure
pipe and injector do not move, tighten bolt
(6). 9) Using spanner-type torque wrench [1],
3 Holder mounting bolt: tighten high-pressure pipe sleeve nuts (7),
(8), (10), and (11) to the specified torque.
59.0 to 74.0 Nm {6.0 to 7.5 kgm}
8) Tighten special nuts (9) of the common rail to a Loosen the sleeve nuts and check that an
the specified torque. excessive force is not applied to the high-
pressure pipe, and then tighten them to
a Loosen the special nuts and check that
the specified torque.
an excessive force is not applied to the
high-pressure pipe, and then tighten them a Check that the O-ring is not forced out.
to the specified torque.
3 Sleeve nut:
3 Special bolt: 39.2 to 44.1 Nm {4 to 4.5 kgm}
59.0 to 74.0 Nm {6.0 to 7.5 kgm}
10)Tighten clamp (12).

11)Install fuel spray prevention caps (13), (14),
(15), and (16) to the sleeve nuts at both ends
of the high-pressure pipe.
140E-6 SERIES 50-47

a When installing the fuel spray prevention

cap, direct its slit down on the cylinder
head side and toward the cylinder block
on the supply pump side and common rail
side.
4] Insert spring clamp (8) in the injector

connector and tighten harness clamp (9)
with bolt (10).
5] Install harness terminal (6) to fuel injector
(5) and tighten two capture nuts (7).
12)Install common rail cover (17). a Remove slack of the harness and
13)Install clamp (18). press it against the injector.
a Tighten the capture nuts alternately.
3 Capture nut:
2 ± 0.2 Nm {0.2 ± 0.02 kgm}
6] Pour engine oil in cam follower sockets
(a) and (b).
2 Cam follower socket:
Engine oil (EO30)
21.Injector harness, rocker arm, and shaft

assembly
1) Tighten the injector harness.
a Since it is difficult to insert from inside
with the O-ring fitted to the connector,
install it according to the following
procedure.
1] With O-ring (2) of connector (1) removed,
take out the harness from inside of the
cylinder head and fit the O-ring.
2 O-ring:
Engine oil (EO30)
2] Install holder (3) to connector (1) and
push in connector (1) to a position where
the O-ring is fitted.
3] Fix holder (3) with mounting bolt (4).
50-48 140E-6 SERIES

2 Portion (c) of push rod and portion

(d) of crosshead:
Engine oil (EO30)
2) Install push rods (11).

a Apply oil to portions (c) of the push rods
and portions (d) of the crosshead.
3) Rocker arm and shaft assembly
Install and tighten rocker arm and shaft
assembly (12) with mounting bolts (13), (14),
and (15).
a Note that the mounting bolts have
different lengths.
Mounting bolt (13): Stem length is 120
mm
Mounting bolt (14): Stem length is 90 mm
Mounting bolt (15): Stem length is 75 mm
a Check that the spherical portion of the
adjustment screw is fitted properly in the
socket of the push rod, and then tighten
the mounting bolt.
140E-6 SERIES 50-49

3 Mounting bolt: 2) Insert feeler gauge I between rocker arm (3)

93 to 103 Nm {9.5 to 10.5 kgm} and crosshead (4) and tighten adjustment
screw (5) to a degree that the feeler gauge
moves lightly.
3) Tighten locknut (6) at this position to fix
adjustment screw (5).
3 Lock nut:
53 to 64.7 Nm {5.4 to 6.6 kgm}
a After tightening the lock nut, check the
valve clearance again.
23.Cylinder head cover

Fit the gasket and install cylinder head cover (1).
a Lightly tighten bolt (2) on the front side on the
intake manifold side since it is used to tighten
22.Adjusting valve clearance the harness clamp, too.
a As the valve clearance, adjust the clearance

between the crosshead and rocker arm to
the following value.
a Valve clearance (cold)
Air intake valve Exhaust valve
0.35 ± 0.02 0.57 ± 0.02
a Rotate the crankshaft and adjust the valve

clearance of each cylinder in the firing order
of 1, 5, 3, 6, 2, and 4.
1) While watching the valve, rotate the
crankshaft forward to match stamp line 24.Electric fuel feed pump and fuel piping
"1.6TOP" (a) of vibration damper (1) to
1) Install brackets (1) and (2).
pointer (2).
2) Install electric fuel feed pump (3) together
with the mounting bracket.
3) Install oil tubes (6), (7), and (8).
3 Oil block side of tube (7):
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
Drive housing side of tube (7):
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
Oil block side of tube (8):
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
Supply pump side of tube (8):
7.9 to 12.7 Nm {0.8 to 1.3 kgm}
50-50 140E-6 SERIES

4) Install fuel tubes (4), (5), and (6).

3 Electric fuel feed pump side of
tube (4):
24 to 27 Nm {2.4 to 2.7 kgm}
14.8 to 19.6 Nm {1.5 to 2.0 kgm}
Common rail side of tube (5):
17.7 to 22.6 Nm {1.8 to 2.3 kgm}
Supply pump side of tubes (5) and
(9):
14.8 to 19.6 Nm {1.5 to 2.0 kgm} 4) Install fuel cooling plate (5).
5) Install fuel tubes (9) and (10). 5) Install fuel tube (6).
3 Fuel junction block side of tube 3 Fuel tube (6):
(10):
84 to 132 Nm {8.5 to 13.5 kgm}
43 to 47 Nm {4.4 to 4.8 kgm}
14.8 to 19.6 Nm {1.5 to 2.0 kgm}
26.Harness
1) Connect connectors CN1 to CN6.
2) Tighten the cylinder head cover bolts, which
6) Install interconnection pipe (11) to the were tightened lightly, to the specified torque
position shown in the figure. and install harness (1) to the clamp.
a If it is installed nearer to the pump by
mistake, the pump is damaged.
27.Fuel tube
Install fuel tube (1).
25.Fuel cooling plate

1) Fit the O-ring and install plate (1).
2) Install bracket (2).
3) Install clamps (3) and (4).
140E-6 SERIES 50-51

4 Air intake manifold connector and

joint (12):
45 kg
28.Air intake manifold

1) Sling and install air intake manifold (1).
a Tighten the bolts in the order of (15) to
(34).
3 Bolt:
58.8 to 73.5 Nm {6.0 to 7.5 kgm}
4 Air intake manifold (1):

45 kg
2) Install brackets (2), (3), (4), (5), and (6).
3) Install brackets (7), (8), (9), and (10).
4) Install oil level gauge (11).
29.Alternator and air compressor

1) Install alternator assembly (1), air
compressor (2), and cover (4).
3 Mounting bolt (3):
24.5 to 29.4 Nm {2.5 to 3.0 kgm}
2) Install belt (5).
1] Push pulley (d) inward with bolt (d).
2] Install belt (5) to pulleys (c), (e), and (f).
3] Return bolt (a) and apply pulley (d) to the
belt.
4] After installing the belt, return bolt (a) until
the threaded portion from the bolt seat to
the nut is 70 mm, and then tighten locknut
(b).
5] Check that the belt is fitted to the
corresponding pulley groove.
5) Sling and install air intake manifold

connector and joint (12) together.
50-52 140E-6 SERIES

32.Water pump
Install water pump (1).
30.Water tube
1) Tighten bolts (2), (3), (4), (5), and (6) to
tighten water tube (1).
a Lightly tighten bolt (7) since it is also used
to tighten the tube connected to the EGR
cooler.
a The water tube depends on the
applicable machine.
3 Bolts (2), (3), (4), (5), (6):
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
33.Exhaust manifold
1) Insert the rings in the manifolds at both ends.
For the direction of each abutment joint, see
the following figure.
Install the ring with stamp "R" directed
toward the center exhaust manifold.
2) Insert the center manifold in the manifolds at
both ends. (See the cross section)
31.Bracket
Install bracket (1).
140E-6 SERIES 50-53

35.EGR valve, fuel filter, and DSOV block

3) Fit the gasket, sling and install the exhaust
manifold, and tighten the mounting bolts in 1) Install EGR valve (1), fuel filter (2), and
the numerical order shown below. DSOV block (2a).
4 Exhaust manifold:
25 kg
a Lightly tighten the three bolts of (1) to (3)
shown below in this order and then the
remaining bolts (4) to (24) in this order.
After that, tighten all bolts (1) to (24) to
the specified torque in this order.
2 Mounting bolt:
(LC-G)
3 Mounting bolt: 2) Install oil tube (3).
58.8 to 73.5 Nm {6 to 7.5 kgm} 3 Block side for air vent:
24.5 to 34.3 Nm {2.5 to 3.5 kgm}
On cylinder block side and EGR
valve side:
34.3 to 44.1 Nm {3.5 to 4.5 kgm}
3) Install oil tube (4).
3 EGR valve side:
43 to 47 Nm {4.4 to 4.8 kgm}
EGR oil pump side:
34.3 to 44.1 Nm {3.5 to 4.5 kgm}
4) Install fuel tubes (5), (6), and (7).
3 Both ends of fuel tube (5):
34.Oil cooler assembly
34.3 to 44.1 Nm {3.5 to 4.5 kgm}
1) Using eyebolts and guide bolts, install the
Fuel junction block side of fuel
gasket and oil cooler assembly (1).
tube (6):
4 Oil cooler assembly: 14.8 to 19.6 Nm {1.5 to 2.0 kgm}
40 kg Fuel junction block side of fuel
2) Install bracket (2). tube (7):
14.8 to 19.6 Nm {1.5 to 2.0 kgm}
DSOV block side of fuel tube (7):
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
5) Install fuel tube (8).
50-54 140E-6 SERIES

3 Both ends of tube:

7.8 to 9.8 Nm {0.8 to 1.0 kgm}
3 Fuel filter side:
24.5 to 34.3 Nm {2.5 to 3.5 kgm}

8) Lay the high-pressure pipe and tighten clamp
(12) lightly.
9) Install harness mounting bracket (13).
36.Fuel pre-filter, engine controller, and oil filler pipe

1) Install electric fuel feed pump cover (1).
2) Install engine controller (2).
3) Install oil filler pipe (3).
4) Install fuel pre-filter (4).
140E-6 SERIES 50-55

3 Fuel tube:
43 to 47 Nm {4.4 to 4.8 kgm}
38.KCCV
1) Install KCCV mounting bracket (1).
37.Engine harness
1) Install the following connectors.
(1) J1
(2) J2
(3) PFUEL
(4) POIL
(5) BREAK OUT
(6) NE
(7) PIM
2) Install KCCV (2).

a The installed position of KCCV depends
on the applicable machine.
3) Install connector PCCV (3).
(8) TIM
(9) PDOSER
(10) SOV1
(11) TWTR
39.Engine controller cover

Install engine controller cover (1).
(12) PCV1
(13) PCV2
(14) G
50-56 140E-6 SERIES

40.Oil filter 42.EGR cooler and bracket

1) Install oil filter head (1). 1) Sling and install EGR cooler and bracket (1).
2) Install oil tube (2).
4 EGR cooler and bracket (1):
80 kg
41.Thermostat and water tube

1) Install thermostat (1).
2) Install water tube (2). 2) Install EGR coolant tubes (2), (3), (4), (5),
and (8).
3) Install EGR air vent tubes (6) and (7).
140E-6 SERIES 50-57

3 Mounting bolts (9) and (10):

19.6 to 29.4 Nm {2.0 to 3.0 kgm}
44.KVGT assembly
1) Install brackets (1), (2), and (3).
2) Install cover (4).
3) Install KVGT assembly (5).
43.Heat insulation plate

45.Doser connector and exhaust elbow
1) Install heat insulation plate (1).
1) Install exhaust elbow mounting bracket (1).
2 Mounting bolt:
(LC-G)
2) Install doser connector and exhaust elbow

(2).
a Apply seizure prevention compound to
2) Install heat insulation plates (2) and (3).
the threaded portions and head seats of
bolts (3), (4), and (5), and then tighten
them.
2 Mounting bolt:
(LC-G)
50-58 140E-6 SERIES

3 Mounting bolt (3): 46.Starting motor assembly

19.6 to 29.4 Nm {2.0 to 3.0 kgm} Install starting motor assembly (1).
Mounting bolt (5):
9.0 ± 0.5 Nm {0.9 ± 0.05 kgm}
47.Intake tube
Install intake tube (1).

4) Install hoses (7), (8) and (9).
3 Joint bolts (10) and (11):
24.5 to 34.3 Nm {2.5 to 3.5kgm}
48.Oil pan
1) Sling the engine assembly, place blocks [1]
in a place where suction tube (1) can be
installed, and stabilize the engine assembly
on them.
5) Install the following connectors.
(12) PAMB 4 Engine assembly:
(13) SVGT 2,000 kg
(14) SEGR 2) Install suction tube (1) and underframe (2).
(15) VGT_REV
(16) B-RES
(17) DOSER
(18) SOV2
(19) VGT_SOL
(20) EGR
3) Sling the engine assembly. Stably place oil

pan (3) fitted with the gasket on blocks [1],
lower the engine assembly onto it, and
tighten the mounting bolts.
140E-6 SERIES 50-59

2) Start the engine, keep its speed at 1,000 rpm

4 Oil pan (3):
or below, and stop it when its speed is
35 kg stabilized.
3) Stop the engine and check the fuel piping
and devices for fuel leakage.
a Check the high-pressure circuit for fuel
leakage focusing on the area where the
color checker is sprayed.
a If any fuel leakage is detected, repair it
and perform the checks from Step 1)
again.
4) Start the engine and keep it running at low
idle.
49.Tightening torque of sensor
If the sensor was replaced, tighten it to the a Check the high-pressure circuit for fuel
following torque. leakage focusing on the area where the
Sensor name Tightening torque
Boost pressure a If any fuel leakage is detected, repair it
23 ± 3 Nm (2.3 ± 0.3 kgm)
sensor and perform the checks from Step 1)
Boost temperature 23 ± 3 Nm (2.3 ± 0.3 kgm) again.
sensor 6) Start the engine and keep it running at high
Coolant idle.
temperature 23 ± 3 Nm (2.3 ± 0.3 kgm) 7) Stop the engine and check the fuel piping
sensor and devices for fuel leakage.
Engine oil
23 ± 3 Nm (2.3 ± 0.3 kgm)
pressure sensor a Check the high-pressure circuit for fuel
NE sensor 4.9 to 7.9 Nm {0.5 to 0.8 kgm} leakage focusing on the area where the
50.Check for fuel leakage
a If fuel supply pump (2), common rail (1), and
high-pressure piping were removed and
again.
installed, check for fuel leakage by the
8) Start the engine and keep it running at high
following method after assembling the
idle, then load the engine.
engine.
a When checking the engine for leakage as
it is installed on the machine, stall the
torque converter or relieve the hydraulic
pump.
again.
a Clean and degrease the engine and the parts
around it in advance so that you can check it
easily for fuel leakage.
1) Spray color checker (developer) over the fuel
supply pump, common rail, fuel injector, and
joints of the high-pressure piping.
50-60 140E-6 SERIES

Removal and installation of supply pump (ENG140-AD70-924-K-00-A)
Removal (ENG140-AD70-520-K-00-A) 8. Disconnect fuel pipes (17) and (18).

1. Disconnect connector PCCV (3) and remove
drain tube (1) and KCCV (2).
9. Remove four mounting bolts (19) to remove

supply pump assembly (20).
2. Disconnect connectors PCV1 (4), PCV2 (5) and
G (6).
3. Remove oil level gauge (7).
4. Disconnect EGR oil tube (9) and EGR oil drain
tube (8).
5. Disconnect fuel pipe (10).
6. Remove the fuel spray prevention caps of high-

pressure pipes (11) and (12) and loosen the
sleeve nuts to disconnect the high-pressure
pipes. Loosen the sleeve nuts on the common
rail side, too.
7. Disconnect fuel tubes (13) and (14) and oil tubes
(15) and (16).
140E-6 SERIES 50-61

a Clean and degrease the engine and the parts

Installation (ENG140-AD70-720-K-00-A)
around it in advance so that you can check it
a perform installation in the reverse order to easily for fuel leakage.
removal. 1) Spray color checker (developer) over the fuel
1. Check of connections of fuel high-pressure supply pump, common rail, fuel injector, and
piping joints of the high-pressure piping.
2) Start the engine, keep its speed at 1,000 rpm
a Check that the inside of the injector sleeve is
or below, and stop it when its speed is
free from dirt.
stabilized.
k Before installing the high-pressure pipe,
check it for the following. If the high-
pressure fuel pipe has any defect, replace a Check the high-pressure circuit for fuel
it with a new one since fuel may leak. leakage focusing on the area where the
• Visually check that the taper seal color checker is sprayed.
portion of the connection (portion (a): a If any fuel leakage is detected, repair it
2 mm area from the tip-end) is free and perform the checks from Step 1)
from longitudinal slits (b) or dents (c). again.
• Make sure that there are no steps or 4) Start the engine and keep it running at low
wear which your fingernail can feel on idle.
the portion (d) (end of taper seal: 5) Stop the engine and check the fuel piping
portion at the area of 2 mm from the and devices for fuel leakage.
tip). (Namely, this portion must be free
from fatigue.) a Check the high-pressure circuit for fuel
again.
6) Start the engine and keep it running at high
idle.
2. Check for fuel leakage and perform the checks from Step 1)
a If fuel supply pump (2), common rail (1), and again.
high-pressure piping were removed and 8) Start the engine and keep it running at high
installed, check for fuel leakage by the idle, then load the engine.
following method after assembling the a When checking the engine for leakage as
engine. it is installed on the machine, stall the
torque converter or relieve the hydraulic
pump.
again.
a If no fuel leakage is detected, check is
completed.
50-62 140E-6 SERIES

3. Install fuel supply pump assembly (1). a If it is installed nearer to the pump by mistake,
the pump is damaged.
a Install the fuel supply pump so that its
6. Tighten high-pressure pipes (3) and (4).
coupling is matched with omitted tooth (A) of
the drive housing.(2). 3 Sleeve nut:
39.2 to 44.1 Nm {4 to 4.5 kgm}
7. Install fuel spray prevention caps to both ends of
fuel piping.
a When installing the fuel spray prevention cap,
direct its slit down on the common rail side
and toward the cylinder block on the supply
pump side.
8. Tighten fuel piping (12).

9. Install oil tube (13).
3 Cylinder block side:
34.3 to 44.1 Nm {3.5 to 4.5 kgm}
10.Install oil tube (14).
4. Tighten oil tubes (5), (6), and (7).
3 EGR oil pump side:
3 Oil block side of tube (5):
34.3 to 44.1 Nm {3.5 to 4.5 kgm}
9.8 to 12.7 Nm {1.0 to 1.3 kgm} 11.Install connectors PCV1 (16), PCV2 (17), and G
Drive housing side of tube (5): (15).
9.8 to 12.7 Nm {1.0 to 1.3 kgm} 12.Install oil level gauge (18).
Oil block side of tube (6):
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
7.9 to 12.7 Nm {0.8 to 1.3 kgm}
5. Tighten fuel pipes (8), (9), (10), and (11).
3 Supply pump side of tubes (8) and (9):
7.9 to 12.7 Nm {0.8 to 1.3 kgm}
Fuel junction block side of tube (10):
43 to 47 Nm {4.4 to 4.8 kgm}
14.8 to 19.6 Nm {1.5 to 2.0 kgm}
Electric fuel feed pump side of tube
(11):
24 to 27 Nm {2.4 to 2.7 kgm}
14.8 to 19.6 Nm {1.5 to 2.0 kgm}
140E-6 SERIES 50-63

13.Install KCCV (20).

14.Install drain tube (19).
15.Install connector PCCV (21).
50-64 140E-6 SERIES

Procedures for replacing engine front oil seal (ENG140-A350-924-K-00-A)
Removal (ENG140-A350-520-K-00-A) a ToolL

1. Belt
Tighten adjustment bolt (1) to release the
tension of the tensioner from the auxiliary belt.
Remove the auxiliary belt.
a Take care not to damage crankshaft (5).
2. Damper assembly
Sling damper assembly (1), remove the
mounting bolts, and remove the damper
assembly.

45 kg
3. Front oil seal

1) Drill several holes of approximately 3 mm in
diameter on front seal (3).
2) Change the end of tool L to the drill type one.
3) Insert the tip of tool L into the drilled holes,
and remove the seal by the impact of slide
hammer (SH). (Apply impact evenly so that
the front seal is not tilted.)
a Remove all the chips.
a If the seal is sleeved, cut and remove
sleeve (6) with a chisel and a hammer.
140E-6 SERIES 50-65

Installation (ENG140-A350-720-K-00-A)
a Check the wear of the shaft and select either a

"standard seal" or a "sleeved seal". If the wear
condition of the shaft is glossy and no scratches
(no scratch is felt when touched by a finger,
wear depth is 10 mm or less), install "standard
seal A". In other cases, install "sleeved seal B".
guide.
a (6): Shows the sleeve.
a Do not remove installation guide (7) from front
3) Remove M2 and install M1.
seal (3) before installing it.
4) Press-fit sleeve and seal assembly (9) by
a Handle front seal (3) and sleeve (6) as an tightening the three bolts (35 mm) evenly
assembly and never separate them from each until the end face of tool M1 reaches the end
other. face of crankshaft (5).
• Standard spare part • Sleeved seal a Seal driving distance from crankshaft (a):
of seal 9.1 to 10.1 mm
a Take care not to damage the lip when
setting the tools for press-fitting the seal.
a After press-fitting the seal, remove the red
1. Procedure for installing standard seal

a Before installing the seal, check that the end
corner and lip sliding contact surface and the
housing are free from flaw, burr, and rust.
a When installing the seal, do not apply oil or 2. Damper assembly
grease to the shaft and seal lip. Also, wipe Sling damper assembly (1), match it with the
away oil or grease thoroughly from the shaft. dowel pin, and tighten 6 mounting bolts (2).
a Never remove the inner plastic tube (7) of the
supply part seal just before installation. 4 Damper assembly (1):
1) Put large inside diameter (b) side of plastic 45 kg
inner tube (7) to the end of crankshaft (5). 3 Mounting bolt (2):
a Take care not to put the wrong end. 245 to 309 Nm {25 to 31.5 kgm}
2) Set the sleeve of the seal to the end of
crankshaft (5). Press-fit sleeve and seal
assembly (9) by tightening the three bolts
evenly until the end face of tool M2 reaches
the end face of crankshaft (5).
50-66 140E-6 SERIES

3. Install belt (1).

1) Push pulley (d) inward with bolt (a).
2) Install belt (1) to pulleys (c), (e), and (f).
3) Return bolt (a) and apply pulley (d) to the
belt.
4) After installing the belt, return bolt (a) until
the threaded portion from the bolt seat to the
nut is 70 mm, and then tighten locknut (b).
5) Check that the belt is fitted to the
corresponding pulley groove.
140E-6 SERIES 50-67

Procedures for replacing engine rear oil seal (ENG140-A510-924-K-00-A)
Removal (ENG140-A510-520-K-00-A) a Tool L

1. Flywheel
flywheel (1) using the guide bolts.
4 Flywheel (1):
60 kg
a Left: standard seal, Right: sleeved seal
2. Rear oil seal

Standard seal
1) Drill several holes of approximately 3 mm in
diameter on rear seal (4).
2) Change the end of tool L to the drill type (DT)
one.
3) Insert the tip of tool L into the holes drilled in
step 1), and remove the seal by the impact of
slide hammer (SH). (Apply impact evenly so
that the rear seal is not tilted.)
Sleeved seal
1) Cut and remove sleeve (7) by using a chisel
and a hammer.
2) Change the end of tool L to the puller type
(PT) one.
3) Hitch the end of tool L to the metal ring of the
rear seal and pull out the seal by applying
impacts using slide hammer (SH).
a Remove all the chips.
a Take care not to damage crankshaft (6).
50-68 140E-6 SERIES

1) Put the large inside diameter side (b) of

Installation (ENG140-A510-720-K-00-A)
installation guide (8) of rear seal (4) to the
a Check the wear of the shaft and select either a end face of crankshaft (6).
"standard seal" or a "sleeved seal". If the wear
a Take extreme care not to put the wrong
condition of the shaft is glossy and no scratches
end.
(no scratch is felt when touched by a finger,
wear depth is 10 mm or less), install "standard
seal A". In other cases, install "sleeved seal B".
guide.
a (7): Shows the sleeve.
a Do not remove installation guide (8) from rear
seal (4) before installing it.
a Handle rear seal (4) and sleeve (7) as an
assembly and never separate them from each
other.
2) Push in rear seal (4) until its metal ring

passes over the large inside diameter side of
the inner plastic tube.
a Lightly tap with a plastic hammer to install
while taking care not to deform the metal
ring.
3) After pushing in the rear seal, remove
installation guide (8).
a When removing the installation guide,
take care not to damage the seal lip.
a Clean, degrease, and dry the contacting surface

against the flywheel housing.
a Clean, degrease, and dry the seal lip sliding
surface (peripheral surface of the crankshaft).
a Check that the housing, the end corner of the
crankshaft and lip sliding surface are free from
flaw, burr, sharp edge, rust, etc.
4) Tighten the four bolts evenly to press fit rear

seal (4) until the end of tool N1 reaches the
end of crankshaft (6).
a First tighten the bolts for tool N1 without
washers until they reach the bottom, and
then tighten the bolts using two washers
per bolt.
a Take extreme care not to damage the lip
when setting the tools for press fitting the
1. Procedure for installing standard seal seal.
a When installing rear seal (4), do not apply oil

or grease to the shaft and seal lip.
140E-6 SERIES 50-69

a After press fitting the seal, remove the red a Tighten tool N2 with the bolts and
sealant layer from its periphery. washers.
2. Procedure for installing sleeved seal 3) Remove N2 and install N3.

4) Tighten the four bolts evenly to press fit the
a When installing the rear seal, do not apply oil sleeve and rear seal assembly (9) until the
or grease to the crankshaft or the contact end of tool N3 reaches the end of crankshaft
face and seal lip face of sleeve (7). (6).
1) Set sleeve and rear seal assembly (9) to tool
a First tighten the bolts for tool N3 without
N2.
washers until they reach the bottom, and
2 Contact face of sleeve (7): then tighten the bolts using two washers
Liquid gasket (LG-7) per bolt.
a After press-fitting the seal, remove the red
a Press fitting depth of rear seal:
13.2 ± 0.2 mm from end of crankshaft
2) Set sleeve (7) of the rear seal to the end of

crankshaft (6). Press fit sleeve and rear seal
assembly (9) by tightening the four bolts
evenly until the end face of tool N2 reaches
the end face of crankshaft (6).
3. Flywheel
1) Using eyebolt [1], sling and install flywheel
(1) to the crankshaft and tighten the bolts.
a Install the flywheel while aligning the
dowel pin of the crankshaft with the dowel
hole of flywheel.
a Take care that the flywheel does not
touch the speed sensor.
2 Threaded part and seat surface of
bolt:
Engine oil (EO30)
50-70 140E-6 SERIES

a The bolt which has five punch marks

4 Flywheel:
must be replaced without being reused.
60 kg
2) Tighten the mounting bolts according to the 3) After installing the flywheel, measure the
following procedure. facial runout and radial runout with dial
gauge [1].
3 Flywheel mounting bolt:
a Facial runout: Max. 0.20 mm
1st time: 118 ± 4.9 Nm {12 ± 0.5
kgm} a Radial runout: Max. 0.13 mm
2nd time: By using tool J, tighten
the bolts by 90 deg. (30 deg. /0) in
the order of (1) to (8).
a When not using tool J, make marks (f) on

the bolts and flywheel with paint etc. and
then tighten the bolts by 90 deg. (+30 deg.
/0) in the order of (1) to (8).
a After tightening, put a punch mark (g) on
each bolt head to indicate the number of
tightening.
a When a new bolt is used, do not put a
punch mark on its head.
140E-6 SERIES 50-71

50-72 140E-6 SERIES

SHOP MANUAL
ENGINE
140E-6 SERIES
Model Serial Number
140E-6
SERIES
60 Maintenance standard
6 60 Maintenance standard
140E-6 SERIES 60-1

Table of contents

60 Maintenance standard................................................................................................................... 60-1
KVGT.................................................................................................................................. 60-3
Engine main body parts............................................................................................................... 60-4
Cylinder head ...................................................................................................................... 60-4
Cylinder block ...................................................................................................................... 60-5
Cylinder liner ....................................................................................................................... 60-7
Crankshaft........................................................................................................................... 60-8
Cam follower and push rod ................................................................................................... 60-9
Piston ............................................................................................................................... 60-10
Connecting rod .................................................................................................................. 60-12
Timing gear ....................................................................................................................... 60-14
Camshaft .......................................................................................................................... 60-16
Valve and valve guide......................................................................................................... 60-17
Rocker arm........................................................................................................................ 60-19
Crosshead and guide ......................................................................................................... 60-20
Flywheel............................................................................................................................ 60-21
Cooling system......................................................................................................................... 60-23
Oil cooler........................................................................................................................... 60-23
Water pump....................................................................................................................... 60-25
60-2 140E-6 SERIES

KVGT
Intake and exhaust system parts (ENG107-A900-001-K-00-A)
KVGT (ENG140-AA10-034-K-00-A)
Unit: mm
No. Item Criteria Remedy
Use light finger pressure to push the compressor
wheel towards the side of the compressor housing.
Radial play (Play in radial
1 direction) Repeat the procedure for the turbine wheel and
housing.
Either wheel shall not contact the housing. Replace the
End play (play in axial whole KVGT
2 direction) 0.06 to 0.11 (including
If values of KDOC temperature: approximately 250°C hydraulic actuator
or below and KVGT solenoid current: approximately and KVGT
Check of KVGT opration 1000mA remain unchanged after performing position sensor).
3 (Check of nozzle ring regeneration for service, KVGT is defective.
operation) Since the time required for manual stationary
regeneration depends on the accumulated soot level,
see failure code CA2639.
140E-6 SERIES 60-3

Cylinder head
Engine main body parts (ENG107-R402-001-K-00-A)
Cylinder head (ENG140-A100-034-K-00-A)
a Order of tightening cylinder head mounting bolts

a Tighten the cylinder head mounting bolts in the order of (1) to (7).
Unit: mm
Tolerance Repair limit Correct by
Strain of cylinder head
1 mounting face grinding or
0 to 0.06 0.09 replace
Engine Standard Replace nozzle
2 Protrusion of nozzle
SAA6D140E-6 2.3 to 2.9 sleeve
Target (Nm Range (Nm
Bolt Procedure {kgm}) {kgm})
137 to 157
1st stage 147 {15}
Tightening torque of cylinder {14 to 16}
head mounting bolt 284 to 294 Tighten in order
3 (apply molybdenum disulfide (1) to (6) 2nd stage 289 {29.5} shown in above
{29 to 30}
or engine oil to underside of figure
bolt head.) Retighten by 90(+30/0)
3rd stage
90 deg. deg.
58.8 to 73.5
(7) – 68.6 {7}
{6 to 7.5}
Tightening torque for injector Target (Nm {kgm}) Range (Nm {kgm})
4 holder mounting bolt
66 {6.75} 58.8 to 73.5 {6.0 to 7.5}
Tightening torque for fuel Tighten
5 injection 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}
60-4 140E-6 SERIES

Cylinder block
Cylinder block (ENG140-A300-034-K-00-A)
140E-6 SERIES 60-5

Cylinder block
Unit: mm
Tolerance Repair limit Correct by
Strain of cylinder head
1 mounting face grinding or
0 to 0.090 0.135 replace
Diameter of main Standard size Tolerance Replace main
bearing metal mounting +0.018 bearing metal
hole 127 cap
-0.006
2 Roundness of mounting
Repair limit: 0.005
hole Replace bearing
Thickness of main 0 metal
bearing metal 3.5
-0.010
Standard size Tolerance Repair limit
Inside diameter of main Replace bearing
3 bearing metal +0.038
120 120.15 metal
+0.006
Standard size Tolerance Correct or
Diameter of cam bushing
4 mounting hole +0.030 replace cylinder
69 block
0
Inside diameter of cam Replace cam
5 bushing +0.040 bushing
65 65.15
0
Level difference between
underside faces of Repair limit: 0.14
6 Reassemble
cylinder block and front
cover
Procedure Target (Nm {kgm}) Range (Nm {kgm})
Tightening torque for 108 to 127 {11 to
1st stage 118 {12}
main cap mounting bolt 13}
7 (Apply engine oil to Retighten
230 to 240 {23.5 to
threads) 2nd stage 235 {24}
24.5}
3rd stage Retighten 90 deg. 90(+30/0) deg.
Tightening torque for 245 to 309 {25 to
8 crank pulley mounting – 275 {28} Retighten
31.5}
bolt
60-6 140E-6 SERIES

Cylinder liner
Cylinder liner (ENG140-A340-034-K-00-A)
Unit: mm
Replace cylinder
1 Projection of cylinder liner Permissible range: 0.07 to 0.15 liner or cylinder
block
Standard Repair limit
Rank Tolerance
size
Inside diameter of cylinder +0.020
S 140 140.14
liner 0
+0.040
2 L 140 140.14
+0.021 Replace cylinder
Roundness of inside of liner
Repair limit: 0.02
cylinder liner
Cylindricality of inside of
Repair limit: 0.02
cylinder liner
Outside diameter of cylinder Standard size Tolerance
liner 170 (0/-0.10)
3
Clearance between cylinder Replace cylinder
Standard clearance: 0 to 0.163
liner and block liner or block
Standard size Tolerance
Outside diameter of cylinder Replace cylinder
+0.090
liner 161.2 liner
4 +0.050
Standard interference Interference limit Replace or correct
Interference of cylinder liner
cylinder liner or
and block 0.02 to 0.12 Min. 0.02 block
Outside diameter of cylinder Replace cylinder
–0.073
liner (at O-ring) 158 liner
5 –0.103
Clearance between cylinder Replace cylinder
liner and block (at O-ring) Standard clearance: 0.024 to 0.089
liner or block
140E-6 SERIES 60-7

Crankshaft
Crankshaft (ENG140-A530-034-K-00-A)
Unit: mm
Standard value Repair limit Replace thrust
bearing metal or
1 End play
0.140 to 0.315 0.50 use oversize
metal
S.T.D. 120 119.88
Outside diameter of main 0.25U.S. 119.75 119.63
-0.050 Use undersize
journal 0.50U.S. 119.50 119.38
-0.068 journal or
0.75U.S. 119.25 119.13 replace
2
1.00U.S. 119.00 118.88
Roundness
0 to 0.009 0.020
Standard clearance Clearance limit Replace main
Clearance of main journal
0.044 to 0.106 0.27 bearing metal
S.T.D. 60 89.88
Outside diameter of crank 0.25U.S. 89.75 89.63
pin journal -0.050 Use undersize
0.50U.S. 89.50 89.38
-0.068 journal or
0.75U.S. 89.25 89.13 replace
3 1.00U.S. 89.00 88.88
Roundness
0 to 0.009 0.020
Standard clearance Clearance limit Replace
Clearance of crank pin
connecting rod
journal 0.042 to 0.110 0.24 bearing metal
Standard clearance Repair limit
Coaxiallity of all main Use undersize
journals: Max. 0.150 0.20 crankshaft or
4 Bend of crankshaft
Coaxiallity of adjacent replace
journals: Max. 0.050 0.10
60-8 140E-6 SERIES

Cam follower and push rod
Cam follower and push rod (ENG140-A710-034-K-00-A)
Umit: mm
Tolerance
Diameter of cam follower size
shaft -0.021
1 22 21.92
-0.034
Diameter of cam follower +0.021
22 22.07
shaft hole 0
Outside diameter of cam +0.05
2 31.7 31.50
roller +0.02
+0.038 Replace
Inside diameter of cam roller 12.7 12.78
3 +0.013
Diameter of cam roller pin 12.63 ±0.006 12.56
Diameter of push rod ball
4 0
end 12.7
-0.20
Diameter of push rod socket 0
5 13.4
end -0.20
6 Bend of push rod Repair limit: 0.3 (Overall swing of indicator)
140E-6 SERIES 60-9

Piston
Piston (ENG140-A580-034-K-00-A)
60-10 140E-6 SERIES

Piston
Unit: mm
Rank Tolerance
size
-0.120
1 Outside diameter of piston S 140 139.830 Replace piston
-0.135
-0.105
L 140 139.830
-0.120
Measuring Standard
No. point Tolerance
size
-0.015
2 No. 1 ring 2.9
-0.035 Replace piston
Thickness of piston ring
-0.010 ring
3 No. 2 ring 2.41
-0.035
-0.010
4 Oil ring 4
-0.030
Judge using groove wear
2 No. 1 ring
gauge (*1)
Judge using groove wear
Width of piston ring groove 3 No. 2 ring Replace piston
gauge (*2)
+0.040
4 Oil ring 4
+0.025
Measuring Standard Clearance
No. point clearance limit
Clearance between piston 2 No. 1 ring Judge using groove wear Replace piston
2 to 4
ring and piston ring groove 3 No. 2 ring gauge or piston ring
Oil ring 0.035 to
4 0.14
0.060
0.42 to 0.57
(Tension
2 No. 1 ring 16.5 to 23.5 2.0
N {1.68 to
2.40 kg})
1.15 to 1.30
No. 2 ring
(Tension Replace piston
(Identifica-
Closed gap of piston ring 3 16.2 to 24.2 1.8 ring or cylinder
tion: 2RN
N {1.65 to liner
white mark)
2.47 kg})
0.30 to 0.50
(Tension
4 Oil ring 84.5 to 111.7 1.0
N {8.61 to
11.39 kg})
Outside diameter of piston Replace piston
0
pin 52 pin
-0.006
5 +0.045
Diameter of piston pin hole 52 Replace piston
+0.035
Clearance between piston Standard clearance Clearance limit Replace piston
pin and piston 0.035 to 0.051 0.10 or piston pin
a *1: Part No. (groove wear gauge) 795-901-1150

*2: Part No. (groove wear gauge) 795-901-1130
140E-6 SERIES 60-11

Connecting rod
Connecting rod (ENG140-A590-034-K-00-A)
Unit: mm
Inside diameter of Standard size Tolerance Repair limit Replace
connecting rod small end bushing
+0.049
bushing (Ream after press 52 52.09 (Spare is half
1 fitting) +0.030 worked)
Clearance between Standard clearance Clearance limit Replace
connecting rod small end bushing or
bushing and piston pin 0.030 to 0.055 0.11 piston pin
Diameter of connecting rod Standard size Tolerance
Replace
2 small end bushing mounting +0.030 connecting rod
hole 57.4
0
Inside diameter of Standard size Tolerance Repair limit
connecting rod large end Replace
3 bearing metal (crank pin +0.042 bearing metal
90 90.15
journal) -0.008
Diameter of connecting rod
large end bearing metal
mounting hole (Before +0.026 Replace
measuring, tighten 95 –
-0.004 connecting rod
4 connecting rod cap
mounting bolt to specified
torque)
Thickness of connecting rod +0.002 Replace
2.5 –
bearing metal -0.008 bearing metal
Item Standard Repair limit
Parallelism and twist of Parallelism (a) 0.20 0.25 Replace
5 connecting rod connecting rod
Twist (b) 0.30 0.35
Dimension (c) 264 –
Tightening torque for Range (Nm
Procedure Target (Nm {kgm})
connecting rod cap {kgm})
6 mounting bolt 1st stage 127.5 {13}
117.7 to 132.4 Retighten
(Apply engine oil to bolt {12.5 to 13.5}
threads and nut seat) 2nd stage Retighten 90 deg. 90 (+30/0) deg.
Permissible range: Dispersion of weight of connecting
– Weight of connecting rod Replace
rods in one engine must not exceed 154 g.
60-12 140E-6 SERIES

Connecting rod
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.
140E-6 SERIES 60-13

Timing gear
Timing gear (ENG140-A5A0-034-K-00-A)
Unit: mm
Standard Tolerance Standard Clearance
Clearance between main size Shaft Hole clearance limit
1 idler gear bushing and shaft
-0.016 +0.034 0.025 to
56 0.20 Replace bushing
-0.029 +0.009 0.063
Clearance between sub idler -0.016 +0.055 0.016 to
2 gear bushing and shaft 56 0.20
-0.029 0 0.084
60-14 140E-6 SERIES

Timing gear
Unit: mm
3 End play of main idler gear Replace thrust
0.06 to 0.24 0.4 bearing
4 End play of sub idler gear 0.11 to 0.23 0.4
Po-
Measuring point Repair
si- Standard
limit
tion
Crank gear and main idler 0.141 to
5 gear (large) 0.425
Main idler gear (small) and 0.129 to
6 fuel supply pump gear
0.391
Main idler gear (small) and 0.129 to
7 cam gear
0.391
– Backlash of each gear Replace
Main idler gear (large) and 0.141 to
8 sub idler gear
0.425 0.6
Sub idler gear and oil 0.080 to
9 pump drive gear
0.417
Sub idler gear and water 0.095 to
10 pump drive gear
0.346
Fuel supply pump gear
0.118 to
11 and EGR oil pump drive
gear 0.369
140E-6 SERIES 60-15

Camshaft
Camshaft (ENG140-A5G0-034-K-00-A)
Unit: mm
Standard Repair limit Replace
1 End play thrust plate
0.1 to 0.25 0.36
Outside diameter of Replace
-0.016
camshaft journal 65 camshaft
2 -0.036
Clearance of camshaft Standard clearance Clearance limit Replace cam
journal 0.016 to 0.096 0.15 bushing
3 Bend of camshaft Repair limit: 0.03 (Overall swing of indicator)
Cam Standard size Tolerance Repair limit Replace
4 Height of cam Intake 55.48 ±0.1 55.08 camshaft
Exhaust 55.75 ±0.1 55.35
60-16 140E-6 SERIES

Valve and valve guide
Valve and valve guide (ENG140-A700-034-K-00-A)
140E-6 SERIES 60-17

Valve and valve guide
Unit: mm
Valve Tolerance
size Replace valve
1 Sinking distance of valve Intake 0 ±0.10 0.70 or valve seat
Exhaust 0 ±0.10 0.70
Valve Standard size Repair limit
2 Thickness of valve lip Intake 2.4 1.9 Replace valve
Exhaust 2.15 1.75
Valve Standard size Tolerance Correct or
3 Valve seat angle Intake 30 deg. ±15´ replace valve or
Exhaust 45 deg. ±15´ valve seat
Valve Standard size Tolerance
-0.045
Intake 10
Diameter of valve stem -0.060 Replace valve
-0.074
Exhaust 10
-0.089
Before head +0.019
is press fitted 10
+0.001
+0.008
Inside diameter of valve -0.009 Replace valve
4
guide After head is (Press fitted part) guide
press fitted 10 +0.011
-0.009
(Other than press
fitted part)
Standard
Valve Clearance limit
Clearance between valve clearance Replace valve
guide and stem Intake 0.036 to 0.068 0.22 or valve 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
Driving height of valve Standard Tolerance
5 guide Correct
22.0 ±0.2
Spring Standard size Repair limit
Free length of valve spring Outer 81.7 –
Inner 72.0 –
In- Standard installed Allowable
stal- load (N{kg}) installed
Spring led load (N{kg})
leng- Replace valve
6 Installed load of valve th spring
spring 51.0 424.3 ± 21.6 377.3 {38.5}
Outer
{43.3 ± 2.2}
46.0 215.6 ± 10.8 192.1 {19.6}
Inner
{22.0 ± 1.1}
Perpendicularity of valve
Repair limit: 2 deg. (both sides)
spring
60-18 140E-6 SERIES

Rocker arm
Rocker arm (ENG140-A770-034-K-00-A)
Unit: mm
Diameter of rocker arm Standard size Tolerance Replace rocker
shaft 32.0 ±0.0065 arm shaft
Inside diameter of rocker +0.087 Replace rocker
1 arm bushing 32.0
+0.035 arm
Standard clearance Clearance limit Replace rocker
Clearance between rocker
arm shaft or
arm shaft and rocker arm 0.0285 to 0.0935 0.13 rocker arm
Valve Standard Tolerance
2 Valve clearance (when cold) Intake 0.35 ±0.02 Adjust
Exhaust 0.57 ±0.02
Tightening torque for Target (Nm {kgm}) Range (Nm {kgm})
3 locknut of rocker arm Tighten
adjustment screw 58.8 {6} 52.9 to 64.7{5.4 to 6.6}
140E-6 SERIES 60-19

Crosshead and guide
Crosshead and guide (ENG140-A790-034-K-00-A)
Unit: mm
Depth of crosshead stem Replace
1 +0.3
receiver 6.2 6.61
0
Inside diameter of
11.04 ±0.02 11.17
crosshead
2 Outside diameter of Replace
+0.011
crosshead guide 11 10.95
0
Projection of crosshead
3 guide 49.0 ±0.25 – Correct
60-20 140E-6 SERIES

Flywheel
Flywheel (ENG140-A560-034-K-00-A)
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
140E-6 SERIES 60-21

Flywheel
Unit: mm
Facial runout of flywheel
1 Repair limit: 0.20
housing
Radial runout of flywheel
2 Repair limit: 0.20 Reassemble
housing
3 Facial runout of flywheel Repair limit: 0.20
4 Radial runout of flywheel Repair limit: 0.13
Tightening torque for Procedure Target (Nm {kgm}) Range (Nm {kgm})
Tighten in
flywheel housing 147 to 235 {15 to
1st stage 191 {19.5} order shown
5 mounting bolt (Apply 24}
in above
engine oil to bolt threads 2nd stage 245 to 309 {25 to
275 {28.0} figure
and seat surface) 31.5}
Tightening torque for Procedure Target (Nm {kgm}) Range (Nm {kgm}) Tighten and
flywheel mounting bolt 113 to 123 {11.5 to retighten in
6 (Apply engine oil to bolt 1st stage 118 {12} order shown
12.5}
threads and seat in above
surface) 2nd stage Retighten 90 deg. 90(+30/0) deg. figure
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.
60-22 140E-6 SERIES

Oil cooler
Cooling system (ENG107-B110-001-K-00-A)
Oil cooler (ENG140-B810-034-K-00-A)
140E-6 SERIES 60-23

Oil cooler
Unit: mm
Lift of thermostat at full Min. 7 mm (Before checking, leave valve in oil of 100°C for
opening 4 to 5 minutes)
1 Check that valve closes fully when its temperature is Replace
Opening/Closing of lowered from 100°C for full opening to 85°C. (Before
thermostat checking valve, leave it in oil for 4 to 5 minutes)
60-24 140E-6 SERIES

Water pump
Water pump (ENG140-BA10-034-K-00-A)
140E-6 SERIES 60-25

Water pump
Unit: mm
No. item Criteria Remedy
Standard Tolerance Standard
Interference between size Shaft Hole interference
1 impeller and shaft
-0.082 -0.120 0.025 to
16
-0.095 -0.150 0.068
Interference between drive +0.015 -0.023 0.025 to
2 gear and shaft 28 Replace
+0.002 -0.055 0.070
Interference between flange +0.015 -0.023 0.025 to
3 25
and shaft +0.002 -0.053 0.068
Clearance between impeller
4 and body Standard clearance: 0.6 to 0.9 (including end play)
5 Wear of water seal ring Limits of size: 1.5
60-26 140E-6 SERIES

INDEX
INDEX
A G
Aftercooler ................................................... 10-18 General assembly of engine .......................... 50-29
Air cleaner.................................................... 10-11 General disassembly of engine ...................... 50-14
Alternator ..................................................... 10-90 General view ................................................ 01-10
Alternator mounting....................................... 10-93
H
B Handling equipment of fuel system devices..... 00-15
Boost oil pump.............................................. 10-53 Handling of electrical equipment .................... 00-22
Handling of hydraulic equipment .................... 00-17
Handling of intake system parts ..................... 00-16
C How to read electric wire code ....................... 00-30
Cam follower and push rod .............................. 60-9 How to read the shop manual ........................ 00-12
Camshaft ..................................................... 60-16 How to read this manual .................................. 50-3
Coating materials list....................................... 50-5
Components layout drawingt ........................... 10-4
Connecting rod ............................................. 60-12
I
Conversion table .......................................... 00-46 Important safety precautions............................ 00-5
Cooling system circuit diagram ...................... 10-85 Intake and exhaust system circuit diagram ........ 10-9
Cooling system parts layout drawing .............. 10-84 Intake and exhaust system layout drawing ........ 10-7
Crankshaft ..................................................... 60-8
Crosshead and guide .................................... 60-20 K
Cylinder block.......................................10-39, 60-5
Cylinder head .......................................10-37, 60-4 KCCV layout drawing .................................... 10-27
Cylinder liner .................................................. 60-7 KCCV ventilator............................................ 10-29
KDPF .......................................................... 10-33
KVGT ..................................................10-12, 60-3
D
Dozing piping drawing ................................... 10-79
L
List of abbreviation........................................ 00-41
E Lubrication system diagram ........................... 10-50
EGR cooler .................................................. 10-24 Lubrication system parts layout drawing ......... 10-49
EGR system circuit diagram .......................... 10-21
EGR system piping drawing........................... 10-19
M
EGR valve ................................................... 10-22
Engine performance curve............................. 01-24 Machine model ............................................... 01-6
Engine wiring harness ................................... 10-98 Main filter ..................................................... 10-83
Exhaust gas regulation.................................... 01-3 Main moving parts ........................................ 10-41
Explanation of terms for maintenance standard ...00- Method of disconnecting and connecting of
13 push-pull type coupler ................................. 00-19
Mixing connector .......................................... 10-26
F
Flywheel ...................................................... 60-21
O
Flywheel and flywheel housing....................... 10-48 Oil cooler ........................................... 10-56, 60-23
Front cover................................................... 10-45 Oil cooler thermo-valve ................................. 10-58
Fuel dozing .................................................. 10-79 Oil filter ........................................................ 10-55
Fuel feed pump ............................................ 10-96 Oil pan ......................................................... 10-59
Fuel feed pump switch .................................. 10-97 Oil pump ...................................................... 10-51
Fuel system circuit diagram ........................... 10-62 Outline of CRI system ................................... 10-65
Fuel system parts layout drawing ................... 10-60
P
Piston .......................................................... 60-10
140E-6 SERIES 1
INDEX
Pre-filter ....................................................... 10-82

Precautions when performing operation.......... 00-33
Procedures for replacing engine front oil seal .. 50-65
Procedures for replacing engine rear oil seal ... 50-68
R
Removal and installation of supply pump ........ 50-61
Rocker arm .................................................. 60-19
Running-in standard and performance test
standard....................................................... 20-9
S
Sensor....................................................... 10-106
Sketches of special tools ............................... 50-11
Special tools list.............................................. 50-9
Specifications ................................................. 01-7
Standard tightening torque table .................... 00-37
Standard value table for engine........................ 20-3
Starting motor............................................... 10-94
Supply pump ................................................ 10-69
T
Thermostat................................................... 10-88
Timing gear ........................................ 10-44, 60-14
V
Valve and valve guide ................................... 60-17
Valve system ................................................ 10-46
W
Water pump ....................................... 10-86, 60-25
Weight table ................................................. 01-23
With built-in safety relay (11 kW) .................... 10-94
2 140E-6 SERIES
KOMATSU 140E-6 SERIES ENGINE
Form No. SEN05641–02
©2012 KOMATSU
All Rights Reserved
Printed in Japan 02–12

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SEN05641-02

ENGINE 140E -6 SERIES

00 Index and foreword

140E-6 SERIES 00-1

00-2 140E-6 SERIES

Oil cooler........................................................................................................................... 10-56

140E-6 SERIES 00-3

Timing gear ....................................................................................................................... 60-14

00-4 140E-6 SERIES

Foreword, safety and general information (ALL-0370-001-A-00-A)

Important safety notice (ALL-1120-012-A-01-A)

General precautions knowledge of welding perform the work. When

140E-6 SERIES 00-5

00-6 140E-6 SERIES

k Slinging with one rope may cause turning

Precautions for using mobile crane

• When installing wire ropes to an angular load,

140E-6 SERIES 00-7

Precautions for using overhead traveling crane Nominal

00-8 140E-6 SERIES

• Check that the O-ring is not damaged or

For tightening torques, see "Others",

140E-6 SERIES 00-9

Fire prevention (ALL-0000-001-K-27-A)

Action if fire occurs (ALL-0000-17A-K-01-A)

00-10 140E-6 SERIES

KDPF is a system for purifying soot in exhaust

Some kinds of rubber and plastics may produce

140E-6 SERIES 00-11

How to read the shop manual (ALL-0320-010-A-03-A)

Composition of shop manual

00-12 140E-6 SERIES

Explanation of terms for maintenance standard (ALL-0330-006-A-01-A)

Standard dimension and tolerance

140E-6 SERIES 00-13

• The performance and function of the products

00-14 140E-6 SERIES

Handling equipment of fuel system devices (PC-AD00-2A4-K-00-A)

Use care for working environment

How to clean parts when dirt is stuck

Precautions for replacing fuel filter cartridge

140E-6 SERIES 00-15

Handling of intake system parts (PC220-A900-2A4-K-00-A)

Be careful of working environment

00-16 140E-6 SERIES

Handling of hydraulic equipment (ALL-C000-2A4-P-01-A)

Be careful of working environment

Disassembly and maintenance work in the field

140E-6 SERIES 00-17

00-18 140E-6 SERIES

Method of disconnecting and connecting of push-pull type coupler (ALL-

140E-6 SERIES 00-19

00-20 140E-6 SERIES

140E-6 SERIES 00-21

Handling of electrical equipment (ALL-E000-2A4-P-01-A)

Precautions for handling electric equipment

Handling wiring harnesses and connectors

Main failures occurring in wiring harness

00-22 140E-6 SERIES

blow it with compressed air and spray it with

High-pressure water entering connector

Entry of water, mud or dirt when disconnecting a

140E-6 SERIES 00-23