PW140-7H55051
ïThis shop manual may contain attachments and optional equipment that are not available in your area. Please consult your local Komatsu distributor for those items you may require.
ïMaterials and specifications are subject to change without notice.
ïPW140-7 mount the SAA4D107E-1 engine.
ïFor details of the engine, see the 107 Series Engine Shop Manual.
Proper service and repair is extremely important for the safe operation of your machine. The service and repair techniques recommended and described in this manual are both effective and safe methods of operation. Some of these operations require the use of tools specially designed for the purpose.
To prevent injury to workers, the symbol is used to mark safety precautions in this manual. The cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation.
Mistakes in operation are extremely dangerous. Read the OPERATION & MAINTENANCE MANUAL carefully BEFORE operating the machine.
1.Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine.
2.When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing.
•Always wear safety glasses when hitting parts with a hammer.
•Always wear safety glasses when grinding parts with a grinder, etc.
3.If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, glasses, cap and other clothes suited for welding work.
4.When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator's compartment.
5.Keep all tools in good condition and learn the correct way to use them.
6.Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.
1.Before adding oil or making repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving.
2.Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them.
3.When disassembling or assembling, support the machine with blocks, jacks or stands before starting work.
4.Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.
1.When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. Before disconnecting or removing components of the oil, water or air circuits, first remove the pressure completely from the circuit.
2.The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned. Wait for the oil and water to cool before carrying out any work on the oil or water circuits.
3.Before starting work, remove the leads from the battery. ALWAYS remove the lead from the negative (-) terminal first.
4.When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage. Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane.
5.When removing covers which are under internal pressure or under pressure from a spring, always leave two bolts in position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove.
6.When removing components, be careful not to break or damage the wiring, Damaged wiring may cause electrical fires.
7.When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips on to the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip, or can even start fires.
8.As a general rule, do not use gasoline to wash parts. In particular, use only the minimum of gasoline when washing electrical parts.
9.Be sure to assemble all parts again in their original places. Replace any damaged part with new parts.
•When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is being operated.
10.When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits. Also check that connecting parts are correctly installed.
11.When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly.
12.When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole.
13.When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any measurements.
14.Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates suddenly, so never let anyone stand at either end of the track.
Be sure to follow the general precautions given below when performing removal or installation (disassembly or assembly) of units.
1.Precautions when performing removal work
•If the engine coolant water contains antifreeze, dispose of it correctly.
•After disconnecting hoses or tubes, cover them or install blind plugs to prevent dirt or dust from entering.
•When draining oil, prepare a container of adequate size to catch the oil.
•Confirm the match marks showing the installation position, and make match marks in the necessary places before removal to prevent any mistake when assembling.
•To avoid loosening any wire contacts, do not pull on the wires. In-order to prevent excessive force to the wiring, hold onto the connectors when disconnecting them.
A. Hoses and tubes using sleeve nuts
•Fasten tags to wires and hoses to identify and show their installation position and help prevent any mistakes when re-installing.
•Count and check the number and thickness of the shims, and keep them in a safe place.
•When raising or lifting components, be sure to use proper lifting equipment of ample strength and safety.
•When using forcing screws to remove any components, tighten the forcing screws uniformly in turn.
•Before removing any unit, clean the surrounding area and install a cover to prevent any dust or dirt from entering after removal.
★ Precautions when handling piping during disassembling
Fit the following blind plugs into the piping after disconnecting it during disassembly operations.
Nominal numberPlug (nut end)Sleeve nut (elbow end) Use the two items below as a set 0207376-5021007221-20210 (Nut), 07222-00210 (Plug) 0307376-5031507221-20315 (Nut), 07222-00312 (Plug) 0407376-5042207221-20422 (Nut), 07222-00414 (Plug) 0507376-5052207221-20522 (Nut), 07222-00515 (Plug) 0607376-5062807221-20628 (Nut), 07222-00616 (Plug) 1007376-5103407221-21034 (Nut), 07222-01018 (Plug) 1207376-5123407221-21234 (Nut), 07222-01219 (Plug)
B. Split flange type hoses and tubes
Nominal numberFlange (hose end)Sleeve head (tube end)Split flange 0407379-0040007378-1040007371-30400 0507379-0050007378-1050007371-30500
C. If the part is not under hydraulic pressure, the following corks can be used:
2.Precautions when carrying out installation work
•Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
•Install the hoses without twisting or interference.
•Replace all gaskets, O-rings, cotter pins and lock plates with new parts.
•Bend the cotter pin or lock plate securely.
•When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion with two or three drops of adhesive.
•When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is no dirt or damage, then coat uniformly with gasket sealant.
•Clean all parts, and correct any damage, dents, burrs or rust.
•Coat rotating parts and sliding parts with engine oil.
•When press-fitting parts, coat the surface with anti-friction compound (LM-P).
•After installing snap rings, check that the snap ring is installed securely in the ring groove.
•When connecting wiring connectors, clean the connector to remove all oil, dirt or water then connect securely.
•When using eye bolts, check that there is no deformation or deterioration, screw them in fully and align in the direction of the hook.
•When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
★ When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other hydraulic equipment removed for repair, bleed the air as follows:
1.Start the engine and run it at low idle.
2.Operate the work equipment control lever to operate the hydraulic cylinders, 4 - 5 times, stopping the cylinders 100 mm from the end of their stroke.
3.Next operate the hydraulic cylinder 3 - 4 times to the end of its stroke.
4.After doing this run the engine at normal speed.
★ When using the machine for the first time after repair or long storage, follow the same procedure.
3.Precautions when completing the operations
•If the engine coolant water has been drained, tighten the drain valve and add coolant water to the specified level. Run the engine to circulate the coolant water through the system. Then check the coolant water level again.
•If the hydraulic equipment has been removed and installed again, add hydraulic oil to the specified level. Run the engine to circulate the oil through the system. Then check the hydraulic oil level again.
•If the piping or hydraulic equipment, have been removed for repair, bleed the air from the system after reassembling the parts.
•For details, see TESTING AND ADJUSTING, Bleeding air.Add the specified amount of grease (molybdenum disulphide grease) to the work equipment related parts.
Removal
Disconnect the cable from the negative (-) terminal of the battery.
1.Close fuel stop valve (1) under the fuel tank.
2.Open the engine hood.
3.Disconnect clamp (3) of fuel hose (2) from bracket (4).
★ When loosening the bolt, fix the nut with wrench so that the hose will not be twisted. (If the hose is dragged and twisted, an excessive force is applied to the connector and the inside of the connector may be broken.)
4.Remove clamp bracket (4).
5.Disconnect fuel return hose connector (5) connected to the supply pump. [*1]
★ When removing a connector of quick coupler type, observe the following points.
•Remove mud from each hose joint in advance (since the lock may be stuck in the mud).
•Never use pliers or a screwdriver to disconnect the connector.
•Pull out lock (L) of each hose joint straight (in direction [a]) while pressing it from both sides.
(If the connector is disconnected forcibly by twisting or bending it to the right and left, its inside may be broken.)
•Put plugs in the adapters of the disconnected hoses to prevent fuel from flowing out.
(Do not use wooden plugs since chips may enter the fuel line.)
6.Disconnect fuel return hose (6).
7.Disconnect hose (7) connected to the fuel filter.
★ Before disconnecting hose (7), be sure to perform steps 3 to 5.
8.Disconnect wiring connector (8).
9.Disconnect hose (9) connected to the prefilter. [*2]
10.Disconnect hose (10) connected to the fuel filter.
11.Remove 2 high-pressure pipe bellows (11) from common rail (12) and fuel supply pump (13). [*3]
12.Disconnect 2 high-pressure pipe clamps (14) between the common rail (12) and fuel supply pump (13). [*4]
★ Since each clamps are divided two, take care not to drop them in the end cover when removing.
13.Disconnect high-pressure pipe (15) from fuel supply pump (13). [*5]
★ Loosen the sleeve nut on the common rail side in advance.
14.Remove the 3 fuel supply pump mounting nuts and fuel supply pump assembly (7). (Locations of nuts: [A]) [*6]
Installation
•Carry out installation in the reverse order to removal.
[*1]
When installing a connector of quick coupler type, observe the following points.
★ Replace the connector with new one in the following cases.
1] The connector was removed with pliers or a screwdriver or by bending it to the right and left.
2] There is damage or deformation in the connector.
★ Check that mud or dirt is not sticking to the hose adapter in advance.
★ Press and insert the connector straight (in direction [b]) without bending it to the right or left.
(If it is difficult to insert the connector, do not push it in forcibly but pull it out. Then, check the convex and concave parts for abnormality and mud.)
Joint bolt 19.6 - 29.4 Nm (2.0 - 3.0 kgm)
[*3]
★ Install each bellows with the slits out and down.
★ The bellows are installed so that fuel will not spout over the hot parts of the engine and catch fire when it leaks for some reason.
[*4]
Clamp mounting bolt: 24 ± 4 Nm {2.45 ± 0.41 kgm}
[*5]
★ Temporarily tighten the high-pressure pipe sleeve nuts on the common rail side and fuel supply pump side and then tighten them to the specified torque in the order of the pump side and common rail side.
Sleeve nut: 35 ± 3.5 Nm {3.6 ± 0.36 kgm}
[*6]
If too much grease is applied to an O-ring at assembly, it will ooze out during operation. Accordingly, do not apply grease too much. (Apply grease to the O-ring groove area of part A.)
DISASSEMBLY
When the supply pump mounting stud bolts of the gear housing were removed, apply adhesive to thier root side and mount them.
Stud bolt: Adhesive (LT-2)
Stud bolt:
12 ± 2 Nm {1.22 ± 0.2 kgm}
Fuel supply pump mounting nut
24 ± 4 Nm {2.45 ± 0.41 kgm}
Special tools
Removal
Disconnect the cable from the negative (-) terminal of the battery.
1.Close fuel stop valve (1) under the fuel tank.
2.Remove blow-by duct (2) mounting bolts and disconnect blow-by duct (2). [*1]
3.Remove cylinder head cover mounting bolts (3) and remove cylinder head cover (4). [*2]
4.Referring to Testing and adjusting, "Adjusting valve clearance", set the No. 1 and 4 cylinders to the top dead center.
5.Disconnect wiring (5).
6.Disconnect bracket (6).
7.Remove high-pressure pipe bellows (7) from the cylinder head and common rail. [*3]
8.Remove high-pressure pipe (8). [*4]
9.Remove retaining nut (9) and then remove inlet connector (10) .
★ Tool A3 is prepared for remove the inlet connector (10).
★ Check that the inlet connector is free from flaw and dirt.
10.Disconnect wiring (11).
★ Since different cylinders have different wiring colors, record their combinations.
DISASSEMBLY AND ASSEMBLYRemoval and installation of fuel injector assembly
11.Loosen locknut (12) and then loosen adjustment screw (13) thoroughly.
12.Remove rocker arm (14).
13.Remove crosshead (15).
★ Since the shapes of holes [a] and [b] of the crosshead are different, record the installed position of the crosshead.
14.Remove fuel injector assembly mounting bolt (16).
15.Using tool A1, remove fuel injector assembly (17).
★ Cover injector sleeve with cloth after removing fuel injector assembly for free from flaw and dirt.
Installation
1.Fuel injector assembly
★ Check that fuel injector sleeve (18) is free from flaw and dirt.
a.Fit O-ring (20) and gasket (21) to fuel injector (19).
★ Replace O-ring and gasket with new one.
b.Apply engine oil (EO15W-40) to the O-ring of the fuel injector (19) and the mounting hole on the head.
c.While setting the concave and convex (A), install holder (22) to fuel injector (19).
d.Install fuel injector assembly (17) to the fuel injector sleeve and tighten the mounting bolt by 3 - 4 turns.
★ When installing the fuel injector assembly, check the direction of the inlet connector mounting hole.
e.Apply engine oil (EO15W-40) to O-ring (22) of inlet connector (10) and the inlet connector mounting hole. While setting part of key to the groove on the head, insert inlet connector (10) to the end.
★ If the injector was replaced with new one, replace the inlet connector with new one, too.
★ Check of inlet connector Check the inlet connector for the following defects. If any defect is detected, replace the inlet connector.
•Burrs and deformation of inlet and outlet of connector
•Clogging and dirt of edge filter (If there is sediment here, do not use connector)
•Breakage and deterioration of O-ring
•Wear, improper contact and trace of leakage on outlet seal
★ If high-pressure fuel leaks, the seat surface is eroded and fine streaks or flaws are made. If this erosion is detected, replace the inlet connector and injector.
DISASSEMBLY AND ASSEMBLYRemoval and installation of fuel injector assembly
f.Install and finger-tighten retainer (9).
g.Tighten right and left mounting bolts (16) of fuel injector assembly alternately.
Fuel injector mounting bolt: 8 ± 0.8 Nm {0.8 ± 0.08 kgm}
h.Tighten retaining nut (9) to the specified torque.
Retaining nut: 50 ± 5 Nm {5.1 ± 0.5 kgm}
2.Install crosshead (15).
★ Since the shapes of holes [a] and [b] of the crosshead are different, take care when installing.
(Install the crosshead in the direction of the intake and exhaust valves recorded when it was removed.)
3.Install rocker arm (14).
★ Before installing the rocker arm, check that adjustment screw (13) is loosened thoroughly.
★ Check that the ball of the adjustment screw is fitted to the socket of the push rod.
Rocker arm mounting bolt: 36 ± 5 Nm {3.7 ± 0.5 kgm}
4.Install wiring (11).
★ Since different cylinders have different wire colors, check their combinations before installing.
★ Installed positions of wirings
Wiring colorCylinder No.
White1, 3
Black2, 4
Wiring mounting nut:
1.5 ± 0.25 Nm {0.15 ± 0.03 kgm}
5.Adjusting valve clearance
Referring to Testing and adjusting, "Adjusting valve clearance", adjust the valve clearance.
•Carry out the following installation in the reverse order to removal.
[*1]
Blow-by duct mounting bolt:
7 ± 2 Nm {0.7 ± 0.2 kgm}
[*2]
★ If the stud bolts were removed, tighten them to the following torque.
Stud bolt:
24 ± 4 Nm {2.4 ± 0.4 kgm}
[*3] [*4]
•Do not bend the high-pressure pipe to collect before installing.
•Be sure to use the genuine high-pressure pipe clamps and observe the tightening torque.
•After installing the high-pressure pipe, be sure to install the bellows to the sleeve nut.
★ Before installing the high-pressure pipe, check it for the following defects. If there is any of these defects, it can cause fuel leakage. Accordingly, replace the high-pressure pipe with new one.
•Check the taper seal of the connecting part (Part "j": Part of 2 mm from the end) for visible lengthwise slit "k" and dent "l".
•Check part "m" (End of the taper seal: Part at 2 mm from the end) for stepped-type wear (fatigue) which your nail can feel.
•Install the high-pressure pipe according to the following procedure.
a.Install the high-pressure pipe and temporarily tighten the sleeve nuts on the common rail side and cylinder head side.
Sleeve nut:
0.2 - 0.8 Nm {0.02 - 0.08 kgm}
b.Tighten the sleeve nuts on the common rail side and cylinder head side to the specified torque.
Sleeve nut:
35 ± 3.5 Nm {3.57 ± 0.36 kgm}
c.Install the sleeve nuts on the common rail side and cylinder head side.
★ Install each bellows with the slits out and down.
★ The bellows are installed so that fuel will not spout over the hot parts of the engine and catch fire when it leaks for some reason.
★ If all of the No. 1 - No. 4 injector assemblies were removed, install the high-pressure pipes, referring to "Removal and installation of cylinder head assembly".
Removal
1.Remove the engine assembly. For details, see "Removal and installation of engine assembly".
2.Remove crank pulley mounting bolts (1) and crank pulley (2).
3.Remove seal (3).
Installation
1.Using tool A4, install front oil seal (3).
★ Replace the front oil seal with new one.
★ Before installing the seal, check that the end corners and lip sliding surfaces of the crankshaft are free from flaw, burr, and rust of the housing.
★ When installing the seal, do not apply oil or grease to the shaft and seal lip "a". Wipe off the oil from the shaft.
★ The projection and runout of seal (3) from cover (C) must be as follows.
•Projection x: Max. 0.38 mm •Runout y: Max. 0.25 mm
2.Crank pulley
a.While checking the dowel pin hole on the back side of the crank pulley (2), install crank pulley (2) to the crankshaft.
★ If the dowel pin was removed, install it before installing the crank pulley.
b.Tightening order of crank pulley mounting bolts (1)
I.Tighten the bolts to 55 ± 5 Nm {5.6 ± 0.5 kgm} in the diagonal order.
II.Loosen the bolts by 180 °.
III.Tighten the bolts to 55 ± 5 Nm {5.6 ± 0.5 kgm} in the diagonal order.
IV.Tighten the bolts by 90 ° ± 5 ° (with angle tightening tool A6).
•When not using angle tightening tool Make a mark on the crank pulley and each bolt with paint and then tighten the bolt by 90 ° ± 5 °.
•Carry out the installation in the reverse order to removal.
Special tools
Removal
Disconnect the cable from the negative (-) terminal of the battery.
1.Remove the work equipment assembly. For details, see "Removal and installation of work equipment assembly".
2.Removal of damper
a.Remove 1 damper mounting bolt (1) at the top.
b.Install guide bolt [1] and remove the 7 remaining damper mounting bolts (1).
c.Remove damper (2).
3.Removal of flywheel
a.Remove 2 flywheel mounting bolts (3) on a diagonal line and install guide bolts [2]. [*1]
b.Sling flywheel (4) and remove the remaining mounting bolts.
c.Pull out flywheel (4) toward you.
d.Remove guide bolts [2] and lift off flywheel (4).
Flywheel 35 kg
4.Removal of rear oil seal
a.Install tool A5 to the crankshaft.
b.Tighten tapping screw [3] of tool A5 into the seal carrier of rear oil seal (5).
c.Turn the handle clockwise to remove rear oil seal (5).
Installation
1.Install the rear seal according to the following procedure.
★ Replace the front oil seal with new one.
★ Do not remove pilot [4] which is attached to rear seal (5) until rear seal (5) is inserted to the crankshaft.
★ Before installing the rear seal, degrease, clean and dry the crankshaft sealing face and the seal lip face to prevent oil leakage.
4.Install rear seal (5) on flywheel housing (7) to the proper depth by using tool A5.
★ Push in rear seal (5) taking care that there are no bend etc. on it.
★ Extrusion of rear seal (5) from flywheel housing (7) (X): less than 0.38 mm
2.Insert pilot [4] to crankshaft (6) and push rear seal (5) into flywheel housing (7).
3.Push in rear seal (5) further and pull out pilot [4].
•Carry out the rest of installation in the reverse order to removal.
★ Tighten the 8 flywheel assembly mounting bolts in the order of [1] through [8] as shown in the figure below.
Flywheel assembly mounting bolt: 137 ±7 Nm {13.97 ± 0.71 kgm}
★ Tighten the bolts using bar [5] for preventing rotation of the flywheel assembly.
•Measurement of radial runout
★ Radial runout: less than 0.13 mm
a.Set dial gauge [6] to the stand, and set it to flywheel housing (7).
b.Bring the dial gauge probe into contact with faucet joint portion (a) or the outer perimeter surface of the flywheel at a right angle.
c.Rotate the flywheel 360° and measure the difference of the maximum swing of the dial gauge indicator.
★ Check that the dial gauge indicator is back in the original position after the flywheel is rotated 360°.
•Measurement of facial runout
★ Facial runout: less than 0.20 mm
d.As in the case of measurement of radial runout, bring the dial gauge probe into contact with end surface (b) near the outer perimeter of the flywheel at a right angle.
★ Conduct measurement pulling the crankshaft to either the front or rear side to prevent errors caused by shakiness.
e.Rotate the flywheel 360 ° and measure the difference of the maximum swing of the dial gauge indicator.
Special tools
Removal
Disconnect the cable from the negative (-) terminal of the battery.
1.Open the right rear inspection cover and open fuel drain valve (1) to drain the fuel.
When fuel tank is full: 275 l
Drain the coolant from the engine.
Coolant water: Approx. 18 l
2.Removal of engine hood
Remove the engine hood. For details, see "Removal and installation of engine hood".
3.Removal of hoses and guard above engine
a.Remove air conditioner compressor drive belt guard (2).
b.Remove radiator hose (3). [*1]
c.Remove aftercooler hose (5). [*2]
d.Disconnect heater hose (6).
4.Disconnection of air conditioner compressor assembly
a.Disconnect wiring connector A01 (7).
b.Remove 2 air conditioner compressor mounting bolts (8).
c.Remove drive belt (9).
d.Disconnect air conditioner compressor assembly (10) and move it so that it will not be an obstacle.
e.Remove bracket (11).
5.Removal of alternator
a.Insert the wrench in part A and turn it to the direction of [a] to loosen fan belt (12).
b.Remove fan belt (12) from alternator (13).
•Set the wrench in hole A securely and then turn the tension pulley to direction [a]. (The tension pulley spring is very strong. If the wrench is installed halfway and turned, it may come off and can cause a serious accident.)
•After removing the fan belt, return the wrench slowly and carefully.
•Take care not to catch your fingers between the pulley and fan belt during the work.
c.Remove the alternator mounting bolts and disconnect alternator assembly (13). (Move the alternator without removing wirings (14) and (15) so that it will not be an obstacle.)
6.Disconnection of muffler and turbocharger assembly
a.Remove guard (16).
b.Loosen 2 U-bands (17).
c.Remove clamp top covers (18) and (19).
d.Remove clamp (20).
e.Slant muffler assembly (21) outward.
