Motor 12V140-3 PDF
Motor 12V140-3 PDF
Motor 12V140-3 PDF
12V140E-3 Series
12V140E-3 Series 1
SEN00294-10 00 Index and foreword
01 Specification SEN00301-03
Specification and technical data SEN00303-03
40 Troubleshooting SEN00314-04
General information on troubleshooting SEN00315-01
Troubleshooting of mechanical system (S-mode) SEN00316-01
Troubleshooting of electrical system (E-mode), Part 1 SEN00317-03
Troubleshooting of electrical system (E-mode), Part 2 SEN00318-03
2 12V140E-3 Series
00 Index and foreword SEN00294-10
Table of contents 1
00 Index and foreword
Index SEN00294-10
Composition of shop manual....................................................................................................... 2
Table of contents ......................................................................................................................... 3
01 Specification
Specification and technical data SEN00303-03
Outline......................................................................................................................................... 2
Specifications .............................................................................................................................. 4
General view ............................................................................................................................... 10
Weight table ................................................................................................................................ 19
Engine performance curves ........................................................................................................ 20
12V140E-3 Series 3
SEN00294-10 00 Index and foreword
4 12V140E-3 Series
00 Index and foreword SEN00294-10
40 Troubleshooting
General information on troubleshooting SEN00315-01
Points to remember when troubleshooting.................................................................................. 2
Error codes and failure codes list................................................................................................ 3
Information in troubleshooting table ............................................................................................ 7
Connection table for connector pin numbers .............................................................................. 9
T- branch box and T- branch adapter table ................................................................................. 45
12V140E-3 Series 5
SEN00294-10 00 Index and foreword
E-25 Code [238/CB238] Ne Speed Sensor Sup. Volt. Error (RH bank) ...................................... 44
E-26 Code [263/CA263] Fuel Temp. Sensor High Error (LH bank)............................................. 46
E-27 Code [263/CB263] Fuel Temp. Sensor High Error (RH bank) ............................................ 48
E-28 Code [265/CA265] Fuel Temp. Sensor Low Error (LH bank).............................................. 50
E-29 Code [265/CB265] Fuel Temp. Sensor Low Error (RH bank) ............................................. 50
E-30 Code [271/CA271] PCV1 Short Error (LH bank) ................................................................ 52
E-31 Code [271/CB271] PCV1 Short Error (RH bank)................................................................ 54
E-32 Code [272/CA272] PCV1 Open Error (LH bank) ................................................................ 56
E-33 Code [272/CB272] PCV1 Open Error (RH bank)................................................................ 57
E-34 Code [273/CA273] PCV2 Short Error (LH bank) ................................................................ 58
E-35 Code [273/CB273] PCV2 Short Error (RH bank)................................................................ 60
E-36 Code [274/CA274] PCV2 Open Error (LH bank) ................................................................ 62
E-37 Code [274/CB274] PCV2 Open Error (RH bank)................................................................ 63
E-38 Code [322/CA322] Injector #1 (L/B #1) System Open/Short Error (LH bank) .................... 64
E-39 Code [323/CA323] Injector #5 (L/B #5) System Open/Short Error (LH bank) .................... 66
E-40 Code [324/CA324] Injector #3 (L/B #3) System Open/Short Error (LH bank) .................... 68
E-41 Code [325/CA325] Injector #6 (L/B #6) System Open/Short Error (LH bank) .................... 70
E-42 Code [331/CA331] Injector #2 (L/B #2) System Open/Short Error (LH bank) .................... 72
E-43 Code [332/CA332] Injector #4 (L/B #4) System Open/Short Error (LH bank) .................... 74
E-44 Code [342/CA342] Caribration Code Incompatibility (LH bank) ......................................... 76
E-45 Code [342/CB342] Caribration Code Incompatibility (RH bank) ......................................... 76
E-46 Code [351/CA351] INJ. Drive Circuit Error (LH bank) ........................................................ 78
E-47 Code [351/CB351] INJ. Drive Circuit Error (RH bank)........................................................ 80
E-48 Code [352/CA352] Sensor Sup. 1 Volt. Low Error (LH bank) ............................................. 82
E-49 Code [352/CB352] Sensor Sup. 1 Volt. Low Error (RH bank) ............................................ 82
E-50 Code [386/CA386] Sensor Sup. 1 Volt. High Error (LH bank) ............................................ 84
E-51 Code [386/CB386] Sensor Sup. 1 Volt. High Error (RH bank)............................................ 86
E-52 Code [441/CA441] Battery Voltage Low Error (LH bank) ................................................... 88
E-53 Code [441/CB441] Battery Voltage Low Error (RH bank)................................................... 88
E-54 Code [442/CA442] Battery Voltage High Error (LH bank)................................................... 89
E-55 Code [442/CB442] Battery Voltage High Error (RH bank) .................................................. 89
6 12V140E-3 Series
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E-76 Code [778/CA778] Eng. G (Bkup) Speed Sensor Error (LH bank)..................................... 30
E-77 Code [778/CB778] Eng. G (Bkup) Speed Sensor Error (RH bank) .................................... 32
E-78 Code [781/CA781] Inter Multi-controller Communication Error (LH bank) ......................... 34
E-79 Code [781/CB781] Inter Multi-controller Communication Error (RH bank) ......................... 36
E-80 Code [1117/CA1117] Persistent Data Lost Error (LH bank) ................................................ 37
E-81 Code [1117/CB1117] Persistent Data Lost Error (RH bank) ............................................... 37
E-82 Code [1257/CA1257] Harness Key error (LH bank) ........................................................... 38
E-83 Code [1257/CB1257] Harness Key error (RH bank) .......................................................... 39
E-84 Code [1548/CB1548] Injector #7 (R/B #1) System Open/Short Error (RH bank) ............... 40
E-85 Code [1549/CB1549] Injector #8 (R/B #2) System Open/Short Error (RH bank) ............... 42
E-86 Code [1551/CB1551] Injector #10 (R/B #4) System Open/Short Error (RH bank) ............. 44
E-87 Code [1552/CB1552] Injector #11 (R/B #5) System Open/Short Error (RH bank) ............. 46
E-88 Code [1553/CB1553] Injector #12 (R/B #6) System Open/Short Error (RH bank) ............. 48
E-89 Code [1622/CB1622] Injector #9 (R/B #3) System Open/Short Error (RH bank) ............... 50
E-90 Code [1633/CA1633] KOMNET Datalink Timeout Error (LH bank) .................................... 52
E-91 Code [2185/CA2185] Throttle Sens. Sup. Volt. High Error (LH bank only) ........................ 54
E-92 Code [2186/CA2186] Throttle Sens. Sup. Volt. Low Error (LH bank only) ......................... 56
E-93 Code [2249/CA2249] Rail Press. Very Low Error (LH bank) .............................................. 57
E-94 Code [2249/CB2249] Rail Press. Very Low Error (RH bank) ............................................. 57
E-95 Code [– –*1/–] Eng. Overheat (LH bank only) .................................................................... 58
E-96 Code [– –*2/–] Eng. Oil Press. Low Speed Derate (LH bank only)..................................... 58
E-97 Code [– –*3/–] Press. Low Torque Derate (LH bank only).................................................. 59
12V140E-3 Series 7
SEN00294-10 00 Index and foreword
8 12V140E-3 Series
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12V140E-3 Series 9
SEN00294-10 00 Index and foreword
© 2009 KOMATSU
All Rights Reserved
Printed in Japan 12-09 (02)
10 12V140E-3 Series
SEN00296-04
12V140E-3 Series
12V140E-3 Series 1
SEN00296-04 00 Index and foreword
Safety notice 1
(Rev. 2008/08)
Important safety notice
Proper service and repair are extremely important for safe machine operation. The service and repair
techniques recommended by Komatsu and described in this manual are both effective and safe.
Some of these techniques require the use of tools specially designed by Komatsu for the specific
purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The
cautions accompanying these symbols should always be followed carefully. If any dangerous situa-
tion arises or may possibly arise, first consider safety, and take the necessary actions to deal with
the situation.
2 12V140E-3 Series
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12V140E-3 Series 3
SEN00296-04 00 Index and foreword
4 12V140E-3 Series
00 Index and foreword SEN00296-04
q If the load is unstable or the wire rope 13) If the hoist stops because of a power fail-
or chains are twisted, lower the load ure, turn the power switch OFF. When
and lift it up again. turning on a switch which was turned OFF
q Do not lift up the load slantingly. by the electric shock prevention earth
13) When lifting down a load, observe the fol- leakage breaker, check that the devices
lowing. related to that switch are not in operation
q When lifting down a load, stop it tem- state.
porarily at 30 cm above the floor, and 14) If you find an obstacle around the hoist,
then lower it slowly. stop the operation.
q Check that the load is stable, and 15) After finishing the work, stop the hoist at
then remove the sling. the specified position and raise the hook
q Remove kinks and dirt from the wire to at least 2 m above the floor. Do not
ropes and chains used for the sling leave the sling installed to the hook.
work, and put them in the specified
place. 7. Selecting wire ropes
1) Select adequate ropes depending on the
5. Precautions for using mobile crane weight of parts to be hoisted, referring to
a Read the Operation and Maintenance the table below.
Manual of the crane carefully in advance
and operate the crane safely. Wire ropes
(Standard “Z” twist ropes without galvanizing)
6. Precautions for using overhead hoist crane (JIS G3525, No. 6, Type 6X37-A)
k When raising a heavy part (heavier Nominal
Allowable load
than 25 kg), use a hoist, etc. In Disas- diameter of rope
sembly and assembly, the weight of a mm kN ton
part heavier than 25 kg is indicated 10 8.8 0.9
after the mark of 4. 12 12.7 1.3
1) Before starting work, inspect the wire 14 17.3 1.7
ropes, brake, clutch, controller, rails, over 16 22.6 2.3
wind stop device, electric shock preven- 18 28.6 2.9
tion earth leakage breaker, crane collision 20 35.3 3.6
prevention device, and power application
25 55.3 5.6
warning lamp, and check safety.
30 79.6 8.1
2) Observe the signs for sling work.
40 141.6 14.4
3) Operate the hoist at a safe place.
4) Check the direction indicator plates (east, 50 221.6 22.6
west, south, and north) and the directions 60 318.3 32.4
of the control buttons without fail.
5) Do not sling a load slantingly. Do not move a The allowable load is one-sixth of the
the crane while the slung load is swinging. breaking strength of the rope used
6) Do not raise or lower a load while the (Safety coefficient: 6).
crane is moving longitudinally or laterally.
7) Do not drag a sling.
8) When lifting up a load, stop it just after it
leaves the ground and check safety, and
then lift it up.
9) Consider the travel route in advance and
lift up a load to a safe height.
10) Place the control switch on a position
where it will not be an obstacle to work
and passage.
11) After operating the hoist, do not swing the
control switch.
12) Remember the position of the main switch
so that you can turn off the power immedi-
ately in an emergency.
12V140E-3 Series 5
SEN00296-04 00 Index and foreword
8. Precautions for disconnecting and con- a Example of O-ring (Fitted to every joint of
necting hoses and tubes in air conditioner hoses and tubes)
circuit
1) Disconnection
k For the environment, the air condi-
tioner of this machine uses the
refrigerant (air conditioner gas:
R134a) which has fewer factors of
the depletion of the ozone layer.
However, it does not mean that you
may discharge the refrigerant into
the atmosphere as it is. Be sure to
recover the refrigerant when dis-
connecting the refrigerant gas cir-
cuit and then reuse it.
a Ask professional traders for collecting a For tightening torque, see the precautions for
and filling operation of refrigerant installation in each section of "Disassembly
(R134a). and assembly".
a Never release the refrigerant (R134a)
to the atmosphere.
k If the refrigerant gas gets in your
eyes or contacts your skin, you
may lose your sight and your skin
may be frozen. Accordingly, put
on safety glasses, safety gloves
and safety clothes when recover-
ing or adding the refrigerant.
Refrigerant gas must be recovered
and added by a qualified person.
2) Connection
1] When installing the air conditioner cir-
cuit hoses and tubes, take care that
dirt, dust, water, etc. will not enter
them.
2] When connecting the air conditioner
hoses and tubes, check that O-rings
(1) are fitted to their joints.
3] Check that each O-ring is not dam-
aged or deteriorated.
4] When connecting the refrigerant pip-
ing, apply compressor oil for refriger-
ant (R134a) (DENSO: ND-OIL8,
VA L E O T H E R M A L S Y S T E M S :
ZXL100PG (equivalent to PAG46))
to its O-rings.
6 12V140E-3 Series
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q Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one
of them is required, consult KOMATSU distributors.
q Materials and specifications are subject to change without notice.
q Shop manuals are divided into the “Chassis volume” and “Engine volume”. For the engine unit, see the
engine volume of the engine model mounted on the machine.
01. Specification
This section explains the specifications of the machine.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is
divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also
explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
12V140E-3 Series 7
SEN00296-04 00 Index and foreword
3. Filing method
File by the brochures in the correct order of the form number printed in the shop manual composition
table.
q Revisions
Revised brochures are shown in the shop manual composition table.
4. Symbols
Important safety and quality portions are marked with the following symbols so that the shop manual will
be used practically.
4
Weight of parts of component or parts. Caution necessary when
Weight
selecting hoisting wire, or when working posture is important, etc.
3
Tightening Places that require special attention for tightening torque during
torque assembly.
5
Oil, coolant Places where oil, etc. must be added, and capacity.
6
Drain Places where oil, etc. must be drained, and quantity to be drained.
5. Units
In this shop manual, the units are indicated with International System of units (SI). For reference, con-
ventionally used Gravitational System of units is indicated in parentheses { }.
8 12V140E-3 Series
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Example:
Standard size Tolerance
–0.022
120
–0.126
Example:
Tolerance
Standard size
Shaft Hole
–0.030 +0.046
60
–0.076 +0
12V140E-3 Series 9
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10 12V140E-3 Series
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12V140E-3 Series 11
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3) Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with
a crane with the wiring still connected, or a
heavy object hits the wiring, the crimping
of the connector may separate, or the sol-
dering may be damaged, or the wiring
may be broken.
12 12V140E-3 Series
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12V140E-3 Series 13
SEN00296-04 00 Index and foreword
2) Connecting connectors
1] Check the connector visually.
Check that there is no oil, dirt, or
water stuck to the connector pins
(mating portion).
Check that there is no deformation,
defective contact, corrosion, or dam-
age to the connector pins.
Check that there is no damage or
breakage to the outside of the con-
nector.
a If there is any oil, water, or dirt
stuck to the connector, wipe it off
with a dry cloth. If any water has
got inside the connector, warm
the inside of the wiring with a
dryer, but be careful not to make
it too hot as this will cause short
circuits.
a If there is any damage or break-
age, replace the connector.
2] Fix the connector securely.
Align the position of the connector
correctly, and then insert it securely.
For connectors with the lock stopper,
push in the connector until the stop-
per clicks into position.
3] Correct any protrusion of the boot and
any misalignment of the wiring har-
ness.
For connectors fitted with boots, cor-
rect any protrusion of the boot. In
addition, if the wiring harness is mis-
aligned, or the clamp is out of posi-
tion, adjust it to its correct position.
a If the connector cannot be cor-
rected easily, remove the clamp
and adjust the position.
q If the connector clamp has been
removed, be sure to return it to
its original position. Check also
that there are no loose clamps.
14 12V140E-3 Series
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3) Heavy duty wire connector (DT 8-pole, 12- q Disconnection q Connection (Example of
pole) incomplete setting of (a))
Disconnection (Left of figure)
While pressing both sides of locks (a)
and (b), pull out female connector (2).
Connection (Right of figure)
1] Push in female connector (2) horizon-
tally until the lock clicks.
Arrow: 1)
2] Since locks (a) and (b) may not be set
completely, push in female connector
(2) while moving it up and down until
the locks are set normally.
Arrow: 1), 2), 3)
a Right of figure: Lock (a) is pulled
down (not set completely) and
lock (b) is set completely.
(1): Male connector
(2): Female connector
(a), (b): Locks
12V140E-3 Series 15
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16 12V140E-3 Series
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4. Handling controller
1) The controller contains a microcomputer
and electronic control circuits. These con-
trol all of the electronic circuits on the
machine, so be extremely careful when
handling the controller.
2) Do not place objects on top of the control-
ler.
3) Cover the control connectors with tape or
a vinyl bag. Never touch the connector
contacts with your hand.
4) During rainy weather, do not leave the
controller in a place where it is exposed to
rain.
5) Do not place the controller on oil, water, or
soil, or in any hot place, even for a short
time. (Place it on a suitable dry stand).
6) Precautions when carrying out arc welding
When carrying out arc welding on the
body, disconnect all wiring harness con-
nectors connected to the controller. Fit an
arc welding ground close to the welding
point.
12V140E-3 Series 17
SEN00296-04 00 Index and foreword
3. Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from
entering. If the opening is left open or is
blocked with a rag, there is danger of dirt
entering or of the surrounding area being
made dirty by leaking oil so never do this. Do
not simply drain oil out onto the ground, but
collect it and ask the customer to dispose of it,
or take it back with you for disposal.
18 12V140E-3 Series
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6. Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit. Normally, flushing is
carried out twice: primary flushing is carried
out with flushing oil, and secondary flushing is
carried out with the specified hydraulic oil.
7. Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the
machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil cir-
cuit. The oil cleaning equipment is used to
remove the ultra fine (about 3 m) particles that
the filter built in the hydraulic equipment can-
not remove, so it is an extremely effective
device.
12V140E-3 Series 19
SEN00296-04 00 Index and foreword
20 12V140E-3 Series
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q 114 engine
q 107 engine
12V140E-3 Series 21
SEN00296-04 00 Index and foreword
q 95, 125 – 170, 12V140 engines 4. Turn-housing type (Round green connector)
4) While pressing lock (E) of the connector, q 140 engine
pull out connector (5) in the direction of Example)
the arrow. Intake air pressure sensor in intake mani-
fold (CANNON-04): PIM etc.
Example)
Fuel pressure sensor in common rail: 1) Disconnect connector (6) according to the
PFUEL etc. (AMP-3) following procedure.
1] Turn housing (H1) in the direction of
the arrow.
a When connector is unlocked,
housing (H1) becomes heavy to
turn.
2] Pull out housing (H1) in the direction
of the arrow.
a Housing (H1) is left on the wiring har-
ness side.
Example)
Injection pressure control valve of fuel
supply pump: PCV (SUMITOMO-2)
Example)
Speed sensor of fuel supply pump:
G (SUMITOMO-3)
a Pull the connector straight up.
22 12V140E-3 Series
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In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by sym-
bols. The electric wire code is helpful in understanding the electric circuit diagram.
Example: AEX 0.85 L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nomi-
nal No. of 0.85
Indicates color of wire by color code.
Color codes are shown in Table 3.
(Table 1)
Using
Sym-
Type Material temperature Example of use
bol
range (°C)
Low-voltage Conduc- Annealed copper for elec-
General wiring
wire for AV tor tric appliance
(Nominal No. 5 and above)
automobile Insulator Soft polyvinyl chloride
Thin-cover Conduc- Annealed copper for elec- –30 to +60
low-voltage tor tric appliance General wiring
AVS
wire for (Nominal No. 3 and below)
automobile Insulator Soft polyvinyl chloride
Heat-resis- Conduc- Annealed copper for elec-
General wiring in extremely
tant low-volt- tor tric appliance
AEX –50 to +110 cold district, wiring at high-tem-
age wire for Heat-resistant crosslinked
Insulator perature place
automobile polyethylene
12V140E-3 Series 23
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2. Dimensions
(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5
Number of
strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32
eter of strand
Conductor
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 –
Cov-
AV Standard – – – – – – – 4.6
er D
AEX Standard 2.0 2.2 2.7 3.0 3.1 – 3.8 4.6
24 12V140E-3 Series
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(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
Remarks: In a color code consisting of 2 colors, the first color is the color of the background and
the second color is the color of the marking.
Example: “GW” means that the background is Green and marking is White.
(Table 4)
Type of wire AVS or AV 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 – – – – – – –
Others Gr – – – – – – –
P – – – – – – –
Sb – – – – – – –
Dg – – – – – – –
Ch – – – – – – –
12V140E-3 Series 25
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3) If the part is not under hydraulic pressure, the following corks can be used.
Nominal Dimensions
Part Number
number 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
26 12V140E-3 Series
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a When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other
hydraulic equipment removed for repair, always bleed the air as follows:
1) Start the engine and run at low idle.
2) Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times, stopping the
cylinder 100 mm from the end of its 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.
a When using the machine for the first time after repair or long storage, follow the same procedure.
12V140E-3 Series 27
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28 12V140E-3 Series
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Type 1
1. Disconnection
1) Hold adapter (1) and push hose joint (2)
into mating adapter (3). (Fig. 1)
a The adapter can be pushed in about
3.5 mm.
a Do not hold rubber cap portion (4).
2) After hose joint (2) is pushed into adapter
(3), press rubber cap portion (4) against
adapter (3) until it clicks. (Fig. 2)
3) Hold hose adapter (1) or hose (5) and pull
it out. (Fig. 3)
a Since some hydraulic oil flows out,
prepare an oil receiving container.
2. Connection
1) Hold hose adapter (1) or hose (5) and
insert it in mating adapter (3), aligning
them with each other. (Fig. 4)
a Do not hold rubber cap portion (4).
2) After inserting the hose in the mating
adapter perfectly, pull it back to check its
connecting condition. (Fig. 5)
a When the hose is pulled back, the
rubber cap portion moves toward the
hose about 3.5 mm. This does not
indicate abnormality, however.
12V140E-3 Series 29
SEN00296-04 00 Index and foreword
Type 2
1. Disconnection
1) Hold the tightening portion and push body
(7) straight until sliding prevention ring (6)
contacts contact surface (a) of the hexag-
onal portion at the male end. (Fig. 6)
2) While holding the condition of Step 1), turn
lever (8) to the right (clockwise). (Fig. 7)
3) While holding the condition of Steps 1)
and 2), pull out whole body (7) to discon-
nect it. (Fig. 8)
2. Connection
q Hold the tightening portion and push body
(7) straight until sliding prevention ring (6)
contacts contact surface (a) of the hexag-
onal portion at the male end. (Fig. 9)
30 12V140E-3 Series
00 Index and foreword SEN00296-04
Type 3
1. Disconnection
1) Hold the tightening portion and push body
(9) straight until sliding prevention ring (8)
contacts contact surface (b) of the hexag-
onal portion at the male end. (Fig. 10)
2) While holding the condition of Step 1),
push cover (10) straight until it contacts
contact surface (b) of the hexagonal por-
tion at the male end. (Fig. 11)
3) While holding the condition of Steps 1)
and 2), pull out whole body (9) to discon-
nect it. (Fig. 12)
2. Connection
q Hold the tightening portion and push body
(9) straight until the sliding prevention ring
contacts contact surface (b) of the hexag-
onal portion at the male end. (Fig. 13)
12V140E-3 Series 31
SEN00296-04 00 Index and foreword
a Fig. A a Fig. B
Remarks: The widths across flats against the thread diameters of flanged bolts (marks with "*") in Fig. A are
the ones indicated in the table for bolts shown in Fig. B.
(Values of tightening torques shown in the table for Fig. A are applied.)
32 12V140E-3 Series
00 Index and foreword SEN00296-04
12V140E-3 Series 33
SEN00296-04 00 Index and foreword
5. Table of tightening torques for hoses (taper seal type and face seal type)
a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the
torque below.
a Apply the following torque when the threads are coated (wet) with engine oil.
7. Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts)
a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114
engine series to the torque below.
Tightening torque
Thread size
Bolts and nuts
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 — —
34 12V140E-3 Series
00 Index and foreword SEN00296-04
8. Table of tightening torques for 102, 107 and 114 engine series (Eye joints)
a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine
series to the torque below.
9. Table of tightening torques for 102, 107 and 114 engine series (Taper screws)
a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114
engine series to the torque below.
Tightening torque
Material In cast iron or steel In aluminum
Thread size (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
12V140E-3 Series 35
SEN00296-04 00 Index and foreword
Conversion table 1
Method of using the conversion table
The conversion table in this section is provided to enable simple conversion of figures. For details of the
method of using the conversion table, see the example given below.
Example: Method of using the conversion table to convert from millimeters to inches
36 12V140E-3 Series
00 Index and foreword SEN00296-04
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 2.874 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
Kilogram to pound
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
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
12V140E-3 Series 37
SEN00296-04 00 Index and foreword
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
38 12V140E-3 Series
00 Index and foreword SEN00296-04
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
12V140E-3 Series 39
SEN00296-04 00 Index and foreword
Temperature
Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centi-
grade temperature reading or vice versa is to enter the accompanying table in the center (boldface column)
of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahren-
heit temperatures and read the corresponding Centigrade temperature in the column at the left.
When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centi-
grade 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
40 12V140E-3 Series
00 Index and foreword SEN00296-04
12V140E-3 Series 41
SEN00296-04 00 Index and foreword
© 2009 KOMATSU
All Rights Reserved
Printed in Japan 03-09 (02)
42 12V140E-3 Series
SEN00303-03
12V140E-3 Series
01 Specification 1
Specification and technical data
Outline.................................................................................................................................................. 2
Specifications ....................................................................................................................................... 4
General view ...................................................................................................................................... 10
Weight table ....................................................................................................................................... 19
Engine performance curves ............................................................................................................... 20
12V140E-3 Series 1
SEN00303-03 01 Specification
Outline 1
1. Applicable machine
2 12V140E-3 Series
01 Specification SEN00303-03
2. Outline of engine
q The 12V140E-3 engine is a high-performance are added: mounting of a recirculation port for
and high-efficiency engine which provides low surging control at the compressor side and a
fuel consumption, low noise, and improved design to improve efficiency of the turbine. As
exhaust gas color, and improved acceleration a result, high performance is attained in a wide
performance, and it cleared the strict exhaust range from the low-speed range to the high-
gas regulation (USA: EPA regulations for speed range, and high performance and low
2006). Accordingly, this newly developed fuel consumption are also obtained.
engine is suitable as a power source of
c o n s t r u c t i o n m a c h i n e r y, a n d i n d u s t r i a l 5) The piston cooling nozzle of 12V140-1 is
machinery used for various purposes. reviewed in regard to oil flow. As a result,
durability of the piston is improved and
q It is the successor of conventional 12V140-1 temperature of the rear surface of the piston is
engine which introduces various kinds of new reduced to prevent deterioration of the piston
technologies while adhering fundamentally to due to exposure of lubricating oil on the
the configuration of V12-cylinder, water- surface to high temperature. Since the high-
cooled, direct injection, and 4-stroke diesel pressure fuel injection system controlled
engine. electronically is employed, less-soot
combustion is attained and the draining
1) High-pressure fuel injection system controlled interval of the oil is lengthened.
electronically
The conventional one is a jerk in-line fuel 6) The high-pressure pump to create high
injection pump-based engine mechanically pressure in the common rail injection system is
controlled by a governor, while in all series of one-third of the conventional in-line fuel
the new one, an electronic control system- and injection pump, and in addition, it is connected
high-pressure injection system-based common compact to the timing gear case as a flange
rail injection system is adopted. This system mount rather than a saddle mount. As a result,
provides high pressure fuel of 118 MPa {1,200 sound radiation is reduced to provide low
kg/cm2} level from the low-speed range to the noise.
high-speed range. In addition, it can control
the form of injection most properly by the 7) Capacity of the lubrication pump is increased
electronic control system according to the by 10% over the conventional engine to
speed and load. As a result, clean exhaust contribute to the reliability and durability.
g a s , c l e a n e x h a u s t g a s c o l o r, l o w f u e l
consumption, and low noise are attained 8) The air cleaner is changed from the
simultaneously. conventional end surface seal type to radial
seal type to prevent the entry of dust due to
2) It adopts a re-entrant piston combustion deformation into the clean side. In addition, the
chamber which has been used since air cleaner clogging sensor for 5 clogging level
introduction into the 6D140E-2 engine and also indication is provided to inform users of a
uses a quality cast iron piston with less thermal precise cleaning time.
expansion and shaker cooling gallery. As a
result, clean exhaust gas, clean exhaust gas 9) A high performance and high efficiency
color, and low fuel consumption are attained combination filter is adopted as an oil filter, and
simultaneously, and also high durability and a filter system to collect small dirts as well as
high reliability are also obtained. large dirts is adopted for all specifications.
3) It also provides a higher compression ratio 10) The fuel filter system includes a high efficiency
than the conventional one to improve main filter and prefilter as standard features to
combustion efficiency and reduce the white allow use of low-grade fuel in the market
exhaust smoke when starting the engine in (corresponding to NAS13 level). In addition,
cold climate areas. In addition, by using the the delivery of the priming pump used to
above-mentioned high-pressure fuel injection replace the filters is increased for higher
system controlled electronically and setting the serviceability.
injection characteristics most properly to
improve the startability and reduce the white 11) In addition, since the engine controller is
exhaust smoke when the temperature is low. mounted on the engine and equipped with the
automatic high-altitude compensation function,
4) It is equipped with an improved turbocharger it can be operated at high altitude without
KOMATSU KTR110 of which high reliability replacing the controller. As a result, the
and high performance have been proven in the serviceability is improved.
12V140-1 engine. The following improvements
12V140E-3 Series 3
SEN00303-03 01 Specification
Specifications 1
671 {899}/2,000
Rated output kW{HP}/rpm
(Gross)
3,825 {390}/1,400
Max. torque Nm{kgm}/rpm
(Gross)
Performance
g/kW·h
Fuel consumption ratio at rated output 210 {156.7}
{g/HP·h}
4 12V140E-3 Series
01 Specification SEN00303-03
895 {1,200}/1,900
Rated output kW{HP}/rpm
(Gross)
5,076 {518}/1,350
Max. torque Nm{kgm}/rpm
(Gross)
Performance
g/kW·h
Fuel consumption ratio at rated output 207 {154}
{g/HP·h}
12V140E-3 Series 5
SEN00303-03 01 Specification
728 {976}/1,800
Rated output kW{HP}/rpm
(Gross)
4,488 {458}/1,350
Max. torque Nm{kgm}/rpm
(Gross)
Performance
g/kW·h
Fuel consumption ratio at rated output 207 {154}
{g/HP·h}
6 12V140E-3 Series
01 Specification SEN00303-03
636 {853}/2,000
Rated output kW{HP}/rpm
(Gross)
3,802 {388}/1,400
Max. torque Nm{kgm}/rpm
(Gross)
Performance
g/kW·h
Fuel consumption ratio at rated output 215 {160}
{g/HP·h}
12V140E-3 Series 7
SEN00303-03 01 Specification
672 {900}/2,050
Rated output kW{HP}/rpm
(Gross)
4,159 {424}/1,300
Max. torque Nm{kgm}/rpm
(Gross)
Performance
g/kW·h
Fuel consumption ratio at rated output 215 {160}
{g/HP·h}
8 12V140E-3 Series
01 Specification SEN00303-03
12V140E-3 Series 9
SEN00303-03 01 Specification
General view 1
SAA12V140E-3 (Left side view of engine)
Machine model: D475A-5E0
1. Center of crankshaft
2. Rear face of flywheel housing
10 12V140E-3 Series
01 Specification SEN00303-03
1. Center of crankshaft
2. Center of engine
12V140E-3 Series 11
SEN00303-03 01 Specification
1. Center of crankshaft
2. Rear face of flywheel housing
12 12V140E-3 Series
01 Specification SEN00303-03
1. Center of crankshaft
2. Center of engine
12V140E-3 Series 13
SEN00303-03 01 Specification
1. Center of crankshaft
2. Rear face of flywheel housing
14 12V140E-3 Series
01 Specification SEN00303-03
1. Center of crankshaft
2. Center of engine
12V140E-3 Series 15
SEN00303-03 01 Specification
1. Center of crankshaft
2. Rear face of flywheel housing
16 12V140E-3 Series
01 Specification SEN00303-03
1. Center of crankshaft
2. Center of engine
12V140E-3 Series 17
SEN00303-03 01 Specification
Dimensions table
Unit: mm
Dimensions of each part
Engine Machine model
A B C D E F G
D475A-5E0 287 1,582 1,772 2,171.5 726 507 507
HD785-7 230 1,585.8 2,046.5 1,745.3 715 210 210
SAA12V140E-3
PC2000-8 353 1,574.8 1,807.7 1,734.3 726 600 600
WA800-3E0, WA900-3E0 230 1,585.8 2,123 1,940 715.2 210 210
a These dimensions are given for reference when the engine is set on a test bench.
18 12V140E-3 Series
01 Specification SEN00303-03
Weight table 1
Unit: kg
No. Item Main parts SAA12V140E-3
1 Turbocharger KOMATSU KTR110L (Water-cooled) 25 x 2
Cylinder head, valve,
2 Cylinder head assembly 22.5 x 12
rocker arm, valve spring
Cylinder block, bearing cap,
3 Cylinder block assembly 810
cylinder liner
4 Gear case 72
5 Gear case 52
D475A-5E0
HD785-7
88.4
6 Oil pan Integral-type WA800-3E0,
WA900-3E0
PC2000-8 89.2
D475A-5E0 127.6
HD785-7 72.5
7 Flywheel assembly Flywheel, ring gear PC2000-8
WA800-3E0, 88.7
WA900-3E0
8 Flywheel housing assembly 133.5
9 Crankshaft assembly Crankshaft, crank gear 210
Camshaft, cam gear L 20
10 Camshaft assembly
thrust plate R 20
Piston, piston ring,
11 Piston and connecting rod assembly 10.5 x 12
piston pin, connecting rod
12 Oil pump 9
13 Fuel supply pump 13
14 Water pump 22
15 Alternator 24V, 90A 12
D475A-5E0
HD785-7
24V, 7.5kW
16 Starting motor WA800-3E0, 18 x 2
WA900-3E0
24V, 11kW PC2000-8
D475A-5E0 35 x 2
HD785-7 33 x 2
17 Aftercooler assembly PC2000-8 43 x 2
WA800-3E0,
40 x 2
WA900-3E0
12V140E-3 Series 19
SEN00303-03 01 Specification
20 12V140E-3 Series
01 Specification SEN00303-03
12V140E-3 Series 21
SEN00303-03 01 Specification
22 12V140E-3 Series
01 Specification SEN00303-03
12V140E-3 Series 23
SEN00303-03 01 Specification
24 12V140E-3 Series
01 Specification SEN00303-03
12V140E-3 Series 25
SEN00303-03 01 Specification
© 2008 KOMATSU
All Rights Reserved
Printed in Japan 07-08 (02)
26 12V140E-3 Series
SEN00307-05
12V140E-3 Series
SEN00307-04
ENGINE
Shop Manual
12V140E-3 Series
10 Structure,function and
maintenance standard
Structure, function and maintenance
standard, Part 1
12V140E-3 Series 1
SEN00307-05 10 Structure,function and maintenance standard
2 12V140E-3 Series
10 Structure,function and maintenance standard SEN00307-05
12V140E-3 Series 3
SEN00307-05 10 Structure,function and maintenance standard
Air cleaner
ERB type
[Air cleaner of automatic exhaust gas discharge type (Radial seal type)]
A: Air inlet
B: To turbocharger (Intake air)
C: To muffler (Dust)
1. Pre-cleaner
2. Air cleaner casing
3. Outer element
4. Inner element
4 12V140E-3 Series
10 Structure,function and maintenance standard SEN00307-05
FRG type
[Air cleaner of cyclone pack type with evacuator valve (Radial seal type)]
Number of
Engine Machine model Type Evacuator valve
elements
1 Inner element,
SAA12V140E-3 HD785-7 FRG (Radial seal type) Automatic discharge
1 Outer element
Structure Operation
q The size of the body is reduced from the conven- q Air containing dust is sucked in vertically through
tional type without changing the diameter of the inlet (1) and the dust is separated by the centrif-
element. ugal effect of guide vane (3).
q Since the inlet is set in the tangential direction, q More than 99.9% of the dust is removed by pri-
air is given sufficient centrifugal force by the sim- mary element (4) and clean air is sucked in the
ple spiral guide vane, not by the guide plate. engine through safety element (5) and outlet (2).
q The dust and water separated by guide vane (3)
swirl along the inside wall of body (9) and enter
evacuator valve (6) and then are discharged out
automatically.
12V140E-3 Series 5
SEN00307-05 10 Structure,function and maintenance standard
Turbocharger
Water-cooled type
Type: KTR110L
6 12V140E-3 Series
10 Structure,function and maintenance standard SEN00307-05
1. Blower housing
2. V-band
3. Diffuser plate
4. Center housing
5. Shroud
6. Turbine housing
7. Blower impeller
8. Seal ring
9. Thrust metal
10. Journal bearing
11. Seal ring
12. Turbine impeller
Specifications
Model: KOMATSU KTR110L (Water-cooled)
Overall length: 308 mm
Overall width: 305 mm
Overall height: 287 mm
Weight: 25 kg
12V140E-3 Series 7
SEN00307-05 10 Structure,function and maintenance standard
Model: KTR110L
8 12V140E-3 Series
10 Structure,function and maintenance standard SEN00307-05
Unit: mm
12V140E-3 Series 9
SEN00307-05 10 Structure,function and maintenance standard
Turbocharger mounting
1. Exhaust manifold
2. Turbocharger
10 12V140E-3 Series
10 Structure,function and maintenance standard SEN00307-05
Aftercooler
Air-cooled type
1. Upper tank
2. Core
3. Lower tank
4. Fin
5. Tube
12V140E-3 Series 11
SEN00307-05 10 Structure,function and maintenance standard
Muffler
1. Turbocharger
2. Muffler
12 12V140E-3 Series
10 Structure,function and maintenance standard SEN00307-05
12V140E-3 Series 13
SEN00307-05 10 Structure,function and maintenance standard
Cylinder head
14 12V140E-3 Series
10 Structure,function and maintenance standard SEN00307-05
Specifications
Cylinder head
Direct injection type
4-valve type
Split-type 1 cylinder, 1 cylinder head
Centralized cooling system for valve bridge and in-
jector
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
Installation: Dry type (without sleeve)
12V140E-3 Series 15
SEN00307-05 10 Structure,function and maintenance standard
Unit: mm
Engine Standard
Replace nozzle or
2 Projection of nozzle
SAA12V140E-3 2.3 – 2.9 gasket
16 12V140E-3 Series
10 Structure,function and maintenance standard SEN00307-05
12V140E-3 Series 17
SEN00307-05 10 Structure,function and maintenance standard
Cylinder block
1. Cylinder block
2. Cylinder liner
3. Clevis seal
4. O-ring
5. O-ring
6. Main bearing metal cap bolt
7. Main bearing metal cap
8. Main bearing metal
9. Piston cooling nozzle
10. Thrust bearing metal
18 12V140E-3 Series
10 Structure,function and maintenance standard SEN00307-05
Piston cooling
With piston cooling nozzle
Cylinder liner
Wet type
Machining on inside: Plateau honing andTufftride
12V140E-3 Series 19
SEN00307-05 10 Structure,function and maintenance standard
20 12V140E-3 Series
10 Structure,function and maintenance standard SEN00307-05
Unit: mm
12V140E-3 Series 21
SEN00307-05 10 Structure,function and maintenance standard
Cylinder liner
Unit: mm
22 12V140E-3 Series
10 Structure,function and maintenance standard SEN00307-05
12V140E-3 Series 23
SEN00307-05 10 Structure,function and maintenance standard
24 12V140E-3 Series
10 Structure,function and maintenance standard SEN00307-05
Crankshaft
Closed die forging
Journal, filet: Induction hardening
Piston
Special thin ductile cast iron
FCD piston
Re-entrant piston
Connecting rod
Closed die forging
With lubricating oil hole
Cap bolt is screw type, installed by plastic-region Top ring (1) : Double-side keystone, inner cut,
tightening. barrel face, hard chromium-plated
Second ring (2): Double-side keystone, inner cut, ta-
per face, hard chromium-plated
Oil ring (3) : M-shaped steel, with coil expand-
er, nitrided surface
12V140E-3 Series 25
SEN00307-05 10 Structure,function and maintenance standard
Crankshaft
26 12V140E-3 Series
10 Structure,function and maintenance standard SEN00307-05
Unit: mm
Correct surface
Surface roughness of main journal 0.8S (Surface roughness of R portion: 3.2S) roughness of crank-
shaft journal
a US: Undersize
12V140E-3 Series 27
SEN00307-05 10 Structure,function and maintenance standard
Camshaft
Unit: mm
28 12V140E-3 Series
10 Structure,function and maintenance standard SEN00307-05
Unit: mm
No. Check item Criteria Remedy
Standard size Tolerance Repair limit
Outside diameter of cam follower
–0.021
shaft 22 21.92
1 –0.034
Inside diameter of cam follower +0.021
22 22.07
shaft hole 0
+0.05
2 Outside diameter of cam roller 31.7 31.50
+0.02
+0.038
Inside diameter of cam roller 12.7 12.78
+0.013
3 Replace
Outside diameter of cam roller pin 12.63 ± 0.006 12.56
12V140E-3 Series 29
SEN00307-05 10 Structure,function and maintenance standard
30 12V140E-3 Series
10 Structure,function and maintenance standard SEN00307-05
Unit: mm
2 No.1 ring
Clearance between piston ring and Check with groove wear gauge Replace piston or
2 – 4 piston ring groove piston ring
3 No.2 ring
12V140E-3 Series 31
SEN00307-05 10 Structure,function and maintenance standard
Connecting rod
32 12V140E-3 Series
10 Structure,function and maintenance standard SEN00307-05
Unit: mm
No. Check item Criteria Remedy
Standard size Tolerance Repair limit Replace bushing
Inside diameter of connecting rod
+0.049 (Refilled part is
small end bushing 52 52.09
+0.030 semi-finished part)
1
Standard clearance Clearance limit
Clearance between connecting rod Replace bushing or
small end bushing and piston pin 0.030 – 0.055 0.11 piston pin
Roughness 3.2S
Inside diameter of con-
8 Replace
necting rod large end
Swell 0.004 (In overall width)
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.
12V140E-3 Series 33
SEN00307-05 10 Structure,function and maintenance standard
Unit: mm
34 12V140E-3 Series
10 Structure,function and maintenance standard SEN00307-05
Vibration damper
1. Vibration damper
2. Pin (between adapter and vibration damper)
3. Adapter
4. Pin (between adapter and crankshaft)
5. Bolt (between adapter and crankshaft)
6. Bolt (between adapter and vibration damper)
12V140E-3 Series 35
SEN00307-05 10 Structure,function and maintenance standard
Timing gear
36 12V140E-3 Series
10 Structure,function and maintenance standard SEN00307-05
Unit: mm
No. Check item Criteria Remedy
Posi-
Measuring point Standard Repair limit
tion
Crank gear and right main idler
a 0.141 – 0.425
gear (Large)
Right main idler gear (Small) and
b 0.130 – 0.390
right sub idler gear
Right sub idler gear and right
c 0.129 – 0.391
cam gear
Right cam gear and accessory
d 0.085 – 0.492
drive gear
Right main idler gear (Small) and
— Backlash of each gear e
right fuel injection pump gear
0.051 – 0.469 Replace
0.6
Right main idler gear (Large) and
f 0.052 – 0.481
water pump driver gear
Right main idler gear (Large) and
g 0.137 – 0.421
oil pump gear
Crank gear and left main idler
h 0.141 – 0.425
gear (Large)
Left main idler gear (Small) and
j 0.129 – 0.391
left cam gear
Left main idler gear (Small) and
k 0.051 – 0.469
left fuel injection pump gear
Tolerance Standard Clearance
Clearance between main idler gear Standard size
Shaft Hole clearance limit
1 bushing and shaft
(Both right and left banks) –0.016 +0.034 Replace bushing
56 0.025 – 0.063 0.20
–0.029 +0.009
Clearance between sub idler gear –0.016 +0.055
2 56 0.016 – 0.084 0.20
bushing and shaft –0.029 0
Standard Repair limit
3 End play of main idler gear
0.09 – 0.26 0.4
12V140E-3 Series 37
SEN00307-05 10 Structure,function and maintenance standard
Valve system
38 12V140E-3 Series
10 Structure,function and maintenance standard SEN00307-05
Specifications
Camshaft
Drawn steel bar (Machining)
Journal and cam sections: Induction hardening
12V140E-3 Series 39
SEN00307-05 10 Structure,function and maintenance standard
40 12V140E-3 Series
10 Structure,function and maintenance standard SEN00307-05
Unit: mm
Bend of valve stem Repair limit: 0.02 (Total runout of indicator, per 100) Replace valve
Standard Tolerance
5 Driving height of valve guide Correct
22.0 ± 0.2
Outer 81.7 —
Free length of valve spring
Inner 72.0 —
Installed Standard installed Allowable installed
Spring Replace valve
6 length load (N {kg}) load (N {kg})
spring
424.3 ± 21.6 377.3
Installed load of valve spring Outer 51.0
{43.3 ± 2.2} {38.5}
215.6 ± 10.8 192.1
Inner 46.0
{22.0 ± 1.1} {19.6}
Perpendicularity of valve spring Repair limit: 2° (Both ends)
12V140E-3 Series 41
SEN00307-05 10 Structure,function and maintenance standard
Unit: mm
42 12V140E-3 Series
10 Structure,function and maintenance standard SEN00307-05
Unit: mm
No. Check item Criteria Remedy
Standard size Tolerance Repair limit
1 Depth of crosshead stem receiver +0.3
6.2 6.61
0
Replace
Inside diameter of crosshead 11.04 ± 0.02 11.17
2
Outside diameter of crosshead +0.011
11 10.95
guide 0
3 Projection of crosshead guide 49.0 ± 0.25 — Correct
12V140E-3 Series 43
SEN00307-05 10 Structure,function and maintenance standard
©2009 KOMATSU
All Rights Reserved
Printed in Japan 12-09 (02)
44
SEN00309-03
12V140E-3 Series
12V140E-3 Series 1
SEN00309-03 10 Structure, function and maintenance standard
2 12V140E-3 Series
10 Structure, function and maintenance standard SEN00309-03
12V140E-3 Series 3
SEN00309-03 10 Structure, function and maintenance standard
Lubrication system 1
Lubrication system diagram 1
4 12V140E-3 Series
10 Structure, function and maintenance standard SEN00309-03
W: Coolant
1. Oil pan
2. Strainer
3. Oil pump (Triple gear pump)
4. Main relief valve
5. Oil cooler
6. Regulator valve
7. Oil cooler bypass valve
8. Oil filter
9. Oil filter safety valve
10. Main gallery
11. Crankshaft
12. Camshaft
13. Rocker arm
14. Cam follower
15. Intake valve and exhaust valve
16. Piston
17. Piston cooling nozzle
18. Timing gear
19. Turbocharger
20. Fuel supply pump
12V140E-3 Series 5
SEN00309-03 10 Structure, function and maintenance standard
Oil pump 1
6 12V140E-3 Series
10 Structure, function and maintenance standard SEN00309-03
Oil cooler 1
12V140E-3 Series 7
SEN00309-03 10 Structure, function and maintenance standard
Oil filter 1
8 12V140E-3 Series
10 Structure, function and maintenance standard SEN00309-03
Unit: mm
No. Check item Criteria Remedy
Tolerance
Standard
Standard size Outside diam- Inside diame-
Clearance between main relief clearance Replace valve or
4 eter of valve ter of body
valve and body body
–0.040 +0.016
33 0.040 – 0.076
–0.060 +0.016
Installed Installed load Allowable load
Free length
length (N {kg}) (N {kg})
5 Main relief valve spring Replace spring
75.8 59.8 621 {63.4} 353 {36}
12V140E-3 Series 9
SEN00309-03 10 Structure, function and maintenance standard
10 12V140E-3 Series
10 Structure, function and maintenance standard SEN00309-03
Unit: mm
No. Check item Criteria Remedy
Tolerance
Standard
Standard size Outside diam- Inside diame-
Clearance between regulator clearance Replace valve or
1 eter of valve ter of body
valve and body body
–0.020 +0.033
22 0.020 – 0.074
–0.041 +0.033
Installed Installed load Allowable load
Free length
length (N {kg}) (N {kg})
2 Regulator valve spring Replace spring
111.5 75 136.0 {13.87} 239 {24.4}
12V140E-3 Series 11
SEN00309-03 10 Structure, function and maintenance standard
Fuel system 1
CRI system diagram 1
12 12V140E-3 Series
10 Structure, function and maintenance standard SEN00309-03
1. NE speed sensor
2. Engine controller
3. Injector
4. Fuel tank
5. Pre-fuel filter
6. Main fuel filter
7. Overflow valve
8. Fuel supply pump assembly
9. PCV
10. High-pressure pump
11. Feed pump
12. Relief valve
13. G speed sensor
14. Common rail
15. Flow damper
16. Pressure limiter
17. High-pressure injection pipe
18. Priming pump (Main)
12V140E-3 Series 13
SEN00309-03 10 Structure, function and maintenance standard
14 12V140E-3 Series
10 Structure, function and maintenance standard SEN00309-03
1. NE speed sensor
2. Engine controller
3. Injector
4. Fuel tank
5. Pre-fuel filter
6. Main fuel filter
7. Overflow valve
8. Fuel supply pump assembly
9. PCV
10. High-pressure pump
11. Feed pump
12. Relief valve
13. G speed sensor
14. Common rail
15. Flow damper
16. Pressure limiter
17. High-pressure injection pipe
18. Electrical priming pump (Main)
19. Water separator
12V140E-3 Series 15
SEN00309-03 10 Structure, function and maintenance standard
Configuration
q The CRI system is divided by the function into
the fuel system and control system.
16 12V140E-3 Series
10 Structure, function and maintenance standard SEN00309-03
2. Control system
12V140E-3 Series 17
SEN00309-03 10 Structure, function and maintenance standard
q The CRI system consists of fuel supply pump, q If the TWV is turned ON (energized), the fuel
common rail, injector, ECU which controls circuit is changed so that the high-pressure
these 3 units, and sensors. fuel in the control chamber will flow through the
q The fuel supply pump generates fuel pressure orifice. As a result, the needle valve is raised
in the common rail. The fuel pressure is con- to start fuel injection by the nozzle cracking
trolled by the fuel discharge rate of the supply pressure of the high-pressure fuel on the noz-
pump. zle side.
q The fuel discharge rate is controlled by turning q If the TWV is turned OFF (de-energized), the
on and off the PCV (Fuel injection pressure fuel circuit is changed so that the high-pres-
control valve) of the fuel supply pump accord- sure fuel will flow to the control chamber
ing to the electric signals from the ECU. through the orifice. As a result, the needle
q The common rail receives the pressurized fuel valve lowers to finish fuel injection.
from the fuel supply pump and distributes it to q Accordingly, the fuel injection timing and fuel
the cylinders. injection rate are controlled respectively by the
q The fuel pressure is sensed by the common timing to turn on the TWV and the length of the
rail fuel pressure sensor installed to the com- turn-on time of the TWV.
mon rail.
q A feedback control is applied so that the actual
fuel pressure will match to the command pres-
sure set according to the engine speed and the
load on the engine.
q 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.
q The injector controls the fuel injection rate and
fuel injection timing by turning ON and OFF the
TWV (2-way solenoid valve).
18 12V140E-3 Series
10 Structure, function and maintenance standard SEN00309-03
12V140E-3 Series 19
SEN00309-03 10 Structure, function and maintenance standard
Operation
20 12V140E-3 Series
10 Structure, function and maintenance standard SEN00309-03
12V140E-3 Series 21
SEN00309-03 10 Structure, function and maintenance standard
2. Common rail
Structure
q Common rail (4) distributes the high-pressure
fuel from the high-pressure pump to the injec-
tors of the cylinders.
q Common rail (4) is equipped with common rail
fuel pressure sensor (2), flow dampers (1), and
pressure limiter (3).
q The fuel injection pipes are connected to flow
dampers (1) to send the high-pressure fuel to
the injectors.
q The piping of the pressure limiter (3) is
returned to the fuel tank.
1) Flow damper
Function
q The flow dampers damp the pressure pulses in 2) Pressure limiter
the high pressure piping and supply the fuel to q If abnormally high pressure is generated, the
the injectors with stable pressure. pressure limiter opens to release that pres-
q If excessive fuel flows out, the flow dampers sure.
block the fuel passage to prevent abnormal q If the common rail fuel pressure reaches about
outflow of the fuel. 140 MPa {1,430 kg/cm2}, the pressure limiter
q If the fuel flows out abnormally, high pressure operates (Opens).
is applied to the piston, which moves to the q If the common rail fuel pressure lowers to 30
right until it reaches the seat to stop the fuel. MPa {310 kg/cm2}, the pressure limiter resets
itself (close) to maintain the pressure.
22 12V140E-3 Series
10 Structure, function and maintenance standard SEN00309-03
12V140E-3 Series 23
SEN00309-03 10 Structure, function and maintenance standard
3. Injector
Outline
q 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 opti-
mum timing, by the optimum quantity, at the
optimum injection rate, and under the optimum
spray condition.
q The TWV (2-way solenoid valve) controls the
start and finish of fuel injection by controlling
the pressure in the control chamber.
q The orifice limits the opening speed of the noz-
zle and controls the fuel injection rate.
q The hydraulic piston transmits the force gener-
ated by the pressure in the control chamber to
the needle valve of the nozzle.
q The nozzle sprays the fuel.
24 12V140E-3 Series
10 Structure, function and maintenance standard SEN00309-03
Structure
12V140E-3 Series 25
SEN00309-03 10 Structure, function and maintenance standard
Operation
1) No fuel injection (A) 3) Finish of fuel injection (C)
q While solenoid (6) is not energized, valve body q If solenoid (6) is de-energized, valve body (5)
(5) is pressed down by spring (7). is lowered by spring (7) and the fuel passage is
q Since the high-pressure fuel is applied from closed.
the common rail to pressure control chamber q Since the high-pressure fuel in the common
(8), nozzle (1) is closed and the fuel is not rail is applied to pressure control chamber (8)
injected. suddenly at this time, nozzle (1) is closed
quickly and fuel injection is finished sharply.
2) Start of fuel injection (B)
q If solenoid (6) is energized, valve body (5) is
raised by electromagnetic power to open the
fuel passage.
q Since the fuel in pressure control chamber (8)
flows out through orifices (3) and (4), nozzle
(1) rises and the fuel injection pump starts.
q The fuel injection rate is increased gradually by
the function of orifices (3) and (4).
q Continuing energization to solenoid (6) pro-
vides the maximum fuel injection rate.
26 12V140E-3 Series
10 Structure, function and maintenance standard SEN00309-03
12V140E-3 Series 27
SEN00309-03 10 Structure, function and maintenance standard
28 12V140E-3 Series
10 Structure, function and maintenance standard SEN00309-03
A: Pressure inlet
B: Mounting screw: M5
Tightening torque:
4.5 ± 0.5 Nm {0.46 ± 0.05 kgm}
q The following graph shows the output charac-
teristics of the atmospheric pressure sensor.
12V140E-3 Series 29
SEN00309-03 10 Structure, function and maintenance standard
A: Mounting screw: M6
Tightening torque:
5.5 ± 0.5 Nm {0.56 ± 0.05 kgm}
1. Sensor
2. O-ring
30 12V140E-3 Series
10 Structure, function and maintenance standard SEN00309-03
12V140E-3 Series 31
SEN00309-03 10 Structure, function and maintenance standard
Various controls
32 12V140E-3 Series
10 Structure, function and maintenance standard SEN00309-03
12V140E-3 Series 33
SEN00309-03 10 Structure, function and maintenance standard
Fuel piping 1
Left bank
34 12V140E-3 Series
10 Structure, function and maintenance standard SEN00309-03
12V140E-3 Series 35
SEN00309-03 10 Structure, function and maintenance standard
Right bank
36 12V140E-3 Series
10 Structure, function and maintenance standard SEN00309-03
12V140E-3 Series 37
SEN00309-03 10 Structure, function and maintenance standard
38 12V140E-3 Series
10 Structure, function and maintenance standard SEN00309-03
12V140E-3 Series 39
SEN00309-03 10 Structure, function and maintenance standard
40 12V140E-3 Series
10 Structure, function and maintenance standard SEN00309-03
Right bank
12V140E-3 Series 41
SEN00309-03 10 Structure, function and maintenance standard
42 12V140E-3 Series
10 Structure, function and maintenance standard SEN00309-03
12V140E-3 Series 43
SEN00309-03 10 Structure, function and maintenance standard
Fuel filter 1
A: Fuel inlet
B: Fuel outlet
Specifications
Filtration area: 1.0 m2
44 12V140E-3 Series
10 Structure, function and maintenance standard SEN00309-03
Pre-fuel filter
A: Fuel inlet
B: Fuel outlet
Specifications
Filtration area: 2.12 m2
12V140E-3 Series 45
SEN00309-03 10 Structure, function and maintenance standard
Water separator 1
A: Fuel inlet
B: Fuel outlet
1. Head
2. Screen
3. Gasket
4. Ring
5. Case
6. Drain cup
46 12V140E-3 Series
10 Structure, function and maintenance standard SEN00309-03
Priming pump 1
12V140E-3 Series 47
SEN00309-03 10 Structure, function and maintenance standard
A: Fuel IN
B: Fuel OUT
1. Connector
2. Vibration prevention rubber
48 12V140E-3 Series
10 Structure, function and maintenance standard SEN00309-03
12V140E-3 Series 49
SEN00309-03 10 Structure, function and maintenance standard
Cooling system 1
Cooling system diagram 1
50 12V140E-3 Series
10 Structure, function and maintenance standard SEN00309-03
A: Lubricating oil
1. Radiator
2. Cooling fan
2A. Hydraulic fan motor
3. Water pump
4. Oil cooler (For engine)
5. Corrosion resistor
6. Thermostat housing
7. Oil cooler (For power train)
8. Oil cooler bypass circuit (For power train)
9. Air bleeding
10. Turbocharger
12V140E-3 Series 51
SEN00309-03 10 Structure, function and maintenance standard
Water pump 1
1. Pump shaft
2. Water seal
3. Pump body
4. Water pump drive gear (Number of teeth: 25)
5. Ball bearing
6. Oil seal
7. Impeller
8. Pump cover
Specifications
Water pump
Type: Centrifugal, gear-driven
Revolving speed: Engine speed x 1.80
52 12V140E-3 Series
10 Structure, function and maintenance standard SEN00309-03
1. Oil cooler
2. Thermostat housing
3. Water pump
12V140E-3 Series 53
SEN00309-03 10 Structure, function and maintenance standard
Thermostat 1
A: To radiator
B: To water pump (When bypassing)
C: To thermostat
1. Thermostat housing
2. Thermostat
3. Cylinder block
Specifications
Valve cracking temperature: 76.5 ± 2°C
Temperature at full opening: 90°C
Lift at full opening: Min. 10 mm
Q'ty: 3
Unit: mm
No. Check item Criteria Remedy
Lift of thermostat at full Min. 10 mm (Before checking, leave it in water tank of 90°C for 4
opening – 5 minutes)
2 Move valve in fully open condition (in water tank of 90°C) to water Replace
Opening/Closing of
tank of 71°C and keep it for 4 -–5 minutes.
thermostat
Valve must fully close.
54 12V140E-3 Series
10 Structure, function and maintenance standard SEN00309-03
Corrosion resistor 1
12V140E-3 Series 55
SEN00309-03 10 Structure, function and maintenance standard
56 12V140E-3 Series
10 Structure, function and maintenance standard SEN00309-03
1. Crankshaft pulley
2. Fan belt
3. Tension pulley
4. Adjustment bolt
5. Tension pulley bracket
6. Fan pulley
7. Fan
12V140E-3 Series 57
SEN00309-03 10 Structure, function and maintenance standard
Tension pulley
SAA12V140E-3 (HD785-7, WA800-3E0, WA900-3E0)
1. Tension shaft
2. Spring
3. Roller bearing
4. Tension bracket
5. Spacer
6. Tension pulley (outside diameter: 154 mm)
7. Ball bearing
8. Oil seal
9. Grease fitting
10. Grease fitting
58 12V140E-3 Series
10 Structure, function and maintenance standard SEN00309-03
The cooling fan is hydraulic motor-driven. For more information, refer to the shop
manual for the machine body.
12V140E-3 Series 59
SEN00309-03 10 Structure, function and maintenance standard
Electrical equipment 1
Alternator 1
Alternator with built-in regulator (Open type, 90A)
Pulley
Specifica- Outside Weight
Engine Machine model Type Number
tions diameter (kg)
of stages
(mm)
D475A-5E0
HD785-7 Open type (brushless) manu-
SAA12V140E-3 24V, 90A 2 95 19
PC2000-8 factured by NIKKO DENKI
WA800-3E0, WA900-3E0
60 12V140E-3 Series
10 Structure, function and maintenance standard SEN00309-03
Alternator mounting
1. Adjustment bolt
2. Alternator pulley
3. Alternator
4. Alternator drive belt
5. Accessory pulley
12V140E-3 Series 61
SEN00309-03 10 Structure, function and maintenance standard
Starting motor 1
For 7.5 kW
E: To chassis ground
R: To alternator terminal R
S: To starting switch terminal C
Number
Specifica- Weight Type of
Engine Machine model Type of pinion
tions (kg) connector
teeth
D475A-5E0 Water-resistant, oil-resistant
SAA12V140E-3 HD785-7 type manufactured by NIKKO 24V, 7.5 kW 11 18 DT
WA800-3E0, WA900-3E0 DENKI
62 12V140E-3 Series
10 Structure, function and maintenance standard SEN00309-03
For 11 kW
E: To chassis ground
R: To alternator terminal R
S: To starting switch terminal C
Number
Specifica- Weight Type of
Engine Machine model Type of pinion
tions (kg) connector
teeth
Water-resistant, oil-resistant type
SAA12V140E-3 PC2000-8 24V, 11 kW 11 18 DT
manufactured by NIKKO DENKI
12V140E-3 Series 63
SEN00309-03 10 Structure, function and maintenance standard
Starting aid 1
Electric heater
1. Body Specifications
2. Heater coil Type of heater: Electrical intake air heater
3. Terminal Rated voltage: 22 V (DC)
4. Connection diagram Load current: 175 A
64 12V140E-3 Series
10 Structure, function and maintenance standard SEN00309-03
Engine controller 1
Features
Mounting of engine controller on engine
q Since the engine controller is mounted on the engine, the operator can service it easily in the field.
q Vibrations are damped by the vibration-proof rubber.
12V140E-3 Series 65
SEN00309-03 10 Structure, function and maintenance standard
1. Engine controller
2. Engine controller cooler
Outline
q The fuel is circulated as refrigerant through
engine controller cooler (2) to prevent engine
controller (1) from overheating.
q The fuel is not circuited in some applicable
machines.
66 12V140E-3 Series
10 Structure, function and maintenance standard SEN00309-03
12V140E-3 Series 67
SEN00309-03 10 Structure, function and maintenance standard
© 2008 KOMATSU
All Rights Reserved
Printed in Japan 07-08 (02)
68 12V140E-3 Series
SEN00311-03
12V140E-3 Series
12V140E-3 Series 1
SEN00311-03 20 Standard value table
Engine SAA12V140E-3
Machine model D475A-5E0
Category
Speed
Min. speed at no load rpm 660 ± 40 660 ± 40
Necessary At 0°C (without starting aid) rpm Min. 110 —
speed for
starting At –20°C (with starting aid) rpm Min. 100 —
Exhaust kPa
At rated output — —
pressure {mmHg}
Exhaust
Whole speed range (20°C ) °C Max. 680 750
temperature
Bosch
At sudden acceleration (Low to High) Max. 4.5 5.5
index
Exhaust gas Bosch
At rated output Max. 1.0 2.0
color index
Bosch
At high idle Max. 1.0 2.0
index
Intake valve mm 0.35 ± 0.02 0.35 ± 0.02
Valve clearance
Exhaust valve mm 0.57 ± 0.02 0.57 ± 0.02
Compression Engine oil temperature: 40 – 60°C MPa Min. 4.1 2.8
pressure Engine speed: 200 – 250 rpm {kg/cm2} {Min. 42} {29}
Body
Engine oil temperature: Min. 80°C SAE5W40E0S {kg/cm2} {3.0 – 4.5} {2.0}
Oil pressure SAE10W30DH
At low idle SAE15W40DH MPa Min. 0.08 0.04
Engine oil temperature: Min. 80°C SAE30DH {kg/cm2} {Min. 0.8} {0.4}
Oil temperature Whole speed range (Oil in oil pan) °C 90 – 110 120
Ratio to fuel consumption at continuous rated
Oil consumption % 0.15 0.3
output
Function of
Cooling system
kPa
radiator pres- Cracking pressure (Differential pressure) — —
{kg/cm2}
sure valve
Hydraulically Hydraulically
Fan speed At rated speed rpm driven on driven on
machine side machine side
Alternator belt
— Deflection under finger pressure of 59 N {6 kg} mm 20 20
tension
2 12V140E-3 Series
20 Standard value table SEN00311-03
Engine SAA12V140E-3
Machine model HD785-7
Category
Speed
Min. speed at no load rpm 650 ± 20 650 ± 20
Necessary At 0°C (without starting aid) rpm Min. 110 —
speed for
starting At –20°C (with starting aid) rpm Min. 100 —
Exhaust kPa
At rated output — —
pressure {mmHg}
Exhaust
Whole speed range (20°C ) °C Max. 700 750
temperature
Bosch
At sudden acceleration (Low to High) Max. 4.5 5.5
index
Exhaust gas Bosch
At rated output Max. 1.0 2.0
color index
Bosch
At high idle Max. 1.0 2.0
index
Intake valve mm 0.35 ± 0.02 0.35 ± 0.02
Valve clearance
Exhaust valve mm 0.57 ± 0.02 0.57 ± 0.02
Compression Engine oil temperature: 40 – 60°C MPa Min. 4.1 2.8
pressure Engine speed: 200 – 250 rpm {kg/cm2} {Min. 42} {29}
Body
Engine oil temperature: Min. 80°C SAE5W40E0S {kg/cm2} {3.0 – 4.5} {2.0}
Oil pressure SAE10W30DH
At low idle SAE15W40DH MPa Min. 0.08 0.04
Engine oil temperature: Min. 80°C SAE30DH {kg/cm2} {Min. 0.8} {0.4}
Oil temperature Whole speed range (Oil in oil pan) °C 90 – 110 120
Ratio to fuel consumption at continuous rated
Oil consumption % 0.15 0.3
output
Function of
Cooling system
kPa
radiator pres- Cracking pressure (Differential pressure) — —
{kg/cm2}
sure valve
Alternator belt
— Deflection under finger pressure of 59 N {6 kg} mm 20 20
tension
12V140E-3 Series 3
SEN00311-03 20 Standard value table
Engine SAA12V140E-3
Machine model PC2000-8
Category
Speed
Min. speed at no load rpm 825 ± 25 825 ± 25
Necessary At 0°C (without starting aid) rpm Min. 110 —
speed for
starting At –20°C (with starting aid) rpm Min. 100 —
Exhaust kPa
At rated output — —
pressure {mmHg}
Exhaust
Whole speed range (20°C ) °C Max. 700 750
temperature
Bosch
At sudden acceleration (Low to High) Max. 4.5 5.5
index
Exhaust gas Bosch
At rated output Max. 1.0 2.0
color index
Bosch
At high idle Max. 1.0 2.0
index
Intake valve mm 0.35 ± 0.02 0.35 ± 0.02
Valve clearance
Exhaust valve mm 0.57 ± 0.02 0.57 ± 0.02
Compression Engine oil temperature: 40 – 60°C MPa Min. 4.1 2.8
pressure Engine speed: 200 – 250 rpm {kg/cm2} {Min. 42} {29}
Body
Engine oil temperature: Min. 80°C SAE5W40E0S {kg/cm2} {3.0 – 4.5} {2.0}
Oil pressure SAE10W30DH
At low idle SAE15W40DH MPa Min. 0.08 0.06
Engine oil temperature: Min. 80°C SAE30DH {kg/cm2} {Min. 0.8} {0.6}
Oil temperature Whole speed range (Oil in oil pan) °C 90 – 110 120
Ratio to fuel consumption at continuous rated
Oil consumption % 0.15 0.3
output
Function of
Cooling system
kPa
radiator pres- Cracking pressure (Differential pressure) — —
{kg/cm2}
sure valve
Hydraulically Hydraulically
Fan speed At rated speed rpm driven on driven on
machine side machine side
Alternator belt
— Deflection under finger pressure of 59 N {6 kg} mm 20 20
tension
4 12V140E-3 Series
20 Standard value table SEN00311-03
Engine SAA12V140E-3
Machine model WA800-3E0
Category
Speed
Min. speed at no load rpm 680 (+50/0) 680 (+50/0)
Necessary At 0°C (without starting aid) rpm Min. 110 —
speed for
starting At –20°C (with starting aid) rpm Min. 100 —
Exhaust kPa
At rated output — —
pressure {mmHg}
Exhaust
Whole speed range (20°C ) °C Max. 680 750
temperature
Bosch
At sudden acceleration (Low to High) Max. 4.5 5.5
index
Exhaust gas Bosch
At rated output Max. 1.0 2.0
color index
Bosch
At high idle Max. 1.0 2.0
index
Intake valve mm 0.35 ± 0.02 0.35 ± 0.02
Valve clearance
Exhaust valve mm 0.57 ± 0.02 0.57 ± 0.02
Compression Engine oil temperature: 40 – 60°C MPa Min. 4.1 2.8
pressure Engine speed: 200 – 250 rpm {kg/cm2} {Min. 42} {29}
Body
Engine oil temperature: Min. 80°C SAE5W40E0S {kg/cm2} {3.0 – 4.5} {2.0}
Oil pressure SAE10W30DH
At low idle SAE15W40DH MPa Min. 0.08 0.04
Engine oil temperature: Min. 80°C SAE30DH {kg/cm2} {Min. 0.8} {0.4}
Oil temperature Whole speed range (Oil in oil pan) °C 90 – 110 120
Ratio to fuel consumption at continuous rated
Oil consumption % 0.15 0.3
output
Function of
Cooling system
kPa
radiator pres- Cracking pressure (Differential pressure) — —
{kg/cm2}
sure valve
Alternator belt
— Deflection under finger pressure of 59 N {6 kg} mm 20 20
tension
12V140E-3 Series 5
SEN00311-03 20 Standard value table
Engine SAA12V140E-3
Machine model WA900-3E0
Category
Speed
Min. speed at no load rpm 680 (+50/0) 680 (+50/0)
Necessary At 0°C (without starting aid) rpm Min. 110 —
speed for
starting At –20°C (with starting aid) rpm Min. 100 —
Exhaust kPa
At rated output — —
pressure {mmHg}
Exhaust
Whole speed range (20°C ) °C Max. 700 750
temperature
Bosch
At sudden acceleration (Low to High) Max. 4.5 5.5
index
Exhaust gas Bosch
At rated output Max. 1.0 2.0
color index
Bosch
At high idle Max. 1.0 2.0
index
Intake valve mm 0.35 ± 0.02 0.35 ± 0.02
Valve clearance
Exhaust valve mm 0.57 ± 0.02 0.57 ± 0.02
Compression Engine oil temperature: 40 – 60°C MPa Min. 4.1 2.8
pressure Engine speed: 200 – 250 rpm {kg/cm2} {Min. 42} {29}
Body
Engine oil temperature: Min. 80°C SAE5W40E0S {kg/cm2} {3.0 – 4.5} {2.0}
Oil pressure SAE10W30DH
At low idle SAE15W40DH MPa Min. 0.08 0.04
Engine oil temperature: Min. 80°C SAE30DH {kg/cm2} {Min. 0.8} {0.4}
Oil temperature Whole speed range (Oil in oil pan) °C 90 – 110 120
Ratio to fuel consumption at continuous rated
Oil consumption % 0.15 0.3
output
Function of
Cooling system
kPa
radiator pres- Cracking pressure (Differential pressure) — —
{kg/cm2}
sure valve
Alternator belt
— Deflection under finger pressure of 59 N {6 kg} mm 20 20
tension
6 12V140E-3 Series
20 Standard value table SEN00311-03
Engine SAA12V140E-3
Machine model D475A-5E0
Procedure
Item
1 2 3 4 5 6
Running time min. 5 15 5 5 20 10
Speed rpm 660 1,000 1,250 1,550 1,800 2,000
Dynamometer load N {kg} 0 {0} 568 {58} 1,127 {115} 2,254 {230} 3,381 {345} 4,508 {460}
Output kW {HP} 0 {0} 43 {57} 106 {142} 263 {352} 457 {612} 677 {907}
a This table shows the values when the fan is not installed.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Engine SAA12V140E-3
Machine model D475A-5E0
Max. speed at Min. speed at
Test item Rated output Max. torque
no load no load
Specification value 671 kW/2,000 rpm 3,825 Nm/1,400 rpm
— 2,150(+25/-50)rpm 660 ± 40 rpm
(Gross value) {899 HP/2,000 rpm} {390 kgm/1,400 rpm}
Speed rpm 2,000 ± 5 1,300 – 1,500 — —
N 4,341 – 4,596 5,174 – 5,498
Dynamometer load — —
{kg} {443 – 469} {528 – 561}
kW 651 – 691
Output (Gross value) — — —
{HP} {873 – 926}
Nm 3,704 – 3,940
Torque (Gross value) — — —
{kgm} {378 – 402}
Fuel consumption sec/1,000cc Min. 19.5 — — —
Coolant temperature °C 70 – 90 70 – 90 70 – 90 70 – 90
Lubricating oil
°C 90 – 110 90 – 110 90 – 110 90 – 110
temperature
Lubricating oil MPa 0.34 – 0.49 Min. 0.08
— —
pressure {kg/cm2} {3.0 – 4.5} {Min. 0.8}
Exhaust temperature °C Max. 650 Max. 680 — —
a This table shows the standard values obtained by using the JIS correction coefficients.
a Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.
a This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
a Use ASTM No.1 or No. 2 diesel fuel as fuel.
a Use SAE15W-40 as lubricating oil.
a Aftercooler outlet temperature must not exceed 50°C.
12V140E-3 Series 7
SEN00311-03 20 Standard value table
Running-in standard
Engine SAA12V140E-3
Machine model HD785-7
Procedure
Item
1 2 3 4 5 6
Running time min. 5 15 5 5 20 10
Speed rpm 650 1,000 1,250 1,550 1,800 1,900
Dynamometer load N {kg} 0 {0} 784 {80} 1,568 {160} 3,136 {320} 4,704 {480} 6,272 {640}
Output kW {HP} 0 {0} 59 {79} 147 {197} 365 {489} 635 {852} 894 {1,200}
a This table shows the values when the fan is not installed.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Engine SAA12V140E-3
Machine model HD785-7
Max. speed at Min. speed at
Test item Rated output Max. torque
no load no load
Specification value 895 kW/1,900 rpm 5,076 Nm/1,350 rpm
— 2,250 ± 25 rpm 650 ± 20 rpm
(Gross value) {1,200 HP/1,900 rpm} {518 kgm/1,350 rpm}
Speed rpm 1,900 ± 5 1,300 – 1,400 — —
N 6,086 – 6,468 6,870 – 7,311
Dynamometer load — —
{kg} {621 – 660} {701 – 746}
kW 868 – 922
Output (Gross value) — — —
{HP} {1,160 – 1,240}
Nm 4,920 – 5,233
Torque (Gross value) — — —
{kgm} {502 – 534}
Fuel consumption sec/1,000cc Min. 15.2 — — —
Coolant temperature °C 70 – 90 70 – 90 70 – 90 70 – 90
Lubricating oil
°C 90 – 110 90 – 110 90 – 110 90 – 110
temperature
Lubricating oil MPa 0.34 – 0.49 Min. 0.08
— —
pressure {kg/cm2} {3.0 – 4.5} {Min. 0.8}
Exhaust temperature °C Max. 650 Max. 700 — —
a This table shows the standard values obtained by using the JIS correction coefficients.
a Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.
a This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
a Use ASTM No.1 or No. 2 diesel fuel as fuel.
a Use SAE15W-40 as lubricating oil.
a Aftercooler outlet temperature must not exceed 50°C.
8 12V140E-3 Series
20 Standard value table SEN00311-03
Running-in standard
Engine SAA12V140E-3
Machine model PC2000-8
Procedure
Item
1 2 3 4 5 6
Running time min. 5 15 5 5 20 10
Speed rpm 825 1,000 1,250 1,550 1,800 1,800
Dynamometer load N {kg} 0 {0} 676 {69} 1,352 {138} 2,695 {275} 4,074 {413} 5,390 {550}
Output kW {HP} 0 {0} 51 {68} 127 {171} 313 {420} 546 {733} 728 {976}
a This table shows the values when the fan is not installed.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Engine SAA12V140E-3
Machine model PC2000-8
Max. speed at Min. speed at
Test item Rated output Max. torque
no load no load
Specification value 728 kW/1,800 rpm 4,488 Nm/1,350 rpm
— 1,980 ± 25 rpm 825 ± 25 rpm
(Gross value) {976 HP/1,800 rpm} {458 kgm/1,350 rpm}
Speed rpm 1,800 ± 5 1,300 – 1,400 — —
N 4,341 – 4,596 6,076 – 6,380
Dynamometer load — —
{kg} {534 – 567} {620 – 659}
kW 706 – 750
Output (Gross value) — — —
{HP} {947 – 1,010}
Nm 4,351 – 4,626
Torque (Gross value) — — —
{kgm} {444 – 472}
Fuel consumption sec/1,000cc Min. 18.6 — — —
Coolant temperature °C 70 – 90 70 – 90 70 – 90 70 – 90
Lubricating oil
°C 90 – 110 90 – 110 90 – 110 90 – 110
temperature
Lubricating oil MPa 0.34 – 0.49 Min. 0.08
— —
pressure {kg/cm2} {3.0 – 4.5} {Min. 0.8}
Exhaust temperature °C Max. 650 Max. 700 — —
a This table shows the standard values obtained by using the JIS correction coefficients.
a Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.
a This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
a Use ASTM No.1 or No. 2 diesel fuel as fuel.
a Use SAE15W-40 as lubricating oil.
a Aftercooler outlet temperature must not exceed 50°C.
12V140E-3 Series 9
SEN00311-03 20 Standard value table
Running-in standard
Engine SAA12V140E-3
Machine model WA800-3E0
Procedure
Item
1 2 3 4 5 6
Running time min. 5 15 5 5 20 10
Speed rpm 680 1,000 1,250 1,550 1,800 2,000
Dynamometer load N {kg} 0 {0} 529 {54} 1,058 {108} 2,107 {215} 3,156 {322} 4,214 {430}
Output kW {HP} 0 {0} 40 {53} 99 {133} 245 {328} 427 {572} 633 {848}
a This table shows the values when the fan is not installed.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Engine SAA12V140E-3
Machine model WA800-3E0
Max. speed at Min. speed at
Test item Rated output Max. torque
no load no load
Specification value 636 kW/2,000 rpm 3,802 Nm/1,400 rpm 2,200 (+10/-20)
— 680 (+50/0) rpm
(Gross value) {853 HP/2,000 rpm} {388 kgm/1,400 rpm} rpm
Speed rpm 2,000 ± 5 1,350 – 1,450 — —
N 4,116 – 4,371 5,155 – 5,468
Dynamometer load — —
{kg} {420 – 446} {526 – 558}
kW 617 – 655
Output (Gross value) — — —
{HP} {827 – 879}
Nm 3,685 – 3,920
Torque (Gross value) — — —
{kgm} {376 – 400}
Fuel consumption sec/1,000cc Min. 20.5 — — —
Coolant temperature °C 70 – 90 70 – 90 70 – 90 70 – 90
Lubricating oil
°C 90 – 110 90 – 110 90 – 110 90 – 110
temperature
Lubricating oil MPa 0.34 – 0.49 Min. 0.08
— —
pressure {kg/cm2} {3.0 – 4.5} {Min. 0.8}
Exhaust temperature °C Max. 650 Max. 680 — —
a This table shows the standard values obtained by using the JIS correction coefficients.
a Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.
a This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
a Use ASTM No.1 or No. 2 diesel fuel as fuel.
a Use SAE15W-40 as lubricating oil.
a Aftercooler outlet temperature must not exceed 50°C.
10 12V140E-3 Series
20 Standard value table SEN00311-03
Running-in standard
Engine SAA12V140E-3
Machine model WA900-3E0
Procedure
Item
1 2 3 4 5 6
Running time min. 5 15 5 5 20 10
Speed rpm 680 1,000 1,250 1,550 1,800 2,050
Dynamometer load N {kg} 0 {0} 549 {56} 1,088 {111} 2,185 {223} 3,273 {334} 4,361 {445}
Output kW {HP} 0 {0} 41 {55} 102 {137} 254 {341} 442 {593} 671 {899}
a This table shows the values when the fan is not installed.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Engine SAA12V140E-3
Machine model WA900-3E0
Max. speed at Min. speed at
Test item Rated output Max. torque
no load no load
Specification value 672 kW/2,050 rpm 4,159 Nm/1,300 rpm
— 2,200(+10/-20)rpm 680(+50/0)rpm
(Gross value) {900 HP/2,050 rpm} {424 kgm/1,300 rpm}
Speed rpm 2,050 ± 5 1,250 – 1,350 — —
N 4,234 – 4,488 5,625 – 5,978
Dynamometer load — —
{kg} {432 – 458} {574 – 610}
kW 652 – 691
Output (Gross value) — — —
{HP} {874 – 927}
Nm 4,028 – 4,283
Torque (Gross value) — — —
{kgm} {411 – 437}
Fuel consumption sec/1,000cc Min. 19.5 — — —
Coolant temperature °C 70 – 90 70 – 90 70 – 90 70 – 90
Lubricating oil
°C 90 – 110 90 – 110 90 – 110 90 – 110
temperature
Lubricating oil MPa 0.34 – 0.49 Min. 0.08
— —
pressure {kg/cm2} {3.0 – 4.5} {Min. 0.8}
Exhaust temperature °C Max. 650 Max. 700 — —
a This table shows the standard values obtained by using the JIS correction coefficients.
a Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.
a This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
a Use ASTM No.1 or No. 2 diesel fuel as fuel.
a Use SAE15W-40 as lubricating oil.
a Aftercooler outlet temperature must not exceed 50°C.
12V140E-3 Series 11
SEN00311-03 20 Standard value table
© 2007 KOMATSU
All Rights Reserved
Printed in Japan 06-07 (02)
12 12V140E-3 Series
SEN00313-04
12V140E-3 Series
12V140E-3 Series 1
SEN00313-04 30 Testing and adjusting
2 12V140E-3 Series
30 Testing and adjusting SEN00313-04
Sym-
Q'ty
Testing/Adjusting item Part No. Part name Remarks
bol
Testing air boost 799-201-2202 Boost gauge kit 1 -101 – 200 kPa {-760 – 1,500 mmHg}
A
pressure 799-401-2220 Hose 1
Testing exhaust
B 799-101-1502 Digital thermometer 1 - 99.9 – 1,299°C
temperature
Commercially Intake: 0.35 mm
Adjusting valve clearance C Thickness gauge 1
available Exhaust: 0.57 mm
1 795-502-1590 Compression gauge 1 0 – 6.9 MPa {0 – 70 kg/cm2}
Testing compression
D 795-471-1310 Adapter 1
pressure 2 For 140E-3, 5
6261-71-6150 Gasket 1
1 799-201-1504 Blow-by checker kit 1 0 – 10 kPa {0 – 1,000 mmH2O}
2 799-201-1590 Gauge 1
Testing blow-by pressure E 3 799-201-1450 Adapter 2
4 799-201-1511 Nozzle 2
5 799-201-1571 Tube 1
Pressure gauge: 2.5, 6, 40, 60 MPa
799-101-5002 Hydraulic tester 1
1 {25, 60, 400, 600 kg/cm2}
Testing oil pressure F
799-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
2 799-401-2320 Gauge 1 Pressure gauge: 1 MPa {10 kg/cm2}
Pressure gauge: 2.5, 6, 40, 60 MPa
799-101-5002 Hydraulic tester 1
1 {25, 60, 400, 600 kg/cm2}
799-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
Testing fuel pressure G 2 795-471-1450 Adapter 1 8 x 1.25 (male) – R1/8 (female)
799-101-5220 Nipple (10 x 1.25 mm) 1
3 Size: 10 x 1.25 mm
07002-11023 O-ring 1
4 799-401-2320 Gauge 1 Pressure gauge: 1 MPa {10 kg/cm2}
1 6151-51-8490 Spacer 1 ø 14
2 6141-71-1710 Joint 1 ø 10
Commercially
3 Hose 1 Inside diameter: Approx. 11 mm
available
Testing leakage through Commercially
4 Hose 1 Inside diameter: Approx. 17 mm
pressure limiter and H available
return rate from injector Commercially
5 Measuring cylinder 1
available
Commercially
6 Stopwatch 1
available
7 07376-70315 Plug 1 Size: 03
799-601-4130 T-adapter 1 For Ne sensor
799-601-4330 Socket 1 For G (Bkup) sensor
Controller • sensor 799-601-4240 Socket 1 For atmospheric pressure sensor
J
• Actuator diagnosis 799-601-4250 Socket 1 For boost pressure sensor
799-601-9420 T-adapter 1 For common rail pressure sensor
799-601-4150 T-adapter 1 For oil pressure sensor
12V140E-3 Series 3
SEN00313-04 30 Testing and adjusting
Sym-
Q'ty
Testing/Adjusting item Part No. Part name Remarks
bol
For boost temperature sensor
795-799-5540 Socket 1
For intake air sensor
For coolant temperature sensor
795-799-5530 Socket 1 For fuel temperature sensor
Oil temperature sensor
799-601-9430 Socket 1 For supply pump PCV
Controller • sensor 799-601-9020 T-adapter 1 For injector
J
• Actuator diagnosis 799-601-4260 T-adapter 1 For controller (4 - pole)
799-601-4211 T-adapter 1 For controller (50 - pole)
799-601-4220 T-adapter 1 For controller (60 - pole)
799-601-4350 T-box 1 For 60 - pole type
799-601-9320 T-box 1 For 24 - pole type
799-601-9310 Plate 1
4 12V140E-3 Series
30 Testing and adjusting SEN00313-04
12V140E-3 Series 5
SEN00313-04 30 Testing and adjusting
Testing exhaust temperature 1 3. Run the engine and test the exhaust tempera-
ture in the whole speed range.
a Testing tool for exhaust temperature
a When testing with the engine mounted on
Symbol Part No. Part name the machine, test on the condition
B 799-101-1502 Digital thermometer described in the shop manual for the
machine.
k Remove and install the testing tools after
the exhaust manifold temperature has low-
ered.
a The test point is subject to machine models.
6 12V140E-3 Series
30 Testing and adjusting SEN00313-04
Adjusting valve clearance 1 5. Hereafter crank the engine similar way in the
firing order. Match the stamped line of the
a Adjusting tool for valve clearance damper to the pointer and adjust the valve
Symbol Part No. Part name clearance of each cylinder.
a Firing order
Commercially
C
available
Clearance gauge R1 – L1 – R5 – L5 – R3 – L3 – R6 – L6 –
R2 – L2 – R4 – L4
12V140E-3 Series 7
SEN00313-04 30 Testing and adjusting
8 12V140E-3 Series
30 Testing and adjusting SEN00313-04
12V140E-3 Series 9
SEN00313-04 30 Testing and adjusting
10 12V140E-3 Series
30 Testing and adjusting SEN00313-04
Testing blow-by pressure 1 3. Run the engine at the rated output and test the
blow-by pressure.
a Testing tool for blow-by pressure
a When testing with the engine mounted on
Symbol Part No. Part name Q'ty the machine, test on the condition
1 799-201-1504 Blow-by checker kit 1 described in the shop manual for the
machine.
2 799-201-1590 Gauge 1
E 3 799-201-1450 Adapter 2
4 799-201-1511 Nozzle 2
5 799-201-1571 Tube 1
12V140E-3 Series 11
SEN00313-04 30 Testing and adjusting
Testing oil pressure 1 3. Run the engine at the rated output and low idle
and test the oil pressure.
a Testing tools for oil pressure a When testing with the engine mounted on
Symbol Part No. Part name the machine, test on the condition
described in the shop manual for the
799-101-5002 Hydraulic tester
1 machine.
F 790-261-1204 Digital hydraulic tester
2 799-401-2320 Hydraulic tester
12 12V140E-3 Series
30 Testing and adjusting SEN00313-04
12V140E-3 Series 13
SEN00313-04 30 Testing and adjusting
Testing fuel pressure 1 3. Run the engine at high idle and measure the
fuel pressure.
a Testing tools for fuel pressure a If the fuel pressure is in the following
Symbol Part No. Part name range, it is normal.
799-101-5002 Hydraulic tester Engine speed Fuel pressure
1
790-261-1204 Digital hydraulic tester 0.15 – 0.3 MPa
High idle
2 795-471-1450 Adapter {1.5 – 3 kg/cm2}
G
799-101-5220 Nipple
3
07002-11023 O-ring
4 799-401-2320 Gauge
1. Remove air bleeder plug (1) on the top of fuel 4. Since the fuel circuits on the LH and RH banks
filter. after the priming pump are independent, test
each circuit.
14 12V140E-3 Series
30 Testing and adjusting SEN00313-04
12V140E-3 Series 15
SEN00313-04 30 Testing and adjusting
a If the engine is of a type that returns the fuel a Prepare an oil pan of about 20 l to receive the
spilling from the injector from the return block fuel flowing out during the test.
installed to the front of intake manifold, check
the engine according to the following (the fig- 1. Preparatory work (case of the LH bank)
ure showing the LH bank for PC2000). 1) Remove tube (4) between common rail (3)
a Testing tools for pressure limiter leakage and and supply pump (5).
injector return rate 2) Insert spacer H1 on supply pump (5) side
Symbol Part No. Part name and tighten the removed joint bolt again.
1 6151-51-8490 Spacer 3) Connect the return pipe to the fuel tank
again, too.
2 6141-71-1710 Joint
a Be sure to provide a gasket to both
Commercially Inside diameter of the hose: ends of the spacer.
3
available Approx. 11 mm
Commercially Inside diameter of the hose:
4
H available Approx. 17 mm
Commercially
5 Measuring cylinder
available
Commercially
6 Stopwatch
available
7 07376-70315 Plug
16 12V140E-3 Series
30 Testing and adjusting SEN00313-04
12V140E-3 Series 17
SEN00313-04 30 Testing and adjusting
18 12V140E-3 Series
30 Testing and adjusting SEN00313-04
a If fuel is used up or if a fuel circuit part is a Don't fill fuel directly after removing main
removed and installed, bleed air from the fuel filter (1).
circuit according to the following procedure.
a The locations of the fuel circuit parts are sub-
ject to machine models (The figure showing
the LH bank for D475A-5).
12V140E-3 Series 19
SEN00313-04 30 Testing and adjusting
20 12V140E-3 Series
30 Testing and adjusting SEN00313-04
12V140E-3 Series 21
SEN00313-04 30 Testing and adjusting
a If fuel is used up or if a fuel circuit part is a Don't fill fuel directly after removing main
removed and installed, bleed air from the fuel filter (1).
circuit according to the following procedure.
a The locations of the fuel circuit parts are sub-
ject to machine models (The figure showing
the LH bank for PC2000).
22 12V140E-3 Series
30 Testing and adjusting SEN00313-04
12V140E-3 Series 23
SEN00313-04 30 Testing and adjusting
3. Turn the left and right lever (1) of the air bleed-
ing piping to the parallel position with the pip-
ing to open the circuit valve.
24 12V140E-3 Series
30 Testing and adjusting SEN00313-04
5. After the specified time (approx. 7 minutes), 10. If the engine does not start, try to start it again
lamp (4) goes off and the electric priming pump according to the following procedure.
stops automatically. k When starting the engine, check that there
a If only the fuel filter was replaced, the air is no person around it.
bleeding work is completed now. a Carry out the work with the air bleeding
valve closed. (Do not open the air bleed-
6. If the fuel was used up or the fuel piping or ing valve after step 7.)
supply pump was replaced and there is not fuel a After the engine fails to start, wait for
in the fuel circuit, turn switch (3) "ON" after the about 2 minutes before trying to start
electric priming pump stops automatically. again.
1) Turn the electric priming pump switch ON.
7. When lamp (4) goes off, the air bleeding work 2) While the electric priming pump is operat-
is completed. ing, crank the engine.
q If the engine does not start, repeat the
8. Turn lever (1) of the air bleeding piping to the above operation.
cross position with the piping to close the cir- a Do not operate the starting motor continu-
cuit valve. ously for more than 20 seconds.
a If the engine fails to start, wait for about 2
minutes and try to start again.
3) After starting the engine, run it at low idle
for about 5 minutes to bleed all air from
the fuel circuit.
4) Stop the engine and check that the air
bleeding valve is closed.
5) After the above operation, start the engine
normally.
12V140E-3 Series 25
SEN00313-04 30 Testing and adjusting
Testing fuel system for leakage 1 9. Inspect the fuel piping and devices for fuel
k
leakage.
Very high pressure is generated in the high-
a Check mainly around the high-pressure
pressure circuit of the fuel system. If fuel
circuit parts coated with the color checker
leaks while the engine is running, it is dan-
for fuel leakage.
gerous since it can catch fire.
a If any fuel leakage is detected, repair it
After testing the fuel system or removing
and inspect again from step 1.
its parts, test it for fuel leakage according
a If no fuel leakage is detected, check is
to the following procedure.
completed.
a Clean and degrease the engine and the parts
around it in advance so that you can test it eas-
ily for fuel leakage.
26 12V140E-3 Series
30 Testing and adjusting SEN00313-04
1. Remove speed sensor (1) and check that its tip Adjusting
is free from steel chips and flaws, and then a If the deflection is out of the standard range,
install it again temporarily. adjust it according to the following procedure.
2 Threads: Gasket sealant (LG-6)
12V140E-3 Series 27
SEN00313-04 30 Testing and adjusting
28 12V140E-3 Series
30 Testing and adjusting SEN00313-04
12V140E-3 Series 29
SEN00313-04 30 Testing and adjusting
© 2009 KOMATSU
All Rights Reserved
Printed in Japan 12-09 (02)
30 12V140E-3 Series
SEN00315-01
12V140E-3 Series
SEN00315-01
ENGINE
Shop Manual
12V140E-3 Series
40 Troubleshooting
General Information on troubleshooting
12V140E-3 Series 1
SEN00315-01 40 Troubleshooting
k When troubleshooting a machine, stop it in a level ground, and check that the lock pin, chocks,
and parking brake are securely fitted.
k When carrying out the operation with two or more workers, keep strictly to the agreed signals, and
do not allow any unauthorized person to come near.
k If the radiator cap is removed when the engine is hot, hot coolant may spurt out and cause burns,
so be sure to wait for the engine to cool down before starting troubleshooting.
k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
k When disconnecting wiring, always disconnect the negative (–) terminal of the battery first.
k When removing the plug or cap from a location which is under pressure from oil, water, or air, al-
ways release the internal pressure first. When installing measuring equipment, be sure to connect
it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and the
prevent reoccurrence of the failure.When carrying out troubleshooting, and important point is of course to un-
derstand the structure and function. However, a short cut to effective troubleshooting is to ask the operator
various questions to form some idea of possible causes of the failure that would produce the reported symp-
toms.
1. When carrying out troubleshooting, do not hurry 2) Be sure to check the CHECKS BEFORE
to disassemble the components. STARTING items.
If components are disassembled immediately 3) Check other inspection items, if necessary.
after any failure occurs: 4) Some other maintenance items can be
q Parts that have no connection with the failure checked externally, so check any item that is
or other unnecessary parts will be disassem- considered to be necessary.
bled. 5) Check the controller for display of an error.
q It will become impossible to find the cause of
the failure.
4. Confirming failure
It will also cause a waste of manhours, parts, or
Confirm the extent of the failure yourself, and
oil or grease, and at the same time, will also lose
judge whether to handle it as a real failure or as
the confidence of the user or operator.
a problem with the method of operation, etc.
For this reason, when carrying out trouble-
a When operating the machine or engine to re-
shooting, it is necessary to carry out thorough
enact the troubleshooting symptoms, do not
prior investigation and to carry out trouble-
carry out any investigation or measurement
shooting in accordance with the fixed procedure.
that may make the problem worse.
2 12V140E-3 Series
40 Troubleshooting SEN00315-01
115 CA115 Eng. Ne and G (Bkup) Speed Sensor Error (LH bank)
115 CB115 Eng. Ne and G (Bkup) Speed Sensor Error (RH bank)
122 CA122 Charge Air Press. Sensor High Error (LH bank only)
123 CA123 Charge Air Press. Sensor Low Error (LH bank only)
135 CA135 Oil Press. Sensor High Error (LH bank only)
141 CA141 Oil Press. Sensor Low Error (LH bank only)
144 CA144 Coolant Temp. Sensor High Error (LH bank only)
145 CA145 Coolant Temp. Sensor Low Error (LH bank only)
153 CA153 Charge Air Temp. Sensor High Error (LH bank only)
154 CA154 Charge Air Temp. Sensor Low Error (LH bank only)
212 CA212 Eng. Oil Temp.Sensor High Error (LH bank only)
213 CA213 Eng. Oil Temp.Sensor Low Error (LH bank only)
221 CA221 Ambient Air Press. Sensor High Error (LH bank only)
222 CA222 Ambient Air Press. Sensor Low Error (LH bank only)
12V140E-3 Series 3
SEN00315-01 40 Troubleshooting
322 CA322 Injector #1 (LA/B #1) System Open/Short Error (LH bank)
323 CA323 Injector #5 (LA/B #5) System Open/Short Error (LH bank)
324 CA324 Injector #3 (LA/B #3) System Open/Short Error (LH bank)
325 CA325 Injector #6 (LA/B #6) System Open/Short Error (LH bank)
331 CA331 Injector #2 (LA/B #2) System Open/Short Error (LH bank)
332 CA332 Injector #4 (LA/B #4) System Open/Short Error (LH bank)
4 12V140E-3 Series
40 Troubleshooting SEN00315-01
691 CA691 Intake Air Temp Sensor High Error (LH bank only)
692 CA692 Intake Air Temp Sensor Low Error (LH bank only)
731 CA731 Eng. G (Bkup) Speed Sensor Phase Error (LH bank)
731 CB731 Eng. G (Bkup) Speed Sensor Phase Error (RH bank)
1548 CB1548 Injector #7 (R/B #1) System Open/Short Error (RH bank)
1549 CB1549 Injector #8 (R/B #2) System Open/Short Error (RH bank)
1551 CB1551 Injector #10 (R/B #4) System Open/Short Error (RH bank)
1552 CB1552 Injector #11 (R/B #5) System Open/Short Error (RH bank)
1553 CB1553 Injector #12 (R/B #6) System Open/Short Error (RH bank)
1622 CB1622 Injector #9 (R/B #3) System Open/Short Error (RH bank)
2185 CA2185 Throttle Sens. Sup. Volt. High Error (LH bank only)
2186 CA2186 Throttle Sens. Sup. Volt. Low Error (LH bank only)
12V140E-3 Series 5
SEN00315-01 40 Troubleshooting
--*2 — Eng. Oil Press. Low Speed Derate (LH bank only)
--*3 — Eng. Oil Press. Low Torque Derate (LH bank only)
6 12V140E-3 Series
40 Troubleshooting SEN00315-01
<Contents of description>
q Standard value in normal state to judge possible causes
q Remarks on judgment
1
<Troubles in wiring harness>
q Disconnection
Connector is connected imperfectly or wiring harness is
broken.
q Ground fault
Wiring harness which is not connected to chassis ground
circuit is in contact with chassis ground circuit.
q Hot short
Wiring harness which is not connected to power source (24
2 V) circuit is in contact with power source (24 V) circuit.
q Short circuit
Independent wiring harnesses are in contact with each
Possible causes other abnormally.
and standard Possible causes of trouble
value in normal (Given numbers are refer-
<Precautions for troubleshooting>
state ence numbers, which do not
(1) Method of indicating connector No. and handling of
indicate priority)
Tadapter
Insert or connect T-adapter as explained below for trouble-
shooting, unless otherwise specified.
3 q If connector No. has no marks of "male" and "female",
disconnect connector and insert T-adapters in both
male side and female side.
q If connector No. has marks of "male" and "female", dis-
connect connector and connect T-adapter to only male
side or female side.
(2) Entry order of pin Nos. and handling of tester leads
Connect positive (+) lead and negative (-) lead of tester as
explained below for troubleshooting, unless otherwise
specified.
q Connect positive (+) lead to pin No. or wiring harness
4
entered on front side.
q Connect negative (-) lead to pin No. or wiring harness
entered on rear side.
12V140E-3 Series 7
SEN00315-01 40 Troubleshooting
8 12V140E-3 Series
40 Troubleshooting SEN00315-01
12V140E-3 Series 9
SEN00315-01 40 Troubleshooting
10 12V140E-3 Series
40 Troubleshooting SEN00315-01
12V140E-3 Series 11
SEN00315-01 40 Troubleshooting
12 12V140E-3 Series
40 Troubleshooting SEN00315-01
12V140E-3 Series 13
SEN00315-01 40 Troubleshooting
14 12V140E-3 Series
40 Troubleshooting SEN00315-01
12V140E-3 Series 15
SEN00315-01 40 Troubleshooting
16 12V140E-3 Series
40 Troubleshooting SEN00315-01
12V140E-3 Series 17
SEN00315-01 40 Troubleshooting
18 12V140E-3 Series
40 Troubleshooting SEN00315-01
12V140E-3 Series 19
SEN00315-01 40 Troubleshooting
20 12V140E-3 Series
40 Troubleshooting SEN00315-01
12V140E-3 Series 21
SEN00315-01 40 Troubleshooting
22 12V140E-3 Series
40 Troubleshooting SEN00315-01
12V140E-3 Series 23
SEN00315-01 40 Troubleshooting
24 12V140E-3 Series
40 Troubleshooting SEN00315-01
12V140E-3 Series 25
SEN00315-01 40 Troubleshooting
26 12V140E-3 Series
40 Troubleshooting SEN00315-01
12V140E-3 Series 27
SEN00315-01 40 Troubleshooting
28 12V140E-3 Series
40 Troubleshooting SEN00315-01
12V140E-3 Series 29
SEN00315-01 40 Troubleshooting
30 12V140E-3 Series
40 Troubleshooting SEN00315-01
12V140E-3 Series 31
SEN00315-01 40 Troubleshooting
32 12V140E-3 Series
40 Troubleshooting SEN00315-01
12V140E-3 Series 33
SEN00315-01 40 Troubleshooting
34 12V140E-3 Series
40 Troubleshooting SEN00315-01
12V140E-3 Series 35
SEN00315-01 40 Troubleshooting
36 12V140E-3 Series
40 Troubleshooting SEN00315-01
12V140E-3 Series 37
SEN00315-01 40 Troubleshooting
38 12V140E-3 Series
40 Troubleshooting SEN00315-01
12V140E-3 Series 39
SEN00315-01 40 Troubleshooting
40 12V140E-3 Series
40 Troubleshooting SEN00315-01
12V140E-3 Series 41
SEN00315-01 40 Troubleshooting
42 12V140E-3 Series
40 Troubleshooting SEN00315-01
12V140E-3 Series 43
SEN00315-01 40 Troubleshooting
44 12V140E-3 Series
40 Troubleshooting SEN00315-01
a The vertical column indicates a part number of T-branch box or T-branch adapter while the horizontal col-
umn indicates a part number of harness checker assembly.
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identificati
Part No. Part name
on symbol
12V140E-3 Series 45
SEN00315-01 40 Troubleshooting
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identificati
Part No. Part name
on symbol
46 12V140E-3 Series
40 Troubleshooting SEN00315-01
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identificati
Part No. Part name
on symbol
12V140E-3 Series 47
SEN00315-01 40 Troubleshooting
©2009 KOMATSU
All Rights Reserved
Printed in Japan 09-09
48
SEN00316-01
12V140E-3 Series
40 Troubleshooting 1
Troubleshooting of mechanical system
(S-mode)
Method of using troubleshooting charts .......................................................................................................... 3
S-1 Starting performance is poor .................................................................................................................... 6
S-2 Engine does not start ............................................................................................................................... 7
S-3 Engine does not pick up smoothly.......................................................................................................... 10
S-4 Engine stops during operations ...............................................................................................................11
S-5 Engine does not rotate smoothly ............................................................................................................ 12
S-6 Engine lacks output (or lacks power) ..................................................................................................... 13
S-7 Exhaust smoke is black (incomplete combustion).................................................................................. 15
S-8 Oil consumption is excessive (or exhaust smoke is blue) ...................................................................... 16
S-9 Oil becomes contaminated quickly ......................................................................................................... 17
S-10 Fuel consumption is excessive............................................................................................................. 18
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) ................................................... 19
S-12 Oil pressure drops ................................................................................................................................ 20
S-13 Oil level rises (Entry of coolant or fuel)................................................................................................. 21
12V140E-3 Series 1
SEN00316-01 40 Troubleshooting
2 12V140E-3 Series
40 Troubleshooting SEN00316-01
Items listed in the [Questions] and [Check items] and related to the [Causes] are marked with E, Q, or w.
E: Causes to be referred to for questions and check items
Q: Causes related to questions and check items
w: Causes highly probable among ones marked with Q
a When narrowing the "auses", apply the items marked with w before those marked with Q.
When narrowing the causes, do not apply the items marked with E. (If no items have other marks and
the causes cannot be narrowed, however, you may apply them.)
12V140E-3 Series 3
SEN00316-01 40 Troubleshooting
4 12V140E-3 Series
40 Troubleshooting SEN00316-01
If we look for the linkage of these three phenomena to possible causes, we find that they have causal rela-
tionship with five causes.
Let us explain here the method of using this causal relationship to pinpoint the most probable cause.
12V140E-3 Series 5
SEN00316-01 40 Troubleshooting
Defective injector
start until the crankshaft revolves 2 turns at maximum.
This phenomenon does not indicate a trouble, however.
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Clean
Clean
Clean
Clean
Remedy
6 12V140E-3 Series
40 Troubleshooting SEN00316-01
installed machine
installed machine
When terminal B and terminal C of starting switch are connected,
Turn starting switch OFF,
engine starts q
connect cord, turn the
switch ON and carry out When terminal B and terminal C at safety relay outlet are con-
troubleshooting nected, engine starts q
When terminal B and terminal C at safety relay outlet are con-
nected, engine does not start q
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Remedy
—
12V140E-3 Series 7
SEN00316-01 40 Troubleshooting
Defective injector
Confirm recent repair history
Degree of
Operated for long period E E E
Questions
machine operation
Exhaust smoke suddenly stopped coming out (when starting again) w Q w w w E E
Non-specified fuel is being used w
Replacement of filters not carried out according to Operation and Maintenance
w w E E Q
Manual
When fuel tank is inspected, it is found to be empty w
Air breather hole of fuel tank cap is clogged Q w
Rust and water are found when fuel tank is drained Q Q Q Q Q
When fuel filter is removed, there is no fuel in it w Q w
w
Check items
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Clean
Remedy
Add
8 12V140E-3 Series
40 Troubleshooting SEN00316-01
c) Exhaust smoke comes out but engine does not start Causes
(fuel is being injected)
While engine is Fuel does not flow out if air bleeding plug of fuel filter is
removed Q Q w w
cranked with start-
ing motor, If spill hose from injector is disconnected, little fuel spills Q Q w
When exhaust manifold is touched immediately after starting engine, temperature of
some cylinders is low w
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Clean
Clean
Remedy
12V140E-3 Series 9
SEN00316-01 40 Troubleshooting
gas is Black w Q w w
When engine is cranked, abnormal sound is generated around cylinder head w
When engine is cranked, interference sound is emitted from around turbocharger w
High idle speed under no load is normal, but speed suddenly drops when load is applied Q w w
There is hunting from engine (rotation is irregular) Q Q w Q
Blow-by gas is excessive w
Replace
Replace
Replace
Replace
Correct
Correct
Remedy
Clean
Clean
Clean
Clean
10 12V140E-3 Series
40 Troubleshooting SEN00316-01
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Remedy
—
Add
12V140E-3 Series 11
SEN00316-01 40 Troubleshooting
Correct
Correct
Correct
Clean
Remedy
Add
12 12V140E-3 Series
40 Troubleshooting SEN00316-01
Suddenly
Power was lost
Gradually Q Q Q Q Q Q Q
Non-specified fuel is being used Q Q
Replacement of filters not carried out according to Operation and Mainte-
nance Manual w Q
Engine oil replenished more frequently Q Q Q
Dust indicator is red (if indicator is installed) w
Air breather hole of fuel tank cap is clogged w
Fuel is leaking from fuel piping w
Output becomes insufficient after short stop of operation w
Color of exhaust Black w w
gas Blue under light load w
When exhaust manifold is touched immediately after starting engine,
temperature of some cylinders is low w
w
Check items
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
Clean
Clean
Clean
12V140E-3 Series 13
SEN00316-01 40 Troubleshooting
14 12V140E-3 Series
40 Troubleshooting SEN00316-01
Adjusting
Adjusting
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Remedy
Clean
12V140E-3 Series 15
SEN00316-01 40 Troubleshooting
Turbocharger 1
q Long-time operation of engine at low idle or high idle
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
16 12V140E-3 Series
40 Troubleshooting SEN00316-01
See S-7
Inspect oil cooler directly q
Inspect oil filter directly q
Spring of oil filter safety valve is hitched or broken q
Inspect turbocharger lubrication drain tube directly q
Replace
Replace
Replace
Replace
Replace
Clean
Clean
Remedy Clean
—
12V140E-3 Series 17
SEN00316-01 40 Troubleshooting
Carry out troubleshooting according to “No-pressure feed by supply pump error (*1)“ in E-mode q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change
change on some cylinders q
If spill hose from injector is disconnected and measured, much fuel spills q
Carry out troubleshooting according to “Abnormality in coolant temperature sensor (*2)“ in E-mode q
Confirm with INSITE or with monitoring function on installed machine side q q
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Remedy
18 12V140E-3 Series
40 Troubleshooting SEN00316-01
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)1
General causes why oil is mixed in coolant Causes
q Internal leakage in lubrication system
Broken hydraulic oil cooler or power train oil cooler on installed machine side
q Internal leakage in cooling system
operation
Suddenly increased Q Q Q
Oil level
Gradually increased Q Q
Hard water is being used as coolant Q Q
Oil level has risen and oil is milky Q Q w
There are excessive air bubbles in radiator, coolant spurts back w w
Check items
on installed machine
Remedy
—
12V140E-3 Series 19
SEN00316-01 40 Troubleshooting
Replace
Replace
Correct
Remedy
Clean
Clean
Clean
Clean
—
Add
20 12V140E-3 Series
40 Troubleshooting SEN00316-01
Clogged water pump drain hole (breather hole) and/or defective seal
q Fuel in oil (smells diluted diesel fuel)
a If oil is in coolant, carry out troubleshooting for "S-11 Oil is in cool-
Degree of
machine operation
Operated for long period E E E E
Fuel consumption increasing w w
Coolant replenished more frequently Q w
There is oil mixed in coolant Q Q Q w
Oil smells of diesel fuel w w
Oil is milky Q w
When engine is started, drops of water come from muffler Q
When radiator cap is removed and engine is run at low idle, an abnormal number of bubbles
appears, or coolant spurts back w Q
Check items
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
12V140E-3 Series 21
SEN00316-01 40 Troubleshooting
Sudden overheated Q w Q
Condition for
Persistent overheating Q w w Q
Coolant tempera- Rises quickly Q w
ture gauge
(if installed) Does not go down from red range w
Radiator coolant level monitor indicates drop of coolant level (if monitor is installed) w
Engine oil level has risen and oil is milky w Q
Fan belt tension is low w
Milky oil is floating on coolant w
There are excessive air bubbles in radiator and coolant spurts back w
When light bulb is held behind radiator core, no light passes through w
Radiator shroud, inside of underguard on applicable machine side are clogged with
Check items
dirt or mud w w
Coolant is leaking because of cracks in hose or loose clamps w
Coolant flows out from radiator overflow hose w
Fan belt whines under sudden acceleration w
Power train oil temperature gauge enters red range faster than engine coolant tem-
perature gauge (if oil temperature gauge and coolant temperature gauge are w
installed) on the installed machine side
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
—
Add
22 12V140E-3 Series
40 Troubleshooting SEN00316-01
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Remedy
12V140E-3 Series 23
SEN00316-01 40 Troubleshooting
Adjusting
Replace
Replace
Replace
Replace
Replace
Replace
Remedy
24 12V140E-3 Series
40 Troubleshooting SEN00316-01
12V140E-3 Series 25
SEN00316-01 40 Troubleshooting
© 2009 KOMATSU
All Rights Reserved
Printed in Japan 03-09 (02)
26 12V140E-3 Series
SEN00317-03
12V140E-3 Series
SEN00317-03
ENGINE
Shop Manual
12V140E-3 Series
40 Troubleshooting
Troubleshooting of electrical system
(E-mode), Part 1
E-1 Code [111/CA111] ECM Critical Internal Failure (LH bank) .................................................................. 4
E-2 Code [111/CB111] ECM Critical Internal Failure (RH bank).................................................................. 6
E-3 Code [115/CA115] Eng. Ne and G (Bkup) Speed Sensor Error (LH bank)........................................... 8
E-4 Code [115/CB115] Eng. Ne and G (Bkup) Speed Sensor Error (RH bank) .......................................... 9
E-5 Code [122/CA122] Charge Air Press. Sensor High Error (LH bank only) ............................................ 10
E-6 Code [123/CA123] Charge Air Press. Sensor Low Error (LH bank only) ............................................. 12
E-7 Code [131/CA131] Throttle Sensor High Error (LH bank only) ............................................................ 14
E-8 Code [132/CA132] Throttle Sensor Low Error (LH bank only) ............................................................. 15
E-9 Code [135/CA135] Oil Press. Sensor High Error (LH bank only) ......................................................... 16
E-10 Code [141/CA141] Oil Press. Sensor Low Error (LH bank only) ........................................................ 18
E-11 Code [144/CA144] Coolant Temp. Sensor High Error (LH bank only)................................................ 20
12V140E-3 Series 1
SEN00317-03 40 Troubleshooting
E-12 Code [145/CA145] Coolant Temp. Sensor Low Error (LH bank only) ................................................ 22
E-13 Code [153/CA153] Charge Air Temp. Sensor High Error (LH bank only)........................................... 24
E-14 Code [154/CA154] Charge Air Temp. Sensor Low Error (LH bank only)............................................ 26
E-15 Code [187/CA187] Sensor Sup. 2 Volt. Low Error (LH bank)............................................................. 27
E-16 Code [187/CB187] Sensor Sup. 2 Volt. Low Error (RH bank) ............................................................ 27
E-17 Code [212/CA212] Eng. Oil Temp.Sensor High Error (LH bank only) ................................................ 28
E-18 Code [213/CA213] Eng. Oil Temp.Sensor Low Error (LH bank only) ................................................. 30
E-19 Code [221/CA221] Ambient Air Press. Sensor High Error (LH bank only) ......................................... 32
E-20 Code [222/CA222] Ambient Air Press. Sensor Low Error (LH bank only).......................................... 34
E-21 Code [227/CA227] Sensor Sup. 2 Volt. High Error (LH bank) ............................................................ 36
E-22 Code [227/CB227] Sensor Sup. 2 Volt. High Error (RH bank) ........................................................... 38
E-23 Code [234/CA234] Eng. Overspeed (LH bank only)........................................................................... 40
E-24 Code [238/CA238] Ne Speed Sensor Sup. Volt. Error (LH bank)....................................................... 42
E-25 Code [238/CB238] Ne Speed Sensor Sup. Volt. Error (RH bank) ...................................................... 44
E-26 Code [263/CA263] Fuel Temp. Sensor High Error (LH bank)............................................................. 46
E-27 Code [263/CB263] Fuel Temp. Sensor High Error (RH bank) ............................................................ 48
E-28 Code [265/CA265] Fuel Temp. Sensor Low Error (LH bank) ............................................................. 50
E-29 Code [265/CB265] Fuel Temp. Sensor Low Error (RH bank)............................................................. 50
E-30 Code [271/CA271] PCV1 Short Error (LH bank) ................................................................................ 52
E-31 Code [271/CB271] PCV1 Short Error (RH bank)................................................................................ 54
E-32 Code [272/CA272] PCV1 Open Error (LH bank) ................................................................................ 56
E-33 Code [272/CB272] PCV1 Open Error (RH bank) ............................................................................... 57
E-34 Code [273/CA273] PCV2 Short Error (LH bank) ................................................................................ 58
E-35 Code [273/CB273] PCV2 Short Error (RH bank)................................................................................ 60
E-36 Code [274/CA274] PCV2 Open Error (LH bank) ................................................................................ 62
E-37 Code [274/CB274] PCV2 Open Error (RH bank) ............................................................................... 63
E-38 Code [322/CA322] Injector #1 (L/B #1) System Open/Short Error (LH bank) .................................... 64
E-39 Code [323/CA323] Injector #5 (L/B #5) System Open/Short Error (LH bank) .................................... 66
E-40 Code [324/CA324] Injector #3 (L/B #3) System Open/Short Error (LH bank) .................................... 68
E-41 Code [325/CA325] Injector #6 (L/B #6) System Open/Short Error (LH bank) .................................... 70
E-42 Code [331/CA331] Injector #2 (L/B #2) System Open/Short Error (LH bank) .................................... 72
E-43 Code [332/CA332] Injector #4 (L/B #4) System Open/Short Error (LH bank) .................................... 74
E-44 Code [342/CA342] Caribration Code Incompatibility (LH bank) ......................................................... 76
E-45 Code [342/CB342] Caribration Code Incompatibility (RH bank)......................................................... 76
E-46 Code [351/CA351] INJ. Drive Circuit Error (LH bank) ........................................................................ 78
E-47 Code [351/CB351] INJ. Drive Circuit Error (RH bank)........................................................................ 80
E-48 Code [352/CA352] Sensor Sup. 1 Volt. Low Error (LH bank)............................................................. 82
E-49 Code [352/CB352] Sensor Sup. 1 Volt. Low Error (RH bank) ............................................................ 82
E-50 Code [386/CA386] Sensor Sup. 1 Volt. High Error (LH bank) ............................................................ 84
E-51 Code [386/CB386] Sensor Sup. 1 Volt. High Error (RH bank) ........................................................... 86
E-52 Code [441/CA441] Battery Voltage Low Error (LH bank) ................................................................... 88
E-53 Code [441/CB441] Battery Voltage Low Error (RH bank)................................................................... 88
E-54 Code [442/CA442] Battery Voltage High Error (LH bank) .................................................................. 89
E-55 Code [442/CB442] Battery Voltage High Error (RH bank) .................................................................. 89
2 12V140E-3 Series
40 Troubleshooting SEN00317-03
12V140E-3 Series 3
SEN00317-03 40 Troubleshooting
4 12V140E-3 Series
40 Troubleshooting SEN00317-03
12V140E-3 Series 5
SEN00317-03 40 Troubleshooting
6 12V140E-3 Series
40 Troubleshooting SEN00317-03
12V140E-3 Series 7
SEN00317-03 40 Troubleshooting
E-3 Code [115/CA115] Eng. Ne and G (Bkup) Speed Sensor Error (LH
bank)
Error code Failure code
Trouble Abnormality in engine Ne and G (Bkup) speed sensor (LH bank)
115 CA115
Contents of q Abnormality occurred in Ne speed sensor circuit and G (Bkup) speed sensor circuit simultaneous-
trouble ly.
Action of
q Engine stop
controller
Phenomenon
q Engine cannot be started (engine has been stopped).
that appears on
q Engine stops (if engine has been running).
machine
Related
information
8 12V140E-3 Series
40 Troubleshooting SEN00317-03
E-4 Code [115/CB115] Eng. Ne and G (Bkup) Speed Sensor Error (RH
bank)
Error code Failure code
Trouble Abnormality in engine Ne and G (Bkup) speed sensor (RH bank)
115 CB115
Contents of
q Abnormality occurred in Ne speed sensor circuit and G (Bkup) speed sensor circuit simultaneously.
trouble
Action of
q Engine stop
controller
Phenomenon
q Engine cannot be started (if engine has been stopped)
that appears on
q Engine stops (if engine has been running).
machine
Related
information
12V140E-3 Series 9
SEN00317-03 40 Troubleshooting
E-5 Code [122/CA122] Charge Air Press. Sensor High Error (LH bank
only)
Error code Failure code Sensor detection of abnormally high charge pressure
Trouble
(LH bank only)
122 CA122
Contents of
q Charge pressure sensor circuit detects abnormally high pressure.
trouble
Action of
controller q Sets charge pressure to fixed value (400 kPa {4.1 kg/cm2}) and continues operation.
Phenomenon
that appears on q Acceleration performance of engine drops.
machine
Related
q Different machine models may have different connector Nos.
information
10 12V140E-3 Series
40 Troubleshooting SEN00317-03
12V140E-3 Series 11
SEN00317-03 40 Troubleshooting
E-6 Code [123/CA123] Charge Air Press. Sensor Low Error (LH bank
only)
Error code Failure code Sensor detection of abnormally low charge pressure
Trouble
(LH bank only)
123 CA123
Contents of
q Abnormally low pressure detected in charge pressure sensor circuit.
trouble
Action of q Sets charge pressure (boost pressure) to fixed value (400 kPa {4.1 kg/cm2}) and continues oper-
controller ation.
Phenomenon
that appears on q Acceleration performance of engine drops.
machine
Related
information
Possible causes Causes Standard value in normal state/Remarks on troubleshooting
and standard
value in normal Carry out troubleshooting for E-5 Code [122/CA122].
state
12 12V140E-3 Series
40 Troubleshooting SEN00317-03
12V140E-3 Series 13
SEN00317-03 40 Troubleshooting
E-7 Code [131/CA131] Throttle Sensor High Error (LH bank only)
Throttle sensor of decelerator pedal type (Case of D475-5)
Circuit diagram related to deceleration pedal type throttle sensor (Case of D475–5)
14 12V140E-3 Series
40 Troubleshooting SEN00317-03
E-8 Code [132/CA132] Throttle Sensor Low Error (LH bank only)
Throttle sensor of decelerator pedal type (Case of D475-5)
12V140E-3 Series 15
SEN00317-03 40 Troubleshooting
E-9 Code [135/CA135] Oil Press. Sensor High Error (LH bank only)
Error code Failure code Oil pressure sensor detection of abnormally high pressure
Trouble
(LH bank only)
135 CA135
Contents of
q Signal voltage in oil pressure sensor circuit is abnormally high.
trouble
Action of
controller q Set oil pressure to default value (250 kPa {2.5 kg/cm2}) and continue operation.
Phenomenon
that appears on
machine
Related
q Different machine models may have different connector Nos.
information
16 12V140E-3 Series
40 Troubleshooting SEN00317-03
12V140E-3 Series 17
SEN00317-03 40 Troubleshooting
E-10 Code [141/CA141] Oil Press. Sensor Low Error (LH bank only)
Error code Failure code Oil pressure sensor detection of abnormally low pressure
Trouble
(LH bank only)
141 CA141
Contents of
q Signal voltage in oil pressure sensor circuit is abnormally low.
trouble
Action of
controller q Sets oil pressure to default value (250 kPa {2.5 kg/cm2}) and continues operation.
Phenomenon
that appears on
machine
Related
information
Possible causes Causes Standard value in normal state/Remarks on troubleshooting
and standard
value in normal Carry out troubleshooting for E-9 Code [135/CA135].
state
18 12V140E-3 Series
40 Troubleshooting SEN00317-03
12V140E-3 Series 19
SEN00317-03 40 Troubleshooting
E-11 Code [144/CA144] Coolant Temp. Sensor High Error (LH bank only)
Error code Failure code Coolant temperature sensor detection of abnormally high tempera-
Trouble
ture (LH bank only)
144 CA144
Contents of
q Signal voltage in coolant temperature sensor circuit is abnormally high.
trouble
Action of
q Fixes coolant temperature at (90 °C) and continues operation.
controller
Phenomenon
that appears on
machine
Related
q Different machine models may have different connector Nos.
information
20 12V140E-3 Series
40 Troubleshooting SEN00317-03
12V140E-3 Series 21
SEN00317-03 40 Troubleshooting
E-12 Code [145/CA145] Coolant Temp. Sensor Low Error (LH bank only)
Error code Failure code Coolant temperature sensor detection of abnormally low tempera-
Trouble
ture (LH bank only)
145 CA145
Contents of
q Signal voltage in coolant temperature sensor circuit is abnormally low.
trouble
Action of
q Fixes coolant temperature at (90 °C) and continues operation.
controller
Phenomenon
that appears on
machine
Related
information
Possible causes Causes Standard value in normal state/Remarks on troubleshooting
and standard
value in normal Carry out troubleshooting for E-11 Code [144/CA144].
state
22 12V140E-3 Series
40 Troubleshooting SEN00317-03
12V140E-3 Series 23
SEN00317-03 40 Troubleshooting
E-13 Code [153/CA153] Charge Air Temp. Sensor High Error (LH bank
only)
Error code Failure code Charge temperature sensor detection of abnormally high tempera-
Trouble
ture (LH bank only)
153 CA153
Contents of
q Signal voltage in charge temperature sensor circuit is abnormally high.
trouble
Action of
q Fixes charge temperature (intake air temperature) at (70 °C) and continues operation.
controller
Phenomenon
that appears on
machine
Related
q Different machine models may have different connector Nos.
information
24 12V140E-3 Series
40 Troubleshooting SEN00317-03
12V140E-3 Series 25
SEN00317-03 40 Troubleshooting
E-14 Code [154/CA154] Charge Air Temp. Sensor Low Error (LH bank
only)
Error code Failure code Charge temperature sensor detection of abnormally low charge
Trouble
temperature (LH bank only)
154 CA154
Contents of
q Signal voltage in charge temperature sensor circuit is abnormally low.
trouble
Action of
q Fixes charge temperature (intake air temperature) at (70 °C) and continues operation.
controller
Phenomenon
that appears on
machine
Related
information
Possible causes Causes Standard value in normal state/Remarks on troubleshooting
and standard
value in normal Carry out troubleshooting for E-13 Code [153/CA153].
state
26 12V140E-3 Series
40 Troubleshooting SEN00317-03
E-15 Code [187/CA187] Sensor Sup. 2 Volt. Low Error (LH bank)
Error code Failure code Power supply 2 sensor detection of abnormally low voltage
Trouble
(LH bank)
187 CA187
Contents of
q Signal voltage in sensor power supply 2 (5 V) circuit is abnormally low.
trouble
q Sets atmospheric pressure sensor to default value (52.44 kPa {0.5 kg/cm2}) and continues opera-
tion.
Action of
controller q Sets oil pressure sensor to default value (250 kPa {2.5 kg/cm2}) and continues operation.
q Fixes charge pressure sensor value (400 kPa {4.1 kg/cm2}) and continues operation.
q Operates G (Bkup) sensor with signals of Ne speed sensor.
Phenomenon
that appears on q Output drops.
machine
Related
information
Possible causes Causes Standard value in normal state/Remarks on troubleshooting
and standard
value in normal Carry out troubleshooting for E-21 Code [227/CA227].
state
E-16 Code [187/CB187] Sensor Sup. 2 Volt. Low Error (RH bank)
Error code Failure code Power supply 2 sensor detection of abnormally low voltage
Trouble
(RH bank)
187 CB187
Contents of
q Signal voltage in sensor power supply 2(5 V) circuit is abnormally low.
trouble
Action of
q Operate G (Bkup) sensor with signals of Ne speed sensor.
controller
Phenomenon
that appears on q Output drops.
machine
Related
information
Possible causes Causes Standard value in normal state/Remarks on troubleshooting
and standard
value in normal Carry out troubleshooting for E-22 Code [227/CB227].
state
12V140E-3 Series 27
SEN00317-03 40 Troubleshooting
E-17 Code [212/CA212] Eng. Oil Temp.Sensor High Error (LH bank only)
Error code Failure code Engine oil temperature sensor detection of abnormally high tem-
Trouble
perature (LH bank only)
212 CA212
Contents of
q Signal voltage in engine oil temperature sensor circuit is abnormally high.
trouble
Action of
q Sets oil pressure to default value (100 °C) and continues operation.
controller
Phenomenon
that appears on
machine
Related
q Different machine models may have different connector Nos.
information
28 12V140E-3 Series
40 Troubleshooting SEN00317-03
12V140E-3 Series 29
SEN00317-03 40 Troubleshooting
E-18 Code [213/CA213] Eng. Oil Temp.Sensor Low Error (LH bank only)
Error code Failure code Engine oil temperature sensor detection of abnormally low temper-
Trouble
ature (LH bank only)
213 CA213
Contents of
q Signal voltage in engine oil temperature sensor circuit is abnormally low.
trouble
Action of
q Sets oil temperature to default value (100 °C) and continues operation.
controller
Phenomenon
that appears on
machine
Related
q Different machine models may have different connector Nos.
information
Possible causes Causes Standard value in normal state/Remarks on troubleshooting
and standard
value in normal Carry out troubleshooting for E-17 Code [212/CA212].
state
30 12V140E-3 Series
40 Troubleshooting SEN00317-03
12V140E-3 Series 31
SEN00317-03 40 Troubleshooting
E-19 Code [221/CA221] Ambient Air Press. Sensor High Error (LH bank
only)
Error code Failure code Atmospheric pressure sensor detection of abnormally high pres-
Trouble
sure (LH bank only)
221 CA221
Contents of
q Signal voltage in atmospheric pressure sensor circuit is abnormally high.
trouble
Action of
controller q Sets atmospheric pressure to default value (52.44 kPa {0.5 kg/cm2}) and continues operation.
Phenomenon
that appears on q Output drops.
machine
Related
q Different machine models may have different connector Nos.
information
32 12V140E-3 Series
40 Troubleshooting SEN00317-03
12V140E-3 Series 33
SEN00317-03 40 Troubleshooting
E-20 Code [222/CA222] Ambient Air Press. Sensor Low Error (LH bank
only)
Error code Failure code Atmospheric pressure sensor detection of abnormally low pressure
Trouble
(LH bank only)
222 CA222
Contents of
q Signal voltage in atmospheric pressure sensor circuit is abnormally low.
trouble
Action of
controller q Sets atmospheric pressure to default value (52.44 kPa {0.5 kg/cm2}) and continues operation.
Phenomenon
that appears on q Output drops.
machine
Related
information
Possible causes Causes Standard value in normal state/Remarks on troubleshooting
and standard
value in normal Carry out troubleshooting for E-19 Code [221/CA221].
state
34 12V140E-3 Series
40 Troubleshooting SEN00317-03
12V140E-3 Series 35
SEN00317-03 40 Troubleshooting
E-21 Code [227/CA227] Sensor Sup. 2 Volt. High Error (LH bank)
Error code Failure code Power supply 2 sensor detection of abnormally high voltage
Trouble
(LH bank)
227 CA227
Contents of
q Signal voltage in sensor power supply 2(5 V) circuit is abnormally high.
trouble
q Sets atmospheric pressure sensor to default value (52.44 kPa {0.5 kg/cm2}) and continues opera-
tion.
Action of
controller q Sets oil pressure sensor to default value (250 kPa {2.5 kg/cm2}) and continues operation.
q Fixes charge pressure sensor value (400 kPa {4.1 kg/cm2}) and continues operation.
q Operates G (Bkup) sensor with signals of Ne speed sensor.
Phenomenon
that appears on q Output drops.
machine
Related
q Different machine models may have different connector Nos.
information
1 Defective related system If another failure code is indicated, carry out troubleshooting for it.
36 12V140E-3 Series
40 Troubleshooting SEN00317-03
12V140E-3 Series 37
SEN00317-03 40 Troubleshooting
E-22 Code [227/CB227] Sensor Sup. 2 Volt. High Error (RH bank)
Error code Failure code Power supply 2 sensor detection of abnormally high voltage
Trouble
(RH bank)
227 CB227
Contents of
q Signal voltage in sensor power supply 2 (5 V) circuit is abnormally high.
trouble
Action of
q Operates G(Bkup) sensor with signals of Ne speed sensor.
controller
Phenomenon
that appears on q Output drops.
machine
Related
q Different machine models may have different connector Nos.
information
1 Defective related system If another failure code is indicated, carry out troubleshooting for it.
38 12V140E-3 Series
40 Troubleshooting SEN00317-03
12V140E-3 Series 39
SEN00317-03 40 Troubleshooting
1 Defective related system If another failure code is indicated, carry out troubleshooting for it.
Possible causes
and standard
value in normal 2 Improper way of use Way of use may be improper. Teach proper way of use to operator.
state
If causes 1 – 2 are not detected, engine controller may be defec-
3 Defective engine controller tive. (Since trouble is in system, troubleshooting cannot be carried
out.)
40 12V140E-3 Series
40 Troubleshooting SEN00317-03
12V140E-3 Series 41
SEN00317-03 40 Troubleshooting
E-24 Code [238/CA238] Ne Speed Sensor Sup. Volt. Error (LH bank)
Error code Failure code
Trouble Ne Speed Sensor Sup. Volt. Error (LH bank)
238 CA238
Contents of
q Abnormality occurred in Ne speed sensor power supply (5 V) circuit.
trouble
Action of
q Controls Ne speed sensor with signals of G (Bkup) speed sensor.
controller
Phenomenon
q Running engine stops (when G (Bkup) speed sensor is also abnormal).
that appears on
q Stopped engine cannot be started (when G (Bkup) speed sensor is also abnormal).
machine
Related
q Different machine models may have different connector Nos.
information
42 12V140E-3 Series
40 Troubleshooting SEN00317-03
12V140E-3 Series 43
SEN00317-03 40 Troubleshooting
E-25 Code [238/CB238] Ne Speed Sensor Sup. Volt. Error (RH bank)
Error code Failure code
Trouble Ne Speed Sensor Sup. Volt. Error (RH bank)
238 CB238
Contents of
q Abnormality occurred in Ne speed sensor power supply (5 V) circuit.
trouble
Action of
q Controls Ne speed sensor with signals of G (Bkup) speed sensor.
controller
Phenomenon
q Running engine stops (when G (Bkup) speed sensor is also abnormal).
that appears on
q Stopped engine cannot be started (when G (Bkup) speed sensor is also abnormal).
machine
Related
q Different machine models may have different connector Nos.
information
44 12V140E-3 Series
40 Troubleshooting SEN00317-03
12V140E-3 Series 45
SEN00317-03 40 Troubleshooting
E-26 Code [263/CA263] Fuel Temp. Sensor High Error (LH bank)
Error code Failure code Fuel temperature sensor detection of abnormally high temperature
Trouble
(LH bank only)
263 CA263
Contents of
q Signal voltage in fuel temperature sensor circuit is abnormally high.
trouble
Action of
q Fixes fuel temperature at (95 °C) and continues operation.
controller
Phenomenon
that appears on
machine
Related
q Different machine models may have different connector Nos.
information
46 12V140E-3 Series
40 Troubleshooting SEN00317-03
12V140E-3 Series 47
SEN00317-03 40 Troubleshooting
E-27 Code [263/CB263] Fuel Temp. Sensor High Error (RH bank)
Error code Failure code Fuel temperature sensor detection of abnormally high temperature
Trouble
(RH bank only)
263 CB263
Contents of
q Signal voltage in fuel temperature sensor circuit is abnormally high.
trouble
Action of
q Fixes fuel temperature at (95 °C) and continues operation.
controller
Phenomenon
that appears on
machine
Related
q Different machine models may have different connector Nos.
information
48 12V140E-3 Series
40 Troubleshooting SEN00317-03
12V140E-3 Series 49
SEN00317-03 40 Troubleshooting
E-28 Code [265/CA265] Fuel Temp. Sensor Low Error (LH bank)
Error code Failure code Fuel temperature sensor detection of abnormally low temperature
Trouble
(LH bank)
265 CA265
Contents of
q Signal voltage in fuel temperature sensor circuit is abnormally low.
trouble
q Substitutes with coolant temperature sensor. If coolant temperature sensor is also in abnormal
Action of
state.
controller
q Sets oil temperature to default value (95 °C) and continues operation.
Phenomenon
that appears on
machine
Related
information
Possible causes Causes Standard value in normal state/Remarks on troubleshooting
and standard
value in normal Carry out troubleshooting for E-26 Code [263/CA263].
state
E-29 Code [265/CB265] Fuel Temp. Sensor Low Error (RH bank)
Error code Failure code Fuel temperature sensor detection of abnormally low temperature
Trouble
(RH bank)
265 CB265
Contents of
q Signal voltage in fuel temperature sensor circuit is abnormally low.
trouble
q Substitutes with coolant temperature sensor. If coolant temperature sensor is also in abnormal
Action of
state.
controller
q Fixes fuel temperature at (95 °C) and continues operation.
Phenomenon
that appears on
machine
Related
information
Possible causes Causes Standard value in normal state/Remarks on troubleshooting
and standard
value in normal Carry out troubleshooting for E-27 Code [263/CB263].
state
50 12V140E-3 Series
40 Troubleshooting SEN00317-03
12V140E-3 Series 51
SEN00317-03 40 Troubleshooting
52 12V140E-3 Series
40 Troubleshooting SEN00317-03
12V140E-3 Series 53
SEN00317-03 40 Troubleshooting
54 12V140E-3 Series
40 Troubleshooting SEN00317-03
12V140E-3 Series 55
SEN00317-03 40 Troubleshooting
56 12V140E-3 Series
40 Troubleshooting SEN00317-03
12V140E-3 Series 57
SEN00317-03 40 Troubleshooting
58 12V140E-3 Series
40 Troubleshooting SEN00317-03
12V140E-3 Series 59
SEN00317-03 40 Troubleshooting
60 12V140E-3 Series
40 Troubleshooting SEN00317-03
12V140E-3 Series 61
SEN00317-03 40 Troubleshooting
62 12V140E-3 Series
40 Troubleshooting SEN00317-03
12V140E-3 Series 63
SEN00317-03 40 Troubleshooting
E-38 Code [322/CA322] Injector #1 (L/B #1) System Open/Short Error (LH
bank)
Error code Failure code Disconnection or short circuit in injector #1 (L/B #1) system (LH
Trouble
bank)
322 CA322
Contents of
q There is disconnection or short circuit in injector in injector #1 circuit.
trouble
Action of
q None in particular.
controller
Phenomenon
q Output drops.
that appears on
q Idle speed is unstable.
machine
Related
q Different machine models may have different connector Nos.
information
64 12V140E-3 Series
40 Troubleshooting SEN00317-03
12V140E-3 Series 65
SEN00317-03 40 Troubleshooting
66 12V140E-3 Series
40 Troubleshooting SEN00317-03
12V140E-3 Series 67
SEN00317-03 40 Troubleshooting
68 12V140E-3 Series
40 Troubleshooting SEN00317-03
12V140E-3 Series 69
SEN00317-03 40 Troubleshooting
Error code Failure code Disconnection or short circuit in injector #6 (L/B #6) system (LH
Trouble
bank)
325 CA325
Contents of
q There is disconnection or short circuit in injector #6 circuit.
trouble
Action of
q None in particular.
controller
Phenomenon
q Output drops.
that appears on
q Idle speed is unstable.
machine
Related
q Different machine models may have different connector Nos.
information
70 12V140E-3 Series
40 Troubleshooting SEN00317-03
12V140E-3 Series 71
SEN00317-03 40 Troubleshooting
Error code Failure code Disconnection or short circuit in injector #2 (L/B #2) system (LH
Trouble
bank)
331 CA331
Contents of
q There is disconnection or short circuit in injector #2 circuit.
trouble
Action of
q None in particular.
controller
Phenomenon
q Output drops.
that appears on
q Idle speed is unstable.
machine
Related
q Different machine models may have different connector Nos.
information
72 12V140E-3 Series
40 Troubleshooting SEN00317-03
12V140E-3 Series 73
SEN00317-03 40 Troubleshooting
E-43 Code [332/CA332] Injector #4 (L/B #4) System Open/Short Error (LH
bank)
Error code Failure code Disconnection or short circuit in injector #4 (L/B #4) system(LH
Trouble
bank)
332 CA332
Contents of
q There is disconnection or short circuit in injector #4 circuit.
trouble
Action of
q None in particular.
controller
Phenomenon
q Output drops.
that appears on
q Idle speed is unstable.
machine
Related
q Different machine models may have different connector Nos.
information
74 12V140E-3 Series
40 Troubleshooting SEN00317-03
12V140E-3 Series 75
SEN00317-03 40 Troubleshooting
76 12V140E-3 Series
40 Troubleshooting SEN00317-03
12V140E-3 Series 77
SEN00317-03 40 Troubleshooting
78 12V140E-3 Series
40 Troubleshooting SEN00317-03
12V140E-3 Series 79
SEN00317-03 40 Troubleshooting
80 12V140E-3 Series
40 Troubleshooting SEN00317-03
12V140E-3 Series 81
SEN00317-03 40 Troubleshooting
E-48 Code [352/CA352] Sensor Sup. 1 Volt. Low Error (LH bank)
Error code Failure code Power supply 1 sensor detection of abnormally low voltage (LH
Trouble
bank)
352 CA352
Contents of
q Signal voltage in sensor power supply 1 (5 V) circuit is abnormally low.
trouble
Action of q Sets atmospheric pressure sensor to default value (52.44 kPa {0.5 kg/cm2}) and continues opera-
controller tion.
Phenomenon
that appears on q Output drops.
machine
Related
information
Possible causes Causes Standard value in normal state/Remarks on troubleshooting
and standard
value in normal Carry out troubleshooting for E-50 Code [386/CA386].
state
E-49 Code [352/CB352] Sensor Sup. 1 Volt. Low Error (RH bank)
Error code Failure code Power supply 1 sensor detection of abnormally low voltage (RH
Trouble
bank)
352 CB352
Contents of
q Signal voltage in sensor power supply 1 (5 V) circuit is abnormally low.
trouble
Action of q Sets atmospheric pressure sensor to default value (52.44 kPa {0.5 kg/cm2}) and continues opera-
controller tion.
Phenomenon
that appears on q Output drops.
machine
Related
information
Possible causes Causes Standard value in normal state/Remarks on troubleshooting
and standard
value in normal Carry out troubleshooting for E-51 Code [386/CB386].
state
82 12V140E-3 Series
40 Troubleshooting SEN00317-03
12V140E-3 Series 83
SEN00317-03 40 Troubleshooting
E-50 Code [386/CA386] Sensor Sup. 1 Volt. High Error (LH bank)
Error code Failure code Power supply 1 sensor detection of abnormally high voltage (LH
Trouble
bank)
386 CA386
Contents of
q Signal voltage in sensor power supply 1 (5 V) circuit is abnormally high.
trouble
Action of
q Limits output and continues operation (Limits common rail pressure).
controller
Phenomenon
that appears on q Output drops.
machine
Related
q Different machine models may have different connector Nos.
information
1 Defective related system If another failure code is indicated, carry out troubleshooting for it.
84 12V140E-3 Series
40 Troubleshooting SEN00317-03
12V140E-3 Series 85
SEN00317-03 40 Troubleshooting
E-51 Code [386/CB386] Sensor Sup. 1 Volt. High Error (RH bank)
Error code Failure code Power supply 1 sensor detection of abnormally high voltage (RH
Trouble
bank)
386 CB386
Contents of trouble q Signal voltage in sensor power supply 1 (5 V) circuit is abnormally high.
Action of
q Limits output and continues operation (Limits common rail pressure).
controller
Phenomenon that
appears on q Output drops.
machine
Related information q Different machine models may have different connector Nos.
86 12V140E-3 Series
40 Troubleshooting SEN00317-03
12V140E-3 Series 87
SEN00317-03 40 Troubleshooting
88 12V140E-3 Series
40 Troubleshooting SEN00317-03
12V140E-3 Series 89
SEN00317-03 40 Troubleshooting
©2009 KOMATSU
All Rights Reserved
Printed in Japan 09-09
90
SEN00318-03
12V140E-3 Series
40 Troubleshooting 1
Troubleshooting of electrical system
(E-mode), Part 2
E-56 Code [449/CA449] Rail Press. Very High Error (LH bank) ..................................................................... 3
E-57 Code [449/CB449] Rail Press. Very High Error (RH bank) .................................................................... 3
E-58 Code [451/CA451] Rail Press. Sensor High Error (LH bank) ................................................................. 4
E-59 Code [451/CB451] Rail Press. Sensor High Error (RH bank) ................................................................ 6
E-60 Code [452/CA452] Rail Press. Sensor Low Error (LH bank).................................................................. 8
E-61 Code [452/CB452] Rail Press. Sensor Low Error (RH bank) ................................................................. 8
E-62 Code [553/CA553] Rail Press. High Error 1 (LH bank) .......................................................................... 9
E-63 Code [553/CB553] Rail Press. High Error 1 (RH bank)........................................................................ 10
E-64 Code [554/CA554] Rail Press. Sensor In Range Error (LH bank).........................................................11
E-65 Code [554/CB554] Rail Press. Sensor In Range Error (RH bank) ........................................................11
E-66 Code [559/CA559] Rail Press. Low Error 1 (LH bank) ......................................................................... 12
E-67 Code [559/CB559] Rail Press. Low Error 1 (RH bank) ........................................................................ 16
E-68 Code [689/CA689] Eng. Ne Speed Sensor Error (LH bank) ................................................................ 20
E-69 Code [689/CB689] Eng. Ne Speed Sensor Error (RH bank)................................................................ 22
12V140E-3 Series 1
SEN00318-03 40 Troubleshooting
E-70 Code [691/CA691] Intake Air Temp Sensor High Error (LH bank only) ................................................ 24
E-71 Code [692/CA692] Intake Air Temp Sensor Low Error (LH bank only)................................................. 26
E-72 Code [731/CA731] Eng. G (Bkup) Speed Sensor Phase Error (LH bank)............................................ 27
E-73 Code [731/CB731] Eng. G (Bkup) Speed Sensor Phase Error (RH bank) ........................................... 27
E-74 Code [757/CA757] All Continuous Data Lost Error (LH bank).............................................................. 28
E-75 Code [757/CB757] All Continuous Data Lost Error (RH bank) ............................................................. 28
E-76 Code [778/CA778] Eng. G (Bkup) Speed Sensor Error (LH bank)....................................................... 30
E-77 Code [778/CB778] Eng. G (Bkup) Speed Sensor Error (RH bank) ...................................................... 32
E-78 Code [781/CA781] Inter Multi-controller Communication Error (LH bank) ........................................... 34
E-79 Code [781/CB781] Inter Multi-controller Communication Error (RH bank)........................................... 36
E-80 Code [1117/CA1117] Persistent Data Lost Error (LH bank) .................................................................. 37
E-81 Code [1117/CB1117] Persistent Data Lost Error (RH bank) ................................................................. 37
E-82 Code [1257/CA1257] Harness Key error (LH bank) ............................................................................. 38
E-83 Code [1257/CB1257] Harness Key error (RH bank) ............................................................................ 39
E-84 Code [1548/CB1548] Injector #7 (R/B #1) System Open/Short Error (RH bank) ................................. 40
E-85 Code [1549/CB1549] Injector #8 (R/B #2) System Open/Short Error (RH bank) ................................. 42
E-86 Code [1551/CB1551] Injector #10 (R/B #4) System Open/Short Error (RH bank) ............................... 44
E-87 Code [1552/CB1552] Injector #11 (R/B #5) System Open/Short Error (RH bank) ............................... 46
E-88 Code [1553/CB1553] Injector #12 (R/B #6) System Open/Short Error (RH bank) ............................... 48
E-89 Code [1622/CB1622] Injector #9 (R/B #3) System Open/Short Error (RH bank) ................................. 50
E-90 Code [1633/CA1633] KOMNET Datalink Timeout Error (LH bank) ...................................................... 52
E-91 Code [2185/CA2185] Throttle Sens. Sup. Volt. High Error (LH bank only) .......................................... 54
E-92 Code [2186/CA2186] Throttle Sens. Sup. Volt. Low Error (LH bank only) ........................................... 56
E-93 Code [2249/CA2249] Rail Press. Very Low Error (LH bank) ................................................................ 57
E-94 Code [2249/CB2249] Rail Press. Very Low Error (RH bank) ............................................................... 57
E-95 Code [– –*1/–] Eng. Overheat (LH bank only) ...................................................................................... 58
E-96 Code [– –*2/–] Eng. Oil Press. Low Speed Derate (LH bank only)....................................................... 58
E-97 Code [– –*3/–] Press. Low Torque Derate (LH bank only).................................................................... 59
2 12V140E-3 Series
40 Troubleshooting SEN00318-03
E-56 Code [449/CA449] Rail Press. Very High Error (LH bank) 1
Error code Failure code
Trouble Common rail pressure abnormally high Error 2 (LH bank)
449 CA449
Contents of
• Common rail pressure sensor circuit detected abnormally high pressure (level 2).
trouble
Action of
• Limits output and continues operation (Limits common rail pressure).
controller
Phenomenon
that appears on • Output drops.
machine
Related
information
E-57 Code [449/CB449] Rail Press. Very High Error (RH bank) 1
Error code Failure code
Trouble Common rail pressure abnormally high Error 2 (RH bank)
449 CB449
Contents of
• Common rail pressure sensor circuit detected abnormally high pressure (level 2).
trouble
Action of
• Limits output and continues operation (Limits common rail pressure).
controller
Phenomenon
that appears on • Output drops.
machine
Related
information
12V140E-3 Series 3
SEN00318-03 40 Troubleshooting
E-58 Code [451/CA451] Rail Press. Sensor High Error (LH bank) 1
Error code Failure code Common rail pressure sensor detected abnormally high pressure
Trouble
451 CA451 (LH bank)
Contents of
• Signal voltage in common rail pressure sensor circuit is abnormally high.
trouble
Action of
• Limits output and continues operation (Limits common rail pressure).
controller
Phenomenon
that appears on • Output drops.
machine
Related
• Different machine models may have different connector Nos.
information
4 12V140E-3 Series
40 Troubleshooting SEN00318-03
12V140E-3 Series 5
SEN00318-03 40 Troubleshooting
E-59 Code [451/CB451] Rail Press. Sensor High Error (RH bank) 1
Error code Failure code Common rail pressure sensor detected abnormally high pressure
Trouble
451 CB451 (RH bank)
Contents of
• Signal voltage in common rail pressure sensor circuit is abnormally high.
trouble
Action of
• Limits output and continues operation (Limits common rail pressure).
controller
Phenomenon
that appears on • Output drops.
machine
Related
• Different machine models may have different connector Nos.
information
6 12V140E-3 Series
40 Troubleshooting SEN00318-03
12V140E-3 Series 7
SEN00318-03 40 Troubleshooting
E-60 Code [452/CA452] Rail Press. Sensor Low Error (LH bank) 1
Error code Failure code Common rail pressure sensor detected abnormally low pressure
Trouble
452 CA452 (LH bank)
Contents of
• Signal voltage in common rail pressure sensor circuit is abnormally low.
trouble
Action of
• Limits output and continues operation (Limits common rail pressure).
controller
Phenomenon
that appears on • Output drops.
machine
Related
information
E-61 Code [452/CB452] Rail Press. Sensor Low Error (RH bank) 1
Error code Failure code Common rail pressure sensor detected abnormally low pressure
Trouble
452 CA452 (RH bank)
Contents of
• Signal voltage in common rail pressure sensor circuit is abnormally low.
trouble
Action of
• Limits output and continues operation (Limits common rail pressure).
controller
Phenomenon
that appears on • Output drops.
machine
Related
information
8 12V140E-3 Series
40 Troubleshooting SEN00318-03
12V140E-3 Series 9
SEN00318-03 40 Troubleshooting
10 12V140E-3 Series
40 Troubleshooting SEN00318-03
E-64 Code [554/CA554] Rail Press. Sensor In Range Error (LH bank) 1
Error code Failure code Common rail pressure sensor detection of in range abnormality
Trouble
554 CA554 (LH bank)
Contents of
• In range error occurred in common rail pressure sensor circuit.
trouble
Action of
• Limits output and continues operation (Limits common rail pressure).
controller
Phenomenon
that appears on • Output drops.
machine
Related
information
E-65 Code [554/CB554] Rail Press. Sensor In Range Error (RH bank) 1
Error code Failure code Common rail pressure sensor detected In range abnormality
Trouble
554 CB554 (RH bank)
Contents of
• In range error occurred in common rail pressure sensor circuit.
trouble
Action of
• Limits output and continues operation (Limits common rail pressure).
controller
Phenomenon
that appears on • Output drops.
machine
Related
information
12V140E-3 Series 11
SEN00318-03 40 Troubleshooting
12 12V140E-3 Series
40 Troubleshooting SEN00318-03
Fig. 1: Locations of overflow valve (1), bypass valve (2), and fuel inlet joint (3)
q Overflow valve (1): Spring is seen through both holes.
q Bypass valve (2): Spring is seen through hole on nut side.
q Fuel inlet joint (3): Gauze filter is seen through both holes.
Note 2: Check, clean, and replace the filters and strainers according to the following procedure.
q Fuel filter: Replace (Replace both prefilter and main filter.)
q Water separator: Disassemble and check. If screen (4) is clogged, clean it.
q Gauze filter: Disassemble and check. Clean, if clogged.
q Upstream strainer of gauze filter: Disassemble and check. Clean, if clogged.
12V140E-3 Series 13
SEN00318-03 40 Troubleshooting
14 12V140E-3 Series
40 Troubleshooting SEN00318-03
Standard value
Measured
C. Check of fuel circuit pressure Checking condition Unit (Reference Good NG
value
value)
Fuel low-pressure circuit pres- MPa Min. 0.15
6 High idle
sure {kg/cm2} {Min. 1.5}
Standard value
E. Check of leakage and return Measured
Checking condition Unit (Reference Good NG
rate value)
value
*1 – *10:
When inspecting with INSITE (bench test tool), see Operation and Maintenance Manual (Testing
method).
When inspecting with the monitoring function of the machine, use the codes specified for each machine
model.
Equivalent to rating <By models>:
When inspecting the engine unit on the bench, operate it under a load equivalent to the rating. When
the engine is installed to the machine, however, the operation load equivalent to the rating depends on
the machine model.
12V140E-3 Series 15
SEN00318-03 40 Troubleshooting
16 12V140E-3 Series
40 Troubleshooting SEN00318-03
Fig. 1: Locations of overflow valve (1), bypass valve (2), and fuel inlet joint (3)
q Overflow valve (1): Spring is seen through both holes.
q Bypass valve (2): Spring is seen through hole on nut side.
q Fuel inlet joint (3): Gauze filter is seen through both holes.
Note 2: Check, clean, and replace the filters and strainers according to the following procedure.
q Fuel filter: Replace (Replace both prefilter and main filter.)
q Water separator: Disassemble and check. If screen (4) is clogged, clean it.
q Gauze filter: Disassemble and check. Clean, if clogged.
q Upstream strainer of gauze filter: Disassemble and check. Clean, if clogged.
12V140E-3 Series 17
SEN00318-03 40 Troubleshooting
18 12V140E-3 Series
40 Troubleshooting SEN00318-03
Standard value
Measured
C. Check of fuel circuit pressure Checking condition Unit (Reference Good NG
value
value)
Fuel low-pressure circuit pres- MPa Min. 0.15
6 High idle
sure {kg/cm2} {Min. 1.5}
Standard value
E. Check of leakage and return Measured
Checking condition Unit (Reference Good NG
rate value)
value
*1 – *10:
When inspecting with INSITE (bench test tool), see Operation and Maintenance Manual (Testing
method).
When inspecting with the monitoring function of the machine, use the codes specified for each machine
model.
Equivalent to rating <By models>:
When inspecting the engine unit on the bench, operate it under a load equivalent to the rating. When
the engine is installed to the machine, however, the operation load equivalent to the rating depends on
the machine model.
12V140E-3 Series 19
SEN00318-03 40 Troubleshooting
20 12V140E-3 Series
40 Troubleshooting SEN00318-03
12V140E-3 Series 21
SEN00318-03 40 Troubleshooting
22 12V140E-3 Series
40 Troubleshooting SEN00318-03
12V140E-3 Series 23
SEN00318-03 40 Troubleshooting
E-70 Code [691/CA691] Intake Air Temp Sensor High Error (LH bank
only) 1
Error code Failure code Intake air temperature sensor detected abnormally high tempera-
Trouble
691 CA691 ture (LH bank)
Contents of
• Intake air temperature sensor circuit detected abnormally high temperature.
trouble
Action of
• Fixes intake air temperature at (25 °C) and continues operation.
controller
Phenomenon
that appears on
machine
Related
information
24 12V140E-3 Series
40 Troubleshooting SEN00318-03
12V140E-3 Series 25
SEN00318-03 40 Troubleshooting
E-71 Code [692/CA692] Intake Air Temp Sensor Low Error (LH bank
only) 1
Error code Failure code Intake air temperature sensor detected abnormally low tempera-
Trouble
692 CA692 ture (LH bank only)
Contents of
• Intake air temperature sensor circuit detected abnormally low temperature.
trouble
Action of
• Fixes intake air temperature at (25 °C) and continues operation.
controller
Phenomenon
that appears on
machine
Related
information
26 12V140E-3 Series
40 Troubleshooting SEN00318-03
E-72 Code [731/CA731] Eng. G (Bkup) Speed Sensor Phase Error (LH
bank) 1
Error code Failure code
Trouble Engine G (Bkup) speed sensor abnormal phase (LH bank)
731 CA731
Contents of
• Engine G (Bkup) sensor circuit detected abnormality in phase.
trouble
Action of
• Controls with signals of engine Ne speed sensor.
controller
Phenomenon
• Running engine stops (when Ne speed sensor is also abnormal).
that appears on
• Stopped engine cannot be started (when Ne speed sensor is also abnormal).
machine
Related
information
E-73 Code [731/CB731] Eng. G (Bkup) Speed Sensor Phase Error (RH
bank) 1
Error code Failure code
Trouble Engine G (Bkup) speed sensor abnormal phase (RH bank)
731 CB731
Contents of
• Engine G (Bkup) sensor circuit detected abnormality in phase.
trouble
Action of
• Controls with signals of engine Ne speed sensor.
controller
Phenomenon
• Running engine stops (when Ne speed sensor is also abnormal).
that appears on
• Stopped engine cannot be started (when Ne speed sensor is also abnormal).
machine
Related
information
12V140E-3 Series 27
SEN00318-03 40 Troubleshooting
E-74 Code [757/CA757] All Continuous Data Lost Error (LH bank) 1
Error code Failure code
Trouble All Engine Controller Data Lost Error (LH bank)
757 CA757
Contents of
• All data in engine controller are lost.
trouble
Action of
• None in particular.
controller
Phenomenon
that appears on • Engine continues operation normally, but it may stop during operation or may not be able to start.
machine
Related
information
E-75 Code [757/CB757] All Continuous Data Lost Error (RH bank) 1
Error code Failure code
Trouble All Engine Controller Data Lost Error (RH bank)
757 CB757
Contents of
• All data in engine controller are lost.
trouble
Action of c
• None in particular.
ontroller
Phenomenon
that appears on • Engine continues operation normally, but it may stop during operation or may not be able to start.
machine
Related
information
28 12V140E-3 Series
40 Troubleshooting SEN00318-03
12V140E-3 Series 29
SEN00318-03 40 Troubleshooting
E-76 Code [778/CA778] Eng. G (Bkup) Speed Sensor Error (LH bank) 1
Error code Failure code
Trouble Engine G (Bkup) speed sensor abnormal (LH bank)
778 CA778
Contents of
• Abnormality occurred in engine G (Bkup) speed sensor circuit.
trouble
Action of
• Controls with signals of Ne speed sensor.
controller
Phenomenon
• Running engine stops (when Ne speed sensor is also abnormal).
that appears on
• Stopped engine cannot be started (when Ne speed sensor is also abnormal).
machine
Related
• Different machine models may have different connector Nos.
information
30 12V140E-3 Series
40 Troubleshooting SEN00318-03
12V140E-3 Series 31
SEN00318-03 40 Troubleshooting
E-77 Code [778/CB778] Eng. G (Bkup) Speed Sensor Error (RH bank) 1
Error code Failure code
Trouble Engine G (Bkup) speed sensor abnormal (RH bank)
778 CB778
Contents of
• Abnormality occurred in engine G (Bkup) speed sensor circuit.
trouble
Action of
• Controls with signals of Ne speed sensor.
controller
Phenomenon
• Running engine stops (when Ne speed sensor is also abnormal).
that appears on
• Stopped engine cannot be started (when Ne speed sensor is also abnormal).
machine
Related
• Different machine models may have different connector Nos.
information
32 12V140E-3 Series
40 Troubleshooting SEN00318-03
12V140E-3 Series 33
SEN00318-03 40 Troubleshooting
34 12V140E-3 Series
40 Troubleshooting SEN00318-03
12V140E-3 Series 35
SEN00318-03 40 Troubleshooting
36 12V140E-3 Series
40 Troubleshooting SEN00318-03
12V140E-3 Series 37
SEN00318-03 40 Troubleshooting
Possible causes Ground fault in wiring har- a Prepare with starting switch OFF, then carry out troubleshoot-
and standard ness ing without turning starting switch ON.
2
value in normal (Short circuit with GND cir- Between wiring harness OEM L (female) (8) Resis-
cuit) Min. 1 Mz
state and chassis ground tance
a Prepare with starting switch OFF, then carry out troubleshoot-
ing without turning starting switch ON.
Between wiring harness OEM L (7) and Resis-
3 Defective engine controller Max. 1 z
chassis ground tance
Between wiring harness OEM L (8) and Resis-
Min. 1 Mz
chassis ground tance
38 12V140E-3 Series
40 Troubleshooting SEN00318-03
12V140E-3 Series 39
SEN00318-03 40 Troubleshooting
40 12V140E-3 Series
40 Troubleshooting SEN00318-03
12V140E-3 Series 41
SEN00318-03 40 Troubleshooting
42 12V140E-3 Series
40 Troubleshooting SEN00318-03
12V140E-3 Series 43
SEN00318-03 40 Troubleshooting
44 12V140E-3 Series
40 Troubleshooting SEN00318-03
12V140E-3 Series 45
SEN00318-03 40 Troubleshooting
46 12V140E-3 Series
40 Troubleshooting SEN00318-03
12V140E-3 Series 47
SEN00318-03 40 Troubleshooting
48 12V140E-3 Series
40 Troubleshooting SEN00318-03
12V140E-3 Series 49
SEN00318-03 40 Troubleshooting
50 12V140E-3 Series
40 Troubleshooting SEN00318-03
12V140E-3 Series 51
SEN00318-03 40 Troubleshooting
52 12V140E-3 Series
40 Troubleshooting SEN00318-03
12V140E-3 Series 53
SEN00318-03 40 Troubleshooting
E-91 Code [2185/CA2185] Throttle Sens. Sup. Volt. High Error (LH bank
only) 1
Throttle sensor of decelerator pedal type (Case of D475-5)
Error code Failure code Throttle sensor detection of abnormally high supply voltage
Trouble
2185 CA2185 (LH bank only)
Contents of
• High voltage abnormality occurred to throttle sensor power supply (5 V) circuit.
trouble
Action of • Sets throttle angle with signal other than throttle sensor signal and continues operation.
controller (depending on each model)
Phenomenon
that appears on • Depends on machine model.
machine
Related
• Different machine models may have different connector Nos.
information
54 12V140E-3 Series
40 Troubleshooting SEN00318-03
Circuit diagram related to deceleration pedal type throttle sensor (Case of D475-5)
12V140E-3 Series 55
SEN00318-03 40 Troubleshooting
E-92 Code [2186/CA2186] Throttle Sens. Sup. Volt. Low Error (LH bank
only) 1
Error code Failure code Throttle sensor detected abnormally low supply voltage
Trouble
2186 CA2186 (LH bank only)
Contents of
• Low-voltage abnormality occurred to throttle sensor power supply (5V) circuit.
trouble
Action of • Sets throttle angle with signal other than throttle sensor signal and continues operation.
controller (depending on each model)
Phenomenon
that appears on • Depends on machine model.
machine
Related
information
56 12V140E-3 Series
40 Troubleshooting SEN00318-03
E-93 Code [2249/CA2249] Rail Press. Very Low Error (LH bank) 1
Error code Failure code
Trouble Supply pump no-pressure feed error 2 (LH bank)
2249 CA2249
Contents of
• Supply pump does not feed fuel (level 2).
trouble
Action of
• Limits common rail pressure.
controller
Phenomenon
that appears on • Output drops.
machine
Related
information
E-94 Code [2249/CB2249] Rail Press. Very Low Error (RH bank) 1
Error code Failure code
Trouble Supply pump no-pressure feed error 2 (RH bank)
2249 CB2249
Contents of
• Supply pump does not feed fuel (level 2).
trouble
Action of ontrol-
• Limits common rail pressure.
ler
Phenomenon
that appears on • Output drops.
machine
Related
information
12V140E-3 Series 57
SEN00318-03 40 Troubleshooting
E-96 Code [– –*2/–] Eng. Oil Press. Low Speed Derate (LH bank only) 1
Error code Failure code
Trouble Engine oil pressure low and speed derate (LH bank only)
– –*2 –
Contents of
• Engine oil pressure is below operating range.
trouble
Action of
• Limits output and continues operation (Limits fuel injection rate and engine speed).
controller
Phenomenon
that appears on • Output drops.
machine
Related
information
58 12V140E-3 Series
40 Troubleshooting SEN00318-03
E-97 Code [– –*3/–] Press. Low Torque Derate (LH bank only) 1
Error code Failure code
Trouble Engine oil pressure low and torque derate (LH bank only)
– –*3 –
Contents of
• Engine oil pressure is below operating range.
trouble
Action of
• Limits output and continues operation (Limits fuel injection rate and engine speed).
controller
Phenomenon
that appears on • Output drops.
machine
Related
information
12V140E-3 Series 59
SEN00318-03 40 Troubleshooting
© 2009 KOMATSU
All Rights Reserved
Printed in Japan 03-09 (02)
60 12V140E-3 Series
SEN00320-02
12V140E-3 Series
12V140E-3 Series 1
SEN00320-02 50 Disassembly and assembly
2 12V140E-3 Series
50 Disassembly and assembly SEN00320-02
12V140E-3 Series 3
SEN00320-02 50 Disassembly and assembly
a The recommended coating materials such as adhesives, gasket sealants, and greases used for disas-
sembly and assembly are listed below.
a For coating materials not listed below, use the equivalent of products shown in this manual.
Cate- Komatsu
Part number Q'ty Container Main features and applications
gory code
• Used to prevent rubber gaskets, rubber cush-
LT-1A 790-129-9030 150 g Tube
ions, and cork plugs from coming out.
• Used for plastic (except polyethylene,
polypropylene, tetrafluoroethylene and vinyl
20 g Polyethylene
LT-1B 790-129-9050 chloride), rubber, metal, and non-metal parts
(2 pcs.) container
which require immediate and strong adhe-
sion.
Polyethylene • Features: Resistance to heat and chemicals.
LT-2 09940-00030 50 g
container • Used to fix and seal bolts and plugs.
790-129-9060
Adhesive: 1 kg • Used to stick and seal metal, glass, and plas-
LT-3 (Set of adhesive Can
Hardener: 500 g tics.
and hardener)
Adhesive
Polyethylene
LT-4 790-129-9040 250 g • Used to seal plugs.
container
Holtz MH 705 790-129-9120 75 g Tube • Heat-resistant seal used to repair engines.
• Quick-setting adhesive.
ThreeBond Polyethylene • Setting time: Within 5 sec. to 3 min.
790-129-9140 50 g
1735 container • Used mainly to stick metals, rubbers, plastics,
and woods.
• Quick-setting adhesive.
• Quick-setting type.
Aron-alpha Polyethylene
790-129-9130 2g (max. strength is obtained after 30 minutes)
201 container
• Used mainly to stick rubbers, plastics, and
metals.
• Features: Resistance to heat and chemicals.
Loctite Polyethylene
79A-129-9110 50 cc • Used for fitted portions used at high tempera-
648-50 container
tures.
• Used to seal various threaded portions, pipe
Polyethylene joints, and flanges.
LG-5 790-129-9080 1 kg
container • Used to seal tapered plugs, elbows, and nip-
ples of hydraulic piping.
• Features: Silicon-based heat and cold-resis-
tant sealant.
LG-6 790-129-9160 200 g Tube • Used to seal flange surfaces and threaded
portions.
• Used to seal oil pan, final drive case, etc.
Gasket sealant
4 12V140E-3 Series
50 Disassembly and assembly SEN00320-02
Cate-
Komatsu code Part number Q'ty Container Main features and applications
gory
LG-10 • Used as lubricant/sealant when the radiator
ThreeBond 790-129-9320 200 g Tube hoses are inserted.
Gasket sealant
• Spray type
• Thin molybdenum disulphide films are made on
metal surfaces to prevent the metals from scuff-
— 09995-00250 190 g Can
ing each other.
• Applicable for the propeller shaft splines, needle
bearings, pins and bolts of various links, etc.
• Feature: Seizure and scuffing prevention com-
compound
prevention
LC-G
— — Can • Used for the mounting bolt in the high tempera-
NEVER-SEEZ
ture area of the exhaust manifold and the turbo-
charger, etc.
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
G2-LI • Feature: Lithium grease with extreme pressure
SYG2-160LI
G0-LI Various Various lubrication performance.
SYGA-160CNLI
*: For cold district • General purpose type.
SYG0-400LI-A (*)
SYG0-160CNLI
(*)
• Used for parts under heavy load.
Caution:
Molybdenum SYG2-400M 400 g x 10 Bellows-type • Do not apply grease to rolling bearings like
disulfide grease SYG2-400M-A 400 g x 20 container swing circle bearings, etc. and spline.
LM-G (G2-M) SYGA-16CNM 16 kg Can • The grease should be applied to work equipment
pins at their assembly only, not applied for
greasing afterwards.
• Seizure resistance, heat resistance and water
Hyper White SYG2-400T-A
Grease
12V140E-3 Series 5
SEN00320-02 50 Disassembly and assembly
Cate-
Komatsu code Part number Q'ty Container Main features and applications
gory
SUNSTAR • Used as primer for cab side.
Glass
PAINT PRIMER 20 ml (Using limit: 4 months after date of manu-
container
580 SUPER facture)
SUNSTAR 417-926-3910
• Used as primer for glass side.
GLASS Glass
20 ml (Using limit: 4 months after date of manu-
PRIMER 580 container
facture)
facture)
SUNSTAR Ecocart • Used as adhesive for glass.
PENGUINE 22M-54-27210 320 ml (Special (Using limit: 6 months after date of manu-
SUPER 560 container) facture)
SUNSTAR • Used to seal joints of glass parts.
Polyethylene
PENGUINE 417-926-3920 320 ml (Using limit: 4 months after date of manu-
container
SEAL No. 2505 facture)
Caulking material
6 12V140E-3 Series
50 Disassembly and assembly SEN00320-02
a Tools with part number 79*T-***-**** means that they are not available from Komatsu Ltd. (i.e. tools to be
made locally).
a Necessity : t . . . . . . Special tools that cannot be substituted and should always be used
: q . . . . . . Special tools that will be useful if available and are substitutable with tools avail-
able on the market
a New/Remodel: N. . . . . . Tools newly developed for this model. They have a new part number respec-
tively.
: R. . . . . . Tools made available by redesigning the existing tools which were developed for
other models. Each of them has a new part number assigned by setting forward
the part number of the existing tool.
: Blank . . Tools already available for other models. They can be used without any modifi-
cation.
a Tools marked with Q in the sketch column are presented in the sketches of the special tools (See "Sketch-
es of special tools")
New/Remodel
Necessity
Sketches
Sym-
Q'ty
Work item Part No. Part name Remarks
bol
12V140E-3 Series 7
SEN00320-02 50 Disassembly and assembly
New/Remodel
Necessity
Sketches
Sym-
Q'ty
Work item Part No. Part name Remarks
bol
795T-621-1430 Plate t 1 Q
795T-621-1441 Push tool t 1 Q
Installation of front oil
J 01050-32240 Bolt t 3
seal
01050-32225 Bolt t 3
01640-02232 Washer t 3
795T-621-1531 Push tool t 1 Q
01050-32050 Bolt t 5
Installation of rear oil 01640-02032 Washer t 5
K
seal 795T-621-1540 Push tool t 1 Q For PC2000-8
01050-32060 Bolt t 5 For PC2000-8
01640-02032 Washer t 5 For PC2000-8
Press fitting of valve
L 795-130-1720 Push tool t 1
stem seal
Adjusting valve Commercially
M Thickness gauge q 1 IN: 0.35 mm, EX: 0.57 mm
clearance available
Removal of front and
N 795-931-1100 Seal puller q 1
rear oil seal
8 12V140E-3 Series
50 Disassembly and assembly SEN00320-02
J Push tool
12V140E-3 Series 9
SEN00320-02 50 Disassembly and assembly
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
K Push tool
10 12V140E-3 Series
50 Disassembly and assembly SEN00320-02
12V140E-3 Series 11
SEN00320-02 50 Disassembly and assembly
© 2009 KOMATSU
All Rights Reserved
Printed in Japan 03-09 (02)
12 12V140E-3 Series
SEN00321-00
12V140E-3 Series
12V140E-3 Series 1
SEN00321-00 50 Disassembly and assembly
1. Preparation work
Before disassembling the engine, check its
parts for cracking, damage, etc. and clean the
entire engine carefully for accurate inspection
of its parts and quick disassembly and assem- 4. Starting motor assembly
bly. Remove engine harness (1) and then remove
a Before cleaning the engine, carefully seal starting motor assemblies (2) and (3).
or remove the openings, electric parts, a Remove the assembly at the top first
and wiring connectors so that water will being followed by that at the bottom.
not enter them.
5. Alternator
1) Remove auxiliary equipment belt (1).
2) Remove alternator (2).
2 12V140E-3 Series
50 Disassembly and assembly SEN00321-00
12V140E-3 Series 3
SEN00321-00 50 Disassembly and assembly
2) Apply a marking to every installation posi- 13. Air intake manifold assembly
tions of clamps (2) and (3) using paint. 1) Remove support (1).
4 12V140E-3 Series
50 Disassembly and assembly SEN00321-00
12V140E-3 Series 5
SEN00321-00 50 Disassembly and assembly
6 12V140E-3 Series
50 Disassembly and assembly SEN00321-00
12V140E-3 Series 7
SEN00321-00 50 Disassembly and assembly
27. Push rod 2) Insert a small L-bar [1] under the fuel con-
Remove push rod (1). nector and pry out fuel injector (2) slowly.
a Do not grip the solenoid valve at the
top of the injector to pull off the injec-
tor.
8 12V140E-3 Series
50 Disassembly and assembly SEN00321-00
12V140E-3 Series 9
SEN00321-00 50 Disassembly and assembly
2) Install the engine again to tool A. 3) Remove thermostat (3) from thermostat
case (2).
35. Alternator bracket
Remove alternator bracket (1).
10 12V140E-3 Series
50 Disassembly and assembly SEN00321-00
38. Front engine hanger 2] Remove shaft (5), thrust plate (6) and
Remove front engine hanger (1). gear (7) as a unit.
3] Remove gear (7) from shaft (5).
4] Pull off oil seal (9) and bushing (10)
from housing (8).
12V140E-3 Series 11
SEN00321-00 50 Disassembly and assembly
2) Remove engine speed sensor (3). 44. Damper and crank pulley assembly
1) Lift damper and crank pulley assembly (1)
temporarily and then remove the mounting
bolts.
2) Lift off damper and crank pulley assembly
(1).
4 Damper and crank pulley assem-
bly: 75 kg
12 12V140E-3 Series
50 Disassembly and assembly SEN00321-00
12V140E-3 Series 13
SEN00321-00 50 Disassembly and assembly
14 12V140E-3 Series
50 Disassembly and assembly SEN00321-00
12V140E-3 Series 15
SEN00321-00 50 Disassembly and assembly
4) Hit the connecting rod head lightly using a 9) Disassemble the piston and connecting
plastic hammer to loosen the connecting rod assembly according to the following
rod cap and connecting rod. procedure.
5) Scrub the carbon off the top wall of the 1] Remove snap ring (4)
liner using fine sandpaper. 2] Support connecting rod (5) with hand
6) Turn the crankshaft until the piston comes and then remove piston pin (6) to dis-
to the top dead center and then remove connect piston (7) from the connect-
the connecting rod cap (2). ing rod.
a When the piston pin is firmly
fixed and unremovable, heat it
(roughly 5 minutes at 100°C)
using an industrial dryer.
3] Remove the snap ring on the other
side.
16 12V140E-3 Series
50 Disassembly and assembly SEN00321-00
2) Remove mounting bolts (2) of main cap 5) Remove upper thrust bearing (5) from
(1). No.7 journal.
3) Insert the bolts in the bolt hole of the main 6) Remove upper bearing (6).
cap (1) and remove the cap, while shaking a Apply marking to the assembly posi-
it. tions of the main cap, main bearing
and thrust bearing using paint or tags
and then keep them on a cap to cap
basis.
12V140E-3 Series 17
SEN00321-00 50 Disassembly and assembly
18 12V140E-3 Series
SEN00321-00 50 Disassembly and assembly
© 2006 KOMATSU
All Rights Reserved
Printed in Japan 03-06 (02)
20 12V140E-3 Series
SEN00322-02
12V140E-3 Series
12V140E-3 Series 1
SEN00322-02 50 Disassembly and assembly
2 12V140E-3 Series
50 Disassembly and assembly SEN00322-02
12V140E-3 Series 3
SEN00322-02 50 Disassembly and assembly
1] Coat the bottom side of shim 8) Using tool F, press-fit cylinder liner (1) to
(2) with a small amount of the cylinder block.
gasket sealant LG-6 and
then assemble the shim.
2] Then apply gasket sealant
LG-6 according to the same
procedure as that employed
when the shim is not used.
4 12V140E-3 Series
50 Disassembly and assembly SEN00322-02
12V140E-3 Series 5
SEN00322-02 50 Disassembly and assembly
5) Install the projection of lower bearing (7) 6) Drive the roll pin of cap No. 7 so that it will
locating it to the notch of main cap (1) and be projected by 2.7 – 3.4 mm from the cap
install. end and then install lower thrust bearings
a Before fitting the bearing, make sure (3) to both sides.
that its back side is free from foreign a Install the thrust bearing with the
matter. grooved surface on the crankshaft
2 Inside of bearing: side.
Engine oil (EO30) 2 Thrust bearing sliding surface:
a Don't apply the engine oil to the bear- Engine oil (EO30)
ing backside. 7) Apply the engine oil to the surface of the
journal of the crankshaft. Then install the
main cap after making sure that the No.
being stamped on respective main caps
(1) is matching the cylinder block No.
2 Crankshaft journal:
Engine oil (EO30)
a When installing the main cap, direct
its cast part number side toward the
front of the engine.
8) Apply engine oil to the threaded portion of
the main cap mounting bolt and washer
and then drive in the bolts alternately until
the main cap is completely fitted.
2 Main cap mounting bolt:
Engine oil (EO30)
a Lower bearing: Without oil hole
a No. 4 bearing is wider than others. Thus, care
must be used to prevent an assembly error.
a Bearing with a
No. 4 bearing: 52 mm
Bearings other than No. 4: 48 mm
6 12V140E-3 Series
50 Disassembly and assembly SEN00322-02
12V140E-3 Series 7
SEN00322-02 50 Disassembly and assembly
3] Install snap ring (10) to one side of 7] Install the projection of connecting
piston (7). rod upper bearing (11) locating it to
the notch of the connecting rod.
a Before fitting the bearing, make
sure that its back side is free
from foreign matter.
a Don't apply the oil to the bearing
backside.
a Make sure that the connecting
rod small end bushing are large
end bearing hole are aligned with
the connecting rod oil hole.
a Before assembling the connect-
ing rod, check the connecting rod
oil hole for settled dusts.
2 Connecting rod bearing inner
surface: Engine oil (EO30)
4] Set the piston (7) and connecting rod
(5). Mate the cast letters "EX i F" on
the piston against the chamfered hole
side in the big end of the connecting
rod and then assemble them.
5] Apply engine oil to the piston pin boss
and inner surface of the connecting
rod bushing and then insert piston pin
(6) while directing the connecting rod
upward.
2 Piston pin: Engine oil (EO30)
6] Install snap ring (4) on the opposite
side.
a Turn the snap ring to make sure
that the left and right side snap
rings are completely fitted in the 8] Install the projection of connecting
ring groove. rod lower bearing (12) locating it to
a Also make sure that the connect- the notch of the connecting rod cap.
ing rod moves lightly. a Before fitting the bearing, make
sure that its back side is free
from foreign matter. Don't apply
the engine oil to the backside.
8 12V140E-3 Series
50 Disassembly and assembly SEN00322-02
2) Apply the engine oil to the cylinder liner. 5) Align the abutment joint of respective pis-
a Apply the engine oil uniformly on the ton rings as well as the piston to the posi-
entire circumference with hands. tion shown in the figure.
2 Cylinder liner: Engine oil (EO30)
12V140E-3 Series 9
SEN00322-02 50 Disassembly and assembly
7) Using the connecting rod puller [1] shown a When assembling a new connecting
in the figure, pull the connecting rod until it rod, record its cylinder No. on the
is closely contacted against the pin jour- connecting rod cap using a electric
nal. pen (stamping is not acceptable). It is
a Make sure the connecting rod bearing strictly prohibited to change the com-
is not displaced. bination of the connecting rod and
a The connecting rod puller [1] is made cap through this operation.
by welding bar b to unnecessary con-
necting rod bolt a.
a Total length of connecting rod puller l:
Approx. 500 mm.
2 Crank pin journal:
Engine oil (EO30)
10 12V140E-3 Series
50 Disassembly and assembly SEN00322-02
12V140E-3 Series 11
SEN00322-02 50 Disassembly and assembly
12 12V140E-3 Series
50 Disassembly and assembly SEN00322-02
2) Install cam follower assembly (3). 10. Supply pump drive case
3 Cam follower assembly mounting 1) Install supply pump drive case (2).
bolt: 2) Install oil tube (1).
44.1 – 58.8 Nm {4.5 – 6.0 kgm}
a Install the oil tube on the left bank
alone.
3 Oil tube joint bolt:
7.9 – 12.7 Nm {0.8 – 1.3 kgm}
12V140E-3 Series 13
SEN00322-02 50 Disassembly and assembly
14 12V140E-3 Series
50 Disassembly and assembly SEN00322-02
12V140E-3 Series 15
SEN00322-02 50 Disassembly and assembly
1] Backlash of each gear a When cover (2) was removed, apply the
(mm) gasket sealant in the position shown in the
Standard figure before installing it again.
Position Measuring points
value 2 Cover: Gasket sealant (LG-7)
Right idler gear (small) and 0.130 – 0.390 q Application diameter: ø2.0 mm
A•A
right sub idler gear (0.125 – 0.363)
Right sub idler gear and right 0.051 – 0.469
B1•B1
supply pump gear (0.125 – 0.363)
Left sub idler gear and left 0.051 – 0.469
B2•B2
supply pump gear (0.125 – 0.363)
Left sub idler gear and left 0.129 – 0.391
C•C
cam gear (0.125 – 0.363)
Right idler gear (small) and 0.129 – 0.391
D•D
right cam gear (0.125 – 0.363)
Right idler gear (large) and
E•E 0.052 – 0.481
water pump drive gear
Right idler gear (large) and
F•F 0.137 – 0.421
oil pump gear
Left supply pump gear and 0.106 – 0.381
G•G
compressor gear (0.138 – 0.354)
Right cam gear and acces- 0.085 – 0.492
H•H
sory drive gear (0.138 – 0.354)
Crank gear and left idler gear
L•L 0.141 – 0.425
(large)
Crank gear and right idler
R•R 0.141 – 0.425
gear (large)
Note): The standard value enclosed in ( ) indicates
the backlash between spur gears
16 12V140E-3 Series
50 Disassembly and assembly SEN00322-02
12V140E-3 Series 17
SEN00322-02 50 Disassembly and assembly
18 12V140E-3 Series
50 Disassembly and assembly SEN00322-02
12V140E-3 Series 19
SEN00322-02 50 Disassembly and assembly
20 12V140E-3 Series
50 Disassembly and assembly SEN00322-02
12V140E-3 Series 21
SEN00322-02 50 Disassembly and assembly
22 12V140E-3 Series
50 Disassembly and assembly SEN00322-02
27. Breather
Install breather (1), blow-by pipe (2) and plate
(3).
3 Breather mounting bolt: 30. Suction pie and under plate
24.5 – 29.4 Nm {2.5 – 3.0 kgm} 1) Using jack [1], install under plate (1) and
a Install plate (3) to the left side bank alone. then fix it temporarily using the oil pan
mounting bolt.
4 Under plate: 25 kg
12V140E-3 Series 23
SEN00322-02 50 Disassembly and assembly
2) Install suction pipe (3) and stay (2). 33. Common rail
1) Install bracket (3).
2) Install common rail (2).
a Install the common rail at this point
since positioning of the high-pres-
sure pipe is needed when installing
the fuel injector.
3 Common rail mounting bolt:
59 – 74 Nm {4 – 5 kgm}
24 12V140E-3 Series
50 Disassembly and assembly SEN00322-02
2) Install the cylinder head gasket. a When tool G is not used in tight-
3) Lift and install cylinder head assembly (1). ening of the 3rd time, check the
4 Cylinder head assembly: 30 kg rotating angle after applying
marking b to the cylinder head
and bolt head using paint.
12V140E-3 Series 25
SEN00322-02 50 Disassembly and assembly
3] Tighten the mounting bolt (No. 7) with 2) Insert fuel injector (2) to the cylinder head
the following torque. along with holder (3).
2 Cylinder head assembly mount-
ing bolt:
Molybdenum disulfide lubri-
cant (LM-P)
3 Cylinder head assembly mount-
ing bolt (No. 7):
66.2 ± 7.4 Nm {6.75 ± 0.75 kgm}
4] After the tightening, stamping punch
mark a to the head of mounting bolts
(No. 1 – 6).
26 12V140E-3 Series
50 Disassembly and assembly SEN00322-02
36. High-pressure pipe (between common rail - a After the tightening, make sure the O-
fuel injector) ring is not projecting from the sleeve
k Install the high-pressure pipe and nut.
clamp paying attention to the following
points.
q It is strictly prohibited to reuse a high-
pressure pipe by modifying its bend
or using the pipe in an unintended
location.
q The clamp used must be a legitimate
one. And it must be installed in the
specified position with the specified
torque.
q After installing the high-pressure pipe
and clamp, make sure that 10 mm
m i n i mu m c l ea r a n c e i s p r o v id e d
between the high-pressure pipe and
adjacent harness. If the clearance is
less than 10 mm, adjust the harness
position to secure the space.
k 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.
q Check the taper seal of the connect-
ing part (Part a: Part of 2 mm from the
end) for visible lengthwise slit b and
dent c.
q Check part d (end of the taper seal:
Part at 2 mm from the end) for
stepped-type wear (fatigue) which
your nail can feel.
12V140E-3 Series 27
SEN00322-02 50 Disassembly and assembly
37. Crosshead
1) Install crosshead (1).
2 Crosshead sliding portion:
9) Install the rubber cover to the sleeve nut
on the high-pressure pipe. Engine oil (EO30)
a Direct the slit downward when install-
ing the rubber cover.
q Injector side (8): Bottom
q Common rail side (9): Cylinder
block side
28 12V140E-3 Series
50 Disassembly and assembly SEN00322-02
12V140E-3 Series 29
SEN00322-02 50 Disassembly and assembly
30 12V140E-3 Series
50 Disassembly and assembly SEN00322-02
12V140E-3 Series 31
SEN00322-02 50 Disassembly and assembly
32 12V140E-3 Series
50 Disassembly and assembly SEN00322-02
12V140E-3 Series 33
SEN00322-02 50 Disassembly and assembly
34 12V140E-3 Series
50 Disassembly and assembly SEN00322-02
12V140E-3 Series 35
SEN00322-02 50 Disassembly and assembly
36 12V140E-3 Series
50 Disassembly and assembly SEN00322-02
60. Alternator
1) Install alternator (2).
2) Install auxiliary equipment belt (1).
3) Adjust tension of the auxiliary equipment
belt.
a Adjust its deflection to 20 mm when
the pushing force of 58.8 Nm {6 kgm}
is applied to the belt center through a
finger.
3 Adjuster lock bolt:
53.9 – 122.6 Nm {5.5 – 12.5 kgm}
12V140E-3 Series 37
SEN00322-02 50 Disassembly and assembly
63. Checking for fuel leakage a When checking while the components
a When removal and installation of fuel sup- to be checked are mounted on the
ply pump (1), common rail (2), or high- machine, stall the torque converter or
pressure pipes (3) and (4) were con- relieve the hydraulic pump.
ducted, check fuel leakage according to 9) Check the fuel piping and devices for fuel
the following procedure after assembling leakage.
the engine. a Check mainly around the high-pres-
a Here, high-pressure pipes (3) and (4) sure circuit parts coated with the color
denote every fuel pipe (the figure shows checker for fuel leakage.
an example). a If any fuel leakage is detected, repair
it and check again from step 1).
a If no fuel leakage is detected, check
is completed.
38 12V140E-3 Series
50 Disassembly and assembly SEN00322-02
12V140E-3 Series 39
SEN00322-02 50 Disassembly and assembly
© 2009 KOMATSU
All Rights Reserved
Printed in Japan 03-09 (02)
40 12V140E-3 Series
SEN00876-02
12V140E-3 Series
12V140E-3 Series 1
SEN00876-02 50 Disassembly and assembly
Removal
1. Remove the connectors (in 3 places).
2. Remove fuel return hose (3) between common
rail (1) and supply pump (2). [*1]
a A fuel return pipe is provided on the right
side bank. Since it does not allow removal
halfway, the whole set of the pipe must be 6. Remove oil tube (9) between supply pump (2)
removed. and the cylinder block. [*4]
7. Disconnect fuel tube (10) between the fuel fil-
ter and supply pump (2) from the supply pump
side. [*5]
2 12V140E-3 Series
50 Disassembly and assembly SEN00876-02
9. Remove 4 mounting bolts (12) and then a Tighten mounting bolt (12) with the
remove supply pump assembly (2). [*7] specified torque after tightening the
sleeve nut of the high-pressure pipe
(between supply pump and common
rail).
2 Supply pump assembly mounting
bolt: Adhesive (LT-2)
2) After installing high-pressure pipes (8) on
supply pump (2) and common rail (1) tem-
porarily, tighten the sleeve nut with the
specified torque.
a Use a spanner type torque wrench
(commercially available part) should
be used for the tightening to ensure
observance of the specified torque.
3 High-pressure pipe sleeve nut
(Supply pump side):
Installation 39.2 – 49 Nm {4 – 5 kgm}
3 High-pressure pipe sleeve nut
q Carry out installation in the reverse order to
removal. (Common rail side):
39.2 – 58.8 Nm {4 – 6 kgm}
[*1] 3) Install the clamp of the high-pressure pipe
3 Fuel return hose (3) joint bolt (Common rail according to the following procedure.
side): 17.7 – 22.6 Nm {1.8 – 2.3 kgm} 1] Manually tighten and install tempo-
rarily the stay and top and bottom
[*2] clamps of the high-pressure pipe.
3 Fuel tube (5) joint bolt: 2] Tighten the top and bottom clamps
24.5 – 34.3 Nm {2.5 – 3.5 kgm} permanently.
a Before tightening the stay perma-
[*3] [*7] nently, deflect the rubber fist.
Install the supply pump and high-pressure pipe by a Take care in the tightening so
finalizing their position the following procedure. that excessive force may not be
1) Install supply pump assembly (2) tempo- applied to the supply pump side
rarily. install position.
a Align the unequal spline portion of the 3 Top and bottom clamp bolt:
supply pump side to unequal spline 9.8 ± 1 Nm {1 ± 0.1 kgm}
portion A of the supply pump drive 3] Tighten respective stays permanently.
case side and then insert the supply 4) Install the rubber cover to the sleeve nut
pump.. on the high-pressure pipe.
a When it is difficult to insert the supply a Direct the slit downward when install-
pump , turn the crankshaft to change ing the rubber cover.
position of unequal spline portion A. q Supply pump side: Bottom side
q Common rail side:
Faced inward (Opposed)
[*4]
3 Oil tube (9) joint bolt:
9.8 – 12.7 Nm {1.0 – 1.3 kgm}
[*5]
3 Fuel tube (10) joint bolt:
24.5 – 34.3 Nm {2.5 -– 3.5 kgm}
[*6]
3 Supply pump mounting bolt (Pump bottom
side): 19.6 – 29.4 Nm {2.0 – 3.0 kgm}
12V140E-3 Series 3
SEN00876-02 50 Disassembly and assembly
q Tool N
4 12V140E-3 Series
50 Disassembly and assembly SEN00876-02
Installation
1. Clean, degrease and then dry the contact sur-
face between the flywheel housing and rear
seal.
12V140E-3 Series 5
SEN00876-02 50 Disassembly and assembly
q Tool A3
6 12V140E-3 Series
50 Disassembly and assembly SEN00876-02
1. Installation procedure of standard seal 4) Apply rear seal (2) on the end of crank-
a Do not apply any grease, oil and others to shaft (4).
the seal lip surface (a). a Install the rear seal in the correct
a Never remove inside plastic cylinder (3) of direction.
the standard spare seal before installing 5) Manually push the metal ring of rear seal
the seal. (2) evenly, and insert in its position.
6) Using the tool K, further press and insert
rear seal (2) evenly.
12V140E-3 Series 7
SEN00876-02 50 Disassembly and assembly
q Tool A3
a CS: Crankshaft
8 12V140E-3 Series
50 Disassembly and assembly SEN00876-02
12V140E-3 Series 9
SEN00876-02 50 Disassembly and assembly
© 2009 KOMATSU
All Rights Reserved
Printed in Japan 03-09 (02)
10 12V140E-3 Series
SEN05155-00
12V140E-3 Series
12V140E-3 Series 1
SEN05155-00 90 Repair and replacement of parts
Flowchart 1
Repair of cylinder block top and counterbore by grinding
a For removal, installation, disassembly and assembly of the engine, see the Shop Manual, "Disassembly
and assembly".
a If the judgment of No. 9 is NO, examine A. If the result is NO again, examine B.
2 12V140E-3 Series
90 Repair and replacement of parts SEN05155-00
12V140E-3 Series 3
SEN05155-00 90 Repair and replacement of parts
4 12V140E-3 Series
90 Repair and replacement of parts SEN05155-00
Sym-
Replacement/Repair item Part No. Part name Q'ty Remarks
bol
1 79A-513-1710 Basic machine 1
2 79A-513-1780 Guide plate 1
3 79A-513-1820 Cutter plate 1
4 79A-513-1860 Cutter 1
5 79A-513-1940 Cutter set gauge 1
6 79A-513-1950 Micrometer 1
7 79A-513-1960 Driver plate 1
8 79A-513-2090 Driver shaft 1
9 79A-513-2110 Driver handle 1
10 79A-513-2120 Service package 1
Repair of counterbore portion N
11 79A-513-2130 Case 1
12 79A-513-2140 Basic machine 1
13 79A-513-2160 Cutter plate 1
14 79A-513-2230 Cutter 1
15 79A-513-2240 Remover pin 1
16 79A-513-2250 Case 1
17 79A-513-2260 Service package 1
18 79A-513-2270 Compound 1 LOCTITE
19 79A-513-2280 Primer 1 LOCTITE
20 79A-513-2320 Bushing 12
12V140E-3 Series 5
SEN05155-00 90 Repair and replacement of parts
© 2009 KOMATSU
All Rights Reserved
Printed in Japan 05-09 (02)
6 12V140E-3 Series
SEN05156-00
12V140E-3 Series
12V140E-3 Series 1
SEN05156-00 90 Repair and replacement of parts
1. Cylinder head
2. Crosshead guide
3. Valve guide
4. Valve seat insert (intake side)
5. Valve (intake valve)
6. Valve (exhaust valve)
7. Valve seat insert (exhaust side)
2 12V140E-3 Series
90 Repair and replacement of parts SEN05156-00
12V140E-3 Series 3
SEN05156-00 90 Repair and replacement of parts
Fig. A Fig. D
a: Projection e: Projection
1. Injector
2. Copper gasket Fig. E
3. Cylinder head
Fig. B
f: Projection
1. Crosshead guide
2. Cylinder head
b: Sink
Fig. C
4 12V140E-3 Series
90 Repair and replacement of parts SEN05156-00
2. Put the cylinder head in a water tub, apply air a Projection tolerance of valve guide:
pressure (0.29 – 0.34 MPa {3.0 – 3.5 kg/cm2} 22 ± 0.2 mm
for about 30 seconds, and check for air leak- a Diameter of cylinder head valve guide hoe:
age. ø17 +0.011/0 mm
12V140E-3 Series 5
SEN05156-00 90 Repair and replacement of parts
6 12V140E-3 Series
90 Repair and replacement of parts SEN05156-00
6. Push in 3 claws (10) of puller head (9) of tool D When pulling out valve seat insert (a) by weld-
with the hand and put them in valve seat insert ing a bar to it
(a). 1. Weld bar (b) (Length: 0.1 – 0.5 mm shorter
than valve seat inside diameter, Diameter:
7. Tighten screw (12) to press 3 claws (10) Approx. 10 mm) to the inside of valve seat
against the inside groove of valve seat insert insert (a).
(a). a Take care that welding spatters will not
a If screw (12) is tightened too strongly, the stick to the head.
insert will be broken and become difficult
to pull out. Accordingly, stop tightening 2. After the temperature of the welded parts has
when 3 claws (10) reach the groove fully. decreased to around the ambient temperature,
insert an unnecessary valve (c) in the reverse
8. Put bridge (8) in the outside of puller head (9), direction and hit its head with a small hammer
place plates (11) and (7) on the bridge, and to pull out valve seat insert (a).
tighten nut (6) to pull out valve seat insert (a). a If a large impact is given, the welded parts
may come off. Take care.
12V140E-3 Series 7
SEN05156-00 90 Repair and replacement of parts
8 12V140E-3 Series
90 Repair and replacement of parts SEN05156-00
12V140E-3 Series 9
SEN05156-00 90 Repair and replacement of parts
a OS: Oversize
a OS: Oversize
10 12V140E-3 Series
90 Repair and replacement of parts SEN05156-00
12V140E-3 Series 11
SEN05156-00 90 Repair and replacement of parts
2. Fit the contact surface of the valve seat insert Final inspection
to the valve by using compound. q Thinly apply red lead to the valve seat insert
1) Thinly apply rough compound mixed with contact surface of a new valve and insert that
oil to the seat surface of a valve and insert valve in the valve guide.
that valve in the valve guide. q Lightly press the valve against the valve seat
2) Install the fitting rod to the valve head and insert and rotate it 10°.
lightly hit valve against the valve seat q Check the valve seat insert contact surface of
while rotating it with both hands to fit the it the valve and ensure that the contact is even
to the valve seat. and is not broken.
3) After the valve and valve seat are fitted q Or , make marks (m) (about 20 places) on the
and their surfaces become smooth, wipe valve seat insert contact surface of a new
off the compound. valve with a pencil and insert that valve in the
4) Apply fine compound and fit the valve and valve guide.
valve seat again similarly to the above q Lightly press the valve against the valve seat
until they are fitted to each other without insert and rotate it 10°.
breakage. q Ensure that all the pencil marks (m) have been
erased evenly.
When master valve is used
12 12V140E-3 Series
90 Repair and replacement of parts SEN05156-00
12V140E-3 Series 13
SEN05156-00 90 Repair and replacement of parts
14 12V140E-3 Series
90 Repair and replacement of parts SEN05156-00
Repair of valve by grinding 1 a Apply dial gauge (1) to the facial runout mea-
suring point of seat contact surface (c) of the
a Valve grinding tool valve and rotate the valve to measure its facial
Symbol Part No. Part name runout while pressing it toward left (d).
Intake valve: Max. 0.045 mm (TIR)
Commercially
H Valve refacer Exhaust valve: Max. 0.030 mm (TIR)
available
a TIR is an abbreviation for Total Indicator Read-
ing, which is the difference between the maxi-
Grinding of seat contact surface of m u m an d m i n i m u m r e a d i ng s i n r u no u t .
valve measurement.
q Using tool H, grind the seat contact surface of
the valve.
e: Block
a Seat contact surface angle of valve (a) a Check the contact of the seat contact surface
Intake valve: 30° ± 0°15' of the valve by either of the following methods.
Exhaust valve: 45° ± 0°15' q Thinly apply red lead to the seat contact sur-
face of the ground valve and insert that valve
in the valve guide.
Check after grinding q Lightly press the valve against the valve seat
q Measure the valve head thickness, sinking insert and rotate it 10°.
quantity of the valve, and contact of the seat q Check the valve seat insert contact surface of
contact surface of the valve, and ensure that the valve and ensure that the contact is even
they are within the standard values. and is not broken.
a Allowable limit of valve head thickness (b) q Make marks (f) (about 20 places) on the seat
Intake valve: contact surface of the ground valve with a pen-
Min. 1.9 mm (Standard size: 2.4 mm) cil and insert that valve in the valve guide.
Exhaust valve: q Lightly press the valve against the valve seat
Min. 1.6 mm (Standard size: 2.15 mm) insert and rotate it 10°.
a Valve sinking quantity Standard: 0 ± 0.1 mm q Ensure that all the pencil marks (f) have been
Allowable limit: 0.7 mm erased evenly.
12V140E-3 Series 15
SEN05156-00 90 Repair and replacement of parts
© 2009 KOMATSU
All Rights Reserved
Printed in Japan 05-09 (02)
16 12V140E-3 Series
SEN05157-00
12V140E-3 Series
12V140E-3 Series 1
SEN05157-00 90 Repair and replacement of parts
2 12V140E-3 Series
90 Repair and replacement of parts SEN05157-00
1. Cylinder liner
2. Clevis seal
3. Cylinder liner O-ring
4. Cylinder block
5. Main bearing metal cap bolt
6. Main bearing metal cap
(No. 1, 2, 3, 5 and 6 are same)
7. Camshaft bushing
12V140E-3 Series 3
SEN05157-00 90 Repair and replacement of parts
4 12V140E-3 Series
90 Repair and replacement of parts SEN05157-00
Fig. A Fig. D
Fig. B Fig. E
Fig. C Fig. F
12V140E-3 Series 5
SEN05157-00 90 Repair and replacement of parts
Roundness 0.005
Straightness 0.010
Length Min. 1,300
i: Upper section
j: Lower section
6 12V140E-3 Series
90 Repair and replacement of parts SEN05157-00
1. Crankshaft
2. Main bearing metal (upper) (All other than No.
4 are the same)
3. Main bearing metal (lower) (All other than No.
4 are the same)
4. Thrust metal (All of upper x 1 and lower x 2 are
the same)
12V140E-3 Series 7
SEN05157-00 90 Repair and replacement of parts
a OS: Oversize
8 12V140E-3 Series
90 Repair and replacement of parts SEN05157-00
12V140E-3 Series 9
SEN05157-00 90 Repair and replacement of parts
Damage of bolt • Presence of crack and damage on threaded portion of bolt Replace bolt
• Presence of bend of bolt
a US: Undersize
a If all the items of this criteria (particularly the wave of the large end hole) cannot be measured after the
connecting rod is rebuilt, do not rebuild since the accuracy of the connecting rod large end hole after
rebuilding cannot be confirmed.
a When reusability is judged, if there are honing marks left on the inside of the connecting rod large end
hole, it is not required to measure the surface roughness of the inside and wave of the large end hole.
a Do not reuse the connecting rod cap mounting bolt more than 5 times.
Each time the bolt is used, make a punch mark on it.
10 12V140E-3 Series
90 Repair and replacement of parts SEN05157-00
Removal of gear
q Make a notch at the tooth bottom of the gear
with a grinder and break the gear to remove
with a chisel.
b: Inspection range
c: Streaks
d: Lengthwise direction
12V140E-3 Series 11
SEN05157-00 90 Repair and replacement of parts
Replacement of crankshaft gear 1 4. Using the drive tool, press fit the gear with the
timing mark out until its side is fitted with the
a Crankshaft gear replacement tools crankshaft flange.
Symbol Part No. Part name a Press fit the gear quickly before it cools
down.
1 790-101-2800 Bearing puller
K
2 790-101-2300 Push puller
Removal of gear
q Make a notch at the tooth bottom of the gear
with a grinder, assemble tools K1 and K2, and
rotate the nut to pull out the gear.
a If the gear cannot be pulled out by the above
method, make a notch at the tooth bottom of
the gear with a grinder, heat the gear with a
gas burner, and drive out the gear with a cop-
per rod etc.
a Take care not to damage the crankshaft.
12 12V140E-3 Series
90 Repair and replacement of parts SEN05157-00
Removal of gear
Set the camshaft assembly on the press stand and
press the camshaft to pull out the gear.
5. Using the drive tool, press fit the gear with the
timing mark out until its side is fitted with the
camshaft flange.
a Press fit the gear quickly before it cools
down.
12V140E-3 Series 13
SEN05157-00 90 Repair and replacement of parts
Replacement of main bearing 4. Apply dial gauges to the inside of the 2 main
bearing metal caps at the longest pitch among
metal cap 1 the caps to be used to center the arbor of the
a When replacing the main bearing metal cap, boring machine.
work on the semi-finished cap according to the
following procedure and install it. 5. While checking the inside diameter of main
bearing metal cap (1), cut little by little.
Repair parts a Cut to the degree that the boring bar tool
almost touches the inside of cylinder block
Part No. Part name
(2).
6215-99-4160 No. 1, 2, 3, 5, 6 main bearing metal cap a Inside diameter of main bearing metal cap
6215-99-4170 No. 4 main bearing metal cap q Machining dimension
6215-99-4180 No. 7 main bearing metal cap Tolerance: 157 +0.025/0 mm
q After machining, remove the main bearing
Inside machining of main bearing metal cap metal cap, assemble it again, and check
1. Remove the cylinder liner. its inside diameter.
Tolerance: 157 +0.025/–0.010 mm
2. Install the replacement main bearing metal cap (Range to upper and lower 10° from mat-
to the cylinder block and tighten it to the speci- ing face of main bearing metal cap)
fied torque. a Finished surface roughness: Max. 10 S
a Match the notches of the cylinder block a Do not cut the inside surface of the cylin-
and main bearing metal cap to each other. der block.
2 Main bearing metal cap mounting bolt:
Apply engine oil to threaded portion and
seat.
a Tighten with the angle tightening wrench
at the 3rd time.
3 Main bearing metal cap mounting bolt:
Unit: Nm {kgm}
Step Target Range
14 12V140E-3 Series
90 Repair and replacement of parts SEN05157-00
12V140E-3 Series 15
SEN05157-00 90 Repair and replacement of parts
a Connecting rod small end bushing replace- 2. Install the bushing to push tool (1), set push
ment tool tool (4), and fix them with nut (2).
Symbol Part No. Part name a Match the oil holes of the bushing and
connecting rod to each other.
L 795-240-6401 Push tool (KIT)
3. Drive push tool (1) with the press to press fit
Pulling out of bushing the bushing.
1. Set the connecting rod to block (3) of tool L. a Since the bushing is semi-finished, its
inside diameter is small and the piston pin
2. Using push tool (1) and nut, drive out the bus- does not go through it.
ing with the press. After press fitting the bushing, machine its
a After removing the bushing, remove sharp inside with a reamer or a honing machine
edges and burrs from and clean the bush- according to the maintenance standard.
ing mounting hole. a After machining, remove all the chips from
the oil hole and oil groove.
a The inside surface roughness of the
machined bushing must be maximum of
3.2 S.
16 12V140E-3 Series
90 Repair and replacement of parts SEN05157-00
Replacement of cam bushing 1 3. Pulling out of No. 3, No. 4 and No. 5 bushings
1) Assemble bar (1), push tool (2), collar (3)
a Cam bushing replacement tools and guide (4) .
Symbol Part No. Part name 2) While hitting bar (1), drive out the bushing
from the cylinder block.
M 795-213-1200 Push tool (KIT)
Removal
1. Pulling out of No. 1 and No. 7 bushings
1) Assemble push tool (2), collar (3) and bar
(1) of tool M.
2) While hitting bar (1), drive out the bushing
from the cylinder block.
12V140E-3 Series 17
SEN05157-00 90 Repair and replacement of parts
18 12V140E-3 Series
90 Repair and replacement of parts SEN05157-00
12V140E-3 Series 19
SEN05157-00 90 Repair and replacement of parts
20 12V140E-3 Series
90 Repair and replacement of parts SEN05157-00
Shims for adjusting counterbore depth (reference) q When grinding the counterbore portion, use
Unit: mm tool N.
12V140E-3 Series 21
SEN05157-00 90 Repair and replacement of parts
Q — OS
— Q SH
Q Q WS
22 12V140E-3 Series
90 Repair and replacement of parts SEN05157-00
1. Wipe off dirt, oil etc. from cylinder block top (c)
and the cylinder liner flange contact surface
with cloths.
3. Press fit cylinder liner to the cylinder block. 4. Set the cylinder liner to the cylinder block,
At this time, apply a little amount of rubber install the used head gasket, and tighten the
lubricant (RF-1) to cylinder block contact sur- cylinder head temporarily.
face (d) of the O-ring and seal of the cylinder At this time, tighten the bolts in the following
liner. order.
a Apply the engine oil just before press fit- 3 Tightening torque:
12V140E-3 Series 23
SEN05157-00 90 Repair and replacement of parts
24 12V140E-3 Series
90 Repair and replacement of parts SEN05157-00
1 ø167
2 ø161.45 ± 0.25
3 ø160.67 ± 0.064
4 176 ± 0.25
5 184.94 ± 0.18
6 ø158 +0.040
+0
12V140E-3 Series 25
SEN05157-00 90 Repair and replacement of parts
Repair of crankshaft by grinding 1 q Finish the oil holes of the main journal and pin
journal to the dimensions shown below.
q When the crankshaft is worn, seized or dam-
aged slightly and needs to be repaired, grind it Main journal portion
to one of the following undersizes.
Undersizes: 0.25, 0.50, 0.75, 1.00 mm
q If the crankshaft is bent or worn unevenly, it
should not be repaired but should be replaced.
(Repairing the crankshaft requires high tech-
nologies)
q Finish fillet portion (R), shoulder portion (r) and
area (R) around the hole of the crankshaft with
extreme care.
R2 3.5 –0
–0.5 3.2S
Main journal (b)
r2 6 —
26 12V140E-3 Series
90 Repair and replacement of parts SEN05157-00
12V140E-3 Series 27
SEN05157-00 90 Repair and replacement of parts
28 12V140E-3 Series
90 Repair and replacement of parts SEN05157-00
a OS: Oversize
q Squareness of thrust surface (TIR)
Tolerance: 0.02 mm
Allowable limit: 0.02 mm
a TIR is an abbreviation for Total Indicator Read-
ing, which is the difference between the maxi-
m u m a nd m i n i m u m r e a d i n gs i n r u n ou t .
measurement.
1.00 US 99.000
a US: Undersize
q Roundness, cylindricality (TIR) and surface
roughness of pin journal
Tolerance: Max. 0.010 mm
Allowable limit: 0.010 mm
Surface roughness: Max. 0.8 µm
12V140E-3 Series 29
SEN05157-00 90 Repair and replacement of parts
Grinding of sides of main journal and pin jour- Work after repair by grinding
nal q Ensure again that each dimension is as speci-
q When repairing the worn surfaces of the main fied.
journal and pin journal, limit the grinding quan- q Clean each part thoroughly and apply rust-pre-
tity to the minimum. ventive oil.
q Width of crankshaft main journal q When storing the crankshaft for a long period,
#1 standard: 57 +0.1/0 mm support it on 3 points or keep it erected with a
#2, 3, 5, 6 standard: 55 +0.1/0 mm sling.
#4 standard: 59 +0.1/0 mm
#7 standard: 59 +0.05/0 mm Balancing (Reference)
q Width of crankshaft pin journal Avoid performing repair that may affect the crank-
Standard: 92 +0.054/0 mm shaft balancing, as much as possible.
q Allowable limit of unbalance:
0.0098 Nm {100 g•cm}
q Limits for reading balance accurately
Bend of crankshaft: 0.07 mm (TIR)
Rotation speed of crankshaft: Max. 325 rpm
q Correct the balance by drilling holes in or grind
the counterweight, if necessary.
Drilling direction: Radial direction
Hole diameter: Max. 15 mm
Hole depth: Max. 50 mm
Number of holes: Max. 6/counterweight
Center of hole:
Match to the center of the counterweight.
(Deviation: Max. 0.5 mm)
Dressing of grinding stone
Distance between holes:
q Dress the grinding stone for each journal. Thickness must be at least 5 mm.
q Adjust the grinding stone edge to the arc of the a TIR is an abbreviation for Total Indicator Read-
fillet with the grinding stone modifying device. ing, which is the difference between the maxi-
q Test and correct the grinding stone edge by m u m an d m i n i m u m r e a d i ng s i n r u no u t .
grinding a piece of wood on trial, while check- measurement.
ing with ball gauges.
Finishing of surface
See "Improvement of surface roughness of crank-
shaft journal".
q Surface roughness standard (Pin journal and
main journal)
Journal surface: Max. 0.8S
Thrust surface: Max. 1.6S
End taper portions, boss portions and fillet por-
tions of pin and main journals: Max. 3.2S
q Polish finishing margin: 0.007 – 0.008 mm
30 12V140E-3 Series
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12V140E-3 Series 31
SEN05157-00 90 Repair and replacement of parts
32 12V140E-3 Series
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12V140E-3 Series 33
SEN05157-00 90 Repair and replacement of parts
34 12V140E-3 Series
90 Repair and replacement of parts SEN05157-00
12V140E-3 Series 35
SEN05157-00 90 Repair and replacement of parts
© 2009 KOMATSU
All Rights Reserved
Printed in Japan 05-09 (02)
36 12V140E-3 Series