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SEN00291-15

ENGINE

12V140E -3 SERIES

SEN00294-15

ENGINE 1SHOP MANUAL

12V140E-3 Series

00 Index and foreword

Index Composition of shop manual .......................................................................................................................... 2 Table of contents ............................................................................................................................................. 3

12V140E-3 Series

SEN00294-15

00 Index and foreword

Composition of shop manual

The contents of this shop manual are shown together with Form No. in a list. Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly. The marks shown to the right of Form No. denote the following: Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.) Note 2: This shop manual can be supplied for each Form No. Note 3: To file this shop manual in the special binder for management, handle it as follows: • Place a divider on the top of each section in the file after matching the Tub No. with No. indicated next to each Section Name shown in the table below: • File overview and other materials in sections in the order shown below and utilize them accordingly. Section Title

Form Number

Shop Manual, contents binder, binder label and tabs

SEN00291-15

00 Index and foreword Index Foreword and general information

SEN00292-15 SEN00294-15 q SEN00296-04

01 Specification Specification and technical data

SEN00301-03 SEN00303-03

10 Structure, function and maintenance standard Structure, function and maintenance standard, Part 1 Structure, function and maintenance standard, Part 2

SEN00304-06 SEN00307-05 SEN00309-04

20 Standard value table Standard service value table

SEN00310-03 SEN00311-03

30 Testing and adjusting Testing and adjusting

SEN00312-04 SEN00313-04

40 Troubleshooting General information on troubleshooting Troubleshooting of mechanical system (S-mode) Troubleshooting of electrical system (E-mode), Part 1 Troubleshooting of electrical system (E-mode), Part 2

SEN00314-04 SEN00315-01 SEN00316-01 SEN00317-03 SEN00318-03

50 Disassembly and assembly General information on disassembly and assembly Disassembly and assembly, Part 1 Disassembly and assembly, Part 2 Disassembly and assembly, Part 3

SEN00319-05 SEN00320-03 SEN00321-01 SEN00322-05 q SEN00876-03

90 Repair and replacement of parts Information related to repair and replacement Parts related to cylinder head Parts related to cylinder block

SEN05154-02 SEN05155-00 SEN05156-01 SEN05157-01 q

12V140E-3 Series

00 Index and foreword

SEN00294-15

Table of contents

00 Index and foreword Index SEN00294-15 2 Composition of shop manual....................................................................................................... Table of contents ......................................................................................................................... 3 Foreword and general information SEN00296-04 2 Safety notice ............................................................................................................................... How to read the shop manual ..................................................................................................... 7 Explanation of terms for maintenance standard.......................................................................... 9 Handling of electric equipment and hydraulic component........................................................... 11 Handling of connectors newly used for engines.......................................................................... 20 How to read electric wire code .................................................................................................... 23 Precautions when carrying out operation.................................................................................... 26 Method of disassembling and connecting push-pull type coupler............................................... 29 Standard tightening torque table ................................................................................................. 32 Conversion table ......................................................................................................................... 36 01 Specification Specification and technical data SEN00303-03 2 Outline......................................................................................................................................... 4 Specifications .............................................................................................................................. General view ............................................................................................................................... 10 Weight table ................................................................................................................................ 19 Engine performance curves ........................................................................................................ 20 10 Structure, function and maintenance standard Structure, function and maintenance standard, Part 1 SEN00307-05 3 Air intake and exhaust unit.......................................................................................................... 4 Air cleaner ................................................................................................................................... Turbocharger............................................................................................................................... 6 Aftercooler ................................................................................................................................... 11 Muffler ......................................................................................................................................... 12 Cylinder head .............................................................................................................................. 14 Cylinder block.............................................................................................................................. 18 Cylinder liner ............................................................................................................................... 22 Main moving parts ....................................................................................................................... 24 Crankshaft................................................................................................................................... 26 Camshaft ..................................................................................................................................... 28 Cam follower and push rod ......................................................................................................... 29 Piston, piston ring, and piston pin ............................................................................................... 30 Connecting rod............................................................................................................................ 32 Flywheel and flywheel housing ................................................................................................... 34 Vibration damper ......................................................................................................................... 35 Timing gear ................................................................................................................................. 36 Valve system ............................................................................................................................... 38 Valve and valve guide ................................................................................................................. 40 Rocker arm and shaft .................................................................................................................. 42 Crosshead and guide .................................................................................................................. 43 Structure, function and maintenance standard, Part 2 SEN00309-04 4 Lubrication system ...................................................................................................................... 12V140E-3 Series

SEN00294-15

00 Index and foreword

Lubrication system diagram..................................................................................................... Oil pump .................................................................................................................................. Oil cooler.................................................................................................................................. Oil filter..................................................................................................................................... Main relief valve....................................................................................................................... Oil cooler bypass valve and regulator valve ............................................................................ Fuel system ................................................................................................................................. CRI system diagram ................................................................................................................ CRI system diagram (Poor fuel spec.)..................................................................................... Outline of CRI system.............................................................................................................. Fuel piping ............................................................................................................................... Fuel piping (Poor fuel spec.).................................................................................................... Fuel filter .................................................................................................................................. Water separator ....................................................................................................................... Priming pump........................................................................................................................... Electric priming pump .............................................................................................................. Cooling system............................................................................................................................ Cooling system diagram .......................................................................................................... Water pump ............................................................................................................................. Thermostat............................................................................................................................... Corrosion resistor .................................................................................................................... Cooling fan drive...................................................................................................................... Electrical equipment .................................................................................................................... Alternator ................................................................................................................................. Starting motor .......................................................................................................................... Starting aid............................................................................................................................... Engine controller...................................................................................................................... Engine controller cooler ...........................................................................................................

4 6 7 8 9 10 12 12 14 16 34 39 44 46 47 48 50 50 52 54 55 57 60 60 62 64 67 68

20 Standard value table Standard service value table SEN00311-03 2 Standard service value table ....................................................................................................... Standard service value table for testing, adjusting, and troubleshooting ................................. 2 7 Running-in standard and performance test standard .............................................................. 30 Testing and adjusting Testing and adjusting SEN00313-04 3 Testing and adjusting tools list..................................................................................................... 5 Testing air boost pressure ........................................................................................................... Testing exhaust temperature ....................................................................................................... 6 7 Adjusting valve clearance............................................................................................................ Testing compression pressure..................................................................................................... 9 Testing blow-by pressure............................................................................................................. 11 Testing oil pressure ..................................................................................................................... 12 Handling fuel system parts .......................................................................................................... 13 Releasing residual pressure in fuel system................................................................................. 13 Testing fuel pressure ................................................................................................................... 14 Reduced cylinder mode operation............................................................................................... 15 No-injection cranking................................................................................................................... 15 Testing leakage-from pressure limiter and return rate from injector ............................................ 16 Bleeding air from fuel circuit (for D475A-5) ................................................................................. 19 Bleeding air from fuel circuit (for PC2000) .................................................................................. 22 Bleeding air from fuel circuit (Poor fuel spec.)............................................................................. 24 Testing fuel system for leakage ................................................................................................... 26 Adjusting speed sensor ............................................................................................................... 27 Testing and adjusting alternator belt tension ............................................................................... 27 Handling controller high-voltage circuit ....................................................................................... 28

12V140E-3 Series

00 Index and foreword

SEN00294-15

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 Troubleshooting of mechanical system (S-mode) SEN00316-01 Method of using troubleshooting charts ...................................................................................... 3 S-1 Starting performance is poor ................................................................................................ 6 7 S-2 Engine does not start............................................................................................................ 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 S-14 Coolant temperature becomes too high (overheating) ....................................................... 22 S-15 Abnormal noise is made ..................................................................................................... 23 S-16 Vibration is excessive ......................................................................................................... 24 Troubleshooting of electrical system (E-mode), Part 1 SEN00317-03 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 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

12V140E-3 Series

SEN00294-15

00 Index and foreword

E-25 Code [238/CB238] Ne Speed Sensor Sup. Volt. Error (RH bank) ...................................... E-26 Code [263/CA263] Fuel Temp. Sensor High Error (LH bank)............................................. E-27 Code [263/CB263] Fuel Temp. Sensor High Error (RH bank) ............................................ E-28 Code [265/CA265] Fuel Temp. Sensor Low Error (LH bank).............................................. E-29 Code [265/CB265] Fuel Temp. Sensor Low Error (RH bank) ............................................. E-30 Code [271/CA271] PCV1 Short Error (LH bank) ................................................................ E-31 Code [271/CB271] PCV1 Short Error (RH bank)................................................................ E-32 Code [272/CA272] PCV1 Open Error (LH bank) ................................................................ E-33 Code [272/CB272] PCV1 Open Error (RH bank)................................................................ E-34 Code [273/CA273] PCV2 Short Error (LH bank) ................................................................ E-35 Code [273/CB273] PCV2 Short Error (RH bank)................................................................ E-36 Code [274/CA274] PCV2 Open Error (LH bank) ................................................................ E-37 Code [274/CB274] PCV2 Open Error (RH bank)................................................................ E-38 Code [322/CA322] Injector #1 (L/B #1) System Open/Short Error (LH bank) .................... E-39 Code [323/CA323] Injector #5 (L/B #5) System Open/Short Error (LH bank) .................... E-40 Code [324/CA324] Injector #3 (L/B #3) System Open/Short Error (LH bank) .................... E-41 Code [325/CA325] Injector #6 (L/B #6) System Open/Short Error (LH bank) .................... E-42 Code [331/CA331] Injector #2 (L/B #2) System Open/Short Error (LH bank) .................... E-43 Code [332/CA332] Injector #4 (L/B #4) System Open/Short Error (LH bank) .................... E-44 Code [342/CA342] Caribration Code Incompatibility (LH bank) ......................................... E-45 Code [342/CB342] Caribration Code Incompatibility (RH bank) ......................................... E-46 Code [351/CA351] INJ. Drive Circuit Error (LH bank) ........................................................ E-47 Code [351/CB351] INJ. Drive Circuit Error (RH bank)........................................................ E-48 Code [352/CA352] Sensor Sup. 1 Volt. Low Error (LH bank) ............................................. E-49 Code [352/CB352] Sensor Sup. 1 Volt. Low Error (RH bank) ............................................ E-50 Code [386/CA386] Sensor Sup. 1 Volt. High Error (LH bank) ............................................ E-51 Code [386/CB386] Sensor Sup. 1 Volt. High Error (RH bank)............................................ E-52 Code [441/CA441] Battery Voltage Low Error (LH bank) ................................................... E-53 Code [441/CB441] Battery Voltage Low Error (RH bank)................................................... E-54 Code [442/CA442] Battery Voltage High Error (LH bank)................................................... E-55 Code [442/CB442] Battery Voltage High Error (RH bank) ..................................................

44 46 48 50 50 52 54 56 57 58 60 62 63 64 66 68 70 72 74 76 76 78 80 82 82 84 86 88 88 89 89

Troubleshooting of electrical system (E-mode), Part 2 SEN00318-03 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 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

12V140E-3 Series

00 Index and foreword

SEN00294-15

E-76 Code [778/CA778] Eng. G (Bkup) Speed Sensor Error (LH bank)..................................... E-77 Code [778/CB778] Eng. G (Bkup) Speed Sensor Error (RH bank) .................................... E-78 Code [781/CA781] Inter Multi-controller Communication Error (LH bank) ......................... E-79 Code [781/CB781] Inter Multi-controller Communication Error (RH bank) ......................... E-80 Code [1117/CA1117] Persistent Data Lost Error (LH bank) ................................................ E-81 Code [1117/CB1117] Persistent Data Lost Error (RH bank) ............................................... E-82 Code [1257/CA1257] Harness Key error (LH bank) ........................................................... E-83 Code [1257/CB1257] Harness Key error (RH bank) .......................................................... E-84 Code [1548/CB1548] Injector #7 (R/B #1) System Open/Short Error (RH bank) ............... E-85 Code [1549/CB1549] Injector #8 (R/B #2) System Open/Short Error (RH bank) ............... E-86 Code [1551/CB1551] Injector #10 (R/B #4) System Open/Short Error (RH bank) ............. E-87 Code [1552/CB1552] Injector #11 (R/B #5) System Open/Short Error (RH bank) ............. E-88 Code [1553/CB1553] Injector #12 (R/B #6) System Open/Short Error (RH bank) ............. E-89 Code [1622/CB1622] Injector #9 (R/B #3) System Open/Short Error (RH bank) ............... E-90 Code [1633/CA1633] KOMNET Datalink Timeout Error (LH bank) .................................... E-91 Code [2185/CA2185] Throttle Sens. Sup. Volt. High Error (LH bank only) ........................ E-92 Code [2186/CA2186] Throttle Sens. Sup. Volt. Low Error (LH bank only) ......................... E-93 Code [2249/CA2249] Rail Press. Very Low Error (LH bank) .............................................. E-94 Code [2249/CB2249] Rail Press. Very Low Error (RH bank) ............................................. E-95 Code [– –*1/–] Eng. Overheat (LH bank only) .................................................................... E-96 Code [– –*2/–] Eng. Oil Press. Low Speed Derate (LH bank only)..................................... E-97 Code [– –*3/–] Press. Low Torque Derate (LH bank only)..................................................

30 32 34 36 37 37 38 39 40 42 44 46 48 50 52 54 56 57 57 58 58 59

50 Disassembly and assembly General information on disassembly and assembly SEN00320-03 2 How to read this manual ............................................................................................................. Coating materials list................................................................................................................... 4 7 Special tools list........................................................................................................................... 9 Sketches of special tools............................................................................................................. Disassembly and assembly, Part 1 SEN00321-01 General disassembly of engine................................................................................................... 2 Disassembly and assembly, Part 2 SEN00322-05 General assembly of engine ....................................................................................................... 2 Disassembly and assembly, Part 3 SEN00876-03 Removal and installation fuel supply pump unit .......................................................................... 2 Removal and installation oil seal unit .......................................................................................... 5 90 Repair and replacement of parts Information related to repair and replacement SEN05155-00 2 Flowchart..................................................................................................................................... 4 Special tool table ......................................................................................................................... Parts related to cylinder head SEN05156-01 Part names related to cylinder head ........................................................................................... 2 Testing and inspection of cylinder head ...................................................................................... 3 5 Pressure test of cylinder head..................................................................................................... Replacement of valve guide........................................................................................................ 5 6 Replacement of valve seat insert ................................................................................................ Replacement of crosshead guide................................................................................................ 13 Repair of cylinder head mounting face by grinding ..................................................................... 14 Repair of valve by grinding.......................................................................................................... 15

12V140E-3 Series

SEN00294-15

00 Index and foreword

Parts related to cylinder block SEN05157-01 Part names related to cylinder block ........................................................................................... 3 Testing and inspection of cylinder block ...................................................................................... 4 Part names related to crankshaft ................................................................................................ 7 Testing and inspection of crankshaft ........................................................................................... 8 Part names related to connecting rod ......................................................................................... 9 Testing and inspection of connecting rod .................................................................................... 10 Replacement of flywheel ring gear .............................................................................................. 11 Replacement of crankshaft gear ................................................................................................. 12 Replacement of camshaft gear ................................................................................................... 13 Replacement of main bearing metal cap..................................................................................... 14 Replacement of connecting rod small end bushing..................................................................... 16 Replacement of cam bushing...................................................................................................... 17 Repair of cylinder block top by grinding ...................................................................................... 19 Repair of counterbore by grinding ............................................................................................... 20 Check and identification after repair by grinding ......................................................................... 22 Gasket sealant application procedure ......................................................................................... 23 Repair standard for cylinder liner O-ring ..................................................................................... 25 Repair of crankshaft by grinding.................................................................................................. 26 Improvement of surface roughness of crankshaft journal ........................................................... 32

12V140E-3 Series

00 Index and foreword

12V140E-3 Series

SEN00294-15

00 Index and foreword

KOMATSU 12V140E-3 Series engine Form No. SEN00294-15 

12V140E-3 Series

SEN00296-04

ENGINE 1SHOP MANUAL

12V140E-3 Series

00 Index and foreword

Foreword and general information Safety notice ................................................................................................................................................... 2 How to read the shop manual ......................................................................................................................... 7 Explanation of terms for maintenance standard ............................................................................................. 9 Handling of electric equipment and hydraulic component .............................................................................11 Handling of connectors newly used for engines ........................................................................................... 20 How to read electric wire code...................................................................................................................... 23 Precautions when carrying out operation...................................................................................................... 26 Method of disassembling and connecting push-pull type coupler................................................................. 29 Standard tightening torque table ................................................................................................................... 32 Conversion table ........................................................................................................................................... 36

12V140E-3 Series

SEN00296-04

00 Index and foreword

Safety notice

(Rev. 2008/08) 1

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 situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation. 1.

General precautions k Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully before operating the machine. In addition, read this manual and understand its contents before starting the work. 1) Before carrying out any greasing or repairs, read all the safety labels stuck to the machine. For the locations of the safety labels and detailed explanation of precautions, see the Operation and Maintenance Manual. 2) Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt, water, or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working. 3) When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. q Always wear safety glasses when hitting parts with a hammer. q Always wear safety glasses when grinding parts with a grinder, etc. 4) When carrying out any operation with 2 or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR warning signs in the operator's compartment. 5) Only qualified workers must carry out work and operation which require license or qualification. 6) Keep all tools in good condition, learn the correct way to use them, and use the proper ones of them. Before starting work, thoroughly check the tools, machine, forklift, service car, etc.

8) 9)

If welding repairs are needed, always have a trained and experienced welder carry out the work. When carrying out weld in g wo rk , al way s wear wel din g gloves, apron, shielding goggles, cap and other clothes suited for welding work. Before starting work, warm up your body thoroughly to start work under good condition. Avoid continuing work for long hours and take rests at proper intervals to keep your body in good condition. Take rests in specified safe places.

Safety points 1 Good arrangement 2 Correct work clothes 3 Following work standard 4 Making and checking signs 5

Prohibition of operation and handling by unlicensed workers

6 Safety check before starting work 7

Wearing protective goggles (for cleaning or grinding work)

Wearing shielding goggles and protectors (for welding work)

9 Good physical condition and preparation 10

Precautions against work which you are not used to or you are used to too much

12V140E-3 Series

00 Index and foreword

Preparations for work 1) Before adding oil or making any repairs, park the machine on a hard and level ground, and apply the parking brake and block the wheels or tracks to prevent the machine from moving. 2) Before starting work, lower the work equipment (blade, ripper, bucket, etc.) to the ground. If this is not possible, insert the lock pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them. 3) When disassembling or assembling, support the machine with blocks, jacks, or stands before starting work. 4) Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the m a c h i n e . N e v e r j u m p o n o r o ff t h e machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.

Precautions during work 1) Before disconnecting or removing components of the oil, water, or air circuits, first release the pressure completely from the circuit. When removing the oil filler cap, a drain plug, or an oil pressure pickup plug, loosen it slowly to prevent the oil from spurting out. 2) The coolant and oil in the circuits are hot when the engine is stopped, so be careful not to get scalded. Wait for the oil and coolant to cool before carrying out any work on the oil or water circuits. 3) Before starting work, stop the engine. When working on or around a rotating part, in particular, stop the engine. When checking the machine without stopping the engine (measuring oil pressure, revolving speed, temperature, etc.), take extreme care not to get rolled or caught in rotating parts or moving parts. 4) Before starting work, remove the leads from the battery. Always remove the lead from the negative (–) terminal first. 5) When raising a heavy component (heavier than 25 kg), use a hoist or crane. Before starting work, check that the slings (wire ropes, chains, and hooks) are free from damage. Always use slings which have ample capacity and install them to proper places. Operate the hoist or crane slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane.

12V140E-3 Series

SEN00296-04

When removing a cover which is under internal pressure or under pressure from a spring, always leave 2 bolts in diagonal positions. Loosen those bolts gradually and alternately to release the pressure, and then remove the cover. 7) When removing components, be careful not to break or damage the electrical wiring. Damaged wiring may cause electrical fires. 8) When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips onto the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip and can even start fires. 9) As a general rule, do not use gasoline to wash parts. Do not use it to clean electrical parts, in particular. 10) Be sure to assemble all parts again in their original places. Replace any damaged parts and parts which must not be reused with new parts. When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is operated. 11) When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits. In addition, check t h a t c o n n e c t i n g pa r ts a r e c o r r e c t l y installed. 12) When assembling or installing parts, always tighten them to the specified torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particul a r ly c a r e fu l t o c he c k t h a t t h e y ar e installed correctly. 13) When aligning 2 holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. 14) When measuring hydraulic pressure, check that the measuring tools are correctly assembled. 15) Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates suddenly, so never let anyone stand at either end of the track. 16) If the engine is operated for a long time in a place which is not ventilated well, you may suffer from gas poisoning. Accordingly, open the windows and doors to ventilate well.

SEN00296-04

Precautions for sling work and making signs 1) Only one appointed worker must make signs and co-workers must communicate with each other frequently. The appointed sign maker must make specified signs clearly at a place where he is well seen from the operator's seat and where he can see the working condition easily. The sign maker must always stand in front of the load and guide the operator safely. q Do not stand under the load. q Do not step on the load. 2) Check the slings before starting sling work. 3) Keep putting on gloves during sling work. (Put on leather gloves, if available.) 4) Measure the weight of the load by the eye and check its center of gravity. 5) Use proper sling according to the weight of the load and method of slinging. If too thick wire ropes are used to sling a light load, the load may slip and fall. 6) Do not sling a load with 1 wire rope alone. If it is slung so, it may rotate and may slip out of the rope. Install 2 or more wire ropes symmetrically. k Slinging with 1 rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident. 7) Limit the hanging angle to 60°, as a rule. Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with 2 or more ropes, the force subjected to each rope will increase with the hanging angle. The table below shows the variation of allowable load in kN {kg} when hoisting is made with 2 ropes, each of which is allowed to sling up to 9.8 kN {1,000 kg} vertically, at various hanging angles. When the 2 ropes sling a load vertically, up to 19.6 kN {2,000 kg} of total weight can be suspended. This weight is reduced to 9.8 kN {1,000 kg} when the 2 ropes make a hanging angle of 120°. If the 2 ropes sling a 19.6 kN {2,000 kg} load at a lifting angle of 150°, each of them is subjected to a force as large as 39.2 kN {4,000 kg}.

00 Index and foreword

When installing wire ropes to an angular load, apply pads to protect the wire ropes. If the load is slippery, apply proper material to prevent the wire rope from slipping. 9) Use the specified eyebolts and fix wire ropes, chains, etc. to them with shackles, etc. 10) Apply wire ropes to the middle portion of the hook. q Slinging near the tip of the hook may cause the rope to slip off the hook during hoisting. The hook has the maximum strength at the middle portion.

11) Do not use twisted or kinked wire ropes. 12) When lifting up a load, observe the following. q Wind in the crane slowly until wire ropes are stretched. When settling the wire ropes with the hand, do not grasp them but press them from above. If you grasp them, your fingers may be caught. q After the wire ropes are stretched, stop the crane and check the condition of the slung load, wire ropes, and pads.

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If the load is unstable or the wire rope or chains are twisted, lower the load and lift it up again. q Do not lift up the load slantingly. 13) When lifting down a load, observe the following. q When lifting down a load, stop it temporarily at 30 cm above the floor, and then lower it slowly. q Check that the load is stable, and then remove the sling. q Remove kinks and dirt from the wire ropes and chains used for the sling work, and put them in the specified place.

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13) If the hoist stops because of a power failure, turn the power switch OFF. When turning on a switch which was turned OFF by the electric shock prevention earth leakage breaker, check that the devices related to that switch are not in operation state. 14) If you find an obstacle around the hoist, stop the operation. 15) After finishing the work, stop the hoist at the specified position and raise the hook to at least 2 m above the floor. Do not leave the sling installed to the hook.

Precautions for using mobile crane a Read the Operation and Maintenance Manual of the crane carefully in advance and operate the crane safely. Precautions for using overhead hoist crane k When raising a heavy part (heavier than 25 kg), use a hoist, etc. In Disassembly and assembly, the weight of a part heavier than 25 kg is indicated after the mark of 4. 1) Before starting work, inspect the wire ropes, brake, clutch, controller, rails, over wind stop device, electric shock prevention earth leakage breaker, crane collision prevention device, and power application warning lamp, and check safety. 2) Observe the signs for sling work. 3) Operate the hoist at a safe place. 4) Check the direction indicator plates (east, west, south, and north) and the directions of the control buttons without fail. 5) Do not sling a load slantingly. Do not move the crane while the slung load is swinging. 6) Do not raise or lower a load while the 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 immediately in an emergency.

12V140E-3 Series

Selecting wire ropes 1) Select adequate ropes depending on the weight of parts to be hoisted, referring to the table below.

Wire ropes (Standard “Z” twist ropes without galvanizing) (JIS G3525, No. 6, Type 6X37-A) Nominal Allowable load diameter of rope mm kN ton 10 8.8 0.9 12 12.7 1.3 14 17.3 1.7 16 22.6 2.3 18 28.6 2.9 20 35.3 3.6 25 55.3 5.6 30 79.6 8.1 40 141.6 14.4 50 221.6 22.6 60 318.3 32.4

The allowable load is one-sixth of the breaking strength of the rope used (Safety coefficient: 6).

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Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit 1) Disconnection k For the environment, the air conditioner 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 disconnecting the refrigerant gas circuit and then reuse it. a Ask professional traders for collecting and filling operation of refrigerant (R134a). 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 recovering or adding the refrigerant. Refrigerant gas must be recovered and added by a qualified person. 2)

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Example of O-ring (Fitted to every joint of hoses and tubes)

For tightening torque, see the precautions for installation in each section of "Disassembly and assembly".

Connection 1] When installing the air conditioner circuit 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 damaged or deteriorated. 4] When connecting the refrigerant piping, apply compressor oil for refrigerant (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.

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How to read the shop manual q q q

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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. Materials and specifications are subject to change without notice. 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. Composition of shop manual This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections. 00. Index and foreword This section explains the shop manuals list, table of contents, safety, and basic information. 01. Specification This section explains the specifications of the machine. 10. Structure, function and maintenance standard This section explains the structure, function, and maintenance standard values of each component. The structure and function sub-section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. The maintenance standard sub-section explains the criteria and remedies for disassembly and service. 20. Standard value table This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting. 30. Testing and adjusting This section explains measuring instruments and measuring methods for testing and adjusting, and method of adjusting each part. The standard values and judgement criteria for testing and adjusting are explained in Testing and adjusting. 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. 50. Disassembly and assembly This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque and quantity and weight of coating material, oil, grease, and coolant necessary for the work are also explained. 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.

Revision and distribution Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most up-to-date information before you start any work.

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Filing method File by the brochures in the correct order of the form number printed in the shop manual composition table. q

Revised edition mark When a manual is revised, the ones and tens digits of the form number of each brochure is increased by 1. (Example: 00, 01, 02 …)

Revisions Revised brochures are shown in the shop manual composition table.

Symbols Important safety and quality portions are marked with the following symbols so that the shop manual will be used practically. Symbol

Item

Safety

Special safety precautions are necessary when performing work.

Caution

Special technical precautions or other precautions for preserving standards are necessary when performing work.

Weight

Weight of parts of component or parts. Caution necessary when selecting hoisting wire, or when working posture is important, etc.

Tightening torque

Places that require special attention for tightening torque during assembly.

Coat

Oil, coolant

Drain

Remarks

Places to be coated with adhesives, etc. during assembly. Places where oil, etc. must be added, and capacity. Places where oil, etc. must be drained, and quantity to be drained.

Units In this shop manual, the units are indicated with International System of units (SI). For reference, conventionally used Gravitational System of units is indicated in parentheses { }.

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Explanation of terms for maintenance standard

The maintenance standard chapter explains the criteria for replacing or reusing products and parts in the machine maintenance work. The following terms are used to explain the criteria. 1.

Standard size and tolerance To be accurate, the finishing size of parts is a little different from one to another. q To specify a finishing size of a part, a temporary standard size is set and an allowable difference from that size is indicated. q The above size set temporarily is called the “standard size” and the range of difference from the standard size is called the “tolerance”. q The tolerance with the symbols of + or – is indicated on the right side of the standard size. q

Example: Standard size 120

Tolerance –0.022 –0.126

The tolerance may be indicated in the text and a table as [standard size (upper limit of tolerance/lower limit of tolerance)]. Example) 120 (–0.022/–0.126)

Usually, the size of a hole and the size of the shaft to be fitted to that hole are indicated by the same standard size and different tolerances of the hole and shaft. The tightness of fit is decided by the tolerance. Indication of size of rotating shaft and hole and relationship drawing of them

Example: Standard size 60

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Tolerance Shaft Hole –0.030 +0.046 –0.076 +0

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Standard clearance and standard value The clearance made when new parts are assembled is called the “standard clearance“, which is indicated by the range from the minimum clearance to the maximum clearance. q When some parts are repaired, the clearance is generally adjusted to the standard clearance. q A value of performance and function of new products or equivalent is called the “standard value“, which is indicated by a range or a target value. q When some parts are repaired, the value of performance/function is set to the standard value.

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Standard interference q When the diameter of a hole of a part shown in the given standard size and tolerance table is smaller than that of the mating shaft, the difference between those diameters is called the “interference”. q The range (A – B) from the difference (A) between the minimum size of the shaft and the maximum size of the hole to the difference (B) between the maximum size of the shaft and the minimum size of the hole is the “standard interference”. q After repairing or replacing some parts, measure the size of their hole and shaft and check that the interference is in the standard range.

Repair limit and allowable value or allowable dimension q The size of a part changes because of wear and deformation while it is used. The limit of changed size is called the “repair limit”. q If a part is worn to the repair limit, it must be replaced or repaired. q The performance and function of a product lowers while it is used. A value which the product can be used without causing a problem is called the “allowable value” or “allowable dimension”. q If a product is worn to the allowable value, it must be checked or repaired. Since the permissible value is estimated from various tests or experiences in most cases, however, it must be judged after considering the operating condition and customer's requirement.

Clearance limit Parts can be used until the clearance between them is increased to a certain limit. The limit at which those parts cannot be used is called the “clearance limit”. q If the clearance between the parts exceeds the clearance limit, they must be replaced or repaired. q

Interference limit The allowable maximum interference between the hole of a part and the shaft of another part to be assembled is called the “interference limit”. q The interference limit shows the repair limit of the part of smaller tolerance. q If the interference between the parts exceeds the interference limit, they must be replaced or repaired. q

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Handling of electric equipment and hydraulic component

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To maintain the performance of the machine over a long period, and to prevent failures or other troubles before they occur, correct “operation“, “maintenance and inspection“, “troubleshooting“, and “repairs” must be carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at improving the quality of repairs. For this purpose, it gives sections on “Handling electric equipment” and “Handling hydraulic equipment” (particularly gear oil and hydraulic oil). Points to remember when handling electric equipment 1. Handling wiring harnesses and connectors Wiring harnesses consist of wiring connecting one component to another component, connectors used for connecting and disconnecting one wire from another wire, and protectors or tubes used for protecting the wiring. Compared with other electrical components fitted in boxes or cases, wiring harnesses are more likely to be affected by the direct effects of rain, water, heat, or vibration. Furthermore, during inspection and repair operations, they are frequently removed and installed again, so they are likely to suffer deformation or damage. For this reason, it is necessary to be extremely careful when handling wiring harnesses. 2.

Main failures occurring in wiring harness 1) Defective contact of connectors (defective contact between male and female) Problems with defective contact are likely to occur because the male connector is not properly inserted into the female connector, or because one or both of the connectors is deformed or the position is not correctly aligned, or because there is corrosion or oxidization of the contact surfaces. The corroded or oxidized contact surfaces may become shiny again (and contact may become normal) by connecting and disconnecting the connector about 10 times. 2)

Defective crimping or soldering of connectors The pins of the male and female connectors are in contact at the crimped terminal or soldered portion, but if there is excessive force brought to bear on the wiring, the plating at the joint will peel and cause improper connection or breakage.

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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 soldering may be damaged, or the wiring may be broken.

High-pressure water entering connector The connector is designed to make it difficult for water to enter (drip-proof structure), but if high-pressure water is sprayed directly on the connector, water may enter the connector, depending on the direction of the water jet. Accordingly, take care not to splash water over the connector. The connector is designed to prevent water from entering, but at the same time, if water does enter, it is difficult for it to be drained. Therefore, if water should get into the connector, the pins will be short-circuited by the water, so if any water gets in, immediately dry the connector or take other appropriate action before passing electricity through it.

Oil or dirt stuck to connector If oil or grease are stuck to the connector and an oil film is formed on the mating surface between the male and female pins, the oil will not let the electricity pass, so there will be defective contact. If there is oil or grease stuck to the connector, wipe it off with a dry cloth or blow it dry with compressed air and spray it with a contact restorer. a When wiping the mating portion of the connector, be careful not to use excessive force or deform the pins. a If there is oil or water in the compressed air, the contacts will become even dirtier, so remove the oil and water from the compressed air completely before cleaning with compressed air.

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Removing, installing, and drying connectors and wiring harnesses 1) Disconnecting connectors 1] Hold the connectors when disconnecting. When disconnecting the connectors, hold the connectors. For connectors held by a screw, loosen the screw fully, then hold the male and female connectors in each hand and pull apart. For connectors which have a lock stopper, press down the stopper with your thumb and pull the connectors apart. a Never pull with one hand. 2] q

When removing from clips Both of the connector and clip have stoppers, which are engaged with each other when the connector is installed.

When removing a connector from a clip, pull the connector in a parallel direction to the clip for removing stoppers. a If the connector is twisted up and down or to the left or right, the housing may break.

Action to take after removing connectors After removing any connector, cover it with a vinyl bag to prevent any dust, dirt, oil, or water from getting in the connector portion. a If the machine is left disassembled for a long time, it is particularly easy for improper contact to occur, so always cover the connector.

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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 damage to the connector pins. Check that there is no damage or breakage to the outside of the connector. 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 breakage, 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 stopper clicks into position. 3] Correct any protrusion of the boot and any misalignment of the wiring harness. For connectors fitted with boots, correct any protrusion of the boot. In addition, if the wiring harness is misaligned, or the clamp is out of position, adjust it to its correct position. a If the connector cannot be corrected 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.

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Heavy duty wire connector (DT 8-pole, 12pole) 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) horizontally 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

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Disconnection

Connection (Example of incomplete setting of (a))

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Drying wiring harness If there is any oil or dirt on the wiring harness, wipe it off with a dry cloth. Avoid washing it in water or using steam. If the connector must be washed in water, do not use high-pressure water or steam directly on the wiring harness. If water gets directly on the connector, do as follows. 1] Disconnect the connector and wipe off the water with a dry cloth. a If the connector is blown dry with compressed air, there is the risk that oil in the air may cause defective contact, so remove all oi l a nd wa ter fr om t he c om pressed air before blowing with air. 2] Dry the inside of the connector with a dryer. If water gets inside the connector, use a dryer to dry the connector. a Hot air from the dryer can be used, but regulate the time that the hot air is used in order not to make the connector or related parts too hot, as this will cause deformation or damage to the connector. 3] Carry out a continuity test on the connector. After drying, leave the wiring harness disconnected and carry out a continuity test to check for any short circuits between pins caused by water. a After completely drying the conn e c t o r, b l o w i t w i t h c o n ta c t restorer and reassemble.

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Handling controller 1) The controller contains a microcomputer and electronic control circuits. These control 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 controller. 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 connectors connected to the controller. Fit an arc welding ground close to the welding point.

Points to remember when troubleshooting electric circuits 1) Always turn the power OFF before disconnecting or connecting connectors. 2) Before carrying out troubleshooting, check that all the related connectors are properly inserted. a Disconnect and connect the related connectors several times to check. 3) Always connect any disconnected connectors before going on to the next step. a If the power is turned ON with the connectors still disconnected, unnecessary abnormality displays will be generated. 4) When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or current), move the related wiring and connectors several times and check that there is no change in the reading of the tester. a If there is any change, there is probably defective contact in that circuit.

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Points to remember when handling hydraulic equipment With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt (foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling hydraulic equipment, it is necessary to be particularly careful. 1.

Be careful of the operating environment. Avoid adding hydraulic oil, replacing filters, or repairing the machine in rain or high winds, or places where there is a lot of dust.

Disassembly and maintenance work in the field If disassembly or maintenance work is carried out on hydraulic equipment in the field, there is danger of dust entering the equipment. It is also difficult to check the performance after repairs, so it is desirable to use unit exchange. Disassembly and maintenance of hydraulic equipment should be carried out in a specially prepared dustproof workshop, and the performance should be checked with special test equipment.

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.

Do not let any dirt or dust get in during refilling operations Be careful not to let any dirt or dust get in when refilling with hydraulic oil. Always keep the oil filler and the area around it clean, and also use clean pumps and oil containers. If an oil cleaning device is used, it is possible to filter out the dirt that has collected during storage, so this is an even more effective method.

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Change hydraulic oil when the temperature is high When hydraulic oil or other oil is warm, it flows easily. In addition, the sludge can also be drained out easily from the circuit together with the oil, so it is best to change the oil when it is still warm. When changing the oil, as much as possible of the old hydraulic oil must be drained out. (Drain the oil from the hydraulic tank; also drain the oil from the filter and from the drain plug in the circuit.) If any old oil is left, the contaminants and sludge in it will mix with the new oil and will shorten the life of the hydraulic oil.

Flushing operations After disassembling and assembling the equipment, 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.

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 circuit. The oil cleaning equipment is used to remove the ultra fine (about 3 m) particles that the filter built in the hydraulic equipment cannot remove, so it is an extremely effective device.

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Handling of connectors newly used for engines a

Mainly, following engines are object for following connectors. q 95E-5 q 107E-1 q 114E-3 q 125E-5 q 140E-5 q 170E-5 q 12V140E-3 Slide lock type (FRAMATOME-3, FRAMATOME-2) q 95 – 170, 12V140 engines q Various pressure sensors and NE speed sensor Examples) Intake air pressure sensor in intake manifold: PIM (125, 170, 12V140 engines) Oil pressure sensor: POIL (125, 170, 12V140 engines) Oil pressure switch (95, 107, 114 engines) Ne speed sensor of flywheel housing: NE (95 – 170, 12V140 engines) Ambient pressure sensor: PAMB (125, 170, 12V140 engines)

Pull lock type (PACKARD-2) 95 – 170, 12V140 engines q Various temperature sensors Example) Intake air temperature sensor in intake manifold: TIM Fuel temperature sensor: TFUEL Oil temperature sensor: TOIL Coolant temperature sensor: TWTR, etc. Disconnect the connector by pulling lock (B) (on the wiring harness side) of connector (2) outward.

Disconnect connector (1) according to the following procedure. 1) Slide lock (L1) to the right. 2) While pressing lock (L2), pull out connector (1) toward you. a Even if lock (L2) is pressed, connector (1) cannot be pulled out toward you, if part A does not float. In this case, float part A with a small screwdriver while press lock (L2), and then pull out connector (1) toward you.

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Push lock type q 95, 107, 114 engines Example) Fuel pressure sensor in common rail (BOSCH-03) Disconnect connector (3) according to the following procedure. 1) While pressing lock (C), pull out connector (3) in the direction of the arrow. q

114 engine

107, 114 engines Example) Intake air pressure/temperature sensor in intake manifold (SUMITOMO-04)

While pressing lock (D), pull out connector (4) in the direction of the arrow.

107 engine

If the lock is on the underside, use flat-head screwdriver [1] since you cannot insert your fingers. While pressing up lock (C) of the connector with flat-head screwdriver [1], pull out connector (3) in the direction of the arrow.

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95, 125 – 170, 12V140 engines While pressing lock (E) of the connector, pull out connector (5) in the direction of the arrow. Example) Fuel pressure sensor in common rail: PFUEL etc. (AMP-3)

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Turn-housing type (Round green connector) 140 engine Example) Intake air pressure sensor in intake manifold (CANNON-04): PIM etc.

Disconnect connector (6) according to the 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 harness side.

Connect the connector according to the following procedure. 1] Insert the connector to the end, while setting its groove. 2] Turn housing (H1) in the direction of the arrow until it “clicks”.

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.

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How to read electric wire code a

The information about the wires unique to each machine model is described in Troubleshooting section, Relational information of troubleshooting.

In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by symbols. 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 nominal No. of 0.85 Indicates color of wire by color code. Color codes are shown in Table 3. Indicates size of wire by nominal No. Size (Nominal No.) is shown in Table 2. Indicates type of wire by symbol. Type, symbol, and material of wire are shown in Table 1. (Since AV and AVS are classified by size (nominal No.), they are not indicated.)

Type, symbol, and material AV and AVS are different in only thickness and outside diameter of the cover. AEX is similar to AV in thickness and outside diameter of AEX and different from AV and AVS in material of the cover.

(Table 1) Type Low-voltage wire for automobile Thin-cover low-voltage wire for automobile

Symbol AV

AVS

Heat-resistant low-voltAEX age wire for automobile

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Material Conductor Insulator Conductor

Annealed copper for electric appliance Soft polyvinyl chloride Annealed copper for electric appliance

Insulator

Soft polyvinyl chloride

Conductor

Annealed copper for electric appliance Heat-resistant crosslinked polyethylene

Insulator

Using temperature range (°C)

Example of use General wiring (Nominal No. 5 and above)

–30 to +60 General wiring (Nominal No. 3 and below) General wiring in extremely –50 to +110 cold district, wiring at high-temperature place

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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 – CovAV Standard – – – – – – – 4.6 er D AEX Standard 2.0 2.2 2.7 3.0 3.1 – 3.8 4.6

Nominal No. Number of strands/Diameter of strand Conductor Sectional area (mm2) d (approx.) AVS Standard CovAV Standard er D AEX Standard

100

50/0.45

84/0.45

41/0.80

70/0.80

85/0.80

108/0.80 127/0.80 169/0.80 217/0.80

7.95

13.36

20.61

35.19

42.73

54.29

63.84

84.96

109.1

3.7 – 5.5 5.3

4.8 – 7.0 7.0

6.0 – 8.2 8.2

8.0 – 10.8 10.8

8.6 – 11.4 11.4

9.8 – 13.0 13.0

10.4 – 13.6 13.6

12.0 – 16.0 16.0

13.6 – 17.6 17.6

“f” of nominal No. denotes flexible”.

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Color codes table

(Table 3) Color Code B Br BrB BrR BrW BrY Ch Dg G GB GL Gr GR GW GY L LB Lg LgB LgR

Color of wire

Color Code LgW LgY LR LW LY O P R RB RG RL RW RY Sb Y YB YG YL YR YW

Black Brown Brown & Black Brown & Red Brown & White Brown & Yellow Charcoal Dark green Green Green & Black Green & Blue Gray Green & Red Green & White Green & Yellow Blue Blue & Black Light green Light green & Black Light green & Red

Color of wire Light green & White Light green & Yellow Blue & Red Blue & White Blue & Yellow Orange Pink Red Red & Black Red & Green Red & Blue Red & White Red & Yellow Sky Blue Yellow Yellow & Black Yellow &Green Yellow & Blue Yellow & Red 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. 4.

Types of circuits and color codes

(Table 4) Type of wire Charge Ground Start Light Instrument Signal Type of circuit Others

12V140E-3 Series

AVS or AV R B R RW Y G L Br Lg O Gr P Sb Dg Ch

AEX

–

R B R D Y G L

–

– –

–

RB YR GW LW BrW LgR

RY YB GR LR BrR LgY

RG YG GY LY BrY LgB

RL YL GB LB BrB LgW

–

YW GL

– –

Gr Br – –

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Precautions when carrying out operation

[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general precautions given below when carrying out the operation.] 1. q q q q q q q q q q

Precautions when carrying out removal work If the coolant contains antifreeze, dispose of it correctly. After disconnecting hoses or tubes, cover them or fit plugs to prevent dirt or dust from entering. When draining oil, prepare a container of adequate size to catch the oil. Confirm the match marks showing the installation position, and make match marks in the necessary places before removal to prevent any mistake when assembling. To prevent any excessive force from being applied to the wiring, always hold the connectors when disconnecting the connectors. Do not pull the wires. Fit wires and hoses with tags to show their installation position to prevent any mistake when installing. Check the number and thickness of the shims, and keep in a safe place. When raising components, be sure to use lifting equipment of ample strength. When using forcing screws to remove any components, tighten the forcing screws uniformly in turn. Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from entering after removal. Precautions when handling piping during disassembly Fit the following plugs into the piping after disconnecting it during disassembly operations. 1) Face seal type hoses and tubes Nominal number 02 03 04 05 06 10 12 2)

Sleeve nut (elbow end)

07376-70210 07376-70315 07376-70422 07376-70522 07376-70628 07376-71034 07376-71234

02789-20210 02789-20315 02789-20422 02789-20522 02789-20628 07221-21034 07221-21234

Split flange type hoses and tubes Nominal number 04 05

Plug (nut end)

Flange (hose end)

Sleeve head (tube end)

Split flange

07379-00400 07379-00500

07378-10400 07378-10500

07371-30400 07371-30500

If the part is not under hydraulic pressure, the following corks can be used. Nominal number

Part Number

06 08 10 12 14 16 18 20 22 24

07049-00608 07049-00811 07049-01012 07049-01215 07049-01418 07049-01620 07049-01822 07049-02025 07049-02228 07049-02430

Dimensions D d L 6 5 8 8 6.5 11 10 8.5 12 12 10 15 14 11.5 18 16 13.5 20 18 15 22 20 17 25 22 18.5 28 24 20 30

07049-02734

22.5

12V140E-3 Series

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2. q q q q q q q q q q q q q

a 3.

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Precautions when carrying out installation work Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque. Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any. Replace all gaskets, O-rings, cotter pins, and lock plates with new parts. Bend the cotter pins and lock plates securely. When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion with 2 – 3 drops of adhesive. When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is no dirt or damage, then coat uniformly with gasket sealant. Clean all parts, and correct any damage, dents, burrs, or rust. Coat rotating parts and sliding parts with engine oil. When press fitting parts, coat the surface with anti-friction compound (LM-P). After fitting snap rings, check that the snap ring is fitted securely in the ring groove. When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect securely. When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align the direction of the hook. When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side. When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other hydraulic equipment removed for repair, 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. When using the machine for the first time after repair or long storage, follow the same procedure. Precautions when completing the operation 1) Refilling with coolant, oil and grease q If the coolant has been drained, tighten the drain valve, and add coolant to the specified level. Run the engine to circulate the coolant through the system. Then check the coolant level again. q If the hydraulic equipment has been removed and installed again, add engine oil to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again. q If the piping or hydraulic equipment have been removed, always bleed the air from the system after reassembling the parts. a For details, see Testing and adjusting, “Bleeding air”. q Add the specified amount of grease (molybdenum disulphide grease) to the work equipment parts. 2) Checking cylinder head and manifolds for looseness Check the cylinder head and intake and exhaust manifold for looseness. If any part is loosened, retighten it. q For the tightening torque, see “Disassembly and assembly”. 3) Checking engine piping for damage and looseness Intake and exhaust system Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for air suction and exhaust gas leakage. If any part is loosened or damaged, retighten or repair it. Cooling system Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for coolant leakage. If any part is loosened or damaged, retighten or repair it. Fuel system Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel leakage. If any part is loosened or damaged, retighten or repair it.

12V140E-3 Series

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Checking muffler and exhaust pipe for damage and looseness 1] Visually check the muffler, exhaust pipe and their mounting parts for a crack and damage. If any part is damaged, replace it. 2] Check the mounting bolts and nuts of the muffler, exhaust pipe and their mounting parts for looseness. If any bolt or nut is loosened, retighten it. Checking muffler function Check the muffler for abnormal sound and sound different from that of a new muffler. If any abnormal sound is heard, repair the muffler, referring to “Troubleshooting” and “Disassembly and assembly”.

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Method of disassembling and connecting push-pull type coupler

k Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to

release the residual pressure from the hydraulic tank.

k Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out

when the hose is disconnected. Accordingly, prepare an oil receiving container. 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.

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

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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 hexagonal 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 disconnect it. (Fig. 8)

Connection Hold the tightening portion and push body (7) straight until sliding prevention ring (6) contacts contact surface (a) of the hexagonal portion at the male end. (Fig. 9)

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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 hexagonal 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 portion at the male end. (Fig. 11) 3) While holding the condition of Steps 1) and 2), pull out whole body (9) to disconnect it. (Fig. 12)

Connection Hold the tightening portion and push body (9) straight until the sliding prevention ring contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 13)

12V140E-3 Series

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Standard tightening torque table 1.

Table of tightening torques for bolts and nuts a Unless there are special instructions, tighten metric nuts and bolts to the torque below. a

The following table applies to the bolts in Fig. A.

Thread diameter of bolt mm 6 8 10 12 14 16 18 20 22 24 27 30 33 36 39 a

Tightening torque Nm 11.8 – 14.7 27 – 34 59 – 74 98 – 123 157 – 196 245 – 309 343 – 427 490 – 608 662 – 829 824 – 1,030 1,180 – 1,470 1,520 – 1,910 1,960 – 2,450 2,450 – 3,040 2,890 – 3,630

kgm 1.2 – 1.5 2.8 – 3.5 6.0 – 7.5 10.0 – 12.5 16 – 20 25 – 31.5 35 – 43.5 50 – 62 67.5 – 84.5 84 – 105 120 – 150 155 – 195 200 – 250 250 – 310 295 – 370

The following table applies to the bolts in Fig. B.

Thread diameter of bolt mm 6 8 10 12 a Fig. A

Width across flats mm 10 13 17 19 22 24 27 30 32 36 41 46 50 55 60

Width across flats mm 10 12 14 17

Tightening torque Nm kgm 5.9 – 9.8 0.6 – 1.0 13.7 – 23.5 1.4 – 2.4 34.3 – 46.1 3.5 – 4.7 74.5 – 90.2 7.6 – 9.2 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.)

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Table of tightening torques for split flange bolts a Unless there are special instructions, tighten split flange bolts to the torque below.

Thread diameter of bolt mm 10 12 16

Width across flats mm 14 17 22

Tightening torque Nm 59 – 74 98 – 123 235 – 285

kgm 6.0 – 7.5 10.0 – 12.5 23.5 – 29.5

Table of tightening torques for O-ring boss piping joints a Unless there are special instructions, tighten O-ring boss piping joints to the torque below.

Nominal No. 02 03,04 05,06 10,12 14

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Thread diameter mm 14 20 24 33 42

Width across flats mm

Tightening torque Nm {kgm} Range Target 35 – 63 { 3.5 – 6.5} 44 { 4.5} 84 – 132 { 8.5 – 13.5} 103 {10.5} Varies depending on type of connec- 128 – 186 {13.0 – 19.0} 157 {16.0} tor. 363 – 480 {37.0 – 49.0} 422 {43.0} 746 – 1,010 {76.0 – 103} 883 {90.0}

Table of tightening torques for O-ring boss plugs a Unless there are special instructions, tighten O-ring boss plugs to the torque below. Nominal No. 08 10 12 14 16 18 20 24 30 33 36 42 52

Thread diameter mm 8 10 12 14 16 18 20 24 30 33 36 42 52

12V140E-3 Series

Width across flats mm 14 17 19 22 24 27 30 32 32 – 36 – –

Tightening torque Nm {kgm} Range Target 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75} 9.81 – 12.74 {1.0 – 1.3} 11.27 {1.15} 14.7 – 19.6 {1.5 – 2.0} 17.64 {1.8} 19.6 – 24.5 {2.0 – 2.5} 22.54 {2.3} 24.5 – 34.3 {2.5 – 3.5} 29.4 {3.0} 34.3 – 44.1 {3.5 – 4.5} 39.2 {4.0} 44.1 – 53.9 {4.5 – 5.5} 49.0 {5.0} 58.8 – 78.4 {6.0 – 8.0} 68.6 {7.0} 93.1 – 122.5 { 9.5 – 12.5} 107.8 {11.0} 107.8 – 147.0 {11.0 – 15.0} 127.4 {13.0} 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5} 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5} 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0}

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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. Tightening torque Nm {kgm}

Nominal No. of hose

Width across flats

03 04 05 06 (10) (12) (14)

22 24 27 32 36 41 46 55

Range 34 – 54 { 3.5 – 5.5} 34 – 63 { 3.5 – 6.5} 54 – 93 { 5.5 – 9.5} 59 – 98 { 6.0 – 10.0} 84 – 132 { 8.5 – 13.5} 128 – 186 {13.0 – 19.0} 177 – 245 {18.0 – 25.0} 177 – 245 {18.0 – 25.0} 197 – 294 {20.0 – 30.0} 246 – 343 {25.0 – 35.0}

Target

44 { 4.5} 74 { 7.5} 78 { 8.0} 103 {10.5} 157 {16.0} 216 {22.0} 216 {22.0} 245 {25.0} 294 {30.0}

Taper seal Thread size (mm) – 14 – 18 22 24 30 33 36 42

Face seal Nominal No. – Thread Number of diameter (mm) threads, type of (Reference) thread 9/16-18UN 14.3 – – 11/16-16UN 17.5 – – 13/16-16UN 20.6 1-14UNS 25.4 1-3/16-12UN 30.2 – – – – – –

Table of tightening torques for face seal joints a Tighten the face seal joints (sleeve nut type) made of plated steel pipes for low pressure service to be used for engines etc. to the torque shown in the following table. a Apply the following torque to the face seal joint while their threaded parts are coated with engine oil (wetted).

Outer diameter of pipe (mm)

Width across flats (mm)

8 10 12 15 (16) 22 (20)

19 22 24 (27) 30 (32) 36

Tightening torque Nm {kgm} Range

Target

14 – 16 {1.4 – 1.6} 24 – 27 {2.4 – 2.7} 43 – 47 {4.4 – 4.8} 60 – 68 {6.1 – 6.8} 90 – 95 {9.2 – 9.7}

15 {1.5} 25.5 {2.6} 45 {4.6} 64 {6.5} 92.5 {9.4}

Face seal Thread diameter Nominal No. – (mm) Number of threads, (Reference) type of thread 9/16-18UN 14.3 11/16-16UN 17.5 13/16-16UN 20.6 1-14UN 25.4 1-3/16-12UN 30.2

Reference: The face seal joints of the dimensions in ( ) are also used, depending on the specification. 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 Bolts and nuts

Thread size mm 6 8 10 12 14

Nm 10 ± 2 24 ± 4 43 ± 6 77 ± 12 —

kgm 1.02 ± 0.20 2.45 ± 0.41 4.38 ± 0.61 7.85 ± 1.22 —

12V140E-3 Series

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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. Thread size mm 6 8 10 12 14

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Tightening torque Nm 8±2 10 ± 2 12 ± 2 24 ± 4 36 ± 5

kgm 0.81 ± 0.20 1.02 ± 0.20 1.22 ± 0.20 2.45 ± 0.41 3.67 ± 0.51

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.

Material Thread size (inch) 1/16 1/8 1/4 3/8 1/2 3/4

12V140E-3 Series

Tightening torque In cast iron or steel In aluminum Nm kgm Nm kgm 15 ± 2 1.53 ± 0.20 5±1 0.51 ± 0.10 20 ± 2 2.04 ± 0.20 15 ± 2 1.53 ± 0.20 25 ± 3 2.55 ± 0.31 20 ± 2 2.04 ± 0.20 35 ± 4 3.57 ± 0.41 25 ± 3 2.55 ± 0.31 55 ± 6 5.61 ± 0.61 35 ± 4 3.57 ± 0.41 75 ± 8 7.65 ± 0.82 45 ± 5 4.59 ± 0.51

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Conversion table

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 1.

Convert 55 mm into inches. 1) Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a horizontal line from (A). 2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down from (B). 3) Take the point where the 2 lines cross as (C). This point (C) gives the value when converting from millimeters to inches. Therefore, 55 mm = 2.165 inches.

Convert 550 mm into inches. 1) The number 550 does not appear in the table, so divide it by 10 (move the decimal point one place to the left) to convert it to 55 mm. 2) Carry out the same procedure as above to convert 55 mm to 2.165 inches. 3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.

Millimeters to inches

(A)

(B)

0 10 20 30 40

0 0 0.394 0.787 1.181 1.575

1 0.039 0.433 0.827 1.220 1.614

2 0.079 0.472 0.866 1.260 1.654

3 0.118 0.512 0.906 1.299 1.693

4 0.157 0.551 0.945 1.339 1.732

50 60 70 80 90

1.969 2.362 2.756 3.150 3.543

2.008 2.402 2.795 3.189 3.583

2.047 2.441 2.835 3.228 3.622

2.087 2.480 2.874 3.268 3.661

2.126 2.520 2.913 3.307 3.701

5 0.197 0.591 0.984 1.378 1.772 (C) 2.165 2.559 2.953 3.346 3.740

6 0.236 0.630 1.024 1.417 1.811

7 0.276 0.669 1.063 1.457 1.850

2.205 2.598 2.992 3.386 3.780

2.244 2.638 3.032 3.425 3.819

1 mm = 0.03937 in 8 9 0.315 0.354 0.709 0.748 1.102 1.142 1.496 1.536 1.890 1.929 2.283 2.677 3.071 3.465 3.858

2.323 2.717 3.110 3.504 3.898

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Millimeters to inches

0 10 20 30 40

0 0 0.394 0.787 1.181 1.575

1 0.039 0.433 0.827 1.220 1.614

2 0.079 0.472 0.866 1.260 1.654

3 0.118 0.512 0.906 1.299 1.693

4 0.157 0.551 0.945 1.339 1.732

5 0.197 0.591 0.984 1.378 1.772

6 0.236 0.630 1.024 1.417 1.811

1 mm = 0.03937 in 7 8 9 0.276 0.315 0.354 0.669 0.709 0.748 1.063 1.102 1.142 1.457 1.496 1.536 1.850 1.890 1.929

50 60 70 80 90

1.969 2.362 2.756 3.150 3.543

2.008 2.402 2.795 3.189 3.583

2.047 2.441 2.835 3.228 3.622

2.087 2.480 2.874 3.268 3.661

2.126 2.520 2.913 3.307 3.701

2.165 2.559 2.953 3.346 3.740

2.205 2.598 2.992 3.386 3.780

2.244 2.638 3.032 3.425 3.819

2.283 2.677 3.071 3.465 3.858

2.323 2.717 3.110 3.504 3.898

Kilogram to pound

0 10 20 30 40

0 0 22.05 44.09 66.14 88.18

1 2.20 24.25 46.30 68.34 90.39

2 4.41 26.46 48.50 70.55 92.59

3 6.61 28.66 50.71 72.75 94.80

4 8.82 30.86 51.91 74.96 97.00

5 11.02 33.07 55.12 77.16 99.21

1 kg = 2.2046 lb 6 7 8 9 13.23 15.43 17.64 19.84 35.27 37.48 39.68 41.89 57.32 59.53 61.73 63.93 79.37 81.57 83.78 85.98 101.41 103.62 105.82 108.03

50 60 70 80 90

110.23 132.28 154.32 176.37 198.42

112.44 134.48 156.53 178.57 200.62

114.64 136.69 158.73 180.78 202.83

116.85 138.89 160.94 182.98 205.03

119.05 141.10 163.14 185.19 207.24

121.25 143.30 165.35 187.39 209.44

123.46 145.51 167.55 189.60 211.64

125.66 147.71 169.76 191.80 213.85

127.87 149.91 171.96 194.01 216.05

130.07 152.12 174.17 196.21 218.26

Liters to U.S. Gallons

0 10 20 30 40

0 1 2 0 0.264 0.528 2.642 2.906 3.170 5.283 5.548 5.812 7.925 8.189 8.454 10.567 10.831 11.095

3 0.793 3.434 6.076 8.718 11.359

4 1.057 3.698 6.340 8.982 11.624

1 l = 0.2642 U.S.Gal 5 6 7 8 9 1.321 1.585 1.849 2.113 2.378 3.963 4.227 4.491 4.755 5.019 6.604 6.869 7.133 7.397 7.661 9.246 9.510 9.774 10.039 10.303 11.888 12.152 12.416 12.680 12.944

50 60 70 80 90

13.209 15.850 18.492 21.134 23.775

14.001 16.643 19.285 21.926 24.568

14.265 16.907 19.549 22.190 24.832

14.529 17.171 19.813 22.455 25.096

12V140E-3 Series

13.473 16.115 18.756 21.398 24.040

13.737 16.379 19.020 21.662 24.304

14.795 17.435 20.077 22.719 25.361

15.058 17.700 20.341 22.983 25.625

15.322 17.964 20.605 23.247 25.889

15.586 18.228 20.870 23.511 26.153

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Liters to U.K. Gallons

0 10 20 30 40

0 0 2.200 4.399 6.599 8.799

1 0.220 2.420 4.619 6.819 9.019

2 0.440 2.640 4.839 7.039 9.239

3 0.660 2.860 5.059 7.259 9.459

4 0.880 3.080 5.279 7.479 9.679

5 1.100 3.300 5.499 7.699 9.899

1 l = 0.21997 U.K.Gal 6 7 8 9 1.320 1.540 1.760 1.980 3.520 3.740 3.950 4.179 5.719 5.939 6.159 6.379 7.919 8.139 8.359 8.579 10.119 10.339 10.559 10.778

50 60 70 80 90

10.998 13.198 15.398 17.598 19.797

11.281 13.418 15.618 17.818 20.017

11.438 13.638 15.838 18.037 20.237

11.658 13.858 16.058 18.257 20.457

11.878 14.078 16.278 18.477 20.677

12.098 14.298 16.498 18.697 20.897

12.318 14.518 16.718 18.917 21.117

12.528 14.738 16.938 19.137 21.337

12.758 14.958 17.158 19.357 21.557

12.978 15.178 17.378 19.577 21.777

kgm to ft.lb

0 10 20 30 40

0 0 72.3 144.7 217.0 289.3

1 7.2 79.6 151.9 224.2 296.6

2 14.5 86.8 159.1 231.5 303.8

3 21.7 94.0 166.4 238.7 311.0

4 28.9 101.3 173.6 245.9 318.3

5 36.2 108.5 180.8 253.2 325.5

6 43.4 115.7 188.1 260.4 332.7

1 kgm = 7.233 ft.lb 7 8 9 50.6 57.9 65.1 123.0 130.2 137.4 195.3 202.5 209.8 267.6 274.9 282.1 340.0 347.2 354.4

50 60 70 80 90

361.7 434.0 506.3 578.6 651.0

368.9 441.2 513.5 585.9 658.2

376.1 448.5 520.8 593.1 665.4

383.4 455.7 528.0 600.3 672.7

390.6 462.9 535.2 607.6 679.9

397.8 470.2 542.5 614.8 687.1

405.1 477.4 549.7 622.0 694.4

412.3 484.6 556.9 629.3 701.6

100 110 120 130 140

723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7

150 160 170 180 190

1084.9 1157.3 1129.6 1301.9 1374.3

1092.2 1164.5 1236.8 1309.2 1381.5

1099.4 1171.7 1244.1 1316.4 1388.7

1106.6 1179.0 1251.3 1323.6 1396.0

1113.9 1186.2 1258.5 1330.9 1403.2

1121.1 1193.4 1265.8 1338.1 1410.4

1128.3 1200.7 1273.0 1345.3 1417.7

1135.6 1207.9 1280.1 1352.6 1424.9

419.5 491.8 564.2 636.5 708.8

1142.8 1215.1 1287.5 1359.8 1432.1

426.8 499.1 571.4 643.7 716.1

1150.0 1222.4 1294.7 1367.0 1439.4

12V140E-3 Series

00 Index and foreword

SEN00296-04

kg/cm2 to lb/in2

0 10 20 30 40

0 0 142.2 284.5 426.7 568.9

1 14.2 156.5 298.7 440.9 583.2

2 28.4 170.7 312.9 455.1 597.4

3 42.7 184.9 327.1 469.4 611.6

4 56.9 199.1 341.4 483.6 625.8

5 71.1 213.4 355.6 497.8 640.1

6 85.3 227.6 369.8 512.0 654.3

1 kg/cm2 = 14.2233 lb/in2 7 8 9 99.6 113.8 128.0 241.8 256.0 270.2 384.0 398.3 412.5 526.3 540.5 554.7 668.5 682.7 696.9

50 60 70 80 90

711.2 853.4 995.6 1,138 1,280

725.4 867.6 1,010 1,152 1,294

739.6 881.8 1,024 1,166 1,309

753.8 896.1 1,038 1,181 1,323

768.1 910.3 1,053 1,195 1,337

782.3 924.5 1,067 1,209 1,351

796.5 938.7 1,081 1,223 1,365

810.7 953.0 1,095 1,237 1,380

825.0 967.2 1,109 1,252 1,394

839.2 981.4 1,124 1,266 1,408

100 110 120 130 140

1,422 1,565 1,707 1,849 1,991

1,437 1,579 1,721 1,863 2,005

1,451 1,593 1,735 1,877 2,020

1,465 1,607 1,749 1,892 2,034

1,479 1,621 1,764 1,906 2,048

1,493 1,636 1,778 1,920 2,062

1,508 1,650 1,792 1,934 2,077

1,522 1,664 1,806 1,949 2,091

1,536 1,678 1,821 1,963 2,105

1,550 1,693 1,835 1,977 2,119

150 160 170 180 190

2,134 2,276 2,418 2,560 2,702

2,148 2,290 2,432 2,574 2,717

2,162 2,304 2,446 2,589 2,731

2,176 2,318 2,460 2,603 2,745

2,190 2,333 2,475 2,617 2,759

2,205 2,347 2,489 2,631 2,773

2,219 2,361 2,503 2,646 2,788

2,233 2,375 2,518 2,660 2,802

2,247 2,389 2,532 2,674 2,816

2,262 2,404 2,546 2,688 2,830

200 210 220 230 240

2,845 2,987 3,129 3,271 3,414

2,859 3,001 3,143 3,286 3,428

2,873 3,015 3,158 3,300 3,442

2,887 3,030 3,172 3,314 3,456

2,901 3,044 3,186 3,328 3,470

2,916 3,058 3,200 3,343 3,485

2,930 3,072 3,214 3,357 3,499

2,944 3,086 3,229 3,371 3,513

2,958 3,101 3,243 3,385 3,527

2,973 3,115 3,257 3,399 3,542

12V140E-3 Series

SEN00296-04

00 Index and foreword

Temperature Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centigrade 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 Fahrenheit 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 Centigrade values, and read the corresponding Fahrenheit temperature on the right.

°C

°F

°C

°F

°C

°F

°C

1°C = 33.8°F °F

–40.4 –37.2 –34.4 –31.7 –28.9

–40 –35 –30 –25 –20

–40.0 –31.0 –22.0 –13.0 –4.0

–11.7 –11.1 –10.6 –10.0 –9.4

11 12 13 14 15

51.8 53.6 55.4 57.2 59.0

7.8 8.3 8.9 9.4 10.0

46 47 48 49 50

114.8 116.6 118.4 120.2 122.0

27.2 27.8 28.3 28.9 29.4

81 82 83 84 85

177.8 179.6 181.4 183.2 185.0

–28.3 –27.8 –27.2 –26.7 –26.1

–19 –18 –17 –16 –15

–2.2 –0.4 1.4 3.2 5.0

–8.9 –8.3 –7.8 –7.2 –6.7

16 17 18 19 20

60.8 62.6 64.4 66.2 68.0

10.6 11.1 11.7 12.2 12.8

51 52 53 54 55

123.8 125.6 127.4 129.2 131.0

30.0 30.6 31.1 31.7 32.2

86 87 88 89 90

186.8 188.6 190.4 192.2 194.0

–25.6 –25.0 –24.4 –23.9 –23.3

–14 –13 –12 –11 –10

6.8 8.6 10.4 12.2 14.0

–6.1 –5.6 –5.0 –4.4 –3.9

21 22 23 24 25

69.8 71.6 73.4 75.2 77.0

13.3 13.9 14.4 15.0 15.6

56 57 58 59 60

132.8 134.6 136.4 138.2 140.0

32.8 33.3 33.9 34.4 35.0

91 92 93 94 95

195.8 197.6 199.4 201.2 203.0

–22.8 –22.2 –21.7 –21.1 –20.6

–9 –8 –7 –6 –5

15.8 17.6 19.4 21.2 23.0

–3.3 –2.8 –2.2 –1.7 –1.1

26 27 28 29 30

78.8 80.6 82.4 84.2 86.0

16.1 16.7 17.2 17.8 18.3

61 62 63 64 65

141.8 143.6 145.4 147.2 149.0

35.6 36.1 36.7 37.2 37.8

96 97 98 99 100

204.8 206.6 208.4 210.2 212.0

–20.0 –19.4 –18.9 –18.3 –17.8

–4 –3 –2 –1 0

24.8 26.6 28.4 30.2 32.0

–0.6 0 0.6 1.1 1.7

31 32 33 34 35

87.8 89.6 91.4 93.2 95.0

18.9 19.4 20.0 20.6 21.1

66 67 68 69 70

150.8 152.6 154.4 156.2 158.0

40.6 43.3 46.1 48.9 51.7

105 110 115 120 125

221.0 230.0 239.0 248.0 257.0

–17.2 –16.7 –16.1 –15.6 –15.0

1 2 3 4 5

33.8 35.6 37.4 39.2 41.0

2.2 2.8 3.3 3.9 4.4

36 37 38 39 40

96.8 98.6 100.4 102.2 104.0

21.7 22.2 22.8 23.3 23.9

71 72 73 74 75

159.8 161.6 163.4 165.2 167.0

54.4 57.2 60.0 62.7 65.6

130 135 140 145 150

266.0 275.0 284.0 293.0 302.0

–14.4 –13.9 –13.3 –12.8 –12.2

6 7 8 9 10

42.8 44.6 46.4 48.2 50.0

5.0 5.6 6.1 6.7 7.2

41 42 43 44 45

105.8 107.6 109.4 111.2 113.0

24.4 25.0 25.6 26.1 26.7

76 77 78 79 80

168.8 170.6 172.4 174.2 176.0

68.3 71.1 73.9 76.7 79.4

155 160 165 170 175

311.0 320.0 329.0 338.0 347.0

12V140E-3 Series

00 Index and foreword

12V140E-3 Series

SEN00296-04

00 Index and foreword

KOMATSU 12V140E-3 Series engine Form No. SEN00296-04

12V140E-3 Series

SEN00303-03

ENGINE 1SHOP MANUAL

12V140E-3 Series

01 Specification

Specification and technical data Outline.................................................................................................................................................. 2 Specifications ....................................................................................................................................... 4 General view ...................................................................................................................................... 10 Weight table ....................................................................................................................................... 19 Engine performance curves ............................................................................................................... 20

12V140E-3 Series

SEN00303-03

01 Specification

Outline

1. Applicable machine Engine

SAA12V140E-3

Engine serial No.

Machine model D475A-5E0

Bulldozer

HD785-7

Dump truck

PC2000-8

Hydraulic excavator

WA800-3E0, WA900-3E0

Wheel loader

12V140E-3 Series

01 Specification

SEN00303-03

2. Outline of engine q

The 12V140E-3 engine is a high-performance and high-efficiency engine which provides low fuel consumption, low noise, and improved exhaust gas color, and improved acceleration performance, and it cleared the strict exhaust gas regulation (USA: EPA regulations for 2006). Accordingly, this newly developed 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 machinery used for various purposes.

It is the successor of conventional 12V140-1 engine which introduces various kinds of new technologies while adhering fundamentally to the configuration of V12-cylinder, watercooled, direct injection, and 4-stroke diesel engine.

High-pressure fuel injection system controlled electronically The conventional one is a jerk in-line fuel injection pump-based engine mechanically controlled by a governor, while in all series of the new one, an electronic control system- and high-pressure injection system-based common rail injection system is adopted. This system provides high pressure fuel of 118 MPa {1,200 kg/cm2} level from the low-speed range to the high-speed range. In addition, it can control the form of injection most properly by the electronic control system according to the speed and load. As a result, clean exhaust 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 simultaneously.

It adopts a re-entrant piston combustion chamber which has been used since introduction into the 6D140E-2 engine and also uses a quality cast iron piston with less thermal expansion and shaker cooling gallery. As a result, clean exhaust gas, clean exhaust gas color, and low fuel consumption are attained simultaneously, and also high durability and high reliability are also obtained. It also provides a higher compression ratio than the conventional one to improve combustion efficiency and reduce the white exhaust smoke when starting the engine in cold climate areas. In addition, by using the above-mentioned high-pressure fuel injection system controlled electronically and setting the injection characteristics most properly to improve the startability and reduce the white exhaust smoke when the temperature is low. It is equipped with an improved turbocharger KOMATSU KTR110 of which high reliability and high performance have been proven in the 12V140-1 engine. The following improvements

12V140E-3 Series

are added: mounting of a recirculation port for surging control at the compressor side and a design to improve efficiency of the turbine. As a result, high performance is attained in a wide range from the low-speed range to the highspeed range, and high performance and low fuel consumption are also obtained. 5)

The piston cooling nozzle of 12V140-1 is reviewed in regard to oil flow. As a result, durability of the piston is improved and temperature of the rear surface of the piston is reduced to prevent deterioration of the piston due to exposure of lubricating oil on the surface to high temperature. Since the highpressure fuel injection system controlled electronically is employed, less-soot combustion is attained and the draining interval of the oil is lengthened.

The high-pressure pump to create high pressure in the common rail injection system is one-third of the conventional in-line fuel injection pump, and in addition, it is connected compact to the timing gear case as a flange mount rather than a saddle mount. As a result, sound radiation is reduced to provide low noise.

Capacity of the lubrication pump is increased by 10% over the conventional engine to contribute to the reliability and durability.

The air cleaner is changed from the conventional end surface seal type to radial seal type to prevent the entry of dust due to deformation into the clean side. In addition, the air cleaner clogging sensor for 5 clogging level indication is provided to inform users of a precise cleaning time.

A high performance and high efficiency combination filter is adopted as an oil filter, and a filter system to collect small dirts as well as large dirts is adopted for all specifications.

10) The fuel filter system includes a high efficiency main filter and prefilter as standard features to allow use of low-grade fuel in the market (corresponding to NAS13 level). In addition, the delivery of the priming pump used to replace the filters is increased for higher serviceability. 11) In addition, since the engine controller is mounted on the engine and equipped with the automatic high-altitude compensation function, it can be operated at high altitude without replacing the controller. As a result, the serviceability is improved.

SEN00303-03

01 Specification

Specifications

1 Engine name

SAA12V140E-3

Machine model

D475A-5E0 mm l {cc} —

12 – 140 x 165 30.5 {30,480} R1-L1-R5-L5-R3-L3-R6-L6-R2-L2-R4-L4

Overall length

1,772

Overall width

1,532.5

Overall height (excluding exhaust pipe)

2,171.5

Overall height (including exhaust pipe)

—

Rated output

kW{HP}/rpm

671 {899}/2,000 (Gross)

Max. torque

Nm{kgm}/rpm

3,825 {390}/1,400 (Gross)

No-load max. speed (High idle speed)

rpm

2,150 ± 50

No-load min. speed (Low idle speed)

rpm

620 + 80/0

g/kW·h {g/HP·h}

210 {156.7}

Dry weight

3,600

Fuel supply pump Governor

— —

DENSO ECD-U2 Electronic control type

Quantity of lubricating oil (Refill capacity)

138 (130)

Quantity of coolant

86 (For only engine)

Alternator Starting motor Battery

— — —

24V, 90A 24V, 7.5kW x 2 12V, 170Ah x 4

Turbocharger Air compressor Others

— — —

KOMATSU KTR110L x 2 — With air-cooled aftercooler

Performance

Dimensions

Number of cylinders – Bore × Stroke Total displacement Firing order

Fuel consumption ratio at rated output

12V140E-3 Series

01 Specification

SEN00303-03

Engine name

SAA12V140E-3

Machine model

HD785-7 mm l {cc} —

12 – 140 x 165 30.5 {30,480} R1-L1-R5-L5-R3-L3-R6-L6-R2-L2-R4-L4

Overall length

2,046.5

Overall width

1,479.7

Overall height (excluding exhaust pipe)

1,745.3

Overall height (including exhaust pipe)

—

Rated output

kW{HP}/rpm

895 {1,200}/1,900 (Gross)

Max. torque

Nm{kgm}/rpm

5,076 {518}/1,350 (Gross)

No-load max. speed (High idle speed)

rpm

2,250 ± 25

No-load min. speed (Low idle speed)

rpm

650 ± 20

g/kW·h {g/HP·h}

207 {154}

Dry weight

3,470

Fuel supply pump Governor

— —

DENSO ECD-U2 Electronic control type

Quantity of lubricating oil (Refill capacity)

138 (130)

Quantity of coolant

86 (For only engine)

Alternator Starting motor Battery

— — —

24V, 90A 24V, 7.5kW x 2 12V, 170Ah x 4

Turbocharger Air compressor Others

— — —

KOMATSU KTR110L x 2 — With air-cooled aftercooler

Performance

Dimensions

Number of cylinders – Bore × Stroke Total displacement Firing order

Fuel consumption ratio at rated output

12V140E-3 Series

SEN00303-03

01 Specification

Engine name

SAA12V140E-3

Machine model

PC2000-8 mm l {cc} —

12 – 140 x 165 30.5 {30,480} R1-L1-R5-L5-R3-L3-R6-L6-R2-L2-R4-L4

Overall length

1,807.7

Overall width

1,588.8

Overall height (excluding exhaust pipe)

1,734.3

Overall height (including exhaust pipe)

—

Rated output

kW{HP}/rpm

728 {976}/1,800 (Gross)

Max. torque

Nm{kgm}/rpm

4,488 {458}/1,350 (Gross)

No-load max. speed (High idle speed)

rpm

1,980 ± 25

No-load min. speed (Low idle speed)

rpm

825 ± 25

g/kW·h {g/HP·h}

207 {154}

Dry weight

3,500

Fuel supply pump Governor

— —

DENSO ECD-U2 Electronic control type

Quantity of lubricating oil (Refill capacity)

138 (130)

Quantity of coolant

86 (For only engine)

Alternator Starting motor Battery

— — —

24V, 90A 24V, 11kW x 2 12V, 170Ah x 4

Turbocharger Air compressor Others

— — —

KOMATSU KTR110L x 2 — With air-cooled aftercooler

Performance

Dimensions

Number of cylinders – Bore × Stroke Total displacement Firing order

Fuel consumption ratio at rated output

12V140E-3 Series

01 Specification

SEN00303-03

Engine name

SAA12V140E-3

Machine model

WA800-3E0 mm l {cc} —

12 – 140 x 165 30.5 {30,480} R1-L1-R5-L5-R3-L3-R6-L6-R2-L2-R4-L4

Overall length

2,123

Overall width

1,463.5

Overall height (excluding exhaust pipe)

1,940

Overall height (including exhaust pipe)

—

Rated output

kW{HP}/rpm

636 {853}/2,000 (Gross)

Max. torque

Nm{kgm}/rpm

3,802 {388}/1,400 (Gross)

No-load max. speed (High idle speed)

rpm

2,200 (+10/-20)

No-load min. speed (Low idle speed)

rpm

680 + 50/0

g/kW·h {g/HP·h}

215 {160}

Dry weight

3,690

Fuel supply pump Governor

— —

DENSO ECD-U2 Electronic control type

Quantity of lubricating oil (Refill capacity)

138 (130)

Quantity of coolant

86 (For only engine)

Alternator Starting motor Battery

— — —

24V, 90A 24V, 7.5kW x 2 12V, 170Ah x 4

Turbocharger Air compressor Others

— — —

KOMATSU KTR110L x 2 — With air-cooled aftercooler

Performance

Dimensions

Number of cylinders – Bore × Stroke Total displacement Firing order

Fuel consumption ratio at rated output

12V140E-3 Series

SEN00303-03

01 Specification

Engine name

SAA12V140E-3

Machine model

WA900-3E0 mm l {cc} —

12 – 140 x 165 30.5 {30,480} R1-L1-R5-L5-R3-L3-R6-L6-R2-L2-R4-L4

Overall length

2,123

Overall width

1,463.5

Overall height (excluding exhaust pipe)

1,940

Overall height (including exhaust pipe)

—

Rated output

kW{HP}/rpm

672 {900}/2,050 (Gross)

Max. torque

Nm{kgm}/rpm

4,159 {424}/1,300 (Gross)

No-load max. speed (High idle speed)

rpm

2,200 + 10/0

No-load min. speed (Low idle speed)

rpm

680 + 50/0

g/kW·h {g/HP·h}

215 {160}

Dry weight

3,690

Fuel supply pump Governor

— —

DENSO ECD-U2 Electronic control type

Quantity of lubricating oil (Refill capacity)

138 (130)

Quantity of coolant

86 (For only engine)

Alternator Starting motor Battery

— — —

24V, 90A 24V, 7.5kW x 2 12V, 170Ah x 4

Turbocharger Air compressor Others

— — —

KOMATSU KTR110L x 2 — With air-cooled aftercooler

Performance

Dimensions

Number of cylinders – Bore × Stroke Total displacement Firing order

Fuel consumption ratio at rated output

12V140E-3 Series

01 Specification

SEN00303-03

12V140E-3 Series

SEN00303-03

General view

01 Specification

SAA12V140E-3 (Left side view of engine) Machine model: D475A-5E0

The shape is subject to machine models.

1. 2.

Center of crankshaft Rear face of flywheel housing

12V140E-3 Series

01 Specification

SEN00303-03

SAA12V140E-3 (Front view of engine) Machine model: D475A-5E0

The shape is subject to machine models.

1. 2.

Center of crankshaft Center of engine

12V140E-3 Series

SEN00303-03

01 Specification

SAA12V140E-3 (Left side view of engine) Machine model: HD785-7

The shape is subject to machine models.

1. 2.

Center of crankshaft Rear face of flywheel housing

12V140E-3 Series

01 Specification

SEN00303-03

SAA12V140E-3 (Front view of engine) Machine model: HD785-7

The shape is subject to machine models.

1. 2.

Center of crankshaft Center of engine

12V140E-3 Series

SEN00303-03

01 Specification

SAA12V140E-3 (Left side view of engine) Machine model: PC2000-8

The shape is subject to machine models.

1. 2.

Center of crankshaft Rear face of flywheel housing

12V140E-3 Series

01 Specification

SEN00303-03

SAA12V140E-3 (Front view of engine) Machine model: PC2000-8

The shape is subject to machine models.

1. 2.

Center of crankshaft Center of engine

12V140E-3 Series

SEN00303-03

01 Specification

SAA12V140E-3 (Left side view of engine) Machine model: WA800-3E0, WA900-3E0

The shape is subject to machine models.

1. 2.

Center of crankshaft Rear face of flywheel housing

12V140E-3 Series

01 Specification

SEN00303-03

SAA12V140E-3 (Front view of engine) Machine model: WA800-3E0, WA900-3E0

The shape is subject to machine models.

1. 2.

Center of crankshaft Center of engine

12V140E-3 Series

SEN00303-03

01 Specification

Dimensions table Unit: mm Engine

SAA12V140E-3

Machine model

Dimensions of each part A

D475A-5E0

287

1,582

1,772

2,171.5

726

507

HD785-7

230

1,585.8

2,046.5

1,745.3

715

210

PC2000-8

353

1,574.8

1,807.7

1,734.3

726

600

WA800-3E0, WA900-3E0

230

1,585.8

2,123

1,940

715.2

210

These dimensions are given for reference when the engine is set on a test bench.

12V140E-3 Series

01 Specification

SEN00303-03

Weight table

1 Unit: kg

No.

Item

Main parts

SAA12V140E-3

Turbocharger

KOMATSU KTR110L (Water-cooled)

25 x 2

Cylinder head assembly

Cylinder head, valve, rocker arm, valve spring

22.5 x 12

Cylinder block assembly

Cylinder block, bearing cap, cylinder liner

Gear case

Oil pan

Flywheel assembly

810

D475A-5E0 HD785-7 WA800-3E0, WA900-3E0

Integral-type

Flywheel, ring gear

Flywheel housing assembly

Crankshaft assembly

Crankshaft, crank gear

Camshaft assembly

Camshaft, cam gear thrust plate

Piston and connecting rod assembly

Piston, piston ring, piston pin, connecting rod

88.4

PC2000-8

89.2

D475A-5E0

127.6

HD785-7

72.5

PC2000-8 WA800-3E0, WA900-3E0

88.7

133.5 210 L

20 10.5 x 12

Oil pump

Fuel supply pump

Water pump

Alternator

Starting motor

Aftercooler assembly

12V140E-3 Series

24V, 90A

24V, 7.5kW

D475A-5E0 HD785-7 WA800-3E0, WA900-3E0

24V, 11kW

PC2000-8

18 x 2

D475A-5E0

35 x 2

HD785-7

33 x 2

PC2000-8

43 x 2

WA800-3E0, WA900-3E0

40 x 2

SEN00303-03

01 Specification

Engine performance curves Engine

SAA12V140E-3

Engine serial No.

1 Machine model

Page

D475A-5E0

HD785-7

PC2000-8

WA800-3E0

WA900-3E0

12V140E-3 Series

01 Specification

SEN00303-03

SAA12V140E-3 (Machine model: D475A-5E0) Rated output: 671 kW {899 HP}/2,000 rpm (Gross) Max. torque: 3,825 Nm {390 kgm}/1,400 rpm (Gross)

12V140E-3 Series

SEN00303-03

01 Specification

SAA12V140E-3 (Machine model: HD785-7) Rated output: 895 kW {1,200 HP}/1,900 rpm (Gross) Max. torque: 5,076 Nm {518 kgm}/1,350 rpm (Gross)

12V140E-3 Series

01 Specification

SEN00303-03

SAA12V140E-3 (Machine model: PC2000-8) Rated output: 728 kW {976 HP}/1,800 rpm (Gross) Max. torque: 4,488 Nm {458 kgm}/1,350 rpm (Gross)

12V140E-3 Series

SEN00303-03

01 Specification

SAA12V140E-3 (Machine model: WA800-3E0) Rated output: 636 kW {853 HP}/2,000 rpm (Gross) Max. torque: 3,802 Nm {388 kgm}/1,400 rpm (Gross)

12V140E-3 Series

01 Specification

SEN00303-03

SAA12V140E-3 (Machine model: WA900-3E0) Rated output: 672 kW {900 HP}/2,050 rpm (Gross) Max. torque: 4,159 Nm {424 kgm}/1,300 rpm (Gross)

12V140E-3 Series

SEN00303-03

01 Specification

KOMATSU 12V140E-3 Series engine Form No. SEN00303-03

12V140E-3 Series

SEN00307-05 12V140E-3 Series SEN00307-04

ENGINE Shop Manual

12V140E-3 Series

Machine model Serial number 12V140E-3 SERIES ENGINE...

10 Structure,function and maintenance standard Structure, function and maintenance standard, Part 1 Air intake and exhaust unit..........................................................................................................................

Air cleaner...................................................................................................................................................

Turbocharger...............................................................................................................................................

Aftercooler................................................................................................................................................... 11 Muffler ......................................................................................................................................................... 12 Cylinder head.............................................................................................................................................. 14 Cylinder block ............................................................................................................................................. 18 Cylinder liner ............................................................................................................................................... 22

12V140E-3 Series

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10 Structure,function and maintenance standard

Main moving parts ....................................................................................................................................... 24 Crankshaft................................................................................................................................................... 26 Camshaft..................................................................................................................................................... 28 Cam follower and push rod ......................................................................................................................... 29 Piston, piston ring, and piston pin ............................................................................................................... 30 Connecting rod............................................................................................................................................ 32 Flywheel and flywheel housing ................................................................................................................... 34 Vibration damper ......................................................................................................................................... 35 Timing gear ................................................................................................................................................. 36 Valve system ............................................................................................................................................... 38 Valve and valve guide ................................................................................................................................. 40 Rocker arm and shaft.................................................................................................................................. 42 Crosshead and guide .................................................................................................................................. 43

12V140E-3 Series

SEN00307-05

10 Structure,function and maintenance standard

Air intake and exhaust unit (Left side view of engine)

a The illustration shows the engine for D475A-5E0. A: Air intake (From air cleaner) B: Air intake (To air-cooled aftercooler) C: Air intake (From air-cooled aftercooler) D: Exhaust gas

12V140E-3 Series

1. Electrical intake air heater 2. Air intake manifold 3. Muffler 4. Turbocharger

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10 Structure,function and maintenance standard

Air cleaner ERB type [Air cleaner of automatic exhaust gas discharge type (Radial seal type)]

a The shape is subject to machine models. 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 Engine

Machine model

D475A-5E0 PC2000-8 SAA12V140E-3 WA800-3E0, WA900-3E0

Type

Method of discharging dust from pre-cleaner

Number of elements

Komaclone, multi-cyclone (ERB type)

Automatic discharge (Exhaust ejector)

1 Inner element, 1 Outer element

12V140E-3 Series

SEN00307-05

10 Structure,function and maintenance standard

FRG type [Air cleaner of cyclone pack type with evacuator valve (Radial seal type)]

a The shape is subject to machine models. 1. Inlet 2. Outlet 3. Guide vane 4. Primary element 5. Safety element

6. Evacuator valve 7. Dust pan 8. Guide plate (Sleeve) 9. Body 10. Element

Engine

Machine model

Type

Evacuator valve

SAA12V140E-3

HD785-7

FRG (Radial seal type)

Automatic discharge

Structure q The size of the body is reduced from the conventional type without changing the diameter of the element. q Since the inlet is set in the tangential direction, air is given sufficient centrifugal force by the simple spiral guide vane, not by the guide plate.

12V140E-3 Series

Number of elements 1 Inner element, 1 Outer element

Operation q Air containing dust is sucked in vertically through inlet (1) and the dust is separated by the centrifugal effect of guide vane (3). q More than 99.9% of the dust is removed by primary element (4) and clean air is sucked in the 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.

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10 Structure,function and maintenance standard

Turbocharger Water-cooled type Type: KTR110L

12V140E-3 Series

10 Structure,function and maintenance standard

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A: Intake air inlet B: Intake air outlet C: Exhaust gas inlet D: Exhaust gas outlet E: Oil inlet F: Oil outlet G: Coolant 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

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10 Structure,function and maintenance standard

Model: KTR110L

a The illustration shows the water-cooled turbocharger.

12V140E-3 Series

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10 Structure,function and maintenance standard

Unit: mm

No.

Check item

Criteria

Remedy

1 End play (Play in axial direction)

Standard 0.08 – 0.13

Repair limit 0.18

2 Radial play (Play in radial direction)

0.43 – 0.68

0.84

Clearance between blower housing and impeller

12V140E-3 Series

Clearance limit (Min.): 0.14

Replace thrust parts Replace bearing parts Replace bearing parts

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10 Structure,function and maintenance standard

Turbocharger mounting

a The illustration shows the engine for D475A-5E0. a The shape is subject to machine models. A: Intake air inlet B: Intake air (Between turbocharger and air-cooled aftercooler) 1. Exhaust manifold 2. Turbocharger

12V140E-3 Series

10 Structure,function and maintenance standard

SEN00307-05

Aftercooler Air-cooled type

a The shape is subject to machine models. a The illustration shows the engine for D475A-5E0. A. Air inlet (From turbocharger) B. Air outlet (To air intake manifold) 1. Upper tank 2. Core 3. Lower tank 4. Fin 5. Tube

12V140E-3 Series

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10 Structure,function and maintenance standard

Muffler

a The shape is subject to machine models. a The illustration shows the engine for D475A-5E0. A: Exhaust gas outlet 1. Turbocharger 2. Muffler

12V140E-3 Series

10 Structure,function and maintenance standard

12V140E-3 Series

SEN00307-05

10 Structure,function and maintenance standard

Cylinder head

a The shape is subject to machine models. A. Air intake B. Exhaust gas

C. To fuel tank D. To radiator

1. Spill pipe 2. Air bleeding pipe 3. Cylinder head 4. Head cover 5. Head cover bolt

6. Cylinder head bolt 7. Injector connector 8. Injector assembly 9. Injector holder mounting bolt 10. Injector holder retainer

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 injector Cylinder head bolt: Plastic-region tightening Valve seat Valve seat inserts are press fitted to both intake and exhaust valves Rocker cover O-ring seal Injector Installation: Dry type (without sleeve)

12V140E-3 Series

SEN00307-05

10 Structure,function and maintenance standard

a Tighten the cylinder head mounting bolt in order of [1] to [7]. Unit: mm

No. 1

Check item

Criteria Tolerance

Repair limit

0 – 0.06

0.09

Engine

Standard

SAA12V140E-3

2.3 – 2.9

Strain of cylinder head mounting face

2 Projection of nozzle

Bolt No.

Tightening torque for cylinder head mounting bolt (Apply molybdenum disulfied or engine oil to threaded part)

[1] – [6]

5 6

Tightening torque for injector holder mounting bolt Tightening torque for fuel injection pipe Tightening torque for head cover mounting bolt

Repair by grinding or replace Replace nozzle or gasket

Procedure

Target (Nm{kgm})

Range (Nm{kgm})

1st phase

147 {15}

137 – 157 {14 – 16}

2nd phase

289 {29.5}

3rd phase

Retighten by 90°

—

68.6 {7}

[7]

Remedy

Tighten in order shown above. If 284 – 294 {29 – 30} there are 5 punch marks, replace the 90(+30/0)° bolt. 58.8 – 73.5 {6 – 7.5}

Target (Nm {kgm})

Range (Nm {kgm})

66.7 {6.8}

58.8 – 73.5 {6 – 7.5}

44.1 {4.5}

39.2 – 49.0 {4 – 5}

32.4 {3.3}

29.4 – 34.3 {3.0 – 3.5}

Retighten

a Do not use a cylinder head mounting bolt more than 5 times. Each time the bolt is used, make a punch mark on its head.

12V140E-3 Series

10 Structure,function and maintenance standard

12V140E-3 Series

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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

12V140E-3 Series

10 Structure,function and maintenance standard

Specifications Cylinder block Crankshaft: 7 bearings Camshaft: High cam type, 7 bearings Main bearing cap bolt: Plastic-region tightening

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Liner ring Upper: Clevis seal (Ethylene-propylene rubber) Middle: O-ring (Ethylene-propylene rubber) Lower: O-ring (Silicon rubber)

Piston cooling With piston cooling nozzle Cylinder liner Wet type Machining on inside: Plateau honing andTufftride

12V140E-3 Series

SEN00307-05

10 Structure,function and maintenance standard

12V140E-3 Series

SEN00307-05

10 Structure,function and maintenance standard

Unit: mm

No. 1

Check item

Criteria

Strain of cylinder head mounting face Inside diameter of main bearing metal mounting hole

Tolerance

Repair limit

0 – 0.09

0.135

Repair by grinding or replace

Standard size

Tolerance +0.025 0

Replace or correct main bearing metal cap

157

Surface roughness of main bearing metal mounting hole

10S or less Correct

Roundness of mounting hole

Repair limit: 0.005 4.5

No.4 only

Thickness of main bearing metal Other than

4.5

No.4

Inside diameter of main bearing metal (When tightening bolt with specified torque)

Standard size No.4 only

148

Other than No.4

148

Inside diameter of cam bushing mounting hole

Tightening torque for main bearing cap (Apply engine oil to threaded portion and washer)

Tightening torque for oil pan mounting bolt Level difference between under — surfaces of cylinder block and front cover

—

Tolerance +0.175 +0.130 +0.145 +0.100

Standard size 69 Standard size

5 Inside diameter of cam bushing

Remedy

–0.050 –0.060 –0.065 –0.075 Repair limit 148.23 148.20 Tolerance +0.030 0 Repair limit

Procedure

Tolerance +0.060 0.025 Target (Nm {kgm})

1st time

284 {29}

270 – 299 {27.5 – 30.5}

2nd time

569 {58}

559 – 579 {57.0 – 59.0}

3rd time

Retighten by 90°

90 (+30/0)°

—

65.7 {6.7}

58.8 – 73.6 {6 – 7.5}

Repair limit: 0.14

Replace bearing metal

65.15

Correct or replace block Replace cam bushing

Range (Nm {kgm})

Retighten

Reassemble

a Do not use a main cap mounting bolt more than 5 times. Each time the bolt is used, make a punch mark on its head.

12V140E-3 Series

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10 Structure,function and maintenance standard

Cylinder liner

Unit: mm

No.

Check item

Criteria

1 Projection of cylinder liner

Inside diameter of cylinder liner

Standard size

140

Tolerance +0.020 0 +0.040 +0.021

Cylindricality of cylinder liner

Repair limit: 0.02

Clearance between cylinder liner and block (counterbore portion)

Interference of cylinder liner and block (Lower portion of counterbore) Outside diameter of cylinder liner (at O-ring)

Rank

Repair limit: 0.02

Outside diameter of cylinder liner (Lower portion of counterbore)

Repair limit: 0.07 – 0.15

Roundness of cylinder liner

Outside diameter of cylinder liner (Counterbore portion)

Clearance between cylinder liner and block (O-ring portion)

Remedy Replace cylinder liner or cylinder

Standard size 170.2

Repair limit 140.12 140.14

Tolerance 0 –0.10

Standard clearance: 0 – 0.163 Standard size

Standard interference

Tolerance +0.090 +0.050 Interference limit

0.02 – 0.12

0.02 or above

Standard size

Tolerance –0.053 –0.103

161.2

158

Replace cylinder liner (Refilling is allowed only for rank L.)

Standard clearance: 0.093 – 0.143

Replace cylinder liner or block Replace cylinder liner Replace or correct cylinder liner or block Replace cylinder liner Replace cylinder liner or block

12V140E-3 Series

10 Structure,function and maintenance standard

12V140E-3 Series

SEN00307-05

10 Structure,function and maintenance standard

Main moving parts

a The shape is subject to machine models. 1. Piston (FCD piston) 2. Piston pin 3. Connecting rod bushing 4. Top ring 5. Second ring 6. Oil ring 7. Connecting rod cap bolt 8. Connecting rod (Front of engine: for L bank, rear: for R bank) 9. Connecting rod cap

10. Connecting rod bearing metal 11. Crank gear (Number of teeth: 45) 12. Crankshaft 13. Vibration damper

12V140E-3 Series

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10 Structure,function and maintenance standard

Specifications

Piston rings

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 tightening.

12V140E-3 Series

Top ring (1)

: Double-side keystone, inner cut, barrel face, hard chromium-plated Second ring (2): Double-side keystone, inner cut, taper face, hard chromium-plated Oil ring (3) : M-shaped steel, with coil expander, nitrided surface

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10 Structure,function and maintenance standard

Crankshaft

12V140E-3 Series

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10 Structure,function and maintenance standard

Unit: mm

No.

Check item

Criteria Standard value

1 End play

Outside diameter of main journal

0.140 – 0.32

0.50

Rank

Standard size

S.T.D.

148

0.25 US

147.75

Surface roughness of main journal

4 Bend of crankshaft

Tightening torque for adapter mounting bolt

Tightening torque for damper mounting bolt

Repair limit 147.97 147.72

0 –0.030

147.50

0.75 US

147.25

147.22

1.00 US

147.00

146.97

147.47

Use undersize journal or replace

Repair limit: 0.010 Journal

Standard clearance

Clearance limit

No.4 only

0.130 – 0.205

0.25

Other than No.4

0.100 – 0.175

0.22

Tolerance

Use undersize journal or replace main metal Correct surface roughness of crankshaft journal

0.8S (Surface roughness of R portion: 3.2S) Rank

Standard size

S.T.D.

100

99.87

0.25 US

99.75

99.62

0.50 US

89.50

0.75 US

99.25

99.12

1.00 US

99.00

98.87

Roundness of main journal Clearance of main journal

Tolerance

0.50 US

Surface roughness of main journal

Outside diameter of main journal

Replace thrust bearing metal or use oversize metal

Repair limit

Roundness of main journal

Clearance of main journal

Remedy

Repair limit

0 –0.030

99.37

Use undersize journal or replace

Repair limit: 0.010 Standard clearance

Clearance limit

0.046 – 0.126

0.17

0.8S (Surface roughness of R portion: 3.2S) Standard Coaxiality of all main journals:

Replace connecting rod bearing metal

Repair limit

0.15 or less Coaxiality of adjacent main journals: 0.07 or less Procedure Target (Nm {kgm})

0.15

Replace

0.07 Range (Nm {kgm})

1st time

74 {7.5}

54 – 93 {5.5 – 9.5}

2nd time

245 {25}

226 – 265 {23 – 27}

3rd time

745 {76}

725 – 765 {74 – 78}

Retighten

108 ± 10 Nm {11 ± 1.0 kgm}

a US: Undersize

12V140E-3 Series

SEN00307-05

10 Structure,function and maintenance standard

Camshaft

Unit: mm

No.

Check item

Criteria Standard

Repair limit

0.1 – 0.25

0.36

Standard size

Standard clearance

Tolerance –0.016 –0.036 Clearance limit

0.016 – 0.096

0.15

1 End play Outside diameter of camshaft journal

2 Clearance of camshaft journal

3 Bend of camshaft

4 Height of cam

Remedy Replace thrust plate

Replace Replace cam bushing

Repair limit: 0.04 (Overall swing of indicator) Cam

Standard size

Tolerance

Repair limit

Intake

55.48

± 0.1

55.08

Exhaust

55.75

± 0.1

55.35

Replace

12V140E-3 Series

SEN00307-05

10 Structure,function and maintenance standard

Cam follower and push rod

Unit: mm No.

Check item Outside diameter of cam follower shaft Inside diameter of cam follower shaft hole

Criteria Standard size 22 22

2 Outside diameter of cam roller

31.7

Inside diameter of cam roller

12.7

Outside diameter of cam roller pin

12.63

3 Standard size

4 Diameter of push rod ball end 5 Diameter of push rod socket end 6 Bend of push rod

12V140E-3 Series

12.7 13.4

Remedy

Tolerance –0.021 –0.034 +0.021 0 +0.05 +0.02 +0.038 +0.013

Repair limit

± 0.006

12.56

21.92 22.07 31.50 12.78 Replace

Tolerance 0 –0.20 0 –0.20

Repair limit: 0.3 (Overall swing of indicator)

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10 Structure,function and maintenance standard

Piston, piston ring, and piston pin

12V140E-3 Series

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10 Structure,function and maintenance standard

Unit: mm

No.

Check item

Outside diameter of piston

Thickness of piston ring

Width of piston ring groove

Clearance between piston ring and 2 – 4 piston ring groove

Closed gap of piston ring

Outside diameter of piston pin

Inside diameter of piston pin hole

Clearance between piston pin and piston

Criteria Rank

Standard size

Tolerance –0.120 –0.135 –0.105 –0.120 Standard size

140

No.

Measuring point

No.1 ring

No.2 ring

Oil ring

2 3

No.1 ring No.2 ring

Oil ring

No.

Measuring point

Standard clearance

No.1 ring

No.2 ring

Oil ring

Remedy Repair limit 139.830 139.845

Tolerance –0.015 2.9 –0.035 –0.010 2.41 –0.035 –0.010 4 –0.030 Judge using groove wear gauge (*1) Judge using groove wear gauge (*2) +0.030 +0.010 Clearance limit

Check with groove wear gauge

0.020 – 0.060

Replace piston(Refilling is allowed only for rank S.)

Replace piston ring

Replace piston

Replace piston or piston ring

0.14

0.42 – 0.57 (Tension: 2 No.1 ring 2.0 16.5 – 23.5 N {1.68 – 2.40 kg}) 1.15 – 1.30 No.2 ring (Tension: 3 (Identification 2RN 1.5 16.2 – 24.2 N white mark) {1.65 – 2.47 kg}) 0.30 – 0.50 (Tension: 4 Oil ring 1.0 84.4 – 112 N {8.61 – 11.39 kg}) Standard size Tolerance 0 52 –0.006 +0.045 Lateral: +0.035 52 +0.055 Vertical: +0.035 Standard clearance Clearance limit Lateral:0.035 – 0.051 0.10 Vertical:0.035 – 0.061

Replace piston ring or cylinder liner

Replace piston pin

Replace piston

Replace piston or piston pin

a *1: Part No. (Groove wear gauge) 795-901-1150 a *2: Part No. (Groove wear gauge) 795-901-1130

12V140E-3 Series

SEN00307-05

10 Structure,function and maintenance standard

Connecting rod

12V140E-3 Series

SEN00307-05

10 Structure,function and maintenance standard

Unit: mm No.

Check item

Criteria

Inside diameter of connecting rod small end bushing

1 Clearance between connecting rod small end bushing and piston pin

Inside diameter of connecting rod small end bushing mounting hole Inside diameter of connecting rod

3 large end bearing metal

4 5

(Crankpin journal) Inside diameter of connecting rod large end hole (Without bearing metal, X, Y, and Z q directions) Thickness of connecting rod bearing metal

Parallelism and twist of connecting rod

Tightening torque for connecting rod cap mounting bolts (Apply engine oil to seat surface of nut of threaded portion of bolts) Inside diameter of connecting rod large end

Standard size

Remedy

Tolerance +0.049 +0.030

Repair limit 52.09

Standard clearance

Clearance limit

0.030 – 0.055

0.11

Standard size

Tolerance

57.4

+0.030 0

Standard size 100 106

Tolerance +0.096 +0.046 +0.026 –0.004

Repair limit 100.15 —

Tighten connecting rod cap with specified torque and measure

Item

–0.025 –0.035 Standard

Repair limit

Parallelism (a)

0 – 0.10

0.15

Twist (b)

0 – 0.25

0.30

Dimensions (c)

340

—

Procedure

Target (Nm {kgm})

1st time

74 {7.5}

Range (Nm {kgm}) 69 – 78 {7 – 8}

2nd time

Retighten 90°

3.0

Roughness

3.2S

Swell

0.004 (In overall width)

—

Replace bushing (Refilled part is semi-finished part) Replace bushing or piston pin Replace connecting rod (Correction not allowed) Replace bearing metal Replace connecting rod (Correction not allowed) Replace bearing metal

Replace connecting rod

Tighten in order shown in figure

90(+30/0)°

Replace

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

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10 Structure,function and maintenance standard

Flywheel and flywheel housing

Unit: mm

No.

Check item

Criteria

1 Facial runout of flywheel housing

Repair limit: 0.25

2 Radial runout of flywheel housing

Repair limit: 0.25

3 Facial runout of flywheel

Repair limit: 0.30

4 Radial runout of flywheel

Repair limit: 0.13

Remedy

Reassemble

Tightening torque for flywheel housing mounting (Apply engine oil to threaded portion) Tightening torque for flywheel mounting bolt (Apply engine oil to threaded portion)

Procedure

Target (Nm {kgm})

Range (Nm {kgm})

1st time

343 {35}

294 – 392 {30 – 40}

2nd time

412 {42}

392 – 432 {40 – 44}

1st time

98 {10}

78 – 118 {8 – 12}

2nd time

294 {30}

275 – 314 {28 – 32}

3rd time

539 {55}

520 – 559 {53 – 57}

Tighten in order shown in above figure

12V140E-3 Series

10 Structure,function and maintenance standard

SEN00307-05

Vibration damper

a The shape is subject to machine models. 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

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10 Structure,function and maintenance standard

Timing gear

12V140E-3 Series

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10 Structure,function and maintenance standard

Unit: mm No.

Check item

Criteria Position

Measuring point

Remedy Standard

Repair limit

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 e 0.051 – 0.469 — Backlash of each gear right fuel injection pump gear 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 clearance limit Shaft Hole 1 bushing and shaft –0.016 +0.034 (Both right and left banks) 56 0.025 – 0.063 0.20 –0.029 +0.009 Clearance between sub idler gear –0.016 +0.055 56 0.016 – 0.084 0.20 2 bushing and shaft –0.029 0 Standard Repair limit 3 End play of main idler gear 0.09 – 0.26 0.4

4 End play of sub idler gear

0.07 – 0.18

0.4

End play of fuel injection pump drive gear

0.07 – 0.20

0.4

6 End play of oil pump drive gear

0.03 – 0.094

0.4

7 End play of accessory drive gear

0.1 – 0.4

0.4

Replace

Replace bushing

Replace thrust bearing

a The shape is subject to machine models.

12V140E-3 Series

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Valve system

12V140E-3 Series

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10 Structure,function and maintenance standard

1. Cam gear 2. Thrust plate 3. Camshaft 4. Cam follower 5. Cam roller 6. Rocker arm shaft 7. Cam follower shaft 8. Rocker arm adjustment screw 9. Locknut 10. Push rod 11. Rocker arm 12. Crosshead adjustment screw 13. Locknut 14. Crosshead 15. Valve guide 16. Exhaust valve 17. Valve spring (Outer) 18. Valve spring (Inner) 19. Spring seat 20. Valve retainer 21. Intake valve 22. Cam roller pin

Valve timing

Specifications Camshaft Drawn steel bar (Machining) Journal and cam sections: Induction hardening

12V140E-3 Series

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Valve and valve guide

12V140E-3 Series

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10 Structure,function and maintenance standard

Unit: mm

No.

Check item

1 Sinking distance of valve

Criteria

Remedy

Valve

Standard size

Tolerance

Repair limit

Intake

± 0.10

0.70

Exhaust

± 0.10

0.70

Valve

Standard size

Repair limit

Intake

2.4

1.9

Exhaust

2.15

1.75

Valve

Standard size

Tolerance

Intake

30°

± 15'

Exhaust

45°

± 15'

Intake

Exhaust

Before head is press fitted

2 Thickness of valve lip

3 Valve seat angle

Outside diameter of valve stem

Standard size Inside diameter of valve guide

Valve

Standard clearance

Intake

0.034 – 0.071

0.22

Exhaust

0.063 – 0.100

0.24

Bend of valve stem

Repair limit: 0.02 (Total runout of indicator, per 100) Standard

Tolerance

22.0

± 0.2

5 Driving height of valve guide

Standard size

Repair limit

Outer

81.7

—

Inner

72.0

—

Standard installed load (N {kg}) 424.3 ± 21.6 {43.3 ± 2.2} 215.6 ± 10.8 {22.0 ± 1.1}

Allowable installed load (N {kg}) 377.3 {38.5} 192.1 {19.6}

Installed load of valve spring

Perpendicularity of valve spring

12V140E-3 Series

Spring

Installed length

Outer

51.0

Inner

46.0

Correct or replace valve or valve seat

Replace valve or valve guide

Replace valve Correct

Spring Free length of valve spring

Replace valve

–0.045 –0.060 Replace valve –0.074 –0.089 +0.019 +0.001 Tolerance Not press Replace valve Press fitfitted por- guide ted portion tion +0.008 +0.011 –0.009 –0.009 Clearance limit

After head is press fitted

Clearance between valve guide and stem

Replace valve or valve seat

Replace valve spring

Repair limit: 2° (Both ends)

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10 Structure,function and maintenance standard

Rocker arm and shaft

Unit: mm

No.

Check item Outside diameter of rocker arm shaft

Criteria Standard size

Tolerance

32.0

± 0.0065

1 Inside diameter of rocker arm bush-

32.0

ing Clearance between rocker arm shaft and rocker arm

2 Valve clearance (When cold)

Tightening torque for locknut of rocker arm adjustment screw

Remedy

Standard clearance 0.0215 – 0.0945 Valve

Standard

+0.088 +0.028 Clearance limit 0.13 Tolerance

Intake

0.35

± 0.02

Exhaust

0.57

± 0.02

Target (Nm {kgm})

Range (Nm {kgm})

58.8 {6}

52.9 – 64.7 {5.4 – 6.6}

Replace rocker arm shaft Replace rocker arm Replace rocker arm shaft or rocker arm

Adjust

Tighten

12V140E-3 Series

SEN00307-05

10 Structure,function and maintenance standard

Crosshead and guide

Unit: mm No.

Check item

Criteria Standard size

1 Depth of crosshead stem receiver

6.2

Remedy

Tolerance +0.3 0

Repair limit 6.61

Inside diameter of crosshead

11.04

± 0.02

11.17

Outside diameter of crosshead guide

+0.011 0

10.95

3 Projection of crosshead guide

49.0

± 0.25

—

12V140E-3 Series

Replace

Correct

SEN00307-05

10 Structure,function and maintenance standard

KOMATSU 12V140E-3 Series engine Form Number : SEN00307-05

SEN00309-04

ENGINE 1SHOP MANUAL

12V140E-3 Series

10 Structure, function and maintenance standard

Structure, function and maintenance standard, Part 2 Lubrication system .......................................................................................................................................... 4 Lubrication system diagram.................................................................................................................. 4 Oil pump ............................................................................................................................................... 6 Oil cooler............................................................................................................................................... 7 Oil filter.................................................................................................................................................. 8 Main relief valve.................................................................................................................................... 9 Oil cooler bypass valve and regulator valve ....................................................................................... 10 Fuel system................................................................................................................................................... 12 CRI system diagram ........................................................................................................................... 12 CRI system diagram (Poor fuel spec.)................................................................................................ 14 Outline of CRI system......................................................................................................................... 16

12V140E-3 Series

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10 Structure, function and maintenance standard

Fuel piping .......................................................................................................................................... 34 Fuel piping (Poor fuel spec.) ............................................................................................................... 39 Fuel filter ............................................................................................................................................. 44 Water separator .................................................................................................................................. 46 Priming pump...................................................................................................................................... 47 Electric priming pump ......................................................................................................................... 48 Cooling system.............................................................................................................................................. 50 Cooling system diagram ..................................................................................................................... 50 Water pump ........................................................................................................................................ 52 Thermostat.......................................................................................................................................... 54 Corrosion resistor................................................................................................................................ 55 Cooling fan drive ................................................................................................................................. 57 Electrical equipment...................................................................................................................................... 60 Alternator ............................................................................................................................................ 60 Starting motor...................................................................................................................................... 62 Starting aid .......................................................................................................................................... 64 Engine controller ................................................................................................................................. 67 Engine controller cooler ...................................................................................................................... 68

12V140E-3 Series

10 Structure, function and maintenance standard

12V140E-3 Series

SEN00309-04

10 Structure, function and maintenance standard

Lubrication system

Lubrication system diagram

The shape is subject to machine models.

12V140E-3 Series

10 Structure, function and maintenance standard

SEN00309-04

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 *1 When install optional parts. Since pre-lubrication pump is to be installed in the machine, so for the detail see the Shop Manual for the Machine.

12V140E-3 Series

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10 Structure, function and maintenance standard

Oil pump

A: B:

From oil pan To oil cooler

1. 2. 3. 4. 5.

Pump body Pump drive gear (Number of teeth: 27) Drive gear Driven gear Pump cover

Specifications Oil pump Type: Gear pump Revolving speed: Engine speed x 1.67

12V140E-3 Series

10 Structure, function and maintenance standard

SEN00309-04

Oil cooler

A: Oil inlet and outlet port (Flow is reversed depending on front and rear oil cooler) B: Oil inlet and outlet port (Flow is reversed depending on front and rear oil cooler) C: Coolant 1. 2.

Specifications Oil cooler Heat dissipation surface area: 0.986 m2 Element: 12 stages

Oil cooler cover Cooler element

12V140E-3 Series

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10 Structure, function and maintenance standard

Oil filter

A: B:

Oil inlet port Oil outlet port

1. 2. 3.

Safety valve Filter head Cartridge

Specifications Oil filter Filtration area: 1.62 m2(0.42 m2 x 4) Rated flow: 480l/min Safety valve Cracking pressure: 196 ± 20 kPa {2.0 ± 0.2 kg/ cm2}

12V140E-3 Series

10 Structure, function and maintenance standard

SEN00309-04

Main relief valve

1. 2. 3.

Specifications Main relief valve Cracking pressure: 1,245 ± 69 kPa {12.7 ± 0.7 kg/cm2}

Valve spring Main relief valve Valve body

Unit: mm No.

Check item

Clearance between main relief valve and body

Criteria Tolerance Standard size Outside diam- Inside diameeter of valve ter of body

Standard clearance

–0.040 –0.060

0.040 – 0.076

Free length

Installed length

75.8

59.8

Main relief valve spring

Cracking pressure of main relief valve

12V140E-3 Series

Remedy

+0.016 +0.016

Installed load Allowable load (N {kg}) (N {kg}) 621 {63.4}

Replace valve or body

Replace spring

353 {36}

Standard: 1,245 ± 69 kPa {12.7 ± 0.7 kg/cm2}

Correct or replace spring

SEN00309-04

10 Structure, function and maintenance standard

Oil cooler bypass valve and regulator valve

A: B: C: D:

From main gallery From oil cooler To oil pan To oil filter

1. 2. 3. 4. 5.

Oil cooler bypass valve Bypass valve spring Regulator valve Regulator valve spring Valve body

Specifications Oil cooler bypass valve Cracking pressure (differential pressure): 392 ± 20 kPa {4.0 ± 0.2 kg/cm2} Regulator valve Cracking pressure: 402 ± 49 kPa {4.1 ± 0.5 kg/ cm2}

12V140E-3 Series

10 Structure, function and maintenance standard

SEN00309-04

Unit: mm No.

Check item

Clearance between regulator valve and body

Criteria Tolerance Standard size Outside diam- Inside diameeter of valve ter of body

Standard clearance

–0.020 –0.041

0.020 – 0.074

Free length

Installed length

111.5

Regulator valve spring

Cracking pressure of regulator valve

Clearance between oil cooler bypass valve and body

Oil cooler bypass valve spring Cracking pressure of oil cooler bypass valve

12V140E-3 Series

Remedy

+0.033 +0.033

Installed load Allowable load (N {kg}) (N {kg}) 136.0 {13.87}

Replace valve or body

Replace spring

239 {24.4} Correct or replace spring

Standard: 402 ± 49 kPa {4.1 ± 0.5 kg/cm2} Tolerance Standard size Outside diam- Inside diameeter of valve ter of body

Standard clearance

–0.020 –0.053

+0.033 +0.033

0.020 – 0.086

Free length

Installed length

Installed load (N {kg})

Allowable load

125.8

89.8

186 {19}

—

Standard: 392 ± 20 kPa {4.0 ± 0.2 kg/cm2}

Replace valve or body

Replace spring Correct or replace spring

SEN00309-04

10 Structure, function and maintenance standard

Fuel system

CRI system diagram

CRI is an abbreviation for common rail injection.

12V140E-3 Series

10 Structure, function and maintenance standard

SEN00309-04

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

SEN00309-04

10 Structure, function and maintenance standard

CRI system diagram (Poor fuel spec.)

CRI is an abbreviation for common rail injection.

12V140E-3 Series

10 Structure, function and maintenance standard

SEN00309-04

12V140E-3 Series

SEN00309-04

10 Structure, function and maintenance standard

Outline of CRI system Outline q The CRI system checks the condition of the engine (engine speed, accelerator angle, coolant temperature, etc.) with sensors. q The microcomputer of the CRI system controls the fuel injection rate, fuel injection timing, fuel injection pressure, etc. totally to operate the engine under the best condition. q The CRI system has a diagnosis function and an alarm function, with which the computer of the system checks the main component parts and notifies the operator of detected failures. q In addition, the CRI system has a failsafe function which stops the engine when a certain part fails and a backup function which continues the operation by changing the control method in such a case.

1 1. Fuel system

Configuration The CRI system is divided by the function into the fuel system and control system.

The fuel system distributes the high-pressure fuel generated by the fuel supply pump to the cylinders through the common rail. The solenoid valve in the injector opens and closes the nozzle needle valve to start and finish fuel injection.

12V140E-3 Series

10 Structure, function and maintenance standard

SEN00309-04

2. Control system

To the ECU (engine control unit), the signals are sent from the sensors installed to the machine. Based on the signals, the ECU calculates and controls the energizing timing and energizing period of the injector to injecta proper quantity of fuel in proper timing. The control system is roughly divided by the electric parts into the sensors, computer, and actuators.

12V140E-3 Series

SEN00309-04

10 Structure, function and maintenance standard

Structure and operation of CRI system

The CRI system consists of fuel supply pump, common rail, injector, ECU which controls these 3 units, and sensors. The fuel supply pump generates fuel pressure in the common rail. The fuel pressure is controlled by the fuel discharge rate of the supply pump. The fuel discharge rate is controlled by turning on and off the PCV (Fuel injection pressure control valve) of the fuel supply pump according to the electric signals from the ECU. The common rail receives the pressurized fuel from the fuel supply pump and distributes it to the cylinders. The fuel pressure is sensed by the common rail fuel pressure sensor installed to the common rail. A feedback control is applied so that the actual fuel pressure will match to the command pressure set according to the engine speed and the load on the engine. The fuel pressure in the common rail is applied to the nozzle side of the injector and to the control chamber through the fuel injection pipe of each cylinder. The injector controls the fuel injection rate and fuel injection timing by turning ON and OFF the TWV (2-way solenoid valve).

If the TWV is turned ON (energized), the fuel circuit is changed so that the high-pressure fuel in the control chamber will flow through the orifice. As a result, the needle valve is raised to start fuel injection by the nozzle cracking pressure of the high-pressure fuel on the nozzle side. If the TWV is turned OFF (de-energized), the fuel circuit is changed so that the high-pressure fuel will flow to the control chamber through the orifice. As a result, the needle valve lowers to finish fuel injection. Accordingly, the fuel injection timing and fuel injection rate are controlled respectively by the timing to turn on the TWV and the length of the turn-on time of the TWV.

12V140E-3 Series

10 Structure, function and maintenance standard

SEN00309-04

Structure and operation of component parts

1. Fuel supply pump

1. 2. 3. 4. 5.

3-thread type cam Overflow valve Drive gear No. 1 high-pressure pump PCV (Fuel injection pressure control valve)

6. 7. 8. 9.

No. 2 high-pressure pump Priming pump Feed pump Gear for G speed sensor

Outline q The fuel supply pump consists of priming pump (7), feed pump (8), and high-pressure pumps (4) and (6). q The function of the fuel supply pump is to generate common rail fuel pressure by controlling the fuel discharge rate.

Since the number of the times of feeding fuel to the common rail is the same as the number of the times of fuel injection, the common rail fuel pressure is smooth and stable. The fuel fed by high-pressure pumps (4) and (6) to the common rail is divided as follows. No. 1 high-pressure pump (on the drive gear side) (4) compensates for drop in the common rail fuel pressure caused by fuel injection into the No. 1, 3, and 5 cylinders. No. 2 high-pressure pump (on the feed pump side) (6) compensates for drop in the common rail fuel pressure caused by fuel injection into the No. 2, 4, and 6 cylinders.

Structure High-pressure pumps (4) and (6) have the pressure feed systems similar to those of the conventional in-line fuel injection pump and the PCVs (Fuel injection pressure control valves) for each cylinder to control the fuel delivery. q By employing the 3-head cam, the necessary number of the cylinders of high-pressure pumps (4) and (6) is reduced to 1/3 of the engine cylinders. q

12V140E-3 Series

q q

SEN00309-04

10 Structure, function and maintenance standard

Operation

(A): The PCV is open when the plunger is in lowering stroke, through which low-pressure fuel is sucked in the plunger chamber. q (B): While the PCV is not energized and is open after the plunger starts the rising stroke, the sucked fuel is returned through the PCV without being pressurized. q (C): If the PCV is energized and closed in the timing for the necessary delivery, the return passage is closed and the pressure in the plunger chamber rises. Accordingly, the fuel is fed through the delivery valve (check valve) to the common rail. That is, the quantity of the fuel corresponding to the plunger lift after the PCV is closed is delivery. The delivery is changed and the common rail fuel pressure is controlled by changing the opening timing of the PCV. (pre-stroke of plunger) q (D): After the cam passes the maximum lift point, the plunger starts the lowering stroke and the pressure in it lowers. At this time, the delivery valve closes to stop feeding the fuel. Since the PCV is de-energized, it opens and the low-pressure fuel is sucked in the plunger chamber, or the state of (A) starts again. q

12V140E-3 Series

10 Structure, function and maintenance standard

1) PCV (Fuel injection pressure control valve)

SEN00309-04

2) Feed pump

q q

The PCV adjusts the fuel delivery from the fuel supply pump to adjust the common rail fuel pressure. It means that the delivery from the fuel supply pump to the common rail is decided by the timing of energizing the PCV.

q q

12V140E-3 Series

The feed pump built in the fuel supply pump assembly draws the fuel from the fuel tank and sends it through the fuel filter to the high-pressure pump chamber. The outer and inner rotors of the feed pump are rotated by the camshaft. The fuel is sucked in on the suction side and discharged on the delivery side according to the increase and decrease of the spaces between the outer and inner rotors.

SEN00309-04

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 injectors 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.

Flow damper

Function The flow dampers damp the pressure pulses in the high pressure piping and supply the fuel to the injectors with stable pressure. q If excessive fuel flows out, the flow dampers block the fuel passage to prevent abnormal outflow of the fuel. q If the fuel flows out abnormally, high pressure is applied to the piston, which moves to the right until it reaches the seat to stop the fuel. q

2) q

Pressure limiter If abnormally high pressure is generated, the pressure limiter opens to release that pressure. If the common rail fuel pressure reaches about 140 MPa {1,430 kg/cm2}, the pressure limiter operates (Opens). If the common rail fuel pressure lowers to 30 MPa {310 kg/cm2}, the pressure limiter resets itself (close) to maintain the pressure.

12V140E-3 Series

10 Structure, function and maintenance standard

3) q

SEN00309-04

Common rail fuel pressure sensor The common rail fuel pressure sensor is installed to the common rail to sense the fuel pressure. This sensor is a semiconductor pressure sensor, which utilizes the phenomenon that the electric resistance of silicon changes according to the pressure applied to it.

12V140E-3 Series

SEN00309-04

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 optimum 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 nozzle and controls the fuel injection rate. q The hydraulic piston transmits the force generated by the pressure in the control chamber to the needle valve of the nozzle. q The nozzle sprays the fuel.

12V140E-3 Series

10 Structure, function and maintenance standard

SEN00309-04

Structure

1. 2. 3. 4. 5. 6.

Inlet connector Terminal Upper body Solenoid Valve body Orifice (out)

The injector consists of the nozzle section, orifice to control the fuel injection rate, hydraulic piston section, and 2-way solenoid valve section.

12V140E-3 Series

7. Orifice (in) 8. Pressure control chamber 9. Command piston 10. Spring 11. Pressure pin 12. Nozzle assembly

SEN00309-04

10 Structure, function and maintenance standard

A: B:

No fuel injection Start of fuel injection

C: D:

Finish of fuel injection From common rail

1. 2. 3. 4.

Nozzle Control piston Orifice (in) Orifice (out)

5. 6. 7. 8.

Valve body Solenoid Spring Pressure control chamber

Finish of fuel injection (C) If solenoid (6) is de-energized, valve body (5) is lowered by spring (7) and the fuel passage is closed. Since the high-pressure fuel in the common rail is applied to pressure control chamber (8) suddenly at this time, nozzle (1) is closed quickly and fuel injection is finished sharply.

Operation 1) q q

2) q

q q

No fuel injection (A) While solenoid (6) is not energized, valve body (5) is pressed down by spring (7). Since the high-pressure fuel is applied from the common rail to pressure control chamber (8), nozzle (1) is closed and the fuel is not injected.

Start of fuel injection (B) If solenoid (6) is energized, valve body (5) is raised by electromagnetic power to open the fuel passage. Since the fuel in pressure control chamber (8) flows out through orifices (3) and (4), nozzle (1) rises and the fuel injection pump starts. The fuel injection rate is increased gradually by the function of orifices (3) and (4). Continuing energization to solenoid (6) provides the maximum fuel injection rate.

12V140E-3 Series

10 Structure, function and maintenance standard

SEN00309-04

Electric circuit diagram

k Since high voltage (65V) is applied to the

wiring harnesses connected to the ECU, COMMON1 and COMMON2 of ECU, and TWV#1 – #6 of the injector, take care not to get an electric shock.

12V140E-3 Series

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10 Structure, function and maintenance standard

4. Various sensors and relays 1) q

Fuel temperature sensor The fuel temperature sensor senses the fuel temperature and sends it to the engine controller. The sensor unit is a thermistor the resistance of which changes according to the temperature. The engine controller applies voltage to the thermistor and senses the temperature by the voltage divided by the resistance in the computer and the resistance of the thermistor.

2) q q

NE speed sensor (Crank angle sensor) If the signal hole made on the flywheel passes the sensor, the magnetic line of force changes. If the magnetic line of force changes, the output of the hall element sensor changes linearly and it is converted into pulse of 0 - 5 V by the wave form shaping circuit in the sensor, and then output.

12V140E-3 Series

10 Structure, function and maintenance standard

3) q

A: B:

Atmospheric pressure sensor This sensor is used to correct altitude.

SEN00309-04

Common rail pressure sensor

Oil pressure sensor

Pressure inlet Mounting screw: M5 Tightening torque: 4.5 ± 0.5 Nm {0.46 ± 0.05 kgm} The following graph shows the output characteristics of the atmospheric pressure sensor.

12V140E-3 Series

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10 Structure, function and maintenance standard

Bkup speed sensor (G sensor) (Cylinder No. sensor) Similarly to the NE speed sensor, this sensor utilizes the pulses of 0 – 5 V generated by the change of the magnetic line of force crossing the sensor unit. The disc gear installed to the central part of the camshaft of the high-pressure pump has teeth (cut parts) around it at intervals of 120°. In addition to the above teeth, one more tooth is installed. Accordingly, 7 pulses are generated every 2 revolutions of the engine. The standard pulse of the No. 1 cylinder is recognized by the combination of the NE speed sensor pulse and Bkup speed sensor pulse.

Charge pressure sensor This sensor is used to sense the charge pressure (boost pressure).

Mounting screw: M6 Tightening torque: 5.5 ± 0.5 Nm {0.56 ± 0.05 kgm}

1. 2.

Sensor O-ring

The following graph shows the output characteristics of the charge pressure sensor.

12V140E-3 Series

10 Structure, function and maintenance standard

8) q

Charge temperature sensor The charge temperature sensor senses the intake air temperature (boost temperature) and sends it to the engine controller. The sensor unit is a thermistor the resistance of which changes according to the temperature. The engine controller applies voltage to the thermistor and senses the temperature by the voltage divided by the resistance in the computer and the resistance of the thermistor.

12V140E-3 Series

SEN00309-04

9) q

Coolant temperature sensor The coolant temperature sensor senses the coolant temperature and sends it to the engine controller. The sensor unit is a thermistor the resistance of which changes according to the temperature. The engine controller applies voltage to the thermistor and senses the temperature by the voltage divided by the resistance in the computer and the resistance of the thermistor.

SEN00309-04

10 Structure, function and maintenance standard

Various controls

12V140E-3 Series

10 Structure, function and maintenance standard

SEN00309-04

The CRI system controls the fuel injection rate and fuel injection timing more properly than the mechanical governor or timer of the conventional fuel injection pump. For the control of the system, calculations necessary to the ECU are performed from the signals sent from the sensors installed to the engine and machine. The energizing timing and energizing period of the injector are so controlled that the optimum quantity of fuel will be injected in the optimum timing.

1. Fuel injection rate control function q

The fuel injection rate control function is employed instead of the function of the conventional governor. It controls the fuel injection according to the signals of engine speed and accelerator angle so that the fuel injection rate will be most proper.

2. Fuel injection timing control function q

The fuel injection timing control function is employed instead of the function of the conventional timer. It controls the fuel injection timing most properly from the engine speed and fuel injection rate.

3. Fuel injection pressure control function (Common rail fuel pressure control function) q

The fuel injection control function (common rail fuel pressure control function) controls the fuel discharge rate of the fuel supply pump by measuring the fuel pressure by the common rail fuel pressure sensor and feeding it back to ECU. This function performs pressure feedback control so that the fuel injection pressure will be the same as the optimum value (command value) set according to the engine speed and fuel injection rate.

12V140E-3 Series

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Fuel piping

10 Structure, function and maintenance standard

Left bank

a a

The shape is subject to machine models. The illustration shows the engine for D475A-5E0.

1. 2. 3. 4. 5. 6.

Main fuel filter Pre-fuel filter Priming pump (Main) Fuel pipe (From pre-fuel filter) Fuel pipe (To feed pump) Drain pipe

12V140E-3 Series

10 Structure, function and maintenance standard

SEN00309-04

The shape is subject to machine models.

7. PCV 8. Fuel injection pipe (No.1 cylinder) 9. Fuel injection pipe (No.2 cylinder) 10. Fuel injection pipe (No.3 cylinder) 11. Fuel injection pipe (No.4 cylinder) 12. Fuel injection pipe (No.5 cylinder)

12V140E-3 Series

13. Fuel injection pipe (No.6 cylinder) 14. Common rail 15. Fuel return pipe 16. Feed pump 17. Oil pump (For pump lubricating oil) 18. High-pressure pump

SEN00309-04

10 Structure, function and maintenance standard

Right bank

a a

The shape is subject to machine models. The illustration shows the engine for D475A-5E0.

1. 2. 3.

Fuel pipe (To feed pump) Fuel pipe (From pre-fuel filter) Priming pump (Main)

12V140E-3 Series

10 Structure, function and maintenance standard

4. 5. 6. 7. 8. 9.

Fuel injection pipe (No.6 cylinder) Fuel injection pipe (No.5 cylinder) Fuel injection pipe (No.4 cylinder) Fuel injection pipe (No.3 cylinder) Fuel injection pipe (No.2 cylinder) Fuel injection pipe (No.1 cylinder)

12V140E-3 Series

SEN00309-04

10. PCV 11. High-pressure pump 12. Feed pump 13. Oil pump (For pump lubricating oil) 14. Fuel return pipe 15. Common rail

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10 Structure, function and maintenance standard

Front view of engine

Rear view of engine

12V140E-3 Series

10 Structure, function and maintenance standard

Fuel piping (Poor fuel spec.)

SEN00309-04

Left bank

The shape is subject to machine models.

1. 2. 3. 4. 5. 6.

Main fuel filter Electrical pre-fuel filter Priming pump Fuel pipe (From pre-fuel filter) Fuel pipe (To feed pump) Drain pipe

12V140E-3 Series

SEN00309-04

The shape is subject to machine models.

10 Structure, function and maintenance standard

13. Fuel injection pipe (No.6 cylinder) 14. Common rail 15. Fuel return pipe 16. Feed pump 17. Oil pump (For pump lubricating oil) 18. High-pressure pump

12V140E-3 Series

10 Structure, function and maintenance standard

SEN00309-04

Right bank

The shape is subject to machine models.

1. 2. 3.

Fuel pipe (To feed pump) Fuel pipe (From pre-fuel filter) Priming pump (Main)

12V140E-3 Series

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10 Structure, function and maintenance standard

4. 5. 6. 7. 8. 9.

10. PCV 11. High-pressure pump 12. Feed pump 13. Oil pump (For pump lubricating oil) 14. Fuel return pipe 15. Common rail

12V140E-3 Series

10 Structure, function and maintenance standard

SEN00309-04

Front view of engine

Rear view of engine

12V140E-3 Series

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10 Structure, function and maintenance standard

Fuel filter

The shape is subject to machine models.

A: B:

Fuel inlet Fuel outlet

1. 2. 3.

Air bleeding plug Filter head Cartridge

Specifications Filtration area: 1.0 m2

12V140E-3 Series

10 Structure, function and maintenance standard

SEN00309-04

Pre-fuel filter

The shape is subject to machine models.

A: B:

Fuel inlet Fuel outlet

1. 2. 3.

Air bleeding plug Filter head Cartridge

Specifications Filtration area: 2.12 m2

12V140E-3 Series

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Water separator

The shape is subject to machine models.

A: B:

Fuel inlet Fuel outlet

1. 2. 3. 4. 5. 6.

Head Screen Gasket Ring Case Drain cup

10 Structure, function and maintenance standard

12V140E-3 Series

10 Structure, function and maintenance standard

SEN00309-04

Priming pump

1. 2. 3. 4. 5. 6. 7. 8.

Spring Cover Shaft Bushing Diaphragm Diaphragm cover Body Check valve

12V140E-3 Series

9. Valve stopper 10. Packing 11. Check valve body 12. Lever pin 13. E-ring 14. Washer 15. Bolt 16. Lever

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Electric priming pump

A: B:

Fuel IN Fuel OUT

1. 2.

Connector Vibration prevention rubber

10 Structure, function and maintenance standard

12V140E-3 Series

10 Structure, function and maintenance standard

12V140E-3 Series

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10 Structure, function and maintenance standard

Cooling system

Cooling system diagram

12V140E-3 Series

10 Structure, function and maintenance standard

SEN00309-04

Lubricating oil

1. 2.

Radiator 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

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Water pump

A: B: C:

From thermostat (Coolant) From radiator (Coolant inlet) To oil cooler (Coolant outlet)

1. 2. 3. 4. 5. 6. 7. 8.

Pump shaft Water seal Pump body Water pump drive gear (Number of teeth: 25) Ball bearing Oil seal Impeller Pump cover

10 Structure, function and maintenance standard

Specifications Water pump Type: Centrifugal, gear-driven Revolving speed: Engine speed x 1.80

12V140E-3 Series

10 Structure, function and maintenance standard

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Water pump mounting

The shape is subject to machine models.

A. B: C:

To radiator inlet (Coolant) From power train cooler (Coolant) To power train oil cooler (Coolant)

1. 2. 3.

Oil cooler Thermostat housing Water pump

12V140E-3 Series

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10 Structure, function and maintenance standard

Thermostat

A: B: C:

To radiator To water pump (When bypassing) To thermostat

1. 2. 3.

Thermostat housing Thermostat Cylinder block

Specifications Valve cracking temperature: 76.5 ± 2? Temperature at full opening: 90? Lift at full opening: Min. 10 mm Q'ty: 3 Unit: mm No.

Check item

Criteria

Remedy

Lift of thermostat at full opening

Min. 10 mm (Before checking, leave it in water tank of 90? for 4 – 5 minutes)

Opening/Closing of thermostat

Move valve in fully open condition (in water tank of 90?) to water tank of 71? and keep it for 4 -–5 minutes. Valve must fully close.

Replace

12V140E-3 Series

10 Structure, function and maintenance standard

SEN00309-04

Corrosion resistor

A: B:

Coolant inlet Coolant outlet

1. 2. 3. 4.

Head Element case (Cartridge) Inhibitor (Solid anti-corrosion agent) Valve

12V140E-3 Series

Specifications Corrosion resistor Filtration area: 0.373 m2x 2 Quantity of anti-corrosion agent: 1,000 g x 2

SEN00309-04

10 Structure, function and maintenance standard

Corrosion resistor mounting

The shape is subject to machine models.

1. 2. 3. 4.

Tube (To radiator) Tube (From thermostat housing) Corrosion resistor head Corrosion resistor cartridge

12V140E-3 Series

10 Structure, function and maintenance standard

SEN00309-04

Cooling fan drive

Mounting (Adjustment bolt type) SAA12V140E-3 (HD785-7)

a a

The shape is subject to machine models. For HD785-7cold area arrangement models, type of grease for fan pulley and fan belt material are different. See the Shop Manual or Operation and Maintenance Manual for HD785-7 -40ºC specification models for the detail.

1. 2. 3. 4. 5. 6. 7.

Crankshaft pulley Fan belt Tension pulley Adjustment bolt Tension pulley bracket Fan pulley Fan

Outside diameter of pulley Unit: mm Machine model

Crankshaft pulley

Tension pulley

Fan pulley

Direction of wind from fan

HD785-7

182

154

398

Suck

WA800-3E0, WA900-3E0

182

154

367

Blow out

Engine SAA12V140E-3

12V140E-3 Series

SEN00309-04

10 Structure, function and maintenance standard

Tension pulley SAA12V140E-3 (HD785-7, WA800-3E0, WA900-3E0)

a a

The shape is subject to machine models. For HD785-7 cold area arrangement models, type of grease is different. See the Shop Manual or Operation and Maintenance Manual for HD785-7 -40ºC specification models for the detail.

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

12V140E-3 Series

10 Structure, function and maintenance standard

SEN00309-04

(For D475A-5E0, PC2000-8) The cooling fan is hydraulic motor-driven. For more information, refer to the shop manual for the machine body.

12V140E-3 Series

SEN00309-04

10 Structure, function and maintenance standard

Electrical equipment

Alternator

Alternator with built-in regulator (Open type, 90A)

The shape is subject to machine models.

1. 2. 3. 4. 5.

Alternator Alternator pulley Terminal B Terminal R Terminal E

Engine

Machine model

Internal connection diagram 6A. Field coil 6B. Initial excitation resistor 6C. Regulator

Type

D475A-5E0 HD785-7 Open type (brushless) manuSAA12V140E-3 PC2000-8 factured by NIKKO DENKI WA800-3E0, WA900-3E0

Pulley SpecificaOutside Number tions diameter of stages (mm)

24V, 90A

Weight (kg)

12V140E-3 Series

10 Structure, function and maintenance standard

SEN00309-04

Alternator mounting

a a

The shape is subject to machine models. For HD785-7 cold area arrangement models, material of alternator drive belt is different. See the Shop Manual or Operation and Maintenance Manual for HD785-7 -40ºC specification models for the detail.

Outside diameter of accessory pulley: 167 mm

1. 2. 3. 4. 5.

Adjustment bolt Alternator pulley Alternator Alternator drive belt Accessory pulley

12V140E-3 Series

SEN00309-04

10 Structure, function and maintenance standard

Starting motor

For 7.5 kW

The shape is subject to machine models.

E: R: S:

To chassis ground To alternator terminal R To starting switch terminal C

1. 2. 3. 4. 5.

Pinion gear Starting motor assembly Magnetic switch Terminal B Terminal C

Engine

Machine model

6. 7.

Type

Safety relay External connection diagram (2-pole connector type) 7A. Safety relay section 7B. Starting motor section

Specifications

D475A-5E0 Water-resistant, oil-resistant SAA12V140E-3 HD785-7 type manufactured by NIKKO 24V, 7.5 kW WA800-3E0, WA900-3E0 DENKI

Number of pinion teeth 11

Weight Type of (kg) connector

12V140E-3 Series

10 Structure, function and maintenance standard

SEN00309-04

For 11 kW

The shape is subject to machine models.

E: R: S:

To chassis ground To alternator terminal R To starting switch terminal C

1. 2. 3. 4. 5. 6.

Pinion gear Starting motor assembly Magnetic switch Terminal B Terminal C Safety relay

8. 9.

External connection diagram (2-pole connector type) 7A. Safety relay section 7B. Starting motor section Jump start prohibition label Jump start prevention cover

Engine

Machine model

Type

Specifications

Number of pinion teeth

Weight (kg)

Type of connector

SAA12V140E-3

PC2000-8

Water-resistant, oil-resistant type manufactured by NIKKO DENKI

24V, 11 kW

12V140E-3 Series

SEN00309-04

10 Structure, function and maintenance standard

Starting aid

Electric heater

The shape is subject to machine models.

1. 2. 3. 4.

Body Heater coil Terminal Connection diagram

Specifications Type of heater: Electrical intake air heater Rated voltage: 22 V (DC) Load current: 175 A

12V140E-3 Series

10 Structure, function and maintenance standard

SEN00309-04

oil pan heater, coolant heater (Option)

The shape is subject to machine models.

1. 2.

oil pan heater coolant heater

12V140E-3 Series

SEN00309-04

10 Structure, function and maintenance standard

oil pan heater

Specifications Rated voltage: 230 V (AC) Capacity : 600 W

Coolant heater

Specifications Rated voltage: 230 V (AC) Capacity : 1.5 kW

12V140E-3 Series

10 Structure, function and maintenance standard

SEN00309-04

Engine controller

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. Unified specifications of engine controller Engine controller CM850 developed by the cooperation between KOMATSU and CUMMINS is employed.

12V140E-3 Series

SEN00309-04

Engine controller cooler

10 Structure, function and maintenance standard

HD785-7, PC2000-8

A: B:

Fuel IN (From feed pump of fuel supply pump) Fuel OUT (Main fuel filter)

1. 2.

Engine controller 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.

12V140E-3 Series

10 Structure, function and maintenance standard

12V140E-3 Series

SEN00309-04

10 Structure, function and maintenance standard

KOMATSU 12V140E-3 Series engine Form No. SEN00309-04

12V140E-3 Series

SEN00311-03

ENGINE 1SHOP MANUAL

12V140E-3 Series

20 Standard value table

Standard service value table Standard service value table ........................................................................................................................... 2 Standard service value table for testing, adjusting, and troubleshooting ............................................. 2 Running-in standard and performance test standard ........................................................................... 7

12V140E-3 Series

SEN00311-03

20 Standard value table

Standard service value table

Air intake and exhaust system

Performance

Category

Standard service value table for testing, adjusting, and troubleshooting1

Necessary speed for starting

Body Lubrication system Cooling system

Machine model

D475A-5E0 Standard value for new machine

Max. speed at no load

rpm

2,150 (+25/-50) 2,150 (+25/-50)

Min. speed at no load

rpm

660 ± 40

At 0°C (without starting aid)

rpm

Min. 110

—

At –20°C (with starting aid)

rpm

Min. 100

—

Measurement conditions

Service limit value

Air intake resistance

Whole speed range

kPa {mmH2O}

Max. 3.73 {Max. 380}

7.47 {762}

Air boost pressure

At rated output

kPa {mmHg}

Min. 126.66 {Min. 950}

—

Exhaust pressure

At rated output

kPa {mmHg}

—

Exhaust temperature

Whole speed range (20°C )

°C

Max. 680

750

At sudden acceleration (Low to High)

Bosch index

Max. 4.5

5.5

At rated output

Bosch index

Max. 1.0

2.0

At high idle

Bosch index

Max. 1.0

2.0

Intake valve

0.35 ± 0.02

Exhaust gas color

Valve clearance

—

SAA12V140E-3

Unit

Item

Speed

Engine

Exhaust valve

0.57 ± 0.02

Min. 4.1 {Min. 42}

2.8 {29}

Compression pressure

Engine oil temperature: 40 – 60°C Engine speed: 200 – 250 rpm

MPa {kg/cm2}

Blow-by pressure

At rated output Engine coolant temperature: Min. 70°C

kPa {mmH2O}

Max. 2.94 {Max. 300}

5.88 {600}

MPa {kg/cm2}

0.29 – 0.44 {3.0 – 4.5}

0.2 {2.0}

MPa {kg/cm2}

Min. 0.08 {Min. 0.8}

0.04 {0.4}

°C

90 – 110

120

0.15

0.3

kPa {kg/cm2}

—

At rated output Engine oil temperature: Min. 80°C Oil pressure

At low idle Engine oil temperature: Min. 80°C

SAE0W30E0S SAE5W40E0S SAE10W30DH SAE15W40DH SAE30DH

Oil temperature Whole speed range (Oil in oil pan) Oil consumption

Ratio to fuel consumption at continuous rated output

Function of radiator pressure valve

Cracking pressure (Differential pressure)

Fan speed

At rated speed

rpm

Hydraulically driven on machine side

Alternator belt tension

Deflection under finger pressure of 59 N {6 kg}

12V140E-3 Series

Air intake and exhaust system

Performance

Category

20 Standard value table

Necessary speed for starting

Body Lubrication system Cooling system

SAA12V140E-3

Machine model

HD785-7 Standard value for new machine

Service limit value

Max. speed at no load

rpm

2,250 ± 25

Min. speed at no load

rpm

650 ± 20

At 0°C (without starting aid)

rpm

Min. 110

—

At –20°C (with starting aid)

rpm

Min. 100

—

Measurement conditions

Air intake resistance

Whole speed range

kPa {mmH2O}

Max. 3.73 {Max. 380}

7.47 {762}

Air boost pressure

At rated output

kPa {mmHg}

Min. 165.40 {Min. 1,250}

—

Exhaust pressure

At rated output

kPa {mmHg}

—

Exhaust temperature

Whole speed range (20°C )

°C

Max. 700

750

At sudden acceleration (Low to High)

Bosch index

Max. 4.5

5.5

At rated output

Bosch index

Max. 1.0

2.0

At high idle

Bosch index

Max. 1.0

2.0

Intake valve

0.35 ± 0.02

Exhaust gas color

Valve clearance

—

Engine

Unit

Item

Speed

SEN00311-03

Exhaust valve

0.57 ± 0.02

Min. 4.1 {Min. 42}

2.8 {29}

Compression pressure

Engine oil temperature: 40 – 60°C Engine speed: 200 – 250 rpm

MPa {kg/cm2}

Blow-by pressure

At rated output Engine coolant temperature: Min. 70°C

kPa {mmH2O}

Max. 2.94 {Max. 300}

5.88 {600}

MPa {kg/cm2}

0.29 – 0.44 {3.0 – 4.5}

0.2 {2.0}

MPa {kg/cm2}

Min. 0.08 {Min. 0.8}

0.04 {0.4}

°C

90 – 110

120

0.15

0.3

kPa {kg/cm2}

—

At rated output Engine oil temperature: Min. 80°C Oil pressure

At low idle Engine oil temperature: Min. 80°C

SAE0W30E0S SAE5W40E0S SAE10W30DH SAE15W40DH SAE30DH

Oil temperature Whole speed range (Oil in oil pan) Oil consumption

Ratio to fuel consumption at continuous rated output

Function of radiator pressure valve

Cracking pressure (Differential pressure)

Fan speed

At rated speed

rpm

860

Alternator belt tension

Deflection under finger pressure of 59 N {6 kg}

12V140E-3 Series

Air intake and exhaust system

Performance

Category

SEN00311-03

Speed Necessary speed for starting

Body Lubrication system Cooling system

Engine

SAA12V140E-3

Machine model

PC2000-8 Unit

Standard value for new machine

Service limit value

Max. speed at no load

rpm

1,980 ± 25

Min. speed at no load

rpm

825 ± 25

At 0°C (without starting aid)

rpm

Min. 110

—

At –20°C (with starting aid)

rpm

Min. 100

—

Item

Measurement conditions

Air intake resistance

Whole speed range

kPa {mmH2O}

Max. 3.73 {Max. 380}

7.47 {762}

Air boost pressure

At rated output

kPa {mmHg}

Min. 125.70 {Min. 950}

—

Exhaust pressure

At rated output

kPa {mmHg}

—

Exhaust temperature

Whole speed range (20°C )

°C

Max. 700

750

At sudden acceleration (Low to High)

Bosch index

Max. 4.5

5.5

At rated output

Bosch index

Max. 1.0

2.0

At high idle

Bosch index

Max. 1.0

2.0

Intake valve

0.35 ± 0.02

Exhaust gas color

Valve clearance

—

20 Standard value table

Exhaust valve

0.57 ± 0.02

Min. 4.1 {Min. 42}

2.8 {29}

Compression pressure

Engine oil temperature: 40 – 60°C Engine speed: 200 – 250 rpm

MPa {kg/cm2}

Blow-by pressure

At rated output Engine coolant temperature: Min. 70°C

kPa {mmH2O}

Max. 2.94 {Max. 300}

5.88 {600}

MPa {kg/cm2}

0.29 – 0.44 {3.0 – 4.5}

0.2 {2.0}

MPa {kg/cm2}

Min. 0.08 {Min. 0.8}

0.06 {0.6}

°C

90 – 110

120

0.15

0.3

kPa {kg/cm2}

—

At rated output Engine oil temperature: Min. 80°C Oil pressure

At low idle Engine oil temperature: Min. 80°C

SAE0W30E0S SAE5W40E0S SAE10W30DH SAE15W40DH SAE30DH

Oil temperature Whole speed range (Oil in oil pan) Oil consumption

Ratio to fuel consumption at continuous rated output

Function of radiator pressure valve

Cracking pressure (Differential pressure)

Fan speed

At rated speed

rpm

Hydraulically driven on machine side

Alternator belt tension

Deflection under finger pressure of 59 N {6 kg}

12V140E-3 Series

Air intake and exhaust system

Performance

Category

20 Standard value table

Necessary speed for starting

Body Lubrication system Cooling system

SAA12V140E-3

Machine model

WA800-3E0 Standard value for new machine

Max. speed at no load

rpm

2,200 (+10/-20) 2,200 (+10/-20)

Min. speed at no load

rpm

680 (+50/0)

At 0°C (without starting aid)

rpm

Min. 110

—

At –20°C (with starting aid)

rpm

Min. 100

—

Measurement conditions

Service limit value

Air intake resistance

Whole speed range

kPa {mmH2O}

Max. 3.73 {Max. 380}

7.47 {762}

Air boost pressure

At rated output

kPa {mmHg}

Min. 125.70 {Min. 950}

—

Exhaust pressure

At rated output

kPa {mmHg}

—

Exhaust temperature

Whole speed range (20°C )

°C

Max. 680

750

At sudden acceleration (Low to High)

Bosch index

Max. 4.5

5.5

At rated output

Bosch index

Max. 1.0

2.0

At high idle

Bosch index

Max. 1.0

2.0

Intake valve

0.35 ± 0.02

Exhaust gas color

Valve clearance

—

Engine

Unit

Item

Speed

SEN00311-03

Exhaust valve

0.57 ± 0.02

Min. 4.1 {Min. 42}

2.8 {29}

Compression pressure

Engine oil temperature: 40 – 60°C Engine speed: 200 – 250 rpm

MPa {kg/cm2}

Blow-by pressure

At rated output Engine coolant temperature: Min. 70°C

kPa {mmH2O}

Max. 2.94 {Max. 300}

5.88 {600}

MPa {kg/cm2}

0.29 – 0.44 {3.0 – 4.5}

0.2 {2.0}

MPa {kg/cm2}

Min. 0.08 {Min. 0.8}

0.04 {0.4}

°C

90 – 110

120

0.15

0.3

kPa {kg/cm2}

—

At rated output Engine oil temperature: Min. 80°C Oil pressure

At low idle Engine oil temperature: Min. 80°C

SAE0W30E0S SAE5W40E0S SAE10W30DH SAE15W40DH SAE30DH

Oil temperature Whole speed range (Oil in oil pan) Oil consumption

Ratio to fuel consumption at continuous rated output

Function of radiator pressure valve

Cracking pressure (Differential pressure)

Fan speed

At rated speed

rpm

980

Alternator belt tension

Deflection under finger pressure of 59 N {6 kg}

12V140E-3 Series

Air intake and exhaust system

Performance

Category

SEN00311-03

Speed Necessary speed for starting

Body Lubrication system Cooling system

Engine

SAA12V140E-3

Machine model

WA900-3E0 Unit

Standard value for new machine

Max. speed at no load

rpm

2,200 (+10/-20) 2,200 (+10/-20)

Min. speed at no load

rpm

680 (+50/0)

At 0°C (without starting aid)

rpm

Min. 110

—

At –20°C (with starting aid)

rpm

Min. 100

—

Item

Measurement conditions

Service limit value

Air intake resistance

Whole speed range

kPa {mmH2O}

Max. 3.73 {Max. 380}

7.47 {762}

Air boost pressure

At rated output

kPa {mmHg}

Min. 132.30 {Min. 1,000}

—

Exhaust pressure

At rated output

kPa {mmHg}

—

Exhaust temperature

Whole speed range (20°C )

°C

Max. 700

750

At sudden acceleration (Low to High)

Bosch index

Max. 4.5

5.5

At rated output

Bosch index

Max. 1.0

2.0

At high idle

Bosch index

Max. 1.0

2.0

Intake valve

0.35 ± 0.02

Exhaust gas color

Valve clearance

—

20 Standard value table

Exhaust valve

0.57 ± 0.02

Min. 4.1 {Min. 42}

2.8 {29}

Compression pressure

Engine oil temperature: 40 – 60°C Engine speed: 200 – 250 rpm

MPa {kg/cm2}

Blow-by pressure

At rated output Engine coolant temperature: Min. 70°C

kPa {mmH2O}

Max. 2.94 {Max. 300}

5.88 {600}

MPa {kg/cm2}

0.29 – 0.44 {3.0 – 4.5}

0.2 {2.0}

MPa {kg/cm2}

Min. 0.08 {Min. 0.8}

0.04 {0.4}

°C

90 – 110

120

0.15

0.3

kPa {kg/cm2}

—

At rated output Engine oil temperature: Min. 80°C Oil pressure

At low idle Engine oil temperature: Min. 80°C

SAE0W30E0S SAE5W40E0S SAE10W30DH SAE15W40DH SAE30DH

Oil temperature Whole speed range (Oil in oil pan) Oil consumption

Ratio to fuel consumption at continuous rated output

Function of radiator pressure valve

Cracking pressure (Differential pressure)

Fan speed

At rated speed

rpm

1,005

Alternator belt tension

Deflection under finger pressure of 59 N {6 kg}

12V140E-3 Series

20 Standard value table

SEN00311-03

Running-in standard and performance test standard

Running-in standard Engine

SAA12V140E-3

Machine model

D475A-5E0 Procedure

Item

Running time

min.

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 a

This table shows the values when the fan is not installed. The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.

Performance test standard Engine

SAA12V140E-3

Machine model

D475A-5E0

Test item

Rated output

Max. torque

Max. speed at no load

Min. speed at no load

Specification value (Gross value)

—

Speed

rpm

2,000 ± 5

1,300 – 1,500

—

Dynamometer load

N {kg}

4,341 – 4,596 {443 – 469}

5,174 – 5,498 {528 – 561}

—

Output (Gross value)

kW {HP}

651 – 691 {873 – 926}

—

Torque (Gross value)

Nm {kgm}

—

3,704 – 3,940 {378 – 402}

—

Fuel consumption

sec/1,000cc

Min. 19.5

—

Coolant temperature

°C

70 – 90

Lubricating oil temperature

°C

90 – 110

Lubricating oil pressure

MPa {kg/cm2}

0.34 – 0.49 {3.0 – 4.5}

—

Min. 0.08 {Min. 0.8}

Exhaust temperature

°C

Max. 650

Max. 680

—

a a a a a a a

671 kW/2,000 rpm 3,825 Nm/1,400 rpm 2,150(+25/-50)rpm {899 HP/2,000 rpm} {390 kgm/1,400 rpm}

660 ± 40 rpm

This table shows the standard values obtained by using the JIS correction coefficients. 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. This table shows the standard values when the air cleaner and the muffler are installed and no load is applied to the alternator. The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long. Use ASTM No.1 or No. 2 diesel fuel as fuel. Use SAE15W-40 as lubricating oil. Aftercooler outlet temperature must not exceed 50°C.

12V140E-3 Series

SEN00311-03

20 Standard value table

Running-in standard Engine

SAA12V140E-3

Machine model

HD785-7 Procedure

Item

Running time

min.

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 a

This table shows the values when the fan is not installed. The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.

Performance test standard Engine

SAA12V140E-3

Machine model

HD785-7

Test item

Rated output

Max. torque

Max. speed at no load

Min. speed at no load

2,250 ± 25 rpm

650 ± 20 rpm

Specification value (Gross value)

—

Speed

rpm

1,900 ± 5

1,300 – 1,400

—

Dynamometer load

N {kg}

6,086 – 6,468 {621 – 660}

6,870 – 7,311 {701 – 746}

—

Output (Gross value)

kW {HP}

868 – 922 {1,160 – 1,240}

—

Torque (Gross value)

Nm {kgm}

—

4,920 – 5,233 {502 – 534}

—

Fuel consumption

sec/1,000cc

Min. 15.2

—

Coolant temperature

°C

70 – 90

Lubricating oil temperature

°C

90 – 110

Lubricating oil pressure

MPa {kg/cm2}

0.34 – 0.49 {3.0 – 4.5}

—

Min. 0.08 {Min. 0.8}

Exhaust temperature

°C

Max. 650

Max. 700

—

a a

895 kW/1,900 rpm 5,076 Nm/1,350 rpm {1,200 HP/1,900 rpm} {518 kgm/1,350 rpm}

a a a a

12V140E-3 Series

20 Standard value table

SEN00311-03

Running-in standard Engine

SAA12V140E-3

Machine model

PC2000-8 Procedure

Item

Running time

min.

Speed

rpm

825

1,000

1,250

1,550

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 a

This table shows the values when the fan is not installed. The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.

Performance test standard Engine

SAA12V140E-3

Machine model

PC2000-8

Test item

Rated output

Max. torque

Max. speed at no load

Min. speed at no load

1,980 ± 25 rpm

825 ± 25 rpm

Specification value (Gross value)

—

Speed

rpm

1,800 ± 5

1,300 – 1,400

—

Dynamometer load

N {kg}

4,341 – 4,596 {534 – 567}

6,076 – 6,380 {620 – 659}

—

Output (Gross value)

kW {HP}

706 – 750 {947 – 1,010}

—

Torque (Gross value)

Nm {kgm}

—

4,351 – 4,626 {444 – 472}

—

Fuel consumption

sec/1,000cc

Min. 18.6

—

Coolant temperature

°C

70 – 90

Lubricating oil temperature

°C

90 – 110

Lubricating oil pressure

MPa {kg/cm2}

0.34 – 0.49 {3.0 – 4.5}

—

Min. 0.08 {Min. 0.8}

Exhaust temperature

°C

Max. 650

Max. 700

—

a a a a a a a

728 kW/1,800 rpm 4,488 Nm/1,350 rpm {976 HP/1,800 rpm} {458 kgm/1,350 rpm}

12V140E-3 Series

SEN00311-03

20 Standard value table

Running-in standard Engine

SAA12V140E-3

Machine model

WA800-3E0 Procedure

Item

Running time

min.

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 a

This table shows the values when the fan is not installed. The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.

Performance test standard Engine

SAA12V140E-3

Machine model

WA800-3E0

Test item

Rated output

Max. torque

Max. speed at no load

Min. speed at no load

2,200 (+10/-20) rpm

680 (+50/0) rpm

Specification value (Gross value)

—

Speed

rpm

2,000 ± 5

1,350 – 1,450

—

Dynamometer load

N {kg}

4,116 – 4,371 {420 – 446}

5,155 – 5,468 {526 – 558}

—

Output (Gross value)

kW {HP}

617 – 655 {827 – 879}

—

Torque (Gross value)

Nm {kgm}

—

3,685 – 3,920 {376 – 400}

—

Fuel consumption

sec/1,000cc

Min. 20.5

—

Coolant temperature

°C

70 – 90

Lubricating oil temperature

°C

90 – 110

Lubricating oil pressure

MPa {kg/cm2}

0.34 – 0.49 {3.0 – 4.5}

—

Min. 0.08 {Min. 0.8}

Exhaust temperature

°C

Max. 650

Max. 680

—

a a

636 kW/2,000 rpm 3,802 Nm/1,400 rpm {853 HP/2,000 rpm} {388 kgm/1,400 rpm}

a a a a

12V140E-3 Series

20 Standard value table

SEN00311-03

Running-in standard Engine

SAA12V140E-3

Machine model

WA900-3E0 Procedure

Item

Running time

min.

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 a

This table shows the values when the fan is not installed. The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.

Performance test standard Engine

SAA12V140E-3

Machine model

WA900-3E0

Test item

Rated output

Max. torque

Max. speed at no load

Min. speed at no load

Specification value (Gross value)

—

Speed

rpm

2,050 ± 5

1,250 – 1,350

—

Dynamometer load

N {kg}

4,234 – 4,488 {432 – 458}

5,625 – 5,978 {574 – 610}

—

Output (Gross value)

kW {HP}

652 – 691 {874 – 927}

—

Torque (Gross value)

Nm {kgm}

—

4,028 – 4,283 {411 – 437}

—

Fuel consumption

sec/1,000cc

Min. 19.5

—

Coolant temperature

°C

70 – 90

Lubricating oil temperature

°C

90 – 110

Lubricating oil pressure

MPa {kg/cm2}

0.34 – 0.49 {3.0 – 4.5}

—

Min. 0.08 {Min. 0.8}

Exhaust temperature

°C

Max. 650

Max. 700

—

a a a a a a a

672 kW/2,050 rpm 4,159 Nm/1,300 rpm 2,200(+10/-20)rpm {900 HP/2,050 rpm} {424 kgm/1,300 rpm}

680(+50/0)rpm

12V140E-3 Series

SEN00311-03

20 Standard value table

KOMATSU 12V140E-3 Series engine Form No. SEN00311-03

12V140E-3 Series

SEN00313-04

ENGINE 1SHOP MANUAL 2 3

12V140E-3 Series

30 Testing and adjusting

Testing and adjusting Testing and adjusting tools list ........................................................................................................................ 3 Testing air boost pressure............................................................................................................................... 5 Testing exhaust temperature........................................................................................................................... 6 Adjusting valve clearance ............................................................................................................................... 7 Testing compression pressure ........................................................................................................................ 9 Testing blow-by pressure ...............................................................................................................................11 Testing oil pressure ....................................................................................................................................... 12 Handling fuel system parts............................................................................................................................ 13 Releasing residual pressure in fuel system .................................................................................................. 13 Testing fuel pressure..................................................................................................................................... 14 Reduced cylinder mode operation ................................................................................................................ 15 No-injection cranking .................................................................................................................................... 15 Testing leakage-from pressure limiter and return rate from injector.............................................................. 16 Bleeding air from fuel circuit (for D475A-5)................................................................................................... 19 Bleeding air from fuel circuit (for PC2000) .................................................................................................... 22 Bleeding air from fuel circuit (Poor fuel spec.) .............................................................................................. 24

12V140E-3 Series

SEN00313-04

30 Testing and adjusting

Testing fuel system for leakage..................................................................................................................... 26 Adjusting speed sensor................................................................................................................................. 27 Testing and adjusting alternator belt tension................................................................................................. 27 Handling controller high-voltage circuit ......................................................................................................... 28

12V140E-3 Series

30 Testing and adjusting

SEN00313-04

Testing/Adjusting item

Symbol

Part No.

Part name

Remarks

799-201-2202 Boost gauge kit

1 -101 – 200 kPa {-760 – 1,500 mmHg}

799-401-2220 Hose

799-101-1502 Digital thermometer

1 - 99.9 – 1,299°C

Commercially Thickness gauge available

795-502-1590 Compression gauge

1 0 – 6.9 MPa {0 – 70 kg/cm2}

795-471-1310 Adapter

Testing air boost pressure

Testing exhaust temperature Adjusting valve clearance Testing compression pressure

1 Q'ty

Testing and adjusting tools list

1 D

Intake: 0.35 mm Exhaust: 0.57 mm

6261-71-6150 Gasket 799-201-1504 Blow-by checker kit

For 140E-3, 5 1 1 0 – 10 kPa {0 – 1,000 mmH2O}

2 Testing blow-by pressure E 3

799-201-1590 Gauge 799-201-1450 Adapter

1 2

4 5

799-201-1511 Nozzle 799-201-1571 Tube

2 1

799-101-5002 Hydraulic tester

799-261-1204 Digital hydraulic tester

1 Pressure gauge: 60 MPa {600 kg/cm2}

799-401-2320 Gauge

1 Pressure gauge: 1 MPa {10 kg/cm2}

799-101-5002 Hydraulic tester

799-261-1204 Digital hydraulic tester

1 Pressure gauge: 60 MPa {600 kg/cm2}

795-471-1450 Adapter 799-101-5220 Nipple (10 x 1.25 mm)

1 8 x 1.25 (male) – R1/8 (female) 1 Size: 10 x 1.25 mm 1

Testing oil pressure

2 1 Testing fuel pressure

G 2 3

Testing leakage through pressure limiter and return rate from injector

799-401-2320 Gauge

1 Pressure gauge: 1 MPa {10 kg/cm2}

1 2

6151-51-8490 Spacer 6141-71-1710 Joint

1 ø 14 1 ø 10

Commercially Hose available

1 Inside diameter: Approx. 11 mm

Commercially Hose available

1 Inside diameter: Approx. 17 mm

12V140E-3 Series

O-ring

Pressure gauge: 2.5, 6, 40, 60 MPa {25, 60, 400, 600 kg/cm2}

Controller • sensor • Actuator diagnosis

07002-11023

Pressure gauge: 2.5, 6, 40, 60 MPa {25, 60, 400, 600 kg/cm2}

Commercially Measuring cylinder available Commercially Stopwatch available 07376-70315 Plug

1 1 1 Size: 03

799-601-4130 T-adapter 799-601-4330 Socket

1 For Ne sensor 1 For G (Bkup) sensor

799-601-4240 Socket 799-601-4250 Socket

1 For atmospheric pressure sensor 1 For boost pressure sensor

799-601-9420 T-adapter 799-601-4150 T-adapter

1 For common rail pressure sensor 1 For oil pressure sensor

Testing/Adjusting item

30 Testing and adjusting

Symbol

Part No.

Part name

799-601-9430 Socket 799-601-9020 T-adapter 799-601-4260 T-adapter

1 For injector 1 For controller (4 - pole)

799-601-4211 T-adapter 799-601-4220 T-adapter

1 For controller (50 - pole) 1 For controller (60 - pole)

799-601-4350 T-box 799-601-9320 T-box

1 For 60 - pole type 1 For 24 - pole type

799-601-9310 Plate

795-799-5530 Socket

Remarks

For boost temperature sensor For intake air sensor For coolant temperature sensor 1 For fuel temperature sensor Oil temperature sensor 1 For supply pump PCV

795-799-5540 Socket

Controller • sensor • Actuator diagnosis

Q'ty

SEN00313-04

12V140E-3 Series

30 Testing and adjusting

SEN00313-04

Testing air boost pressure a

Testing tools for air boost pressure

Symbol A

Part No.

Part name

799-201-2202

Boost gauge kit

790-401-2220

Hose

k Be careful not to touch any hot part when

a 1.

removing or installing the testing tools. The test point is subject to machine models. Remove air boost pressure pickup plug ((L1) on left bank or (R1) on right bank) from the bottom of the air intake connector. 4.

Install nipple [1] of boost gauge kit A and connect it to gauge [2]. a Example of (L1) on the left bank

Run the engine at the rated output and test the air boost pressure. a When testing with the engine mounted on the machine, test on the condition described in the shop manual for the machine.

12V140E-3 Series

After finishing testing, remove the testing tools and return the removed parts.

SEN00313-04

30 Testing and adjusting

Testing exhaust temperature a

Run the engine and test the exhaust temperature in the whole speed range. a When testing with the engine mounted on the machine, test on the condition described in the shop manual for the machine.

After finishing testing, remove the testing tools and return the removed parts.

Testing tool for exhaust temperature

Symbol

Part No.

799-101-1502

Part name Digital thermometer

k Remove and install the testing tools after

a 1.

the exhaust manifold temperature has lowered. The test point is subject to machine models. Remove an exhaust temperature pickup plug (1) of the subject section for measuring from the top of the exhaust manifold. a Subject section for measuring includes front left, rear left, front right and rear right (4 points in total).

Install sensor [1] of digital thermometer B and connect it to thermometer [2]. a Installation example to the rear right-hand side (RR)

For engines mounted with the exhaust temperature sensor, connect temperature gauge [2] to the sensor on machine.

12V140E-3 Series

30 Testing and adjusting

SEN00313-04

Adjusting valve clearance a

Adjusting tool for valve clearance

Symbol

Part No.

Commercially available

Part name Clearance gauge

Hereafter crank the engine similar way in the firing order. Match the stamped line of the damper to the pointer and adjust the valve clearance of each cylinder. a Firing order R1 – L1 – R5 – L5 – R3 – L3 – R6 – L6 – R2 – L2 – R4 – L4

Valve clearance adjusting method 1.

Remove cylinder head cover.

Rotate the crankshaft forward and match stamped line of R1.6 TOP on vibration damper (1) to pointer (2), by setting RH No. 1 cylinder to the compression top dead center while watching the movement of the intake valve of RH No. 6 cylinder. a Crank the engine using the barring tool (B) mounted to the front right-hand side of the flywheel housing. a At near the compression top dead center of the RH No. 1 cylinder, the intake valve of RH No. 6 cylinder moves.(opens).

Loosen locknut (6) of RH No. 1 cylinder adjust screw (5). Insert a clearance gauge C of specified clearance between the crosshead (4) and rocker arm (3) and adjust the adjustment screw to the degree that the clearance gauge can be moved lightly. a Valve clearance Air Intake valve: 0.35 mm, Exhaust valve: 0.57 mm

Tighten locknut (6) to secure adjustment screw. 3 Locknut tightening torque: 52.9 – 64.7 Nm {5.4 – 6.6 kgm} a After tightening the locknut, check the valve clearance again.

12V140E-3 Series

SEN00313-04

30 Testing and adjusting

After finishing adjustment, return the removed parts. 3 Cylinder head cover mounting bolt: 14.7 – 34.3 Nm {1.5 – 3.5 kgm}

12V140E-3 Series

30 Testing and adjusting

SEN00313-04

Testing compression pressure a

Testing tools for compression pressure

Symbol 1 D

Part No.

Part name

795-502-1590

Compression gauge

795-471-1310

Adapter

6261-71-6150

Gasket

k When

measuring the compression pressure, take care not to burn yourself on the exhaust manifold, muffler, etc. or get caught in a rotating part. Measure the compression pressure after the engine is warmed up. (Engine oil temperature: 40 – 60°C).

Install adapter D2 to the mounting hole on the injector and compression gauge D1. a Fit the gasket to the injector end without fail a Fix the adapter with the injector holder. 3 Holder mounting bolt: 58.8 – 73.5 Nm {6.0 – 7.5 kgm} a Apply a little amount of engine oil to the connecting parts of the adapter and gauge so that air will not leak easily.

Install rocker arm assembly (2) and adjust the valve clearance. 3 Rocker arm assembly mounting bolt: 93 – 103 Nm {9.5 – 10.5 kgm} a See “Adjusting valve clearance“.

Connect the INSITE (bench test tool) to the engine and set the engine in the no-injection cranking mode. k If the engine is not set in the no-injection cranking mode, it will start and will be dangerous. Accordingly, be sure to set the engine in this mode.

Remove cylinder head cover (1) of the cylinder to be tested for compression pressure.

Bring the cylinder to be tested to the compression top dead center and remove rocker arm assembly (2). a See “Adjusting valve clearance“.

Disconnect fuel high-pressure tube (3) and injector wiring harness and remove injector (4). a Disconnect the terminal of the injector wiring harness on the injector side and the bracket on the rocker housing side and r e mo v e t he i n j ec to r w i r i ng h a r n es s (Loosen the 2 terminal nuts alternately) from the injector. a Pass injector under the fuel path projected sideways and pull up the injector through wire (Do not pry the injector top up).

12V140E-3 Series

SEN00313-04

Rotate the engine with the starting motor and measure the compression pressure. a Read the pressure gauge pointer when it is stabilized.

After finishing testing, remove the testing tools and return the removed parts. a Install the injector and fuel high-pressure tube according to the following procedure. 1) Push in injector (11) with the hand to assemble holder (12) temporarily. 2) Tighten bolt (13) and washer (14) temporarily. 2 Spherical part of washer: Engine oil 3) Tighten sleeve nut (15) of the fuel highpressure tube temporarily. 4) Tighten bolt (13) permanently. 3 Bolt: 58.8 – 73.5 Nm {6.0 – 7.5 kgm} 5) Tighten sleeve nut (15) permanently. 3 Sleeve nut: 39.2 – 49.0 Nm {4 – 5 kgm}

30 Testing and adjusting

Tighten the clamp and spacer with the bolt. 5) Install rocker arm assembly. 3 Rocker arm assembly mounting bolt: 93 – 103 Nm {9.5 – 10.5 kgm} a Adjust the valve clearance. For details, see “Adjusting valve clearance“. 6) Install head cover. 3 Cylinder head cover mounting bolt: 27.5 – 34.3 Nm {2.8 – 3.5 kgm}

Install the injector wiring harness according to the following procedure 1) Install the injector wiring harness to the cylinder head and fix the connector side with the plate.Install O-ring (16). 2) Install cap (17) with clip on the injector side of wiring harness. Press wiring harness (18) between the injector top and cap to the injector main body without slack. 3) Tighten nut (19) on the injector side. 3 Nut: 2 ± 0.2 Nm {0.2 ± 0.02 kgm}

12V140E-3 Series

30 Testing and adjusting

SEN00313-04

Testing blow-by pressure a

a a a

Run the engine at the rated output and test the blow-by pressure. a When testing with the engine mounted on the machine, test on the condition described in the shop manual for the machine.

After finishing testing, remove the testing tools and return the removed parts.

Testing tool for blow-by pressure

Symbol

Part No.

Part name

Q'ty

799-201-1504

Blow-by checker kit

799-201-1590

Gauge

799-201-1450

Adapter

799-201-1511

Nozzle

799-201-1571

Tube

The test point is subject to machine models. Measure blow-by pressure after the engine is warmed up. (Engine coolant temperature: Min. 70°C) Breather is provided to each RH and LH banks. Test the breather on either one of the banks. Install adaptor E3 and nozzle E4 to the tip of each breather hose on the RH and LH. Connect tube E5 and gauge E2 to either one of the nozzles.Close the tube connecting mate of other nozzle with a piece of short cut tube, etc.

12V140E-3 Series

SEN00313-04

30 Testing and adjusting

Testing oil pressure a

1 2

Part No.

Hydraulic tester

790-261-1204

Digital hydraulic tester

799-401-2320

Hydraulic tester

The test point is subject to machine models.

Remove oil temperature sensor (1) on the LH side of the cylinder block. Keep the removed oil temperature sensor and the wiring harness connector connected.to each other. a Don't remove the oil pressure sensor from the block because the engine controller detects abnormal low pressure error of the oil pressure sensor.

Run the engine at the rated output and low idle and test the oil pressure. a When testing with the engine mounted on the machine, test on the condition described in the shop manual for the machine.

After finishing testing, remove the testing tools and return the removed parts.

Part name

799-101-5002

Testing tools for oil pressure

Symbol F

Install nipples [1] and [2] of hydraulic tester F1 and connect them to hydraulic tester F2. a Since the screw size of the sensor mount is 14 x P1.5, nipple (799-101-5230) may be used.

12V140E-3 Series

30 Testing and adjusting

Handling fuel system parts a

SEN00313-04

Precautions for testing and maintaining fuel system The common rail fuel injection system (CRI) consists of more precise parts than the conventional fuel injection pump and nozzle. If foreign matter enters this system, it can cause a trouble. When testing and maintaining the fuel system, take care more than the past. If dust, etc. sticks to any part, wash that part thoroughly with clean fuel. Precautions for replacement of fuel filter cartridge The fuel filter cartridge used must be a genuine Komatsu part. The fuel injection pump and nozzle of the common rail type fuel injection system (CRI) are consisted of more precision parts than those used for the current pumps and nozzles. This system, therefore, employs a special filter with highly efficient filtering performance to prevent mixing of foreign substances. Thus, substituting it with a non-genuine filter could cause troubles in the fuel system. It is strictly prohibited to use such part.

12V140E-3 Series

Releasing residual pressure in fuel system

Pressure is generated in the low-pressure circuit and high-pressure circuit of the fuel system while the engine is running. Low-pressure circuit: Feed pump – Fuel filter – Supply pump High-pressure circuit: Supply pump – Common rail – Injector a The pressure in both low-pressure circuit and high-pressure circuit lowers to a safety level automatically 30 seconds after the engine is stopped. a Before the fuel circuit is tested and its parts are removed, the residual pressure in the fuel circuit must be released completely. Accordingly, observe the following. k Before testing the fuel system or removing its parts, wait at least 30 seconds after stopping the engine until the residual pressure in the fuel circuit is released. (Do not start the work just after stopping the engine since there is residual pressure.)

SEN00313-04

30 Testing and adjusting

Testing fuel pressure a

Testing tools for fuel pressure

Symbol 1 G

2 3 4

Part No.

Part name

799-101-5002

Hydraulic tester

790-261-1204

Digital hydraulic tester

795-471-1450

Adapter

799-101-5220

Nipple

07002-11023

O-ring

799-401-2320

Gauge

Run the engine at high idle and measure the fuel pressure. a If the fuel pressure is in the following range, it is normal. Engine speed

Fuel pressure

High idle

0.15 – 0.3 MPa {1.5 – 3 kg/cm2}

Test only the fuel pressure in the low-pressure circuit from the feed pump through the engine controller cooler and fuel filter to the supply pump. k Since the pressure in the high-pressure circuit from the supply pump through the common rail to the injector is very high, it cannot be measured. a The position of the oil filler varies depending on the applicable machine. 1.

Remove air bleeder plug (1) on the top of fuel filter.

Since the fuel circuits on the LH and RH banks after the priming pump are independent, test each circuit.

After finishing testing, remove the testing tools and return the removed parts.

Install adapter G2 and connect to gauge G4.

12V140E-3 Series

30 Testing and adjusting

Reduced cylinder mode operation a

SEN00313-04

Reduced cylinder mode operation means to run the engine with the fuel injectors of 1 or more cylinders disabled electrically to reduce the number of effective cylinders. The purposes and effects of this operation are as follows. This operation is used to find out a cylinder which does not output power normally (or, combustion in it is abnormal). When a cylinder is selected for the reduced cylinder mode operation, if the engine speed and output do not change from the normal operation (all-cylinder operation), that cylinder has 1 or more defects. The possible defects are as follows. q Leakage through cylinder head gasket q Defective injection q Defective piston, piston ring, or cylinder liner q Defective valve mechanism (Moving valve system) q Defect in electrical system Since the common rail fuel injection system controls the injector of each cylinder electronically, the operator can perform the reduced cylinder mode operation easily with switches to find out a defective cylinder. a Perform the reduced cylinder mode operation with the engine mounted on the machine or connected to INSITE (bench test tool). Before performing, see Testing method in the shop manual for the machine or INSITE (bench test tool).

12V140E-3 Series

No-injection cranking a

No-injection cranking means to crank the engine with the starting motor while all the injections are stopped electrically. The purpose and effect of this operation are as follows. When a machine or engine has been stored for a long time, implementing the no-injection cranking before starting the engine lubricates the engine parts and thus prevents its seizure. Perform the no-injection operation with the engine mounted on the machine or connected to INSITE (bench test tool). Before performing, see Testing method in the shop manual for the machine or INSITE (bench test tool).

SEN00313-04

30 Testing and adjusting

Testing leakage-from pressure limiter and return rate from injector

Type of engine having intake manifold equipped with return block

If the engine is of a type that returns the fuel spilling from the injector from the return block installed to the front of intake manifold, check the engine according to the following (the figure showing the LH bank for PC2000). Testing tools for pressure limiter leakage and injector return rate

Symbol

Part No.

Part name

6151-51-8490

Spacer

6141-71-1710

Joint

Commercially available

Inside diameter of the hose: Approx. 11 mm

Commercially available

Inside diameter of the hose: Approx. 17 mm

Commercially available

Measuring cylinder

Commercially available

Stopwatch

07376-70315

Plug

Prepare an oil pan of about 20 l to receive the fuel flowing out during the test.

Preparatory work (case of the LH bank) 1) Remove tube (4) between common rail (3) and supply pump (5). 2) Insert spacer H1 on supply pump (5) side and tighten the removed joint bolt again. 3) Connect the return pipe to the fuel tank again, too. a Be sure to provide a gasket to both ends of the spacer.

12V140E-3 Series

30 Testing and adjusting

SEN00313-04

Insert joint H2 on common rail (3) side and tighten the removed joint bolt again. a Be sure to fit the gaskets to both ends of the joint. Connect test hose H3 to the end of joint H2. a Bind the connecting part of the test hose with a wire, etc. to prevent it from coming off. a The above is the preparation work for testing the leakage from the pressure limiter.

Testing leakage from pressure limiter 1) Lay test hose H3 so that it will not slacken and put its end in the oil pan. 2) Connect INSITE (bench test tool) to the engine and set it so that it can check the engine speed. 3) Start the engine and keep its speed to 1,600 rpm with no load. 4) After the engine speed is stabilized, test the leakage in 1 minute with measuring cylinder H5. a You may test for 20 seconds and judge by multiplying the result by 3. a If the leakage from the pressure limiter is in the following range, it is normal.

12V140E-3 Series

Engine speed

Leakage (cc/min)

At rated output

Max. 10

After finishing testing, stop the engine.

SEN00313-04

30 Testing and adjusting

Testing return rate from injector a Keep the hose on the pressure limiter side connected and keep its end in the oil pan while testing the return rate from the injector. 1) Disconnect return hose (2) of return block (1) and connect test hose H4. a Apply plug H7 to the return hose side to stop oil, and fix it to the fuel tank. a Bind the connecting part of the test hose with a wire, etc. to prevent it from coming off. 2) Lay test hose H4 so that it will not slacken and put its end in the oil pan. 6)

4) 5)

After finishing testing, stop the engine.

Work after finishing testing After finishing all testing, remove the testing tools and return the removed parts.

Check the RH bank following the identical procedure.

Connect INSITE (bench test tool) to the engine and set it so that it can check the engine speed. Run the engine at the rated output. After the engine speed is stabilized, test the return rate in 1 minute with measuring cylinder H5. a You may test for 20 seconds and judge by multiplying the result by 3. a If the supply pump is not supplying fuel, the engine speed may not rise. In this case, record the engine speed, too, during the test. a If the return rate (spill) from the injector is in the following range, it is normal. Rated output speed Limit of return rate (spill) (rpm) (cc/min)

1,600

960

1,700

1,020

1,800

1,080

1,900

1,140

2,000

1,200

12V140E-3 Series

30 Testing and adjusting

SEN00313-04

Bleeding air from fuel circuit (for D475A-5)

a a

If fuel is used up or if a fuel circuit part is removed and installed, bleed air from the fuel circuit according to the following procedure. The locations of the fuel circuit parts are subject to machine models (The figure showing the LH bank for D475A-5). Remove fuel pre-filter (6) and fill it with fuel. a Fill the fuel filter with clean fuel and take care that dirt will not enter it. a Check that the cap is fitted to part (a) (central hole) of the fuel pre-filter (6), and then add fuel through part (b) (holes around the central hole). a After filling the fuel pre-filter (6) with fuel, remove the cap from part (a). a If clean fuel is not available, do not remove the filter but fill it with the fuel by operating priming pump (3).

12V140E-3 Series

Don't fill fuel directly after removing main filter (1).

Install fuel pre-filter (6) to the pre-filter head. a Apply engine oil thinly over the packing on the fuel pre-filter side.

SEN00313-04 a

After the packing of the fuel pre-filter touches the sealing face of the filter head, tighten the fuel filter 1/2 – 3/4 turns.

Loosen air bleed plugs (2) and (4) of the fuel main filter and operate priming pump (3). a Operate the priming pump until the fuel flows out of the hole of plug (2). When bubbles stop coming out, tighten plug (2). 3 Air bleeding plug: 2.0 – 3.9 Nm {0.2 – 0.4 kgm}

Continue priming pump operation until fuel flows out of the hole of plug (4). When bubbles stop coming out, tighten plug (4). 3 Air bleeding plug: 2.0 – 3.9 Nm {0.2 – 0.4 kgm}

Loosen air bleeder (5) of the fuel supply pump and operate priming pump (3) 90 – 100 times. a Operate the priming pump until the fuel flows out of the air bleeder and tighten the air bleeder. Then, operate the priming pump several times more until it becomes heavy. 3 Air bleeder: 4.9 – 6.9 Nm {0.5 – 0.7 kgm}

30 Testing and adjusting

12V140E-3 Series

30 Testing and adjusting

Move over to the RH side of the engine. Loosen the air bleeder (8) of the fuel supply pump and operate priming pump (7). a Operate the priming pump until the fuel flows out of the air bleeder and the fuel is checked. Further operate the priming pump until it becomes heavy. 3 Air bleeder: 4.9 – 6.9 Nm {0.5 – 0.7 kgm}

Crank the engine with the starting motor to start engine. a The air in the high-pressure circuit is bled automatically if the engine is cranked. a If the engine does not start, there may be still air in the low-pressure circuit. In this case, repeat the above procedure from step 3.

12V140E-3 Series

SEN00313-04

30 Testing and adjusting

Bleeding air from fuel circuit (for PC2000)

a a

If fuel is used up or if a fuel circuit part is removed and installed, bleed air from the fuel circuit according to the following procedure. The locations of the fuel circuit parts are subject to machine models (The figure showing the LH bank for PC2000). Remove fuel pre-filter and fill it with fuel. a Fill the fuel filter with clean fuel and take care that dirt will not enter it. a Check that the cap is fitted to part (a) (central hole) of the fuel pre-filter, and then add fuel through part (b) (holes around the central hole). a After filling the fuel pre-filter with fuel, remove the cap from part (a). a If clean fuel is not available, do not remove the filter but fill it with the fuel by operating priming pump (3).

Don't fill fuel directly after removing main filter (1).

Install fuel pre-filter to the filter head. a Apply engine oil thinly over the packing on the fuel pre-filter side.

12V140E-3 Series

30 Testing and adjusting a

SEN00313-04

After the packing of the fuel pre-filter touches the sealing face of the filter head, tighten the fuel filter 1/2 – 3/4 turns.

Loosen air bleed plug (2) (plug on the outlet side) of the fuel main filter and operate priming pump (3). a Operate the priming pump until the fuel flows out of the plug hole and tighten the plug after checking the fuel. 3 Air bleeding plug: 2.0 – 3.9 Nm {0.2 – 0.4 kgm}

Loosen air bleeder (5) of the fuel supply pump and operate priming pump (3) 90 - 100 times. a Operate the priming pump until the fuel flows out of the air bleeder and tighten the air bleeder. Then, operate the priming pump several times more until it becomes heavy. 3 Air bleeder: 4.9 – 6.9 Nm {0.5 – 0.7 kgm}

Bleed the air from the RH bank to the above procedure.

Start the engine with the starting motor. a The air in the high-pressure circuit is bled automatically if the engine is cranked. a If the engine does not start, there may be still air in the low-pressure circuit. In this case, repeat the above procedure from step 3.

12V140E-3 Series

SEN00313-04

Bleeding air from fuel circuit (Poor fuel spec.)

30 Testing and adjusting

Reference: q The electric priming pump switch is installed to the chassis. q Each figure shows D475A-5E0 for an example. a Bleed air from the fuel circuit in the following cases according to this procedure. q When the fuel filter is replaced q When fuel is used up q When the engine is started for the first time after the fuel piping or supply pump is replaced a If the fuel filter was replaced, do not fill the main filter and prefilter with the fuel. 1.

Turn the starting switch to the "OFF" position.

Check that the fuel valve on the fuel tank side is open.

Turn the left and right lever (1) of the air bleeding piping to the parallel position with the piping to open the circuit valve.

Turn "ON" switch (3) of electric priming pump (2) installed to the chassis. a The electric priming pump operates and lamp (4) blinks.

The electric priming pump has a timer in it to start and stop itself automatically (See the following figure). a The electric priming pump stops while the lamp is blinking. This phenomenon is not abnormal, however. a If the switch is turned to the "OFF" position while the lamp is blinking, the lamp goes off and the electric priming pump stops. k While the electric priming pump is operating, pressure is applied to the fuel circuit. Do not loosen the air bleeding plug at this time, since the fuel may spout out.

Reference: The operating procedure sticker is stuck near the air bleeding piping lever.

12V140E-3 Series

30 Testing and adjusting

After the specified time (approx. 7 minutes), lamp (4) goes off and the electric priming pump stops automatically. a If only the fuel filter was replaced, the air bleeding work is completed now.

If the fuel was used up or the fuel piping or supply pump was replaced and there is not fuel in the fuel circuit, turn switch (3) "ON" after the electric priming pump stops automatically.

When lamp (4) goes off, the air bleeding work is completed.

Turn lever (1) of the air bleeding piping to the cross position with the piping to close the circuit valve.

Start the engine with the starting motor. a Do not operate the starting motor continuously for more than 20 seconds. q After starting the engine, run it at low idle for about 5 minutes to bleed all air from the fuel circuit. q Stop the engine and check that the air bleeding valve is closed.

12V140E-3 Series

SEN00313-04

10. If the engine does not start, try to start it again according to the following procedure. k When starting the engine, check that there is no person around it. a Carry out the work with the air bleeding valve closed. (Do not open the air bleeding valve after step 7.) a After the engine fails to start, wait for about 2 minutes before trying to start again. 1) Turn the electric priming pump switch ON. 2) While the electric priming pump is operating, crank the engine. q If the engine does not start, repeat the above operation. a Do not operate the starting motor continuously 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.

SEN00313-04

Testing fuel system for leakage 1

k Very high pressure is generated in the high-

pressure circuit of the fuel system. If fuel leaks while the engine is running, it is dangerous since it can catch fire. After testing the fuel system or removing its parts, test it for fuel leakage according to the following procedure. Clean and degrease the engine and the parts around it in advance so that you can test it easily for fuel leakage.

Spray color checker (developer) over the fuel supply pump, common rail, fuel injector, and joints of the high-pressure piping.

Run the engine at speed below 1,000 rpm and stop it after its speed is stabilized.

Inspect the fuel piping and devices for fuel leakage. a Check mainly around the high-pressure circuit parts coated with the color checker for fuel leakage. a If any fuel leakage is detected, repair it and inspect again from step 1.

Run the engine at low idle.

Run the engine at high idle.

Run the engine at high idle and load it. a When checking while the components to be checked are mounted on the machine, stall the torque converter or relieve the hydraulic pump.

30 Testing and adjusting

12V140E-3 Series

30 Testing and adjusting

Adjusting speed sensor a a

SEN00313-04

The G (Bkup) speed sensor and Ne speed sensor for the common rail fuel injection system cannot be adjusted. Adjust speed sensor (1), which detects the signal of the flywheel ring gear to use it for the electronic system on the machine side, according to the following procedure.

Remove speed sensor (1) and check that its tip is free from steel chips and flaws, and then install it again temporarily. 2 Threads: Gasket sealant (LG-6)

Screw in sensor (1) until its tip touches the tooth tip of flywheel ring gear (2).

Return sensor (1) by 3/4 – 1 turn. a Clearance (a) of 1.1 – 1.5 mm will be made between the sensor tip and gear tooth tip. While fixing sensor (1), tighten nut (3). 3 Nut: 49 – 68.6 Nm {5 – 7 kgm}

12V140E-3 Series

Testing and adjusting alternator belt tension 1 Testing Press the intermediate point of the belt between alternator pulley and drive pulley with a finger and measure deflection (a) of the belt. a Pressing force: Approx. 59 Nm {Approx. 6 kg} a Deflection (a): Approx. 20 mm (1 piece)

Adjusting a If the deflection is out of the standard range, adjust it according to the following procedure. 1.

Loosen nut (B) and bolt (2) alternately.

Adjust belt tension using nut (A).

Tighten bolt (2) to have adjust bolt (1) and plate (3) made orthogonal to each other.

Tighten nut (B) to fix plate (3). a After adjusting, test the belt tension again.

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Handling controller high-voltage circuit 1 1.

When disconnecting or connecting a connector between engine controller and engine, be sure to turn the starting switch OFF.

Don't start the engine with T-adapter inserted or connected to a connector between the engine controller and the engine for diagnosis. a You may turn the starting switch to the OFF or ON position but must not turn it to the START position.

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KOMATSU 12V140E-3 Series engine Form No. SEN00313-04

12V140E-3 Series

SEN00315-01 12V140E-3 Series SEN00315-01

ENGINE Shop Manual

12V140E-3 Series

Machine model Serial number 12V140E-3 SERIES ENGINE...

40 Troubleshooting General Information on troubleshooting Points to remember when troubleshooting .................................................................................................

Error codes and failure codes list................................................................................................................

Information in troubleshooting table ............................................................................................................

Connection table for connector pin numbers ..............................................................................................

T- branch box and T- branch adapter table ................................................................................................. 45

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40 Troubleshooting

Points to remember when 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 understand 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 symptoms. 1. When carrying out troubleshooting, do not hurry to disassemble the components. If components are disassembled immediately after any failure occurs: q Parts that have no connection with the failure or other unnecessary parts will be disassembled. q It will become impossible to find the cause of the failure. It will also cause a waste of manhours, parts, or oil or grease, and at the same time, will also lose the confidence of the user or operator. For this reason, when carrying out troubleshooting, it is necessary to carry out thorough prior investigation and to carry out troubleshooting in accordance with the fixed procedure. 2. Points to ask user or operator 1) Have any other problems occurred apart from the problem that has been reported? 2) Was there anything strange about the machine before the failure occurred? 3) Did the failure occur suddenly, or were there problems with the machine condition before this? 4) Under what conditions did the failure occur? 5) Had any repairs been carried out before the failure? When were these repairs carried out? 6) Has the same kind of failure occurred before? 3. Check before troubleshooting 1) Check for symptoms of any abnormality in the machine and engine.

2) Be sure to check the CHECKS BEFORE STARTING items. 3) Check other inspection items, if necessary. 4) Some other maintenance items can be checked externally, so check any item that is considered to be necessary. 5) Check the controller for display of an error. 4. Confirming failure Confirm the extent of the failure yourself, and judge whether to handle it as a real failure or as a problem with the method of operation, etc. a When operating the machine or engine to reenact the troubleshooting symptoms, do not carry out any investigation or measurement that may make the problem worse. 5. Troubleshooting Use the results of the investigation and inspection in Items 2 – 4 to narrow down the causes of failure, then use the troubleshooting matrix to locate the position of the failure exactly. a The basic procedure for troubleshooting is as follows. 1) Start from the simple points. 2) Start from the most likely points. 3) Investigate other related parts or information. 6. Measures to remove root cause of failure Even if the failure is repaired, if the root cause of the failure is not repaired, the same failure will occur again. To prevent this, always investigate why the problem occurred. Then, remove the root cause.

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40 Troubleshooting

Error codes and failure codes list *1 – *3: Machine monitor in KES 6 digit display

INSITE error code

Machine failure code

111

CA111

ECM Critical Internal Failure (LH bank)

111

CB111

ECM Critical Internal Failure (RH bank)

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)

131

CA131

Throttle Sensor High Error (LH bank only)

132

CA132

Throttle 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)

187

CA187

Sensor Sup. 2 Volt. Low Error (LH bank)

187

CB187

Sensor Sup. 2 Volt. Low Error (RH bank)

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)

227

CA227

Sensor Sup. 2 Volt. High Error (LH bank)

227

CB227

Sensor Sup. 2 Volt. High Error (RH bank)

234

CA234

Eng. Over (LH bank only)

238

CA238

Ne Speed Sensor Sup. Volt. Error (LH bank)

238

CB238

Ne Speed Sensor Sup. Volt. Error (RH bank)

263

CA263

Fuel Temp. Sensor High Error (LH bank)

263

CB263

Fuel Temp. Sensor High Error (RH bank)

265

CA265

Fuel Temp. Sensor Low Error (LH bank)

265

CB265

Fuel Temp. Sensor Low Error (RH bank)

271

CA271

PCV1 Short Error (LH bank)

12V140E-3 Series

Failure phenomenon

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40 Troubleshooting

*1 – *3: Machine monitor in KES 6 digit display

INSITE error code

Machine failure code

271

CB271

PCV1 Short Error (RH bank)

272

CA272

PCV1 Open Error (LH bank)

272

CB272

PCV1 Open Error (RH bank)

273

CA273

PCV2 Short Error (LH bank)

273

CB273

PCV2 Short Error (RH bank)

274

CA274

PCV2 Open Error (LH bank)

274

CB274

PCV2 Open Error (RH bank)

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)

342

CA342

Caribration Code Incompatibility (LH bank)

342

CB342

Caribration Code Incompatibility (RH bank)

351

CA351

Inj. Drive Circuit Error (LH bank)

351

CB351

Inj. Drive Circuit Error (RH bank)

352

CA352

Sensor Sup. 1 Volt. Low Error (LH bank)

352

CB352

Sensor Sup. 1 Volt. Low Error (RH bank)

386

CA386

Sensor Sup. 1 Volt. High Error (LH bank)

386

CB386

Sensor Sup. 1 Volt. High Error (RH bank)

441

CA441

Battery Voltage Low Error (LH bank)

441

CB441

Battery Voltage Low Error (RH bank)

442

CA442

Battery Voltage High Error (LH bank)

442

CB442

Battery Voltage High Error (RH bank)

449

CA449

Rail Press. Very High Error (LH bank)

449

CB449

Rail Press. Very High Error (RH bank)

451

CA451

Rail Press. Sensor High Error (LH bank)

451

CB451

Rail Press. Sensor High Error (RH bank)

452

CA452

Rail Press. Sensor Low Error (LH bank)

452

CB452

Rail Press. Sensor Low Error (RH bank)

553

CA553

Rail Press. High Error 1 (LH bank)

Failure phenomenon

12V140E-3 Series

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40 Troubleshooting

*1 – *3: Machine monitor in KES 6 digit display

INSITE error code

Machine failure code

553

CB553

Rail Press. High Error 1 (RH bank)

554

CA554

Rail Press. Sensor In Range Error (LH bank)

554

CB554

Rail Press. Sensor In Range Error (RH bank)

559

CA559

Rail Press. Low Error 1 (LH bank)

559

CB559

Rail Press. Low Error 1 (RH bank)

689

CA689

Eng. Ne Speed Sensor Error (LH bank)

689

CB689

Eng. Ne Speed Sensor Error (RH bank)

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)

757

CA757

All Continuous Data Lost Error (LH bank)

757

CB757

All Continuous Data Lost Error (RH bank)

778

CA778

Eng. G (Bkup) Speed Sensor Error (LH bank)

778

CB778

Eng. G (Bkup) Speed Sensor Error (RH bank)

781

CA781

Inter Multi-controller Communication Error (LH bank)

781

CB781

Inter Multi-controller Communication Error (RH bank)

1117

CA1117

Persistent Data Lost Error (LH bank)

1117

CB1117

Persistent Data Lost Error (RH bank)

1257

CA1257

Harness Key error (LH bank)

1257

CB1257

Harness Key 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)

1633

CA1633

KOMNET Data Time Error (LH bank)

2185

CA2185

Throttle Sens. Sup. Volt. High Error (LH bank only)

2186

CA2186

Throttle Sens. Sup. Volt. Low Error (LH bank only)

2249

CA2249

Rail Press. Very Low Error (LH bank)

2249

CB2249

Rail Press. Very Low Error (RH bank)

12V140E-3 Series

Failure phenomenon

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40 Troubleshooting

*1 – *3: Machine monitor in KES 6 digit display

INSITE error code

Machine failure code

--*1

—

Eng. Overheat (LH bank only)

--*2

—

Eng. Oil Press. Low Speed Derate (LH bank only)

--*3

—

Eng. Oil Press. Low Torque Derate (LH bank only)

Failure phenomenon

a INSITE error code: An error code of 3 or 4 digits displayed on the INSITE (bench test tool) when the occurrence condition of the failure is confirmed with the INSITE. a Machine failure code: An error code of 5 or 6 digits displayed on the machine monitor when the occurrence condition of the failure is confirmed with the machine monitor, etc. on the machine side.

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40 Troubleshooting

Information in troubleshooting table a The following information is summarized in the troubleshooting table and the related electrical circuit diagram. Before carrying out troubleshooting, understand that information fully.

Error code

Failure code

Display on INSITE Contents of trouble Action of controller Problem that appears on machine Related information

Display on applicable machine

Contents of trouble detected by engine controller Action taken by engine controller to protect system or devices when engine controller detects trouble Phenomenon that appears on engine as trouble as result of action taken by engine controller (shown above) Information related to detected trouble or troubleshooting Causes

Possible causes and standard value in normal state

Trouble Problem that appears on engine

Standard value in normal state/Remarks on troubleshooting

<Contents of description> q Standard value in normal state to judge possible causes q Remarks on judgment <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 V) circuit is in contact with power source (24 V) circuit. q Short circuit Independent wiring harnesses are in contact with each other abnormally.

Possible causes of trouble (Given numbers are refer<Precautions for troubleshooting> 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 troubleshooting, unless otherwise specified. q If connector No. has no marks of "male" and "female", 3 disconnect connector and insert T-adapters in both male side and female side. q If connector No. has marks of "male" and "female", disconnect 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

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40 Troubleshooting

Related circuit diagram

This drawing is a part of the electric circuit diagram related to troubleshooting. q Connector No.: Indicates (Model - Number of pins) and (Color). q "Connector No. and pin No." from each branching/merging point: Shows the ends of branch or source of merging within the parts of the same wiring harness. q Arrow(io): Roughly shows the location on the machine.

12V140E-3 Series

40 Troubleshooting

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Connection table for connector pin numbers (Rev. 2009. 04) a The terms of male and female refer to the pins, while the terms of male housing and female housing refer to the mating portion of the housing.

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T- branch box and T- branch adapter table (Rev. 2009. 03)

799-601-2600 799-601-3100 799-601-3200 799-601-3380 799-601-3410 799-601-3420 799-601-3430 799-601-3440 799-601-3450 799-601-3460 799-601-3510 799-601-3520 799-601-3530 799-601-2910 799-601-3470 799-601-2710 799-601-2720 799-601-2730 799-601-2740 799-601-2950 799-601-2750 799-601-2760 799-601-2770 799-601-2780

T-box(for ECONO) T-box(for MS) T-box(for MS) Plate for MS (14-pin) Adapter for BENDIX (MS) Adapter for BENDIX (MS) Adapter for BENDIX (MS) Adapter for BENDIX (MS) Adapter for BENDIX (MS) Adapter for BENDIX (MS) Adapter for BENDIX (MS) Adapter for BENDIX (MS) Adapter for BENDIX (MS) Adapter for BENDIX (MS) Case Adapter for MIC Adapter for MIC Adapter for MIC Adapter for MIC Adapter for MIC Adapter for ECONO Adapter for ECONO Adapter for ECONO Adapter for ECONO

24 24 17 17 5 10 5 17 19 14

MS-24P MS-24P MS-17P MS-17P MS-5P MS-10P MS-5P MS-17P MS-19P MS-14P

5 13 17 21 9 2 3 4 8

MIC-5P q MIC-13P q MIC-17P q MIC-21P q MIC-9P ECONO2P q ECONO3P q ECONO4P q ECONO8P q ECONO12 q P DLI-8P q DLI-12P q DLI-16P q ECONO12 q P

799-601-2810 Adapter for DLI 799-601-2820 Adapter for DLI 799-601-2830 Adapter for DLI

8 12 16

799-601-2840 Extension cable (ECONO type)

Case T-box(for DRC 60, ECONO) Case Adapter for X (T-adapter) Adapter for X Adapter for X Adapter for X Adapter for SWP Adapter for SWP Adapter for SWP Adapter for SWP Adapter for SWP Adapter for M (T-adapter) Adapter for M Adapter for M Adapter for M Adapter for M Adapter for M

12V140E-3 Series

q q q q q q q q q q

q q q q q q q q q

M2P M3P M4P M6P M8P

Out of kit

799-601-4201

799-601-4101

799-601-9300

799-601-9200

q q q q q

X2P X3P X4P SW6P SW8P SW12P SW14P SW16P

q q q q q q q q q q q q q q

q q q

60 1 2 3 4 6 8 12 14 16 1 2 3 4 6 8

799-601-9100

799-601-9000

799-601-8000

q q

799-601-7500

799-601-7400

799-601-7100

799-601-7000

799-601-2800

21 37 37

799-601-2790 Adapter for ECONO

799-601-2850 799-601-4350 799-601-4360 799-601-7010 799-601-7020 799-601-7030 799-601-7040 799-601-7050 799-601-7060 799-601-7310 799-601-7070 799-601-7320 799-601-7080 799-601-7090 799-601-7110 799-601-7120 799-601-7130 799-601-7340

Identificati on symbol

799-601-2700

Part name

T-adapter kit 799-601-2500

Part No.

Number of pins

a The vertical column indicates a part number of T-branch box or T-branch adapter while the horizontal column indicates a part number of harness checker assembly.

q q q q q q q q q q q q q q q q

q q q q

q q q q q q q q q q q q q

q q q q q

q q

SEN00315-01

799-601-7140 Adapter for S 799-601-7150 Adapter for S (White) 799-601-7160 Adapter for S (Blue) 799-601-7170 Adapter for S (Blue) 799-601-7330 Adapter for S (White) 799-601-7350 Adapter for S (White) 799-601-7180 Adapter for AMP040 799-601-7190 Adapter for AMP040 799-601-7210 Adapter for AMP040 799-601-7220 Adapter for AMP040 799-601-7230 Short connector for X 799-601-7240 Case 799-601-7270 Case 799-601-7510 Adapter for 070 799-601-7520 Adapter for 070 799-601-7530 Adapter for 070 799-601-7540 Adapter for 070 799-601-7550 Adapter for 070 799-601-7360 Adapterfor relay 799-601-7370 Adapterfor relay 799-601-7380 Adapter for JFC 799-601-9010 Adapter for DTM 799-601-9020 Adapter for DT 799-601-9030 Adapter for DT 799-601-9040 Adapter for DT 799-601-9050 Adapter for DT 799-601-9060 Adapter for DT (Gray) 799-601-9070 Adapter for DT (Black) 799-601-9080 Adapter for DT (Green) 799-601-9090 Adapter for DT (Brown) 799-601-9110 Adapter for DT (Gray) 799-601-9120 Adapter for DT (Black) 799-601-9130 Adapter for DT (Green) 799-601-9140 Adapter for DT (Brown) 799-601-9210 Adapter for HD30-18 799-601-9220 Adapter for HD30-18 799-601-9230 Adapter for HD30-18 799-601-9240 Adapter for HD30-18 799-601-9250 Adapter for HD30-24 799-601-9260 Adapter for HD30-24 799-601-9270 Adapter for HD30-24 799-601-9280 Adapter for HD30-24 799-601-9290 Adapter for HD30-24 799-601-9310 Plate for HD30 (24-pin) 799-601-9320 T-box (for ECONO) 799-601-9330 Case 799-601-9340 Case 799-601-9350 Adapter for DRC 799-601-9360 Adapter for DRC 799-601-9410* Socket for engine (CRI-T2) Adapter for engine (CRI-T2) 799-601-9420 Adapter for engine (CRI-T3) PFUEL Oil pressure sensor Socket for engine (CRI-T2) 799-601-9430* Socket for engine (CRI-T3) PCV

q q q q q q q q q q q q q q

q q

Out of kit

799-601-4201

799-601-4101

799-601-9300

799-601-9200

799-601-9100

q q

799-601-9000

799-601-8000

q q q q q q q q q q q q

799-601-7500

799-601-7400

07-10 07-12 07-14 07-18 07-20 REL-5P REL-6P — DTM2 DT2 DT3 DT4 DT6 DT8GR DT8B DT8G DT8BR DT12GR DT12B DT12G DT12BR D18-8 D18-14 D18-20 D18-21 D24-9 D24-16 D24-21 D24-23 D24-31

799-601-7100

10 12 14 18 20 5 6 2 2 2 3 4 6 8 8 8 8 12 12 12 12 8 14 20 21 9 16 21 23 31

799-601-7000

S8P S10P S12P S16P S16PW S12PW A8P A12P A16P A20P —

799-601-2800

8 10 12 16 16 12 8 12 16 20 2

799-601-2700

Identificati on symbol

799-601-2500

Part name

T-adapter kit

Number of pins

Part No.

40 Troubleshooting

q q q q q q q q q

q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q

40 24 2

DRC-40 DRC-24 G

q q

q q q

12V140E-3 Series

SEN00315-01

40 Troubleshooting

799-601-9440* Socket for engine (CRI-T2) 795-799-5520* Socket for engine (HPI-T2) Socket for engine (HPI-T2) 795-799-5530* Socket for engine (CRI-T3) Temperature sensor Socket for engine (HPI-T2) 795-799-5540* Socket for engine (CRI-T3) TIM 795-799-5460 Cable for engine (HPI-T2) 795-799-5470 Cable for engine (HPI-T2) 795-799-5480 Cable for engine (HPI-T2) 799-601-4110 Adapter for engine (140-T3) PIM 799-601-4130 Adapter for engine (CRI-T3) NE, CAM Adapter for engine (CRI-T3) 799-601-4140 Atomosphere pressure 799-601-4150 Adapter for engine (CRI-T3) POIL Adapter for engine (CRI-T3) 799-601-4160 Oil pressure switch 799-601-4180 Adapter for engine (CRI-T3) PEVA Socket for engine (CRI-T3) 799-601-4190* Common rail pressure Socket for engine (CRI-T3) 799-601-4230* Air intake pressure/temperature 799-601-4240* Socket for engine (CRI-T3) PAMB 799-601-4250* Socket for engine (CRI-T3) PIM 799-601-4330* Socket for engine (CRI-T3) G Socket for engine (CRI-T3) 799-601-4340* Pump actuator Socket for engine (CRI-T3)(95) 799-601-4380* Air intake pressure/temperature 799-601-4260 Adapter for controller (ENG) 799-601-4211 Adapter for controller (ENG) 799-601-4220 Adapter for controller (ENG) 799-601-4390* Socket for controller (95 ENG) 799-601-4280* Box for controller (PUMP) 799-601-9720 Adapter for controller (HST) 799-601-9710 Adapter for controller (HST) 799-601-9730 Adapter for controller (HST) 799-601-9890 Multi-adapter for DT2 – 4 and DTM2

q q

FCIB

q q

4160

q q

4180

q q

1,2,3L

q q

1,2,3,4C

q q

3 3 3

1,2,3A 1,2,3B 1,2,3,G

q q q q q q

2,PA

q q

1,2,3,4T

4 DTP4 50 DRC50 60 DRC60 60 — 121 — 16 HST16A 16 HST16B 26 HST26A 2, 3, — 4

Out of kit

FCIG

799-601-4201

799-601-4101

q q q q

799-601-9300

— — — ITT3N FCIN

799-601-9200

3 3 3 4 3

799-601-9100

q q

799-601-9000

799-601-8000

799-601-7500

q q

799-601-7400

799-601-7100

799-601-7000

1,2,3 S

799-601-2800

3 2

799-601-2700

Identificati on symbol

799-601-2500

Part name

Number of pins

Part No.

T-adapter kit

q q

q q q

q q q q q

q q q q q q

“*” Shows not T-adapter but socket.

12V140E-3 Series

SEN00315-01

40 Troubleshooting

KOMATSU 12V140E-3 Series engine Form Number : SEN00315-01

SEN00316-01

ENGINE 1SHOP MANUAL

12V140E-3 Series

40 Troubleshooting

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

SEN00316-01

40 Troubleshooting

S-14 Coolant temperature becomes too high (overheating) ......................................................................... 22 S-15 Abnormal noise is made ....................................................................................................................... 23 S-16 Vibration is excessive ........................................................................................................................... 24

12V140E-3 Series

40 Troubleshooting

Method of using troubleshooting charts

SEN00316-01

The troubleshooting chart consists of the “questions“, “check items“, “causes“, and “troubleshooting“ blocks. The questions and check items are used to pinpoint high probability causes by simple inspection or from phenomena without using troubleshooting tools. Next, troubleshooting tools or direct inspection are applied to check the narrowed causes in order from the most probable one to make final confirmation according to the troubleshooting procedure. [Questions]: Items to be drawn from the user or operator. They correspond to A and B in the chart on the right. The items in A are basic ones. The items in B can be drawn from the user or operator, depending on their level. [Check items]: Simple check items used by the serviceman to narrow down the causes. They corresponds to C in the chart on the right. [Causes]: Items to be narrowed from the questions and check items. The serviceman narrows down the probable causes from A, B, and C. [Troubleshooting]: Items to finally verify whether the narrowed down causes are undoubtedly the real causes using the troubleshooting tools and direct inspections. 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

SEN00316-01

40 Troubleshooting

<Example of troubleshooting> Exhaust smoke is black Let us assume that [Clogged air cleaner element] is taken to be the cause of black exhaust gas. Three symptoms have causal relationship with this problem: [Color of exhaust gas gradually became black], [Power was lost gradually], and [Air cleaner clogging caution lamp is flashing].

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 relationship with five causes. Let us explain here the method of using this causal relationship to pinpoint the most probable cause.

12V140E-3 Series

SEN00316-01

40 Troubleshooting

S-1 Starting performance is poor 1

Q w w

Q Q

Defective or deteriorated battery

Defective alternator (generator section)

Defective alternator (regulator section)

Defective intake air heater system

Defective injector

Stuck or seized supply pump plunger

Clogged feed pump gauze filter

Clogged fuel filter element

E E

E w

Q Q Q Q w

w w Q Q w w w w

w w w E w Q Q w w w Q

w w

Q Q Q Q Q w

Q Q Q

q q q q q q q q

Replace

Clean

q Clean

Replace

Correct

Inspect air cleaner directly q When compression pressure is measured, it is found to be low q q When air is bled from fuel system, air comes out Inspect fuel filter and strainer directly Inspect feed pump gauze filter directly Carry out troubleshooting according to “No-pressure feed by supply pump (*1)“ in Emode When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change on some cylinders When starting switch is turned to HEAT, intake air heater mount does not become warm Is voltage 20 – 30 V between alternator terminal B and terminal E with Yes engine at low idle? None When specific gravity of electrolyte and voltage of battery are measured, they are low Remedy

Leaking or clogged fuel piping, entry of air

Clogged air breather hole of fuel tank cap

Worn piston ring and cylinder

Correct

Confirm recent repair history Degree of Operated for long period machine operation Became worse gradually Starting performance Engine starts easily when warm Non-specified fuel is being used Replacement of filters not carried out according to Operation and Maintenance Manual Engine oil replenished more frequently When engine is preheated or when temperature is low, preheating monitor does not indicate normally (if monitor is installed) During operation, charge level monitor indicates abnormal charge (if monitor is installed) Dust indicator is red (if indicator is installed) Air breather hole of fuel tank cap is clogged Fuel is leaking from fuel piping When priming pump is operated, it makes no reaction or it is heavy Starting motor cranks engine slowly Fuel does not flow out if air bleeding plug of fuel filter is While engine is removed cranked with startIf spill hose from injector is disconnected, ing motor, little fuel spills When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Engine does not pick up smoothly and combustion is irregular There is hunting from engine (rotation is irregular) Blow-by gas is excessive

Defective contact of valve and valve seat

Clogged air cleaner element

Causes

Clean

Troubleshooting

Check items

Questions

General causes for poor starting performance are q Defective electrical system q Insufficient supply of fuel q Insufficient intake of air q Improper selection of fuel (particularly during winter) q Coolant in exhaust pipe a The common rail fuel injection system (CRI) recognizes the fuel injection timing electrically. Accordingly, even if the starting operation is carried out, the engine may not start until the crankshaft revolves 2 turns at maximum. This phenomenon does not indicate a trouble, however.

*1: Code [559/CA559], [559/CB559] and code [2249/CA2249], [2249/CB2249] in E-mode

12V140E-3 Series

40 Troubleshooting

SEN00316-01

S-2 Engine does not start

Defective steering circuit wiring

Defective PTO or hydraulic pump Carry out troubleshooting on installed machine

—

w w w Q Q w

w Q

w w Q

q q

When specific gravity of electrolyte and voltage of battery are measured, they are low There is not voltage (20 - 30 V) between battery relay terminal B and terminal E When terminal B and terminal C of starting switch are connected, engine starts When terminal B and terminal C at safety relay outlet are connected, engine starts

q q q

When terminal B and terminal C at safety relay outlet are connected, engine does not start Replace

Replace

Correct

Replace

q Replace

Remedy

12V140E-3 Series

Defective starting motor (motor section)

Defective starting motor (safety relay section)

Defective starting switch

Defective battery relay

Inspect flywheel ring gear directly Troubleshooting

Defective connection of battery terminal

E E

Battery electrolyte is low Battery terminal is loose When starting switch is turned ON, there is no operating sound from battery relay When starting switch is turned to START, starting pinion does not move out Speed of rotation is low When starting switch is Makes grating noise turned to START, starting Soon disengages pinion moves out, but Makes rattling noise and does not turn

Turn starting switch OFF, connect cord, turn the switch ON and carry out troubleshooting

Carry out troubleshooting on installed machine

Confirm recent repair history Degree of machine opera- Operated for long period tion Condition of horn when Horn does not sound starting switch is turned Horn volume is low ON

Defective or deteriorated battery

Broken flywheel ring gear

Causes

Replace

Check items

Questions

a) Engine does not turn General causes why engine does not turn q Engine seized inside o See "S-4 Engine stops during operations". q Water hammer caused by coolant which entered cylinder q Defective electrical system q Problem in drive devices on applicable machine side o Troubleshoot the applicable machine side

SEN00316-01

40 Troubleshooting

b) Engine turns but no exhaust smoke comes out General causes why engine turns but no exhaust smoke comes out q Fuel is not being supplied q Supply of fuel is extremely small q Improper selection of fuel (particularly in winter)

Defective injector

E E Q

When air is bled from fuel system, air comes out Inspect fuel filter directly Inspect feed pump gauze filter directly Inspect feed pump directly Carry out troubleshooting according to “No-pressure feed by supply pump error (*1)“ in E-mode Carry out troubleshooting according to “Abnormality in PCV1 (*2) or Abnormality in PCV2 (*3)“ in E-mode Inspect overflow valve directly Engine can be started in reduced cylinder mode

q q q q q

q q q Replace

Replace

Correct

Replace

Clean

Replace

Correct

q q Add

Remedy

Defective operation of flow damper

Defective operation of overflow valve (Does not close)

Wrong connection of supply pump PCV

Defective supply pump PCV

Stuck or seized supply pump plunger

Broken supply pump shaft spline

Seized, abnormally worn feed pump

Clogged feed pump gauze filter

Clogged fuel filter element

Leaking, clogging and entry of air to fuel piping

Clogged air breather hole of fuel tank cap

Insufficient fuel in tank

Confirm recent repair history Degree of Operated for long period E E E machine operation Exhaust smoke suddenly stopped coming out (when starting again) w Q w w w Non-specified fuel is being used w Replacement of filters not carried out according to Operation and Maintenance w w E E 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 Fuel is leaking from fuel piping w When priming pump is operated, it makes no reaction or it is heavy w Q Q If air bleeding plug of fuel filter is removed, fuel does not flow While engine is Q Q Q w Q out cranked with starting motor, If spill hose from injector is disconnected, little fuel spills Q w w w w

Replace

Troubleshooting

Check items

Questions

Use of improper fuel

Causes

*1: Code [559/CA559], [559/CB559] and code [2249/CA2249], [2249/CB2249] in E-mode *2: Code [271/CA271], [271/CB271] and code [272/CA272], [272/CB272] in E-mode *3: Code [273/CA273], [273/CB273] and code [274/CA274], [274/CB274] in E-mode

12V140E-3 Series

40 Troubleshooting

SEN00316-01

c) Exhaust smoke comes out but engine does not start (fuel is being injected) General causes why exhaust smoke comes out but engine does not start q Lack of rotating force due to defective electrical system q Insufficient supply of fuel q Insufficient intake of air q Improper selection of fuel

Defective intake air heater system

Defective coolant temperature sensor and/or wiring harness

Defective or deteriorated battery

Clogged injector and/or defective spray

Stuck and/or seized supply pump plunger

Clogged feed pump gauze filter

Clogged fuel filter and/or strainer

Leaking, clogging of fuel system, and entry of air

Clogged air breather hole of fuel tank cap

Use of improper fuel

Worn piston ring and/or cylinder liner

Worn dynamic valve system (Valve, rocker lever, etc.)

Confirm recent repair history Degree of machine Operated for long period E E E E operation Suddenly failed to start w w Q Non-specified fuel is being used Q Q Q Q Replacement of filters not carried out according to Operation and Maintenance w w w Manual Engine oil replenished more frequently w When engine is preheated or when temperature is low, preheating monitor does not w indicate normally (if monitor is installed) Dust indicator is red (if indicator is installed) w Air breather hole of fuel tank cap is clogged Q Rust and water are found when fuel tank is drained w w When fuel filter is removed, there is no fuel in it w Fuel is leaking from fuel piping w When priming pump is operated, it makes no reaction or it is heavy w Q Q Starting motor cranks engine slowly w When engine is cranked, abnormal sound is generated around cylinder head w Fuel does not flow out if air bleeding plug of fuel filter is While engine is Q Q w w removed cranked with starting 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 w some cylinders is low

q q q q q q q

Replace

Clean

Replace

Clean

Correct

Clean

q Replace

Replace

Remedy

Replace

Inspect air cleaner directly q Inspect dynamic valve system directly q When compression pressure is measured, it is found to be low q When air is bled from fuel system, air comes out Inspect fuel filter, strainer directly Inspect feed pump gauze filter directly Carry out troubleshooting according to “No-pressure feed by supply pump error (*1)“ in E-mode When injector unit is tested, spray condition is bad When specific gravity of electrolyte and voltage of battery are measured, they are low Coolant temperature gauge does not indicate normally (if coolant temperature gauge is installed) When starting switch is turned to HEAT, intake air heater mount does not become warm Clean

Troubleshooting

Check items

Questions

Clogged air cleaner element

Causes

*1: Code [559/CA559], [559/CB559] and code [2249/CA2249], [2249/CB2249] in E-mode

12V140E-3 Series

SEN00316-01

40 Troubleshooting

S-3 Engine does not pick up smoothly

General causes why engine does not pick up smoothly q Insufficient intake of air q Insufficient supply of fuel q Defective spray condition of fuel q Improper selection of fuel q Controller is controlling in derate mode (limiting injection rate (output) because of an error in electrical system)

Q w

w w

q q q

Correct

Replace

Clean

Correct

q q Clean

Replace

Adjusting

Remedy

Replace

Inspect air cleaner directly q When compression pressure is measured, it is found to be low q q Inspect valve clearance directly q When turbocharger is rotated by hand, it is found to be heavy q When air is bled from fuel system, air comes out Inspect fuel filter and strainer directly Inspect feed pump gauze filter directly Carry out troubleshooting according to “No-pressure feed by supply pump error (*1)“ in E-mode When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change on some cylinders

Clogged injector and/or defective spray

Defective operation of flow damper (Maximum leakage from injector)

Stuck or seized supply pump plunger

Clogged feed pump gauze filter

Clogged fuel filter and/or strainer

Leaking, clogging of or entry of air to fuel piping

Clogged air breather hole of fuel tank cap

Worn piston ring and/or cylinder liner

Seized turbocharger or interference of turbocharger

Improper valve clearance

Defective contact of valve and valve seat

Confirm recent repair history Degree of E E E E E machine operation Operated for long period Engine pick-up suddenly became worse w Q Q Non-specified fuel is being used w w w Replacement of filters not carried out according to Operation and Maintenance Manual w w w Engine oil replenished more frequently w Dust indicator is red (if indicator is installed) w Air breather hole of fuel tank cap is clogged w Rust and water are found when fuel tank is drained w w Fuel is leaking from fuel piping w When priming pump is operated, it makes no reaction or it is heavy w Q Q When exhaust manifold is touched immediately after starting engine, temperature of Q some cylinders is low Blue under light load w Color of exhaust gas is Black w Q 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 Blow-by gas is excessive w

Clean

Troubleshooting

Check items

Questions

Clogged air cleaner element

Causes

*1: Code [559/CA559], [559/CB559] and code [2249/CA2249], [2249/CB2249] in E-mode

12V140E-3 Series

40 Troubleshooting

SEN00316-01

S-4 Engine stops during operations

General causes why engine stops during operations q Seized parts inside engine q Insufficient supply of fuel q There is overheating q Problem in drive devices on applicable machine side o Troubleshoot the applicable machine side

Problem in drive devices on installed machine side

Broken auxiliary equipment (pump, compressor, etc.)

Stuck or seized supply pump plunger

Broken supply pump shaft spline

Broken or seized feed pump

Clogged feed pump gauze filter

Clogged fuel filter and/or strainer

Leaking and/or clogged fuel piping

Clogged air breather hole of fuel tank cap

Insufficient fuel in tank

Broken or seized gear train

Broken or seized crankshaft bearing

Broken or seized piston and/or connecting rod

Broken dynamic valve system (valve, rocker arm, etc.)

Causes

Confirm recent repair history

Operated for long period

Q w Q w w

w Q

Condition when engine Engine overheated and stopped stopped Engine stopped slowly

Q w w Q

Non-specified fuel is being used

Q Q Q Q Q Q Q Q

Replacement of filters not carried out according to Operation and Maintenance Manual

w w

Engine stopped after hunting

w w

Fuel level monitor indicates low level (if monitor is installed) When fuel tank is inspected, it is found to be empty

Air breather hole of fuel tank cap is clogged

w w Q Q w w Q Q

Fuel is leaking from fuel piping When priming pump is operated, it makes no reaction or it is heavy

Check items

Rust and water are found when fuel tank is drained

w w w w

Metal particles are found when oil pan is drained Does not turn at all When engine is cranked by hand

Turns in opposite direction

Moves by amount of gear backlash

w w

Supply pump shaft does not turn

q q q q q q q q

Replace

Clean

Correct

Clean

Add

Replace

q Replace

Remedy

Replace

Inspect dynamic valve system directly Inspect piston and connecting rod directly Inspect crankshaft bearing directly Inspect gear train directly Inspect fuel filter and strainer directly Inspect feed pump gauze filter directly Inspect feed pump directly Carry out troubleshooting according to “No-pressure feed by supply pump error (*1)“ in E-mode Engine rotates when pump auxiliary equipment (pump, compressor, etc.) is removed

Replace

Troubleshooting

Engine turns, but stops when load is applied to machine

—

Questions

Abnormal noise was heard and engine stopped sudw w w w denly

Carry out troubleshooting on installed machine

Degree of machine operation

*1: Code [559/CA559], [559/CB559] and code [2249/CA2249], [2249/CB2249] in E-mode

12V140E-3 Series

SEN00316-01

40 Troubleshooting

S-5 Engine does not rotate smoothly

General causes why engine does not rotate smoothly q Air in fuel system q Defective speed sensor (Error at degree that it is not indicated)

Q w

When priming pump is operated, it makes no reaction or it is heavy

Defective G (Bkup) speed sensor or wiring harness

Defective Ne speed sensor and/or wiring harness

Clogged injector and/or defective spray (dirt in injector)

Defective operation of flow damper (Maximum leakage from injector)

Clogged fuel filter or strainer

Clogged feed pump gauze filter

Q Q Q Q Q Q Q Q Q Q Q Q w Q Q w w w w Q Q w w Q Q q

When air is bled from fuel system, air comes out Inspect feed pump gauze filter directly Inspect fuel filter and strainer directly When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change on some cylinders Carry out troubleshooting according to “Abnormality in engine Ne speed sensor (*1)“ in Emode Carry out troubleshooting according to “Abnormality in engine Bkup speed sensor (*2)“ in Emode

q q q q q

Correct

Replace

Clean

Add

Remedy

Leaking or clogging or entry of air to fuel piping

Clogged air breather hole of fuel tank cap

Insufficient fuel in tank

E E

Replace

Confirm recent repair history Degree of machine Operated for long period operation Occurs at a certain speed range Occurs at low idle Condition of hunting Occurs even when speed is raised Occurs on slopes Replacement of filters not carried out according to Operation and Maintenance Manual When fuel tank is inspected, it is found to be empty Air breather hole of fuel tank cap is clogged Rust and water are found when fuel tank is drained Fuel is leaking from fuel piping

Correct

Troubleshooting

Check items

Questions

Low setting of low idle speed

Causes

*1: Code [689/CA689] and [689/CB689] in E-mode *2: Code [778/CA778] and [778/CB778] in E-mode

12V140E-3 Series

40 Troubleshooting

SEN00316-01

S-6 Engine lacks output (or lacks power) General causes why engine lacks output q Insufficient intake of air q Insufficient supply of fuel q Defective spray condition of fuel q Improper selection of fuel q Overheat o See "S-14 Coolant temperature becomes too high (Overheating)" q Controller is controlling in derate mode (limiting injection rate (output) because of an error in electrical system)

1 Defective fuel temperature sensor and/or wiring harness

Defective boost pressure sensor and/or wiring harness

Defective drive of injector (signal and/or solenoid)

Defective installation of boost pressure sensor (air leakage)

Clogged injector or defective spray (dirt in injector)

Stuck or seized supply pump plunger

Clogged feed pump gauze filter

Clogged fuel filter and/or strainer

Leaking or clogged fuel piping

Clogged air breather hole of fuel tank cap

Worn piston ring and/or cylinder liner

Improper valve clearance

Defective contact of valve and valve seat

Seized turbocharger or interference of turbocharger

Air leakage from air intake piping

Clogged air cleaner element

Causes

Q Q Q Q

Confirm recent repair history

E E

Suddenly Q Power was lost Gradually Q Q Q Q Q Non-specified fuel is being used Q Q Replacement of filters not carried out according to Operation and Maintew Q nance Manual 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 w Color of exhaust Black gas Blue under light load w When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low

w Q

High idle speed is too high High idle speed under no load is normal, but speed suddenly drops when load is applied Engine does not pick up smoothly and combustion is irregular There is hunting from engine (rotation is irregular) Blow-by gas is excessive

w w Q w

Q Q Q Q Q Q w

Inspect air cleaner directly Inspect air intake piping directly When boost pressure is measured, it is found to be low When compression pressure is measured, it is found to be low Inspect valve clearance directly Inspect fuel filter and strainer directly Inspect feed pump gauze filter directly Carry out troubleshooting according to “No-pressure feed by supply pump error (*1)“ in E-mode When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change on some cylinders Inspect boost pressure sensor mount directly Carry out troubleshooting according to “Abnormality in charge pressure sensor (*2)“ in E-mode Carry out troubleshooting according to “Abnormality in fuel temperature sensor (*3)“ in E-mode

Remedy

12V140E-3 Series

When engine is cranked, interference sound is emitted from around turbocharger When engine is cranked, abnormal sound is generated around cylinder head

Clean

w Q

q q q q q

q q q q q q q q q

Replace

Correct

Replace

Clean

Replace

Correct

Clean

Replace

Adjusting

Replace

q Correct

Troubleshooting

Check items

Questions

Degree of machine Operated for long period operation

SEN00316-01

40 Troubleshooting

*1: Code [559/CA559], [559/CB559] and code [2249/CA2249], [2249/CB2249] in E-mode *2: Code [122/CA122] and code[123/CA123] in E-mode. *3: Code [263/CA263], [263/CB263] and code [265/CA265], [265/CB265] in E-mode

12V140E-3 Series

40 Troubleshooting

SEN00316-01

S-7 Exhaust smoke is black (incomplete combustion)

E w w

Defective coolant temperature sensor or wiring harness

Improper fuel injection pressure

Improper injection timing

Clogged fuel spill piping (on cylinder head side)

Abnormally worn injector

Clogged or seized injector

Stuck or seized supply pump plunger

Worn piston ring and/or cylinder liner

E Q Q Q Q

Q w

Q Q w w Q w

Q Q

Q Q Q

w w Q Q Q Q w w w Q Q Q Q

w Q Q Q

Q Q w w w

q q q

q q

Replace

Adjusting

Correct

Replace

Correct

Adjusting

Replace

Inspect air cleaner directly q When turbocharger is rotated by hand, it is fount to be heavy q When compression pressure is measured, it is found to be low q Inspect valve clearance directly q When muffler is removed, exhaust sound improves Carry out troubleshooting according to “No-pressure feed by supply pump error (*1)“ in E-mode When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change on some cylinder Inspect fuel spill piping (on cylinder head side) directly Carry out troubleshooting according to “Abnormality in coolant temperature sensor error (*2)“ in E-mode Remedy

Crushed or clogged muffler

Leakage of air between turbocharger and cylinder head

Improper valve clearance

Defective contact of valve and valve seat

Replace

Confirm recent repair history Degree of machine operation Operated for long period Suddenly became black Color of exhaust Gradually became black gas Blue under light load Non-specified fuel is being used Oil replenished more frequently Suddenly Power was lost Gradually Dust indicator is red (if indicator is installed) Muffler is crushed Air leaks between turbocharger and cylinder head, and clamp is loosened Engine is operated in low-temperature mode at normal temperature When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low When engine is cranked, interference sound is emitted from around turbocharger When engine is cranked, abnormal sound is generated around cylinder head Torque converter stall speed or pump relief speed is high (Fuel is injected excessively) Exhaust noise is abnormal Engine does not pick up smoothly and combustion is irregular Blow-by gas is excessive If spill hose from injector is disconnected, abnormally much fuel spills

Seized turbocharger or interference of turbocharger

Clogged air cleaner element

Causes

Clean

Troubleshooting

Check items

Questions

General causes why exhaust smoke is black q Insufficient intake of air q Excessive injection of fuel q Defective spray condition of fuel q Improper selection of fuel q Overheat o See "S-14 Coolant temperature becomes too high (Overheating)" q Controller is controlling in derate mode (limiting injection rate (output) because of an error in electrical system)

*1: Code [559/CA559], [559/CB559] and code [2249/CA2249], [2249/CB2249] in E-mode *2: Code [144/CA144] and code[145/CA145] in E-mode 12V140E-3 Series

SEN00316-01

40 Troubleshooting

S-8 Oil consumption is excessive (or exhaust smoke is blue)

Oil leakage from oil pan, cylinder head, etc.

Oil leakage from oil drain plug

Oil leakage from oil piping

Oil leakage from oil filter

Oil leakage from oil cooler

Broken oil cooler

Worn piston ring and/or cylinder liner

Broken piston ring

Clogged breather or breather hose

Turbocharger 1 Worn seal at blower end

Worn seal at turbocharger end

Worn or damaged rear oil seal

Q Q

w Q Q w

w w w w w w w Q w w w Q

w w w w

Q w

q q q q q q q q q q Correct

Correct

Replace

Correct

Replace

Clean

q q q q Replace

Remedy

E w

Replace

When intake manifold is removed, dust is found inside When intake manifold is removed, inside is found contaminated abnormally Excessive play of turbocharger shaft Check breather and breather hose directly When compression pressure is measured, it is found to be low Inspect rear oil seal directly Pressure-tightness test of oil cooler shows there is leakage There is external leakage of oil from engine

E E E

Replace

Confirm recent repair history Degree of machine operOperated for long period ation Oil consumption suddenly increased Oil replenished more frequently Oil becomes contaminated quickly Outside of engine is contaminated with oil There are loose piping clamps in intake system Inside of turbocharger intake outlet pipe is contaminated with oil Inside of turbocharger exhaust outlet pipe is contaminated with oil There is oil in coolant Oil level in clutch chamber or damper chamber on the installed machine side is increasing Exhaust smoke is blue under light load Excessive Amount of blow-by gas None

Worn or damaged valve (stem, guide, seal)

Dust sucked in from intake system

Causes

Correct

Troubleshooting

Check items

Questions

General causes why oil consumption is excessive q Abnormal combustion of oil q Long-time operation of engine at low idle or high idle (Do not run engine continuously at idle without load for more than 20 minutes) q External leakage of oil q Wear of parts in lubrication system

12V140E-3 Series

40 Troubleshooting

SEN00316-01

S-9 Oil becomes contaminated quickly

Exhaust smoke is bad

Clogged turbocharger lubrication drain tube

Defective oil filter safety valve

Clogged oil filter

Clogged oil cooler

Clogged breather and/or breather hose

Worn piston ring and/or cylinder liner

Worn valve and/or valve guide

Defective seal at turbocharger turbine end

Causes

Confirm recent repair history Degree of machine operation Operated for long period E E E Non-specified fuel is being used Q Engine oil replenished more frequently w Even when engine oil temperature rises, oil filter clogging monitor indicates clogging (if monitor is w Q installed) Metal particles are found when oil filter is drained Q Q w Inside of exhaust pipe is contaminated with oil w Engine oil temperature rises quickly w w Blue under light load Color of exhaust gas Black w Excessive Q Q w Q Amount of blow-by gas None w

Excessive play of turbocharger shaft When compression pressure is measured, it is found to be low Inspect breather and breather hose directly Inspect oil cooler directly Inspect oil filter directly Spring of oil filter safety valve is hitched or broken Inspect turbocharger lubrication drain tube directly

q q q q q

—

Clean

Replace

Clean

Replace

q Remedy

12V140E-3 Series

See S-7

Replace

Troubleshooting

Check items

Questions

General causes why oil becomes contaminated q Entry of exhaust gas into oil due to internal wear q Clogging of lubrication passage q Use of improper fuel q Use of improper oil q Operation under excessive load

SEN00316-01

40 Troubleshooting

S-10 Fuel consumption is excessive

General causes why fuel consumption is excessive q Leakage of fuel q Defective condition of fuel injection (fuel pressure, injection timing) q Excessive injection of fuel

Defective coolant temperature sensor or wiring harness

Improper injection timing

Defective operation of injector

Defective spray by injector

Defective supply pump plunger

Defective common rail fuel pressure

E Q

Q Q Q Q

Q Q w w w

w w Q Q Q Q

Q Q

Remove and inspect head cover directly q Inspect feed pump oil seal directly Carry out troubleshooting according to “No-pressure feed by supply pump error (*1)“ in E-mode When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change change on some cylinders If spill hose from injector is disconnected and measured, much fuel spills Carry out troubleshooting according to “Abnormality in coolant temperature sensor (*2)“ in E-mode Confirm with INSITE or with monitoring function on installed machine side

q q q q q Correct

Correct

Replace

q Replace

Correct

Replace

q Correct

Remedy

Defective feed pump oil seal

Fuel leakage from fuel filter, piping, etc.

E E

Replace

Confirm recent repair history Degree of Operated for long period machine operation More than other machines of same model Condition of fuel Gradually increased consumption Suddenly increased There is external leakage of fuel from engine Combustion is irregular Engine oil level rises and oil smells of diesel fuel When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Low idle speed is high Torque converter stall speed or hydraulic pump relief speed is high Color of exhaust Black gas White

Correct

Troubleshooting

Check items

Questions

Fuel leakage inside head cover

Causes

*1: Code [559/CA559], [559/CB559] and code [2249/CA2249], [2249/CB2249] in E-mode *2: Code [144/CA144] and code[145/CA145] in E-mode

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 q Internal leakage in lubrication system q Internal leakage in cooling system

Broken hydraulic oil cooler or power train oil cooler on installed machine side

Broken oil cooler core and/or O-ring

Insufficient protrusion of cylinder liner

Damaged cylinder liner O-ring and/or hole caused by pitting

Cracks inside cylinder block

Broken cylinder head and/or head gasket

Causes

Degree of machine operation Oil level

Operated for long period

Suddenly increased

Q Q

Oil level has risen and oil is milky

There are excessive air bubbles in radiator, coolant spurts back

w w

Hydraulic oil or power train oil on installed machine side is milky

When hydraulic oil or power train oil is drained, water is found

q q

Inspect cylinder block and liner directly

Inspect cylinder liner directly

12V140E-3 Series

Replace

Remedy

Replace

Pressure-tightness test of oil cooler shows there is leakage

—

Pressure-tightness test of cylinder head shows there is leakage

Carry out troubleshooting on installed machine

Check items

Q Q

Gradually increased

Hard water is being used as coolant

Troubleshooting

Replace

Questions

Confirm recent repair history

SEN00316-01

General causes why oil pressure drops q Leakage, clogging, and/or wear of lubrication system q Defective oil pressure control q Selection of oil by the temperature etc. specified in the Operation and Maintenance Manual is not observed q Deterioration of oil due to overheating

Defective oil level sensor and/or wiring harness

Defective oil pressure sensor and/or defective wiring harness

Leaking, crushed, clogged hydraulic piping

Clogged oil filter

Defective oil pump

Clogged and/or broken pipe in oil pan

Clogged strainer in oil pan

Defective oil pump relief valve

Q w Q w Q w w w Q

Q w Q w

Q Q w

w w w w w w

Metal particles are found in oil filter q Inspect oil pan strainer and pipe directly Oil pump rotation is heavy, there is play in oil pump Valve and spring of oil pump relief valve are fatigued and damaged Inspect oil filter directly Carry out troubleshooting according to “Abnormality in oil pressure sensor (*1)“ in E-mode If oil level sensor is replaced, oil level monitor indicates normally

See S-13

q q q q q q Replace

Replace

Correct

Clean

Adjusting

Replace

Add

Remedy

Coolant and fuel mixing in oil

Lack of oil in oil pan

Clean

Metal particles are found when oil filter is drained

—

Confirm recent repair history Degree of machine operation Operated for long period Oil pressure monitor indicates low oil pressure (if monitor is installed) Non-specified oil is being used Replacement of filters not carried according to Operation and Maintenance Manual Indicates pressure drop at low idling time Oil pressure Indicates pressure drop at low and high idling times monitor Indicates pressure drop on slopes (if installed) Indicates pressure drop occasionally Oil level monitor indicates oil level drop (if monitor is installed) Oil level in oil pan is low External hydraulic piping is leaking or crushed Oil is milky or smells of diesel oil Metal particles are found when oil pan is drained

Clean

Troubleshooting

Check items

Questions

Worn journal of bearing

Causes

Clean

S-12 Oil pressure drops

40 Troubleshooting

*1: Code [135/CA135] and code[141/CA141] in E-mode

12V140E-3 Series

40 Troubleshooting

SEN00316-01

S-13 Oil level rises (Entry of coolant or fuel)

General causes why oil level rises q Coolant in oil (milky) q Fuel in oil (smells diluted diesel fuel) a If oil is in coolant, carry out troubleshooting for "S-11 Oil is in coolant".

Confirm recent repair history Degree of Operated for long period machine operation Fuel consumption increasing Coolant replenished more frequently There is oil mixed in coolant Oil smells of diesel fuel Oil is milky When engine is started, drops of water come from muffler When radiator cap is removed and engine is run at low idle, an abnormal number of bubbles appears, or coolant spurts back Exhaust smoke is white Water pump drain hole (breather hole) is clogged When water pump drain hole (breather hole) is cleaned, coolant comes out Oil level in clutch or damper chamber of installed machine is low Oil level in hydraulic tank of installed machine is low

Defective seal of auxiliary equipment (pump, compressor)

w Q Q

Defects in supply pump

Defective thermostat seat

Clogged water pump drain hole (breather hole) and/or defective seal

Worn or damaged rear oil seal

Damaged cylinder liner O-ring and/or hole caused by pitting

Cracks inside cylinder block

Fuel leakage inside head cover

Broken oil cooler core and/or O-ring

E w w

Q Q

Q w w w w

When compression pressure is measured, it is found to be low Remove and inspect head cover directly Inspect cylinder block and/or liner directly Inspect rear oil seal directly Pressure-tightness test of oil cooler shows there is leakage Remove and inspect water pump directly Remove and inspect thermostat cover directly Remove and inspect supply pump directly Inspect seal of auxiliary equipment directly

q q q q q q q q Replace

Replace

Correct

Replace

Correct

Replace

Correct

q Remedy

12V140E-3 Series

E E

Replace

Troubleshooting

Check items

Questions

Broken cylinder head and/or head gasket

Causes

SEN00316-01

40 Troubleshooting

S-14 Coolant temperature becomes too high (overheating) General causes why coolant temperature becomes too high q Lack of cooling air (deformation, and/or damages of fan) q Drop in heat dissipation efficiency q Problem in coolant circulation system q Rise in oil temperature in power train on applicable machine side o Trouble shoot on the applicable machine side

Rise in power train oil temperature on applicable machine side

Defective coolant temperature gauge

Slipping fan belt and/or worn fan pulley

Defective radiator cap (pressure valve)

Clogged radiator core

Clogged or crushed radiator fins

Defective operation of thermostat

Broken water pump

Lack of coolant

Damaged cylinder liner O-ring and/or hole caused by pitting

Clogged or broken oil cooler

E E Q w

Q Q

Q w w w

w w w Q w w w w w

w w w w

q q q q q q Replace

Correct

Replace

Correct

Replace

Add

—

Carry out troubleshooting on installed machine

Replace

When compression pressure is measured, it is found to be low Inspect cylinder liner directly Inspect oil cooler directly Temperature difference between upper and lower tanks of radiator is large When operation of thermostat is tested, it does not open at cracking temperature Temperature difference between upper and lower tanks of radiator is slight Inspect radiator core directly When operation of radiator cap is carried out, its cracking pressure is low Inspect fan belt and pulley directly When coolant temperature is measured, it is found to be normal

E E

Replace

Confirm recent repair history Degree of Operated for long period machine operation Sudden overheated Condition for Persistent overheating Coolant tempera- Rises quickly ture gauge Does not go down from red range (if installed) Radiator coolant level monitor indicates drop of coolant level (if monitor is installed) Engine oil level has risen and oil is milky Fan belt tension is low Milky oil is floating on coolant There are excessive air bubbles in radiator and coolant spurts back When light bulb is held behind radiator core, no light passes through Radiator shroud, inside of underguard on applicable machine side are clogged with dirt or mud Coolant is leaking because of cracks in hose or loose clamps Coolant flows out from radiator overflow hose Fan belt whines under sudden acceleration Power train oil temperature gauge enters red range faster than engine coolant temperature gauge (if oil temperature gauge and coolant temperature gauge are installed) on the installed machine side

Replace

Troubleshooting

Check items

Questions

Broken cylinder head and/or head gasket

Causes

Remedy

12V140E-3 Series

40 Troubleshooting

SEN00316-01

S-15 Abnormal noise is made

12V140E-3 Series

Improper fuel injection timing (abnormality in coolant temperature sensor)

Dirt caught in injector

Clogged or seized injector

Deformed cooling fan and/or looseness or interference of fan belt

Removed or seized gear train bushing

Improper gear train backlash

Excessive wear of piston ring and/or cylinder liner

Improper valve clearance

Defective inside of muffler (dividing board out of position)

Q Q

Q Q w w

w w w

w w w Q w

Q w

Q Q

w Q Q

Q w

When turbocharger is rotated by hand, it is fount to be heavy Inspect dynamic valve system directly When muffler is removed, abnormal noise disappears Inspect valve clearance directly When compression pressure is measured, it is found to be low Inspect gear train directly Inspect fan and fan belt directly When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change on some cylinders Abnormal noise is heard only when engine is started Confirm with INSITE or with monitoring function on installed machine side

q q q q q q q q q q Correct

Correct

Replace

Correct

Replace

q Correct

Remedy

Broken dynamic valve system (valve and/or rocker lever)

Replace

Confirm recent repair history Degree of Operated for long period machine operation Gradually increased Condition of abnormal noise Suddenly increased Non-specified fuel is being used Oil replenished more frequently Metal particles are found when oil filter is drained Air leaks between turbocharger and cylinder head When engine is cranked, interference sound is emitted from around turbocharger When engine is cranked, abnormal sound is generated around EGR gas piping When engine is cranked, abnormal sound is generated around cylinder head When engine is cranked, beat noise is emitted around muffler When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Color of exhaust Blue under light load gas Black Engine does not pick up smoothly and combustion is irregular Abnormal noise is loud when engine is accelerated Blow-by gas is excessive

Interference or seizure of turbocharger

Leakage of air between turbocharger and cylinder head

Causes

Replace

Troubleshooting

Check items

Questions

General causes why abnormal noise is emitted q Abnormality due to defective parts q Abnormal combustion q Air leakage from air intake system a Judge if the noise is an internal noise or an external noise before starting troubleshooting. a While the engine is not sufficiently warmed up, it is operated in the low-temperature mode. Accordingly, the engine sound rises slightly higher. This is no abnormality, however. a When the engine is accelerated, the engine sound rises slightly for approx. 3 seconds maximum. This is no abnormality, however.

SEN00316-01

40 Troubleshooting

S-16 Vibration is excessive

Confirm recent repair history Degree of machine operation Operated for long period Condition of vibra- Suddenly increased tion Gradually increased Non-specified oil is being used Metal particles are found when oil filter is drained Metal particles are found when oil pan is drained Oil pressure is low at low idle Vibration occurs at mid-range speed Vibration follows engine speed

Q Q w w Q

E Q

Q Q Q Q Q Q

Exhaust smoke is black

Inspect dynamic valve system directly Inspect main bearing and connecting rod bearing directly Inspect gear train directly Inspect camshaft bushing directly Confirm with INSITE or with monitoring function on installed machine side Inspect engine mounting bolts and cushions directly When alignment is checked, radial runout or facial runout is detected Inspect front support spigot joint portion directly Inspect output shaft or inside of damper directly

Broken output shaft and/or parts in damper on installed machine side

Worn front support spigot joint portion

Misalignment between engine and devices on installed machine side

Loose engine mounting bolts and/or broken cushions

Improper injection timing

Worn camshaft bushing

Improper gear train backlash

E Q

q q q q q q q Replace

Adjusting

Replace

Adjusting

Replace

q Remedy

Worn main bearing and/or connecting rod bearing

Stuck dynamic valve system (valve, rocker lever, etc.)

Causes

Replace

Troubleshooting

Check items

Questions

General causes why vibration occurs q Defective parts (abnormal wear, breakage, etc.) q Misalignment between installed machine q Abnormal combustion a If abnormal noise vibration occur, carry out troubleshooting for "S-15 Abnormal noise is emitted", too.

12V140E-3 Series

40 Troubleshooting

12V140E-3 Series

SEN00316-01

40 Troubleshooting

KOMATSU 12V140E-3 Series engine Form No. SEN00316-01

12V140E-3 Series

SEN00317-03 12V140E-3 Series SEN00317-03

ENGINE Shop Manual

12V140E-3 Series

Machine model Serial number 12V140E-3 SERIES ENGINE...

40 Troubleshooting Troubleshooting of electrical system (E-mode), Part 1 E-1 Code [111/CA111] ECM Critical Internal Failure (LH bank) ..................................................................

E-2 Code [111/CB111] ECM Critical Internal Failure (RH bank)..................................................................

E-3 Code [115/CA115] Eng. Ne and G (Bkup) Speed Sensor Error (LH bank)...........................................

E-4 Code [115/CB115] Eng. Ne and G (Bkup) Speed Sensor Error (RH bank) ..........................................

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

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

12V140E-3 Series

40 Troubleshooting

12V140E-3 Series

SEN00317-03

40 Troubleshooting

E-1 Code [111/CA111] ECM Critical Internal Failure (LH bank) Error code

Failure code

111

CA111

Trouble Engine Controller Internal Failure (LH bank) Contents of trouble Action of controller Problem that appears on machine Related information

Abnormality occurred in controller.

None in particular.

Engine continues operation normally, but it may stop during operation or may not be able to start.

Different machine models may have different connector Nos. Causes

Standard value in normal state/Remarks on troubleshooting

Check fuse or circuit breaker on machine side directly for defect. (If fuse is burnt or circuit breaker is turned OFF, circuit probably has ground fault.) a Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring harwithout turning starting switch ON. ness Wiring harness between PW L (female) (3), ResisMax. 1  2 (Disconnection in wiring or (4) – battery (+) tance defective contact in connecWiring harness between PW L (female) (1), Resistor) Max. 1  (2) – chassis ground tance a Prepare with starting switch OFF, then carry out troubleshooting Ground fault in wiring harwithout turning starting switch ON. ness 3 Wiring harness between PW L(female) (3), Resis(Short circuit with GND cirMin. 1 M (4) – battery (+) tance cuit) a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 4 Defective engine controller PW L Voltage 1 Defective fuse

Possible causes and standard value in normal state

Between (3), (4) – (1), (2)

20 – 30 V

12V140E-3 Series

40 Troubleshooting

SEN00317-03

Circuit diagram related to controller power supply

12V140E-3 Series

SEN00317-03

40 Troubleshooting

E-2 Code [111/CB111] ECM Critical Internal Failure (RH bank) Error code

Failure code

111

CB111

Trouble Contents of trouble Action of controller Problem that appears on machine Related information

Abnormality occurred in controller.

None in particular.

Engine continues operation normally, but it may stop during operation or may not be able to start.

Different machine models may have different connector Nos. Causes

Possible causes and standard value in normal state

Engine Controller Internal Failure (RH bank)

Standard value in normal state/Remarks on troubleshooting

Check fuse or circuit breaker on machine side directly for possible defect. Defective fuse (If fuse is burnt or circuit breaker is turned OFF, circuit probably has ground fault.) a Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring harwithout turning starting switch ON. ness Wiring harness between PW R (female) (3), ResisMax. 1  (Disconnection in wiring or (4) – battery (+) tance defective contact in connecWiring harness between PW R (female) (1), Resistor) Max. 1  (2) – chassis ground tance a Prepare with starting switch OFF, then carry out troubleshooting Ground fault in wiring harwithout turning starting switch ON. ness (Short circuit with GND cir- Wiring harness between PW R (female) (3), ResisMin. 1 M (4) – battery (+) and chassis ground tance cuit) a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting Defective engine controller PW R Voltage Between (3), (4) – (1), (2)

20 – 30 V

12V140E-3 Series

40 Troubleshooting

SEN00317-03

Circuit diagram related to controller power supply

12V140E-3 Series

SEN00317-03

40 Troubleshooting

E-3 Code [115/CA115] Eng. Ne and G (Bkup) Speed Sensor Error (LH bank) Error code

Failure code

115

CA115

Trouble Abnormality in engine Ne and G (Bkup) speed sensor (LH bank) 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 (engine has been stopped). that appears on q Engine stops (if engine has been running). machine Related information Causes

Possible causes and standard value in normal state

Standard value in normal state/Remarks on troubleshooting

Defective Ne speed sensor system

Carry out troubleshooting for code [689/CA689].

Defective G (Bkup) speed sensor system

Carry out troubleshooting for code [778/CA778].

Defective mount of Ne speed Check mount of Ne speed sensor directly for defect (defective sensor installation of sensor, internal defect of flywheel, etc.)

Check mount of G (Bkup) speed sensor directly for defect Defective mount of G (Bkup) (defective installation of sensor, internal defect of supply pump, speed sensor etc.)

Defective connection of sen- Check Ne speed sensor and G (Bkup) speed sensor directly for sor (Wrong connection) defective connection (wrong connection). If causes 1 – 5 are not detected, engine controller may be defec6 Defective engine controller tive. (Since trouble is in system, troubleshooting cannot be carried out.) 5

12V140E-3 Series

SEN00317-03

40 Troubleshooting

E-4 Code [115/CB115] Eng. Ne and G (Bkup) Speed Sensor Error (RH bank) Error code

Failure code

115

CB115

Trouble Abnormality in engine Ne and G (Bkup) speed sensor (RH bank) Contents of q trouble Action of q controller Phenomenon q that appears on q machine Related information

Abnormality occurred in Ne speed sensor circuit and G (Bkup) speed sensor circuit simultaneously. Engine stop Engine cannot be started (if engine has been stopped) Engine stops (if engine has been running).

Causes

Possible causes and standard value in normal state

Standard value in normal state/Remarks on troubleshooting

Defective Ne speed sensor system

Carry out troubleshooting for code [689/CB689].

Defective G(Bkup) speed sensor system

Carry out troubleshooting for code [778/CB778].

Defective mount of Ne speed Check mount of Ne speed sensor directly for defect (defective sensor installation of sensor, internal defect of flywheel, etc.)

Check mount of G (Bkup) speed sensor directly for defect Defective mount of G (Bkup) (defective installation of sensor, internal defect of supply pump, speed sensor etc.)

Defective connection (Wrong Check Ne speed sensor and G (Bkup) speed sensor directly for connection) defective connection (wrong connection). If causes 1 – 5 are not detected, engine controller may be defec6 Defective engine controller tive. (Since trouble is in system, troubleshooting cannot be carried out.) 5

12V140E-3 Series

SEN00317-03

40 Troubleshooting

E-5 Code [122/CA122] Charge Air Press. Sensor High Error (LH bank only) Error code

Failure code Trouble

122

CA122

Contents of q trouble Action of q controller Phenomenon that appears on q machine Related q information

Charge pressure sensor circuit detects abnormally high pressure. Sets charge pressure to fixed value (400 kPa {4.1 kg/cm2}) and continues operation. Acceleration performance of engine drops. Different machine models may have different connector Nos. Causes

Standard value in normal state/Remarks on troubleshooting

Defective sensor power sup- If code [187/CA187] or [227/CA227] is indicated, carry out troubleply system shooting for it first. a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting.

Defective charge pressure 2 sensor (Internal trouble)

Possible causes and standard value in normal state

Sensor detection of abnormally high charge pressure (LH bank only)

Short circuit in wiring harness 3 (With another wiring harness)

4 Defective engine controller

PIM Between (1) – (2)

Power supply

4.75 – 5.25 V

Pressure sensor voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness and controller, too, for another cause of trouble, and then judge. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between LH J1 (female) (37) Resis– PIM (female) (1) and LH J1 (female) (47) – Min. 1  tance PIM (female) (3) Wiring harness between LH J1 (female) Resis(37) – PIM (female) (1) and LH J1 (female) Min. 1  tance (44) – PIM (female) (2) Wiring harness between LH J1 (female) (47) Resis– PIM (female) (3) and LH J1 (female) (44) – Min. 1  tance PIM (female) (2) a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. LH J1 Between (37) – (47)

Voltage

Voltage Power supply

4.75 – 5.25 V

12V140E-3 Series

40 Troubleshooting

SEN00317-03

Circuit diagram related to charge pressure sensor

12V140E-3 Series

SEN00317-03

40 Troubleshooting

E-6 Code [123/CA123] Charge Air Press. Sensor Low Error (LH bank only) Error code

Failure code Trouble

123 Contents of q trouble Action of q controller Phenomenon that appears on q machine Related information Possible causes and standard value in normal state

CA123

Sensor detection of abnormally low charge pressure (LH bank only)

Abnormally low pressure detected in charge pressure sensor circuit. Sets charge pressure (boost pressure) to fixed value (400 kPa {4.1 kg/cm2}) and continues operation. Acceleration performance of engine drops.

Causes

Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for E-5 Code [122/CA122].

12V140E-3 Series

40 Troubleshooting

12V140E-3 Series

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) Error code

Failure code

131

CA131

Trouble Throttle sensor detection of abnormally high level (LH bank only) Contents of q trouble Action of q controller Phenomenon that appears on q machine Related q information

Throttle sensor circuit detection of abnormally high level. Sets throttle angle with signal other than throttle sensor signal and continues operation. (depending on each model) Depends on machine model. Different machine models may have different connector Nos. Causes

Defective sensor power sup- If code [2185/CA2185] or [2186/CA2186] is indicated, carry out ply system troubleshooting for it first. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Defective deceleration sen2 sor (Internal trouble)

Possible causes and standard value in normal state

Standard value in normal state/Remarks on troubleshooting

Ground fault in wiring harness 3 (Short circuit with GND circuit)

DEC (male)

Resistance

Between (A) – (C)

4.0 – 6.0 k

Between (B) – (A)

0.25 – 5.0 k

Between (B) – (C)

0.25 – 5.0 k

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between OEM L(female) ResisMin. 1 M (22) – DEC (female) (A) and chassis ground tance Wiring harness between OEM L(female) (9) – DEC (female) (B) and chassis ground

Resistance

Min. 1 M

Wiring harness between OEM L(female) ResisMin. 1 M (23) – DEC (female) (C) and chassis ground tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 4 Defective engine controller

OEM L

Voltage

Between (22) – (23)

Power supply

4.75 – 5.25 V

Between (9) – (23)

Signal

0.5 – 4.5 V

Circuit diagram related to deceleration pedal type throttle sensor (Case of D475–5)

12V140E-3 Series

SEN00317-03

40 Troubleshooting

E-8 Code [132/CA132] Throttle Sensor Low Error (LH bank only) Throttle sensor of decelerator pedal type (Case of D475-5) Error code

Failure code

132

CA132

Trouble Throttle sensor detection of abnormally low level (LH bank only) Contents of q trouble Action of q controller Phenomenon that appears on q machine Related information Possible causes and standard value in normal state

12V140E-3 Series

Signal voltage in throttle sensor circuit is abnormally low. Sets throttle angle with signal other than throttle sensor signal and continues operation. (depending on each model) Varies by installed machine

Causes

Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for E-7 Code [131/CA131].

SEN00317-03

40 Troubleshooting

E-9 Code [135/CA135] Oil Press. Sensor High Error (LH bank only) Error code

Failure code Trouble

135

CA135

Contents of q trouble Action of q controller Phenomenon that appears on machine Related q information

Signal voltage in oil pressure sensor circuit is abnormally high. Set oil pressure to default value (250 kPa {2.5 kg/cm2}) and continue operation.

Different machine models may have different connector Nos. Causes

Standard value in normal state/Remarks on troubleshooting

Defective oil pressure sen2 sor (Internal trouble)

Possible causes and standard value in normal state

Oil pressure sensor detection of abnormally high pressure (LH bank only)

Ground fault in wiring harness 3 (Short circuit with GND circuit)

Short circuit in wiring harness 4 (With another wiring harness)

POIL Between (1) – (2)

Voltage Power supply

4.75 – 5.25 V

Sensor voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness and controller, too, for another cause of trouble, and then judge. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between LH J1 (female) ResisMin. 1 M (37) – POIL (female) (1) and chassis ground tance Wiring harness between LH J1 (female) (47) – POIL (female) (2) and chassis ground

Resistance

Min. 1 M

Wiring harness between LH J1 (female) (13) ResisMin. 1 M – POIL (female) (3) and chassis ground tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between LH J1 (female) (37) Resis– POIL (female) (1) and LH J1 (female) (47) Min. 1 M tance – POIL (female) (2) Wiring harness between LH J1 (female) (37) – POIL (female) (1) and LH J1 (female) (13) – POIL (female) (3)

Resistance

Min. 1 M

Wiring harness between LH J1 (female) (47) Resis– POIL (female) (2) and LH J1 (female) (13) Min. 1 M tance – POIL (female) (3) a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. 5 Defective engine controller

LH J1 Between (37) – (47)

Voltage Power supply

4.75 – 5.25 V

12V140E-3 Series

40 Troubleshooting

SEN00317-03

Circuit diagram related to oil pressure sensor

12V140E-3 Series

SEN00317-03

40 Troubleshooting

E-10 Code [141/CA141] Oil Press. Sensor Low Error (LH bank only) Error code

Failure code Trouble

141 Contents of q trouble Action of q controller Phenomenon that appears on machine Related information Possible causes and standard value in normal state

CA141

Oil pressure sensor detection of abnormally low pressure (LH bank only)

Signal voltage in oil pressure sensor circuit is abnormally low. Sets oil pressure to default value (250 kPa {2.5 kg/cm2}) and continues operation.

Causes

Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for E-9 Code [135/CA135].

12V140E-3 Series

40 Troubleshooting

12V140E-3 Series

SEN00317-03

40 Troubleshooting

E-11 Code [144/CA144] Coolant Temp. Sensor High Error (LH bank only) Error code

Failure code Trouble

144

CA144

Contents of q trouble Action of q controller Phenomenon that appears on machine Related q information

Signal voltage in coolant temperature sensor circuit is abnormally high. Fixes coolant temperature at (90 °C) and continues operation.

Different machine models may have different connector Nos. Causes

Defective coolant tempera1 ture sensor (Internal trouble)

Possible causes and standard value in normal state

Coolant temperature sensor detection of abnormally high temperature (LH bank only)

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. TWTR (male)

Coolant temperature

Resistance

Between (A) – (B)

10 – 100 °C

0.6 – 20 k

a Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring harwithout turning starting switch ON. ness Wiring harness between LH J1 (female) ResisMax. 1  2 (Disconnection in wiring or (15) – TWTR (female) (A) tance defective contact in connecWiring harness between LH J1 (female) (38) Resistor) Max. 1  – TWTR (female) (B) tance a Prepare with starting switch OFF, then carry out troubleshooting Ground fault in wiring harwithout turning starting switch ON. ness Wiring harness between LH J1 (female) 3 Resis(Short circuit with GND cir(15) – TWTR (female) (A) and chassis Min. 1 M tance cuit) ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4 Defective engine controller LH J1 (female) Coolant temperature Resistance Between (15) – (38)

10 – 100 °C

0.6 – 20 k

12V140E-3 Series

40 Troubleshooting

SEN00317-03

Circuit diagram related to coolant temperature sensor

12V140E-3 Series

SEN00317-03

40 Troubleshooting

E-12 Code [145/CA145] Coolant Temp. Sensor Low Error (LH bank only) Error code

Failure code Trouble

145 Contents of q trouble Action of q controller Phenomenon that appears on machine Related information Possible causes and standard value in normal state

CA145

Coolant temperature sensor detection of abnormally low temperature (LH bank only)

Signal voltage in coolant temperature sensor circuit is abnormally low. Fixes coolant temperature at (90 °C) and continues operation.

Causes

Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for E-11 Code [144/CA144].

12V140E-3 Series

40 Troubleshooting

12V140E-3 Series

SEN00317-03

40 Troubleshooting

E-13 Code [153/CA153] Charge Air Temp. Sensor High Error (LH bank only) Error code

Failure code Trouble

153

CA153

Contents of q trouble Action of q controller Phenomenon that appears on machine Related q information

Signal voltage in charge temperature sensor circuit is abnormally high. Fixes charge temperature (intake air temperature) at (70 °C) and continues operation.

Different machine models may have different connector Nos. Causes

Defective charge tempera1 ture sensor (Internal trouble)

Possible causes and standard value in normal state

Charge temperature sensor detection of abnormally high temperature (LH bank only)

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Intake air temperaTIM (male) Resistance ture Between (A) – (B)

Between (23) – (47)

10 – 100 °C

0.5 – 20 k

Between (A) – chasAll range Min. 1 M sis ground a Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring harwithout turning starting switch ON. ness Wiring harness between LH J1 (female) ResisMax. 1  2 (Disconnection in wiring or (23) – TIM (female) (A) tance defective contact in connecWiring harness between LH J1 (female) (47) Resistor) Max. 1  – TIM (female) (B) tance a Prepare with starting switch OFF, then carry out troubleshooting Ground fault in wiring harwithout turning starting switch ON. ness 3 (Short circuit with GND cir- Wiring harness between LH J1 (female) (23) ResisMin. 1 M – TIM (female) (A) and chassis ground tance cuit) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Intake air tempera4 Defective engine controller LH J1 (female) Resistance ture 10 – 100 °C

0.5 – 20 k

12V140E-3 Series

40 Troubleshooting

SEN00317-03

Circuit diagram related to charge temperature sensor

12V140E-3 Series

SEN00317-03

40 Troubleshooting

E-14 Code [154/CA154] Charge Air Temp. Sensor Low Error (LH bank only) Error code

Failure code Trouble

154 Contents of q trouble Action of q controller Phenomenon that appears on machine Related information Possible causes and standard value in normal state

CA154

Charge temperature sensor detection of abnormally low charge temperature (LH bank only)

Signal voltage in charge temperature sensor circuit is abnormally low. Fixes charge temperature (intake air temperature) at (70 °C) and continues operation.

Causes

Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for E-13 Code [153/CA153].

12V140E-3 Series

SEN00317-03

40 Troubleshooting

E-15 Code [187/CA187] Sensor Sup. 2 Volt. Low Error (LH bank) Error code

Failure code Trouble

187 Contents of trouble

Action of controller

CA187

Power supply 2 sensor detection of abnormally low voltage (LH bank)

Signal voltage in sensor power supply 2 (5 V) circuit is abnormally low.

Sets atmospheric pressure sensor to default value (52.44 kPa {0.5 kg/cm2}) and continues operation. Sets oil pressure sensor to default value (250 kPa {2.5 kg/cm2}) and continues operation. Fixes charge pressure sensor value (400 kPa {4.1 kg/cm2}) and continues operation. Operates G (Bkup) sensor with signals of Ne speed sensor.

q q q

Phenomenon that appears on q machine Related information Possible causes and standard value in normal state

Output drops.

Causes

Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for E-21 Code [227/CA227].

E-16 Code [187/CB187] Sensor Sup. 2 Volt. Low Error (RH bank) Error code

Failure code Trouble

187 Contents of q trouble Action of q controller Phenomenon that appears on q machine Related information Possible causes and standard value in normal state

12V140E-3 Series

CB187

Power supply 2 sensor detection of abnormally low voltage (RH bank)

Signal voltage in sensor power supply 2(5 V) circuit is abnormally low. Operate G (Bkup) sensor with signals of Ne speed sensor. Output drops.

Causes

Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for E-22 Code [227/CB227].

SEN00317-03

40 Troubleshooting

E-17 Code [212/CA212] Eng. Oil Temp.Sensor High Error (LH bank only) Error code

Failure code Trouble

212

CA212

Contents of q trouble Action of q controller Phenomenon that appears on machine Related q information

Signal voltage in engine oil temperature sensor circuit is abnormally high. Sets oil pressure to default value (100 °C) and continues operation.

Different machine models may have different connector Nos. Causes

Defective oil temperature 1 sensor (Internal trouble)

Possible causes and standard value in normal state

Engine oil temperature sensor detection of abnormally high temperature (LH bank only)

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. TOIL (male)

Oil temperature

Resistance

Between (A) – (B)

0 – 100 °C

0.5 – 36 k

a Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring harwithout turning starting switch ON. ness Wiring harness between LH J1 (female) (17) ResisMax. 1  2 (Disconnection in wiring or – TOIL (female) (A) tance defective contact in connecWiring harness between LH J1 (female) (47) Resistor) Max. 1  – TOIL (female) (B) tance a Prepare with starting switch OFF, then carry out troubleshooting Ground fault in wiring harwithout turning starting switch ON. ness 3 (Short circuit with GND cir- Wiring harness between LH J1 (female) (17) ResisMin. 1 M – TOIL (female) (A) and chassis ground tance cuit) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4 Defective engine controller LH J1 Oil temperature Resistance (17) – (47)

0 – 100 °C

0.5 – 36 k

12V140E-3 Series

40 Troubleshooting

SEN00317-03

Circuit diagram related to engine oil temperature sensor

12V140E-3 Series

SEN00317-03

40 Troubleshooting

E-18 Code [213/CA213] Eng. Oil Temp.Sensor Low Error (LH bank only) Error code

Failure code Trouble

213 Contents of q trouble Action of q controller Phenomenon that appears on machine Related q information Possible causes and standard value in normal state

CA213

Engine oil temperature sensor detection of abnormally low temperature (LH bank only)

Signal voltage in engine oil temperature sensor circuit is abnormally low. Sets oil temperature to default value (100 °C) and continues operation.

Different machine models may have different connector Nos. Causes

Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for E-17 Code [212/CA212].

12V140E-3 Series

40 Troubleshooting

12V140E-3 Series

SEN00317-03

40 Troubleshooting

E-19 Code [221/CA221] Ambient Air Press. Sensor High Error (LH bank only) Error code

Failure code Trouble

221

CA221

Contents of q trouble Action of q controller Phenomenon that appears on q machine Related q information

Signal voltage in atmospheric pressure sensor circuit is abnormally high. Sets atmospheric pressure to default value (52.44 kPa {0.5 kg/cm2}) and continues operation. Output drops. Different machine models may have different connector Nos. Causes

Atmospheric pressure sensor detection of abnormally high pressure (LH bank only)

Standard value in normal state/Remarks on troubleshooting

Defective sensor power sup- If code [352/CA352] or [386/CA386] is indicated, carry out troubleply system shooting for it first. a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. PAMB

Defective atmospheric pres2 sure sensor (Internal trouble)

Possible causes and standard value in normal state

Ground fault in wiring harness 3 (Short circuit with GND circuit)

Short circuit in wiring harness 4 (With another wiring harness)

Voltage

Between (1) – (2)

Power supply

4.75 – 5.25 V

Between (3) – (2)

Signal

0.5 – 4.5 V

Sensor voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness and controller, too, for another cause of trouble, and then judge. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between LH J1 (female) (37) ResisMin. 1 M – PAMB (female) (1) and chassis ground tance Wiring harness between LH J1 (female) (38) – PAMB (female) (3) and chassis ground

Resistance

Min. 1 M

Wiring harness between LH J1 (female) (3) ResisMin. 1 M – PAMB (female) (2) and chassis ground tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between LH J1 (female) (37) Resis– PAMB (female) (1) and LH J1 (female) Min. 1 M tance (38) – PAMB (female) (3) Wiring harness between LH J1 (female) (37) – PAMB (female) (1) and LH J1 (female) (3) – PAMB (female) (2)

Resistance

Min. 1 M

Wiring harness between LH J1 (female) (38) Resis– PAMB (female) (3) and LH J1 (female) (3) Min. 1 M tance – PAMB (female) (2) a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. 5 Defective engine controller

LH J1

Voltage

Between (37) – (38)

4.75 – 5.25 V

Between (3) – (38)

0.5 – 4.5 V

12V140E-3 Series

40 Troubleshooting

SEN00317-03

Circuit diagram related to atmospheric pressure sensor

12V140E-3 Series

SEN00317-03

40 Troubleshooting

E-20 Code [222/CA222] Ambient Air Press. Sensor Low Error (LH bank only) Error code

Failure code Trouble

222 Contents of q trouble Action of q controller Phenomenon that appears on q machine Related information Possible causes and standard value in normal state

CA222

Atmospheric pressure sensor detection of abnormally low pressure (LH bank only)

Signal voltage in atmospheric pressure sensor circuit is abnormally low. Sets atmospheric pressure to default value (52.44 kPa {0.5 kg/cm2}) and continues operation. Output drops.

Causes

Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for E-19 Code [221/CA221].

12V140E-3 Series

40 Troubleshooting

12V140E-3 Series

SEN00317-03

40 Troubleshooting

E-21 Code [227/CA227] Sensor Sup. 2 Volt. High Error (LH bank) Error code

Failure code Trouble

227 Contents of trouble Action of controller

CA227 q

Signal voltage in sensor power supply 2(5 V) circuit is abnormally high.

q q q

Phenomenon that appears on q machine Related q information

Output drops. Different machine models may have different connector Nos. Causes

Standard value in normal state/Remarks on troubleshooting

1 Defective related system

If another failure code is indicated, carry out troubleshooting for it.

Defective sensor (Internal trouble)

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Atmospheric presPAMB connector Disconnect devices sure sensor at right in order. If Oil pressure sensor POIL connector error code disapCharge pressure pears subsequently, PIM connector sensor that device has a defect in it. G (Bkup) sensor G connector

Possible causes and standard value in normal state

Power supply 2 sensor detection of abnormally high voltage (LH bank)

a Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring harwithout turning starting switch ON. ness Wiring harness between LH J1 (female) (37) ResisMax. 1  3 (Disconnection in wiring or – respective sensors (female) tance defective contact in connecWiring harness between LH J1 (female) (47) Resistor) Max. 1  – respective sensors (female) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harWiring harness between LH J1 (female) (37) Resisness – respective sensors (female) and chassis Min. 1 M 4 tance (Short circuit with GND cir- ground Wiring harness between LH J1 (female) (47) cuit) Resis– respective sensors (female) and chassis Min. 1 M tance ground a Prepare with starting switch OFF, then carry out troubleshooting Short circuit in wiring harwithout turning starting switch ON. Wiring harness between LH J1 (female) ness 5 (37) – respective sensors (female) and LH Resis(With another wiring harMin. 1 M J1 (female) (47) – respective sensors tance ness) (female) a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 6 Defective engine controller LH J1 Voltage Between (37) – (47)

4.75 – 5.25 V

12V140E-3 Series

40 Troubleshooting

SEN00317-03

Circuit diagram related to sensor power supply 2 (5 V)

12V140E-3 Series

SEN00317-03

40 Troubleshooting

E-22 Code [227/CB227] Sensor Sup. 2 Volt. High Error (RH bank) Error code

Failure code Trouble

227

CB227

Contents of q trouble Action of q controller Phenomenon that appears on q machine Related q information

Signal voltage in sensor power supply 2 (5 V) circuit is abnormally high. Operates G(Bkup) sensor with signals of Ne speed sensor. Output drops. Different machine models may have different connector Nos. Causes

Standard value in normal state/Remarks on troubleshooting

1 Defective related system

If another failure code is indicated, carry out troubleshooting for it.

Possible causes and standard value in normal state

Defective sensor (Internal trouble)

Ground fault in wiring harness 3 (Short circuit with GND circuit)

Short circuit in wiring harness 4 (With another wiring harness)

5 Defective engine controller

Power supply 2 sensor detection of abnormally high voltage (RH bank)

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Disconnect devices at right in order. If error code disapG (Bkup)speed senG connector pears subsequently, sor that device has a defect in it. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between RH J1 (female) Resis(37) – respective sensors (female) and Min. 1 M tance chassis ground Wiring harness between RH J1 (female) Resis(47) – respective sensors (female) and Min. 1 M tance chassis ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between RH J1 (female) (37) – respective sensors (female) and RH ResisMin. 1 M J1 (female) (47) – respective sensors tance (female) a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. RH J1

Voltage

Between (37) – (47)

4.75 – 5.25 V

12V140E-3 Series

40 Troubleshooting

SEN00317-03

Circuit diagram related to sensor power supply 2 (5 V)

12V140E-3 Series

SEN00317-03

40 Troubleshooting

E-23 Code [234/CA234] Eng. Overspeed (LH bank only) Error code

Failure code

234

CA234

Trouble Engine overspeed (LH bank only) Contents of q trouble Action of q controller Phenomenon that appears on q machine Related information

Possible causes and standard value in normal state

Engine speed is above operating range. Limits fuel injection rate until engine speed lowers to operating range. Engine speed fluctuates.

Causes

Standard value in normal state/Remarks on troubleshooting

1 Defective related system

If another failure code is indicated, carry out troubleshooting for it.

2 Improper way of use

Way of use may be improper. Teach proper way of use to operator.

3 Defective engine controller

If causes 1 – 2 are not detected, engine controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)

12V140E-3 Series

40 Troubleshooting

12V140E-3 Series

SEN00317-03

40 Troubleshooting

E-24 Code [238/CA238] Ne Speed Sensor Sup. Volt. Error (LH bank) Error code

Failure code

238

CA238

Trouble Ne Speed Sensor Sup. Volt. Error (LH bank) Contents of q trouble Action of q controller Phenomenon q that appears on q machine Related q information

Abnormality occurred in Ne speed sensor power supply (5 V) circuit. Controls Ne speed sensor with signals of G (Bkup) speed sensor. Running engine stops (when G (Bkup) speed sensor is also abnormal). Stopped engine cannot be started (when G (Bkup) speed sensor is also abnormal). Different machine models may have different connector Nos. Causes

Possible causes and standard value in normal state

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnect devices Defective Ne speed sensor at right in order. If 1 error code disap(Internal trouble) Ne speed sensor NE connector pears subsequently, that device has a defect in it. a Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring harwithout turning starting switch ON. ness Wiring harness between LH J1 (female) (16) ResisMax. 1  2 (Disconnection in wiring or – Ne (female) (1) tance defective contact in connecWiring harness between LH J1 (female) (48) Resistor) Max. 1  – Ne (female) (2) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harWiring harness between LH J1 (female) (16) Resisness Min. 1 M 3 tance (Short circuit with GND cir- – Ne (female) (1) and chassis ground cuit)

Short circuit in wiring harness 4 (With another wiring harness)

5 Defective engine controller

Standard value in normal state/Remarks on troubleshooting

Wiring harness between LH J1 (female) (48) ResisMin. 1 M – Ne (female) (2) and chassis ground tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between LH J1 (female) (16) Resis– Ne (female) (1) and LH J1 (female) (48) – Min. 1 M tance Ne (female) (2) a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. LH J1

Voltage

Between (16) – (48)

4.75 – 5.25 V

12V140E-3 Series

40 Troubleshooting

SEN00317-03

Circuit diagram related to Ne speed sensor power supply

12V140E-3 Series

SEN00317-03

40 Troubleshooting

E-25 Code [238/CB238] Ne Speed Sensor Sup. Volt. Error (RH bank) Error code

Failure code

238

CB238

Trouble Ne Speed Sensor Sup. Volt. Error (RH bank) Contents of q trouble Action of q controller Phenomenon q that appears on q machine Related q information

Possible causes and standard value in normal state

Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnect devices Defective Ne speed sensor at right in order. If 1 error code disap(Internal trouble) Ne speed sensor NE connector pears subsequently, that device has a defect in it. a Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring harwithout turning starting switch ON. ness Wiring harness between LH J1 (female) ResisMax. 1  2 (Disconnection in wiring or (16) – Ne (female) (1) tance defective contact in connecWiring harness between RH J1 (female) Resistor) Max. 1  (48) – Ne (female) (2) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harWiring harness between LH J1 (female) (16) Resisness Min. 1 M 3 tance (Short circuit with GND cir- – Ne (female) (1) and chassis ground cuit)

Short circuit in wiring harness 4 (With another wiring harness)

Wiring harness between RH J1 (female) ResisMin. 1 M (48) – Ne (female) (2) and chassis ground tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between LH J1 (female) Resis(16) – Ne (female) (1) and RH J1 (female) Min. 1 M tance (48) – Ne (female) (2) a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.

5 Defective engine controller

Voltage LH J1 (16) – RH J1 (48) 4.75 – 5.25 V

12V140E-3 Series

40 Troubleshooting

SEN00317-03

Circuit diagram related to Ne speed sensor power supply

12V140E-3 Series

SEN00317-03

40 Troubleshooting

E-26 Code [263/CA263] Fuel Temp. Sensor High Error (LH bank) Error code

Failure code Trouble

263

CA263

Contents of q trouble Action of q controller Phenomenon that appears on machine Related q information

Signal voltage in fuel temperature sensor circuit is abnormally high. Fixes fuel temperature at (95 °C) and continues operation.

Different machine models may have different connector Nos. Causes

Defective fuel temperature 1 sensor (Internal trouble)

Possible causes and standard value in normal state

Fuel temperature sensor detection of abnormally high temperature (LH bank only)

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. LH TFUEL (male)

Fuel temperature

Resistance

Between (A) – (B)

10 – 100 °C

0.6 – 20 k

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harWiring harness between LH J1 (female) Resisness Max. 1  2 tance (Disconnection or defective (30) – LH TFUEL (female) (A) contact in connector) Wiring harness between LH J1 (female) (47) ResisMax. 1  – LH TFUEL (female) (B) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harWiring harness between LH J1 (female) (30) ness ResisMax. 3 – LH TFUEL (female) (A) and chassis (Short circuit with GND cirtance 1 M ground cuit) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. LH J1 (female)

Fuel temperature

Resistance

Between (30) – (47)

10 – 100 °C

0.6 – 20 k

4 Defective engine controller

12V140E-3 Series

40 Troubleshooting

SEN00317-03

Circuit diagram related to fuel temperature sensor

12V140E-3 Series

SEN00317-03

40 Troubleshooting

E-27 Code [263/CB263] Fuel Temp. Sensor High Error (RH bank) Error code

Failure code Trouble

263

CB263

Contents of q trouble Action of q controller Phenomenon that appears on machine Related q information

Signal voltage in fuel temperature sensor circuit is abnormally high. Fixes fuel temperature at (95 °C) and continues operation.

Different machine models may have different connector Nos. Causes

Defective fuel temperature 1 sensor (Internal trouble)

Possible causes and standard value in normal state

Fuel temperature sensor detection of abnormally high temperature (RH bank only)

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. RH TFUEL (male)

Fuel temperature

Resistance

Between (A) – (B)

10 – 100 °C

0.6 – 20 k

a Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring harwithout turning starting switch ON. ness Wiring harness between RH J1 (female) ResisMax. 1  2 (Disconnection in wiring or (30) – RH TFUEL (female) (A) tance defective contact in connecWiring harness between RH J1 (female) Resistor) Max. 1  (47) – RH TFUEL (female) (B) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harWiring harness between RH J1 (female) ness ResisMax. 3 (30) – RH TFUEL (female) (A) and chassis (Short circuit with GND cirtance 1 M ground cuit) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. RH J1 (female)

Fuel temperature

Resistance

Between (30) – (47)

10 – 100 °C

0.6 – 20 k

4 Defective engine controller

12V140E-3 Series

40 Troubleshooting

SEN00317-03

Circuit diagram related to fuel temperature sensor

12V140E-3 Series

SEN00317-03

40 Troubleshooting

E-28 Code [265/CA265] Fuel Temp. Sensor Low Error (LH bank) Error code

Failure code Trouble

265 Contents of trouble Action of controller

CA265

Fuel temperature sensor detection of abnormally low temperature (LH bank)

Signal voltage in fuel temperature sensor circuit is abnormally low.

Substitutes with coolant temperature sensor. If coolant temperature sensor is also in abnormal state. Sets oil temperature to default value (95 °C) and continues operation.

Phenomenon that appears on machine Related information Possible causes and standard value in normal state

Causes

Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for E-26 Code [263/CA263].

E-29 Code [265/CB265] Fuel Temp. Sensor Low Error (RH bank) Error code

Failure code Trouble

265 Contents of trouble Action of controller

CB265

Fuel temperature sensor detection of abnormally low temperature (RH bank)

Signal voltage in fuel temperature sensor circuit is abnormally low.

Substitutes with coolant temperature sensor. If coolant temperature sensor is also in abnormal state. Fixes fuel temperature at (95 °C) and continues operation.

Phenomenon that appears on machine Related information Possible causes and standard value in normal state

Causes

Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for E-27 Code [263/CB263].

12V140E-3 Series

40 Troubleshooting

12V140E-3 Series

SEN00317-03

40 Troubleshooting

E-30 Code [271/CA271] PCV1 Short Error (LH bank) Error code

Failure code

271

CA271

Trouble PCV1 Short circuit Error (LH bank) Contents of q trouble Action of q controller Phenomenon that appears on machine Related q information

There is short circuit in PCV1 circuit of supply pump. None in particular.

Different machine models may have different connector Nos. Causes

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Defective supply pump 1 PCV1 (Internal trouble)

Possible causes and standard value in normal state

Ground fault in wiring harness 2 (Short circuit with GND circuit)

Hot short in wiring harness (Contact with 24 V)

LH PCV1 (male)

Resistance

Between (1) – (2)

2.3–5.3 

Between (1), (2) – chassis Min. 1 M ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between LH J1 (female) (4) ResisMin. 1 M – LH PCV1 (female) (1) and chassis ground tance Wiring harness between LH J1 (female)(5) – ResisMin. 1 M LH PCV1 (female) (2) and chassis ground tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between LH J1 (female) (4) Voltage Max. 1 V – LH PCV1 (female) (1) and chassis ground Wiring harness between LH J1 (female) (5) Voltage Max. 1 V – LH PCV1 (female) (2) and chassis ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. LH J1 (female)

Resistance

Between (4) – (5)

2.3 – 5.3 

Between (4), (5) – chassis ground

Min. 1 M

4 Defective engine controller

12V140E-3 Series

40 Troubleshooting

SEN00317-03

Circuit diagram related to supply pump PCV1

12V140E-3 Series

SEN00317-03

40 Troubleshooting

E-31 Code [271/CB271] PCV1 Short Error (RH bank) Error code

Failure code

271

CB271

Trouble PCV1 Short circuit Error (RH bank) Contents of q trouble Action of q controller Phenomenon that appears on machine Related q information

There is short circuit in PCV1 circuit of supply pump. None in particular.

Different machine models may have different connector Nos. Causes

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Defective supply pump 1 PCV1 (Internal trouble)

Possible causes and standard value in normal state

Ground fault in wiring harness 2 (Short circuit with GND circuit)

Hot short in wiring harness (Contact with 24 V)

RH PCV1 (male)

Resistance

Between (1) – (2)

2.3–5.3 

Between (1), (2) – chassis Min. 1 M ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between RH J1 (female) (4) ResisMin. 1 M – RH PCV1 (female) (1) and chassis ground tance Wiring harness between RH J1 (female) (5) ResisMin. 1 M – RH PCV1 (female) (2) and chassis ground tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between RH J1 (female) (4) Voltage Max. 1 V – RH PCV1 (female) (1) and chassis ground Wiring harness between RH J1 (female) (5) Voltage Max. 1 V – RH PCV1 (female) (2) and chassis ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. RH J1 (female)

Resistance

Between (4) – (5)

2.3 – 5.3 

Between (4), (5) – chassis ground

Min. 1 M

4 Defective engine controller

12V140E-3 Series

40 Troubleshooting

SEN00317-03

Circuit diagram related to supply pump PCV1

12V140E-3 Series

SEN00317-03

40 Troubleshooting

E-32 Code [272/CA272] PCV1 Open Error (LH bank) Error code

Failure code

272

CA272

Trouble PCV1 Disconnection Error (LH bank) Contents of q trouble Action of q controller Phenomenon that appears on machine Related q information

There is disconnection in PCV1 circuit of supply pump. None in particular.

Different machine models may have different connector Nos. Causes

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Defective supply pump 1 PCV1 (Internal disconnection)

Possible causes and standard value in normal state

LH PCV1 (male)

Resistance

Between (1) – (2)

2.3 – 5.3 

Resistance

Between (4) – (5)

2.3 – 5.3 

Between (4), (5) – chassis ground

Min. 1 M

3 Defective engine controller

Circuit diagram related to supply pump PCV1

12V140E-3 Series

SEN00317-03

40 Troubleshooting

E-33 Code [272/CB272] PCV1 Open Error (RH bank) Error code

Failure code

272

CB272

Trouble PCV1 Disconnection Error (RH bank) Contents of q trouble Action of q controller Phenomenon that appears on machine Related q information

There is disconnection in PCV1 circuit of supply pump. None in particular.

Different machine models may have different connector Nos. Causes

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Defective supply pump 1 PCV1 (Internal disconnection)

Possible causes and standard value in normal state

RH PCV1 (male)

Resistance

Between (1) – (2)

2.3 – 5.3 

Resistance

Between (4) – (5)

2.3 – 5.3 

Between (4), (5) – chassis ground

Min. 1 M

3 Defective engine controller

Circuit diagram related to supply pump PCV1

12V140E-3 Series

SEN00317-03

40 Troubleshooting

E-34 Code [273/CA273] PCV2 Short Error (LH bank) Error code

Failure code

273

CA273

Trouble PCV2 Short circuit Error (LH bank) Contents of q trouble Action of q controller Phenomenon that appears on machine Related q information

There is short circuit in PCV2 circuit of supply pump. None in particular.

Different machine models may have different connector Nos. Causes

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Defective supply pump 1 PCV2 (Internal trouble)

Possible causes and standard value in normal state

Ground fault in wiring harness 2 (Short circuit with GND circuit)

Hot short in wiring harness (Contact with 24 V)

LH PCV2 (male)

Resistance

Between (1) – (2)

2.3 – 5.3 

Between (1), (2) – chassis Min. 1 M ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between LH J1 (female) (9) ResisMin. 1 M – LH PCV2 (female) (1) and chassis ground tance Wiring harness between LH J1 (female) (10) ResisMin. 1 M – LH PCV2 (female) (2) and chassis ground tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between LH J1 (female) (9) Voltage Max. 1 V – LH PCV2 (female) (1) and chassis ground Wiring harness between LH J1 (female) (10) Voltage Max. 1 V – LH PCV2 (female) (2) and chassis ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. LH J1 (female)

Resistance

Between (9) – (10)

2.3 – 5.3 

Between (9), (10) – chassis ground

Min. 1 M

4 Defective engine controller

12V140E-3 Series

40 Troubleshooting

SEN00317-03

Circuit diagram related to supply pump PCV2

12V140E-3 Series

SEN00317-03

40 Troubleshooting

E-35 Code [273/CB273] PCV2 Short Error (RH bank) Error code

Failure code

273

CB273

Trouble PCV2 Short circuit Error (RH bank) Contents of q trouble Action of q controller Phenomenon that appears on machine Related q information

There is short circuit in PCV2 circuit of supply pump. None in particular.

Different machine models may have different connector Nos. Causes

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Defective supply pump 1 PCV2 (Internal trouble)

Possible causes and standard value in normal state

Ground fault in wiring harness 2 (Short circuit with GND circuit)

Hot short in wiring harness (Contact with 24 V)

RH PCV2 (male)

Resistance

Between (1) – (2)

2.3 – 5.3 

Between (1), (2) – chassis Min. 1 M ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between RH J1 (female) (9) ResisMin. 1 M – RH PCV2 (female) (1) and chassis ground tance Wiring harness between RH J1(female) (10) ResisMin. 1 M – RH PCV2 (female) (2) and chassis ground tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between RH J1 (female) (9) Voltage Max. 1 V – RH PCV2 (female) (1) and chassis ground Wiring harness between RH J1 (female) (10) – RH PCV2 (female) (2) and chassis Voltage Max. 1 V ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. RH J1 (female)

Resistance

Between (9) – (10)

2.3 – 5.3 

Between (9), (10) – chassis ground

Min. 1 M

4 Defective engine controller

12V140E-3 Series

40 Troubleshooting

SEN00317-03

Circuit diagram related to supply pump PCV2

12V140E-3 Series

SEN00317-03

40 Troubleshooting

E-36 Code [274/CA274] PCV2 Open Error (LH bank) Error code

Failure code

274

CA274

Trouble PCV2 Disconnection Error (LH bank) Contents of q trouble Action of q controller Phenomenon that appears on machine Related q information

There is disconnection in PCV2 circuit of supply pump. None in particular.

Different machine models may have different connector Nos. Causes

Defective supply pump 1 PCV2 (Internal disconnection)

Possible causes and standard value in normal state

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. LH PCV2 (male)

Resistance

Between (1) – (2)

2.3 – 5.3 

a Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring harwithout turning starting switch ON. ness Wiring harness between LH J1 (female) (9) ResisMax. 1  2 (Disconnection in wiring or – LH PCV2 (female) (1) tance defective contact in connecWiring harness between LH J1 (female) (10) Resistor) Max. 1  – LH PCV2 (female) (2) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. LH J1 (female)

Resistance

Between (9) – (10)

2.3 – 5.3 

Between (9), (10) – chassis ground

Min. 1 M

3 Defective engine controller

Circuit diagram related to supply pump PCV2

12V140E-3 Series

SEN00317-03

40 Troubleshooting

E-37 Code [274/CB274] PCV2 Open Error (RH bank) Error code

Failure code

274

CB274

Trouble PCV2 Disconnection Error (RH bank) Contents of q trouble Action of q controller Phenomenon that appears on machine Related q information

There is disconnection in PCV2 circuit of supply pump. None in particular.

Different machine models may have different connector Nos. Causes

Defective supply pump 1 PCV2 (Internal disconnection)

Possible causes and standard value in normal state

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. RH PCV2 (male)

Resistance

Between (1) – (2)

2.3 – 5.3 

a Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring harwithout turning starting switch ON. ness Wiring harness between RH J1 (female) (9) ResisMax. 1  2 (Disconnection in wiring or – RH PCV2 (female) (1) tance defective contact in connecWiring harness between RH J1 (female) Resistor) Max. 1  (10) – RH PCV2 (female) (2) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. RH J1 (female)

Resistance

Between (9) – (10)

2.3 – 5.3 

Between (9), (10) – chassis ground

Min. 1 M

3 Defective engine controller

Circuit diagram related to supply pump PCV2

12V140E-3 Series

SEN00317-03

40 Troubleshooting

E-38 Code [322/CA322] Injector #1 (L/B #1) System Open/Short Error (LH bank) Error code

Failure code Trouble

322

CA322

Contents of q trouble Action of q controller Phenomenon q that appears on q machine Related q information

Disconnection or short circuit in injector #1 (L/B #1) system (LH bank)

There is disconnection or short circuit in injector in injector #1 circuit. None in particular. Output drops. Idle speed is unstable. Different machine models may have different connector Nos. Causes

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Possible causes and standard value in normal state

Defective injector #1 (Internal trouble)

LH CN1 (male)

Resistance

Between (1) – (2)

0.4 – 1.1 

Between (1), (2) – chassis Min. 1 M ground a Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring harwithout turning starting switch ON. ness Wiring harness between LH J1 (female) (45) ResisMax. 1  2 (Disconnection in wiring or – LH CN1 (female) (1) tance defective contact in connecWiring harness between LH J1 (female) Resistor) Max. 1  (53) – LH CN1 (female) (2) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harWiring harness between LH J1 (female) (45) Resisness Min. 1 M 3 – LH CN1 (female) (1) and chassis ground tance (Short circuit with GND cirWiring harness between LH J1 (female) cuit) Resis(53) – LH CN1 (female) (2) and chassis Min. 1 M tance ground Defective another cylinder Prepare with starting switch OFF, then carry out troubleshooting 4 injector or wiring harness without turning starting switch ON. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. LH J1 (female)

Resistance

Between (45) – (53)

0.4 – 1.1 

Between (45), (53) – chassis ground

Min. 1 M

5 Defective engine controller

12V140E-3 Series

40 Troubleshooting

SEN00317-03

Circuit diagram related to injector #1

12V140E-3 Series

SEN00317-03

40 Troubleshooting

E-39 Code [323/CA323] Injector #5 (L/B #5) System Open/Short Error (LH bank) Error code

Failure code Trouble

323

CA323

Contents of q trouble Action of q controller Phenomenon q that appears on q machine Related q information

Disconnection or short circuit in injector #5 (L/B #5) system (LH bank)

There is disconnection or short circuit in injector #5 circuit. None in particular. Output drops. Idle speed is unstable. Different machine models may have different connector Nos. Causes

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Possible causes and standard value in normal state

Defective injector #5 (Internal trouble)

LH CN5 (male)

Resistance

Between (1) – (2)

0.4 – 1.1 

cuit)

Wiring harness between LH J1 (female) (60) – LH CN5 (female) (2) and chassis ground

Defective another cylinder injector or wiring harness

If multiple failure codes are displayed for injector malfunction, carry out troubleshooting for them, too. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. LH J1 (female)

Resistance

Between (46) – (60)

0.4 – 1.1 

Between (46), (60) – chassis ground

Min. 1 M

5 Defective engine controller

Resistance

Min. 1 M

12V140E-3 Series

40 Troubleshooting

SEN00317-03

Circuit diagram related to injector #5

12V140E-3 Series

SEN00317-03

40 Troubleshooting

E-40 Code [324/CA324] Injector #3 (L/B #3) System Open/Short Error (LH bank) Error code

Failure code Trouble

324

CA324

Contents of q trouble Action of q controller Phenomenon q that appears on q machine Related q information

Disconnection or short circuit in injector #3 (L/B #3) system (LH bank)

There is disconnection or short circuit in injector #3 circuit. None in particular. Output drops. Idle speed is unstable. Different machine models may have different connector Nos. Causes

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Possible causes and standard value in normal state

Defective injector #3 (Internal trouble)

LH CN3 (male)

Resistance

Between (1) – (2)

0.4 – 1.1 

Between (1), (2) – chassis Min. 1 M ground a Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring harwithout turning starting switch ON. ness Wiring harness between LH J1 (female) (55) ResisMax. 1  2 (Disconnection in wiring or – LH CN3 (female) (1) tance defective contact in connecWiring harness between LH J1 (female) (52) Resistor) Max. 1  – LH CN3 (female) (2) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harWiring harness between LH J1 (female) (55) Resisness Min. 1 M 3 – LH CN3 (female) (1) and chassis ground tance (Short circuit with GND cirWiring harness between LH J1 (female) cuit) Resis(52) – LH CN3 (female) (2) and chassis Min. 1 M tance ground Defective another cylinder If multiple failure codes are displayed for injector malfunction, carry 4 injector or wiring harness out troubleshooting for them, too. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. LH J1 (female)

Resistance

Between (55) – (52)

0.4 – 1.1 

Between (55), (52) – chassis ground

Min. 1 M

5 Defective engine controller

12V140E-3 Series

40 Troubleshooting

SEN00317-03

Circuit diagram related to injector #3

12V140E-3 Series

SEN00317-03

40 Troubleshooting

E-41 Code [325/CA325] Injector #6 (L/B #6) System Open/Short Error (LH bank) Error code

Failure code Trouble

325

CA325

Contents of q trouble Action of q controller Phenomenon q that appears on q machine Related q information

Disconnection or short circuit in injector #6 (L/B #6) system (LH bank)

There is disconnection or short circuit in injector #6 circuit. None in particular. Output drops. Idle speed is unstable. Different machine models may have different connector Nos. Causes

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Possible causes and standard value in normal state

Defective injector #6 (Internal trouble)

LH CN6 (male)

Resistance

Between (1) – (2)

0.4 – 1.1 

Between (1), (2) – chassis Min. 1 M ground a Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring harwithout turning starting switch ON. ness Wiring harness between LH J1 (female) ResisMax. 1  2 (Disconnection in wiring or (57) – LH CN6 (female) (1) tance defective contact in connecWiring harness between LH J1 (female) (59) Resistor) Max. 1  – LH CN6 (female) (2) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harWiring harness between LH J1 (female) Resisness (57) – LH CN6 (female) (1) and chassis Min. 1 M 3 tance (Short circuit with GND cir- ground Wiring harness between LH J1 (female) cuit) Resis(59) – LH CN6 (female) (2) and chassis Min. 1 M tance ground Defective another cylinder If multiple failure codes are displayed for injector malfunction, carry 4 injector or wiring harness out troubleshooting for them, too. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. LH J1 (female)

Resistance

Between (57) – (59)

0.4 – 1.1 

Between (57), (59) – chassis ground

Min. 1 M

5 Defective engine controller

12V140E-3 Series

40 Troubleshooting

SEN00317-03

Circuit diagram related to injector #6

12V140E-3 Series

SEN00317-03

40 Troubleshooting

E-42 Code [331/CA331] Injector #2 (L/B #2) System Open/Short Error (LH bank) Error code

Failure code Trouble

331

CA331

Contents of q trouble Action of q controller Phenomenon q that appears on q machine Related q information

Disconnection or short circuit in injector #2 (L/B #2) system (LH bank)

There is disconnection or short circuit in injector #2 circuit. None in particular. Output drops. Idle speed is unstable. Different machine models may have different connector Nos. Causes

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Possible causes and standard value in normal state

Defective injector #2 (Internal trouble)

LH CN2 (male)

Resistance

Between (1) – (2)

0.4 – 1.1 

cuit)

Wiring harness between LH J1 (female) (51) – LH CN2 (female) (2) and chassis ground

Defective another cylinder injector or wiring harness

Resistance

Between (54) – (51)

0.4 – 1.1 

Between (54), (51) – chassis ground

Min. 1 M

5 Defective engine controller

Resistance

Min. 1 M

12V140E-3 Series

40 Troubleshooting

SEN00317-03

Circuit diagram related to injector #2

12V140E-3 Series

SEN00317-03

40 Troubleshooting

E-43 Code [332/CA332] Injector #4 (L/B #4) System Open/Short Error (LH bank) Error code

Failure code Trouble

332

CA332

Contents of q trouble Action of q controller Phenomenon q that appears on q machine Related q information

Disconnection or short circuit in injector #4 (L/B #4) system(LH bank)

There is disconnection or short circuit in injector #4 circuit. None in particular. Output drops. Idle speed is unstable. Different machine models may have different connector Nos. Causes

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Possible causes and standard value in normal state

Defective injector #4 (Internal trouble)

LH CN4 (male)

Resistance

Between (1) – (2)

0.4 – 1.1 

cuit)

Wiring harness between LH J1 (female) (58) – LH CN4 (female) (2) and chassis ground

Defective another cylinder injector or wiring harness

Resistance

Between (56) – (58)

0.4 – 1.1 

Between (56), (58) – chassis ground

Min. 1 M

5 Defective engine controller

Resistance

Min. 1 M

12V140E-3 Series

40 Troubleshooting

SEN00317-03

Circuit diagram related to injector #4

12V140E-3 Series

SEN00317-03

40 Troubleshooting

E-44 Code [342/CA342] Caribration Code Incompatibility (LH bank) Error code

Failure code

342

CA342

Trouble Engine Controller data matching failure (LH bank) Contents of q trouble Action of q controller Phenomenon that appears on q machine Related information Possible causes and standard value in normal state

Matching error occurred in engine controller data. None in particular. Engine continues operation normally, but it may stop during operation or may not be able to start.

Causes

Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for E-1 Code [111/CA111].

E-45 Code [342/CB342] Caribration Code Incompatibility (RH bank) Error code

Failure code

342

CB342

Trouble Engine Controller data matching failure (RH bank) Contents of q trouble Action of q controller Phenomenon that appears on q machine Related information Possible causes and standard value in normal state

Matching error occurred in engine controller data. None in particular. Engine continues operation normally, but it may stop during operation or may not be able to start.

Causes

Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for E-2 Code [111/CB111].

12V140E-3 Series

40 Troubleshooting

12V140E-3 Series

SEN00317-03

40 Troubleshooting

E-46 Code [351/CA351] INJ. Drive Circuit Error (LH bank) Error code

Failure code

351

CA351

Trouble Injector drive circuit error (LH bank) Contents of q trouble Action of q controller Phenomenon that appears on q machine Related q information

Possible causes and standard value in normal state

Abnormality occurred in injector drive circuit. Limits output and continues operation (Limits common rail pressure). Output drops. Different machine models may have different connector Nos. Causes

Standard value in normal state/Remarks on troubleshooting

1 Defective related system

If another failure code (code of abnormality in injector system) is indicated, carry out troubleshooting for it.

2 Defective fuse

Check fuse or circuit breaker on installed machine side directly for possible defect. (If fuse is burnt or circuit breaker is turned OFF, circuit probably has ground fault.)

a Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring harwithout turning starting switch ON. ness Wiring harness between PW L (female) (3), ResisMax. 1  3 (Disconnection in wiring or (4) – battery (+) tance defective contact in connecWiring harness between PW L (female) (1), Resistor) Max. 1  (2) – chassis ground tance a Prepare with starting switch OFF, then carry out troubleshooting Ground fault in wiring harwithout turning starting switch ON. ness 4 Resis(Short circuit with GND cir- Wiring harness between PW L (female) (3), Min. 1 M (4) – battery (+) and chassis ground tance cuit) a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 5 Defective engine controller PW L Voltage Between (3), (4) – (1), (2)

20 – 30 V

12V140E-3 Series

40 Troubleshooting

SEN00317-03

Circuit diagram related to controller power supply

12V140E-3 Series

SEN00317-03

40 Troubleshooting

E-47 Code [351/CB351] INJ. Drive Circuit Error (RH bank) Error code

Failure code

351

CB351

Trouble Injector drive circuit error (RH bank) Contents of q trouble Action of q controller Phenomenon that appears on q machine Related q information

Possible causes and standard value in normal state

Abnormality occurred in injector drive circuit. Limits output and continues operation (Limits common rail pressure). Output drops. Different machine models may have different connector Nos. Causes

Standard value in normal state/Remarks on troubleshooting

1 Defective related system

If another failure code (code of abnormality in injector system) is indicated, carry out troubleshooting for it.

2 Defective fuse

Check fuse or circuit breaker on installed machine side directly for possible defect. (If fuse is burnt or circuit breaker is turned OFF, circuit probably has ground fault.)

a Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring harwithout turning starting switch ON. ness Wiring harness between PW R (female) (3), ResisMax. 1  3 (Disconnection in wiring or (4) – battery (+) tance defective contact in connecWiring harness between PW R (female) (1), Resistor) Max. 1  (2) – chassis ground tance a Prepare with starting switch OFF, then carry out troubleshooting Ground fault in wiring harwithout turning starting switch ON. ness 4 Wiring harness between PW R (female) (3), Resis(Short circuit with GND cirMin. 1 M (4) – battery (+) and chassis ground tance cuit) a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 5 Defective engine controller PW R Voltage Between (3), (4) – (1), (2)

20 – 30 V

12V140E-3 Series

40 Troubleshooting

SEN00317-03

Circuit diagram related to controller power supply

12V140E-3 Series

SEN00317-03

40 Troubleshooting

E-48 Code [352/CA352] Sensor Sup. 1 Volt. Low Error (LH bank) Error code

Failure code Trouble

352 Contents of q trouble Action of q controller Phenomenon that appears on q machine Related information Possible causes and standard value in normal state

CA352

Power supply 1 sensor detection of abnormally low voltage (LH bank)

Signal voltage in sensor power supply 1 (5 V) circuit is abnormally low. Sets atmospheric pressure sensor to default value (52.44 kPa {0.5 kg/cm2}) and continues operation. Output drops.

Causes

Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for E-50 Code [386/CA386].

E-49 Code [352/CB352] Sensor Sup. 1 Volt. Low Error (RH bank) Error code

Failure code Trouble

352 Contents of q trouble Action of q controller Phenomenon that appears on q machine Related information Possible causes and standard value in normal state

CB352

Power supply 1 sensor detection of abnormally low voltage (RH bank)

Signal voltage in sensor power supply 1 (5 V) circuit is abnormally low. Sets atmospheric pressure sensor to default value (52.44 kPa {0.5 kg/cm2}) and continues operation. Output drops.

Causes

Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for E-51 Code [386/CB386].

12V140E-3 Series

40 Troubleshooting

12V140E-3 Series

SEN00317-03

40 Troubleshooting

E-50 Code [386/CA386] Sensor Sup. 1 Volt. High Error (LH bank) Error code

Failure code Trouble

386

CA386

Contents of q trouble Action of q controller Phenomenon that appears on q machine Related q information

Signal voltage in sensor power supply 1 (5 V) circuit is abnormally high. Limits output and continues operation (Limits common rail pressure). Output drops. Different machine models may have different connector Nos. Causes

1 Defective related system

Possible causes and standard value in normal state

Standard value in normal state/Remarks on troubleshooting If another failure code is indicated, carry out troubleshooting for it.

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Disconnect devices at Defective sensor (Internal right in order. If error 2 LH common rail trouble) code disappears subLH PFUEL connector pressure sensor sequently, that device has a defect in it. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring har- Wiring harness between LH J1 (female) (33) ResisMax. 1  ness – LH PFUEL (female) (1) tance 3 (Disconnection in wiring or Wiring harness between LH J1 (female) (25) ResisMax. 1  defective contact in connec– LH PFUEL (female) (2) tance tor) Wiring harness between LH J1 (female) (47) ResisMax. 1  – LH PFUEL (female) (3) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between LH J1 (female) (33) ResisGround fault in wiring harMin. 1 M – LH PFUEL (female) (1) and chassis ground tance ness 4 Resis(Short circuit with GND cir- Wiring harness between LH J1 (female) (25) Min. 1 M – LH PFUEL (female) (2) and chassis ground tance cuit)

Short circuit in wiring harness 5 (With another wiring harness)

6 Defective engine controller

Power supply 1 sensor detection of abnormally high voltage (LH bank)

Wiring harness between LH J1 (female) (47) ResisMin. 1 M – LH PFUEL (female) (3) and chassis ground tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between LH J1 (female) (33) Resis– LH PFUEL (female) (1) and LH J1 (female) Min. 1 M tance (25) – LH PFUEL (female) (2) Wiring harness between LH J1 (female) (33) Resis– LH PFUEL (female) (1) and LH J1 (female) Min. 1 M tance (47) – LH PFUEL (female) (3) Wiring harness between LH J1 (female) (25) ResisMin. 1 M – LH PFUEL (female) (2) and LH J1 (female) tance (47) – LH PFUEL (female) (3) a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. LH J1

Voltage

Between (33) – (47)

4.75 – 5.25V

12V140E-3 Series

40 Troubleshooting

SEN00317-03

Circuit diagram related to sensor power supply 1 (5 V)

12V140E-3 Series

SEN00317-03

40 Troubleshooting

E-51 Code [386/CB386] Sensor Sup. 1 Volt. High Error (RH bank) Error code

Failure code Trouble

386

CB386

Contents of trouble q Action of controller Phenomenon that appears on machine

Power supply 1 sensor detection of abnormally high voltage (RH bank)

Signal voltage in sensor power supply 1 (5 V) circuit is abnormally high.

Limits output and continues operation (Limits common rail pressure).

Output drops.

Related information q

Different machine models may have different connector Nos. Causes

Defective related system

Standard value in normal state/Remarks on troubleshooting If another failure code is indicated, carry out troubleshooting for it. a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.

Disconnect devices at Defective sensor(Interright in order. If error nal trouble) code disappears subsequently, that device has a defect in it.

RH common rail pressure sensor

RH PFUEL connector

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between RH J1 (female) (33) – ResisMax. 1  RH PFUEL (female) (1) tance

Possible causes and standard value in normal state

Disconnection in wiring harness 3 (Disconnection in wirWiring harness between RH J1 (female) (25) – ResisMax. 1  ing or defective contact RH PFUEL (female) (2) tance in connector) Wiring harness between RH J1 (female) (47) – ResisMax. 1  RH PFUEL (female) (3) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between RH J1 (female) (33) – ResisGround fault in wiring Min. 1 M RH PFUEL (female) (1) and chassis ground tance harness 4 Resis(Short circuit with GND Wiring harness between RH J1 (female) (25) – Min. 1 M RH PFUEL (female) (2) and chassis ground tance circuit)

Short circuit in wiring harness 5 (With another wiring harness)

Wiring harness between RH J1 (female) (47) – ResisMin. 1 M RH PFUEL (female) (2) and chassis ground tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between RH J1 (female) (33) – ResisRH PFUEL (female) (1) and RH J1 (female) Min. 1 M tance (25) – RH PFUEL (female) (2) Wiring harness between wiring RH J1 (female) (33) – RH PFUEL (female) (1) and RH J1 (female) (47) – RH PFUEL (female) (3)

Resistance

Min. 1 M

Wiring harness between RH J1 (female) (25) – ResisMin. 1 M RH PFUEL (female) (2) and RH J1 (female) tance (47) – RH PFUEL (female) (3) a Prepare with starting switch OFF, then turn starting switch ON and Defective engine concarry out troubleshooting. troller RH J1 Voltage Between (33) – (47) 4.75 – 5.25V

12V140E-3 Series

40 Troubleshooting

SEN00317-03

Circuit diagram related to sensor power supply 1 (5 V)

12V140E-3 Series

SEN00317-03

40 Troubleshooting

E-52 Code [441/CA441] Battery Voltage Low Error (LH bank) Error code

Failure code

441

CA441

Trouble Supply voltage abnormally low (LH bank) Contents of q trouble Action of q controller Phenomenon that appears on q machine Related information Possible causes and standard value in normal state

Abnormally low supply voltage in circuit. None in particular. Engine continues operation normally, but it may stop during operation or may not be able to start.

Causes

Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for E-1 Code [111/CA111].

E-53 Code [441/CB441] Battery Voltage Low Error (RH bank) Error code

Failure code

441

CB441

Trouble Supply voltage abnormally low (RH bank) Contents of q trouble Action of q controller Phenomenon that appears on q machine Related information Possible causes and standard value in normal state

Abnormally low supply voltage in circuit. None in particular. Engine continues operation normally, but it may stop during operation or may not be able to start.

Causes

Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for E-2 Code [111/CB111].

12V140E-3 Series

SEN00317-03

40 Troubleshooting

E-54 Code [442/CA442] Battery Voltage High Error (LH bank) Error code

Failure code

442

CA442

Trouble Supply voltage abnormally high (LH bank) Contents of q trouble Action of q controller Phenomenon that appears on q machine Related information Possible causes and standard value in normal state

Abnormally low supply voltage in circuit. None in particular. Engine continues operation normally, but it may stop during operation or may not be able to start.

Causes

Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for E-1 Code [111/CA111].

E-55 Code [442/CB442] Battery Voltage High Error (RH bank) Error code

Failure code

442

CB442

Trouble Supply voltage abnormally high (RH bank) Contents of q trouble Action of q controller Phenomenon that appears on q machine Related information Possible causes and standard value in normal state

12V140E-3 Series

Abnormally low supply voltage in circuit. None in particular. Engine continues operation normally, but it may stop during operation or may not be able to start.

Causes

Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for E-2 Code [111/CB111].

SEN00317-03

40 Troubleshooting

KOMATSU 12V140E-3 Series engine Form Number : SEN00317-03

SEN00318-03

ENGINE 1SHOP MANUAL

12V140E-3 Series

40 Troubleshooting

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

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

12V140E-3 Series

40 Troubleshooting

SEN00318-03

E-56 Code [449/CA449] Rail Press. Very High Error (LH bank) Error code

Failure code

449

CA449

Trouble

Common rail pressure abnormally high Error 2 (LH bank)

Contents of trouble

• Common rail pressure sensor circuit detected abnormally high pressure (level 2).

Action of controller

• Limits output and continues operation (Limits common rail pressure).

Phenomenon that appears on • Output drops. machine Related information Possible causes and standard value in normal state

Causes

Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for E-66 Code [559/CA559].

E-57 Code [449/CB449] Rail Press. Very High Error (RH bank) Error code

Failure code

449

CB449

Trouble

Common rail pressure abnormally high Error 2 (RH bank)

Contents of trouble

• Common rail pressure sensor circuit detected abnormally high pressure (level 2).

Action of controller

• Limits output and continues operation (Limits common rail pressure).

Phenomenon that appears on • Output drops. machine Related information Possible causes and standard value in normal state

12V140E-3 Series

Causes

Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for E-67 Code [559/CB559].

SEN00318-03

40 Troubleshooting

E-58 Code [451/CA451] Rail Press. Sensor High Error (LH bank) Error code

Failure code

451

CA451

Trouble

Common rail pressure sensor detected abnormally high pressure (LH bank)

Contents of trouble

• Signal voltage in common rail pressure sensor circuit is abnormally high.

Action of controller

• Limits output and continues operation (Limits common rail pressure).

Phenomenon that appears on • Output drops. machine Related information

• Different machine models may have different connector Nos.

Causes 1

Standard value in normal state/Remarks on troubleshooting

Defective common rail pres2 sure sensor (Internal trouble)

LH PFUEL

Voltage

Between (1) – (3)

Power supply

4.75 – 5.25 V

Between (2) – (3)

Signal

0.25 – 4.6 V

Disconnection in wiring harness 3 (Disconnection in wiring or defective contact in connector)

Wiring harness between LH J1 (female) (33) – LH PFUEL (female) (1)

Resistance

Max. 1 z

Wiring harness between LH J1 (female) (25) – LH PFUEL (female) (2)

Resistance

Max. 1 z

Wiring harness between LH J1 (female) (47) – LH PFUEL (female) (3)

Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Ground fault in wiring harness 4 (Short circuit with GND circuit)

Wiring harness between LH J1 (female) (33) – LH PFUEL (female) (1) and chassis ground

Resistance

Min. 1 Mz

Wiring harness between LH J1 (female) (25) – LH PFUEL (female) (2) and chassis ground

Resistance

Min. 1 Mz

Wiring harness between LH J1 (female) (47) – LH PFUEL (female) (3) and chassis ground

Resistance

Min. 1 Mz

12V140E-3 Series

40 Troubleshooting

SEN00318-03

Causes

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Possible causes and standard value in normal state

Short circuit in wiring harness 5 (With another wiring harness)

Wiring harness between LH J1 (female) (33) – LH PFUEL (female) (1) and LH J1 (female) (25) – LH PFUEL (female) (2)

Resistance

Min. 1 Mz

Wiring harness between LH J1 (female) (33) – LH PFUEL (female) (1) and LH J1 (female) (47) – LH PFUEL (female) (3)

Resistance

Min. 1 Mz

Wiring harness between LH J1 (female) (25) – LH PFUEL (female) (2) and LH J1 (female) (47) – LH PFUEL (female) (3)

Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. 6 Defective engine controller

LH J1

Voltage

Between (33) – (47)

4.75 – 5.25 V

Between (25) – (47)

0.25 – 4.6 V

Circuit diagram related to common rail pressure sensor

12V140E-3 Series

SEN00318-03

40 Troubleshooting

E-59 Code [451/CB451] Rail Press. Sensor High Error (RH bank) Error code

Failure code

451

CB451

Trouble

Common rail pressure sensor detected abnormally high pressure (RH bank)

Contents of trouble

• Signal voltage in common rail pressure sensor circuit is abnormally high.

Action of controller

• Limits output and continues operation (Limits common rail pressure).

Phenomenon that appears on • Output drops. machine Related information

• Different machine models may have different connector Nos.

Causes 1

Standard value in normal state/Remarks on troubleshooting

Defective sensor power sup- If code [352/CB352] or [386/CB386] is indicated, carry out troubleply system shooting for it first. a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting.

Defective common rail pres2 sure sensor (Internal trouble)

RH PFUEL

Voltage

Between (1) – (3)

Power supply

4.75 – 5.25 V

Between (2) – (3)

Signal

0.25 – 4.6 V

Disconnection in wiring harness 3 (Disconnection in wiring or defective contact in connector)

Wiring harness between RH J1 (female) (33) – RH PFUEL (female) (1)

Resistance

Max. 1 z

Wiring harness between RH J1 (female) (25) – RH PFUEL (female) (2)

Resistance

Max. 1 z

Wiring harness between RH J1 (female) (47) – RH PFUEL (female) (3)

Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Ground fault in wiring harness 4 (Short circuit with GND circuit)

Wiring harness between RH J1 (female) (33) – RH PFUEL (female) (1) and chassis ground

Resistance

Min. 1 Mz

Wiring harness between RH J1 (female) (25) – RH PFUEL (female) (2) and chassis ground

Resistance

Min. 1 Mz

Wiring harness between RH J1 (female) (47) – RH PFUEL (female) (3) and chassis ground

Resistance

Min. 1 Mz

12V140E-3 Series

40 Troubleshooting

SEN00318-03

Causes

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Possible causes and standard value in normal state

Short circuit in wiring harness 5 (With another wiring harness)

Wiring harness between RH J1 (female) (33) – RH PFUEL (female) (1) and RH J1 (female) (25) – RH PFUEL (female) (2)

Resistance

Min. 1 Mz

Wiring harness between RH J1 (female) (33) – RH PFUEL (female) (1) and RH J1 (female) (47) – RH PFUEL (female) (3)

Resistance

Min. 1 Mz

Wiring harness between RH J1 (female) (25) – RH PFUEL (female) (2) and RH J1 (female) (47) – RH PFUEL (female) (3)

Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. 6 Defective engine controller

RH J1

Voltage

Between (33) – (47)

4.75 – 5.25 V

Between (25) – (47)

0.25 – 4.6 V

Circuit diagram related to common rail pressure sensor

12V140E-3 Series

SEN00318-03

40 Troubleshooting

E-60 Code [452/CA452] Rail Press. Sensor Low Error (LH bank) Error code

Failure code

452

CA452

Trouble

Common rail pressure sensor detected abnormally low pressure (LH bank)

Contents of trouble

• Signal voltage in common rail pressure sensor circuit is abnormally low.

Action of controller

• Limits output and continues operation (Limits common rail pressure).

Phenomenon that appears on • Output drops. machine Related information Possible causes and standard value in normal state

Causes

Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for E-58 Code [451/CA451].

E-61 Code [452/CB452] Rail Press. Sensor Low Error (RH bank) Error code

Failure code

452

CA452

Trouble

Common rail pressure sensor detected abnormally low pressure (RH bank)

Contents of trouble

• Signal voltage in common rail pressure sensor circuit is abnormally low.

Action of controller

• Limits output and continues operation (Limits common rail pressure).

Phenomenon that appears on • Output drops. machine Related information Possible causes and standard value in normal state

Causes

Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for E-59 Code [451/CB451].

12V140E-3 Series

40 Troubleshooting

SEN00318-03

E-62 Code [553/CA553] Rail Press. High Error 1 (LH bank) Error code

Failure code

553

CA553

Trouble

Common rail pressure abnormally high Error 1 (LH bank)

Contents of trouble

• Common rail pressure sensor circuit detected abnormally high pressure (level 1).

Action of controller

• None in particular.

Phenomenon that appears on • Output drops. machine Related information Causes

Possible causes and standard value in normal state

Standard value in normal state/Remarks on troubleshooting

1 Defective related system

If another failure code is indicated, carry out troubleshooting for it.

2 Use of improper fuel

Check fuel used directly. (High viscosity)

Defective electrical system of Common rail pressure sensor may have electric trouble. common rail pressure sensor Carry out troubleshooting for code [451/CA451] (E-58).

Defective mechanical system 4 of common rail pressure sen- Check mechanical system of common rail pressure sensor directly. sor 5 Defective overflow valve

Check overflow valve directly for broken spring, worn seat, and stuck ball.

6 Clogging of overflow piping

Check overflow piping directly for clogging.

7 Defective pressure limiter

Check pressure limiter directly for mechanical defect.

12V140E-3 Series

SEN00318-03

40 Troubleshooting

E-63 Code [553/CB553] Rail Press. High Error 1 (RH bank) Error code

Failure code

553

CB553

Trouble

Common rail pressure abnormally high Error 1 (RH bank)

Contents of trouble

• Common rail pressure sensor circuit detected abnormally high pressure (level 1).

Action of controller

• None in particular.

Phenomenon that appears on • Output drops. machine Related information Causes

Possible causes and standard value in normal state

Standard value in normal state/Remarks on troubleshooting

1 Defective related system

If another failure code is indicated, carry out troubleshooting for it.

2 Use of improper fuel

Check fuel used directly. (High viscosity)

Defective electrical system of Common rail pressure sensor may have electric trouble. common rail pressure sensor Carry out troubleshooting for code [451/CB451] (E-59).

Defective mechanical system 4 of common rail pressure sen- Check mechanical system of common rail pressure sensor directly. sor 5 Defective overflow valve

Check overflow valve directly for broken spring, worn seat, and stuck ball.

6 Clogging of overflow piping

Check overflow piping directly for clogging.

7 Defective pressure limiter

Check pressure limiter directly for mechanical defect.

12V140E-3 Series

40 Troubleshooting

SEN00318-03

E-64 Code [554/CA554] Rail Press. Sensor In Range Error (LH bank) Error code

Failure code

554

CA554

Trouble

Common rail pressure sensor detection of in range abnormality (LH bank)

Contents of trouble

• In range error occurred in common rail pressure sensor circuit.

Action of controller

• Limits output and continues operation (Limits common rail pressure).

Phenomenon that appears on • Output drops. machine Related information Possible causes and standard value in normal state

Causes

Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for E-58 Code [451/CA451].

E-65 Code [554/CB554] Rail Press. Sensor In Range Error (RH bank) Error code

Failure code

554

CB554

Trouble

Common rail pressure sensor detected In range abnormality (RH bank)

Contents of trouble

• In range error occurred in common rail pressure sensor circuit.

Action of controller

• Limits output and continues operation (Limits common rail pressure).

Phenomenon that appears on • Output drops. machine Related information Possible causes and standard value in normal state

12V140E-3 Series

Causes

Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for E-59 Code [451/CB451].

SEN00318-03

40 Troubleshooting

E-66 Code [559/CA559] Rail Press. Low Error 1 (LH bank) Error code

Failure code

559

CA559

Trouble

Supply pump no-pressure feed error 1 (LH bank)

Contents of trouble

• Supply pump does not feed fuel (level 1).

Action of controller

• Limits common rail pressure.

Phenomenon that appears on • Output drops. machine Related information Causes 1 Defective related system

If another failure code is indicated, carry out troubleshooting for it.

2 Use of improper fuel

Improper fuel may be used. Check fuel used directly.

Loosening of fuel pipe and leaked fuel

Fuel pipe may be loosened or fuel may be leaked. Check fuel pipe directly.

4 Clogging of filter/strainer

a For contents of troubleshooting, see Note 2.

Clogging of fuel tank air 5 breather

Fuel tank air breather may be clogged. Clean air breather and check the hose directly.

Possible causes and standard value in normal state

Standard value in normal state/Remarks on troubleshooting

Supply pump PCV may have electric trouble. Carry out troubleDefective supply pump PCV shooting for following codes [271/CA271] (E-30), [272/CA272] (Eelectrical system 32), [273/CA273] (E-34), [274/CA274] (E-36).

Defective low-pressure circuit device

a For contents of troubleshooting, see Note 1. For checking of fuel low-pressure circuit, see Testing and adjusting, Testing fuel pressure. Pressure in fuel low-pressure circuit

a For testing of return (spill) limit from injector, see Testing and adjusting, Testing leakage from pressure limiter and return rate from injector.

8 Defective injector

9 Defective pressure limiter

Speed at rated operation

Return (Spill) limit from injector

1,600 rpm

960 cc/min

1,700 rpm

1,020 cc/min

1,800 rpm

1,080 cc/min

1,900 rpm

1,140 cc/min

2,000 rpm

1,200 cc/min

a For testing of leakage from pressure limiter, see Testing and adjusting, Testing leakage from pressure limiter and return rate from injector. Leakage from pressure limiter

10 Defective supply pump

Max. 0.15 – 0.29 MPa {Max. 1.5 – 3.0 kg/cm2}

Max. 10 cc/min (at rated output)

If causes 1 – 9 are not detected, supply pump may be defective.

12V140E-3 Series

40 Troubleshooting

SEN00318-03

Note 1: When low-pressure circuit is defective, check the following: q Fuel level q Clogged fuel tank breather q Water separator/Prefilter filled with water q Clogged fuel filter q Clogged screen in water separator q Stuck or worn feed pump, clogged filter q Leaked or clogged low-pressure fuel pipe q Bypass valve malfunction, defective assembly of other parts (See Fig.1.) q Fuel in oil pan (fuel leakage in head cover) 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

SEN00318-03

40 Troubleshooting

Check sheet for no-pressure feed Model Machine serial No.

Work No. #

Date of check

Engine Engine serial No.

Service meter #

Worker's name

A. Visual check 1

Fuel leakage to outside

Clogging of fuel tank breather

Good NG

B. Check with machine monitor (Fault history function, monitoring function, and reduced cylinder mode function) 3

Check of error/failure code

Good NG

Unit

Standard value (Reference value)

Measured Good NG value

Low idle

rpm

High idle

rpm

Equivalent to rating <By models>

rpm

Low idle

High idle

100

—

Check of monitoring information Code

Displayed item

Engine speed

Checking condition

Throttle opening

Fuel injection command

Equivalent to rating <By models>

mm3

Common rail pressure command

Equivalent to rating <By models>

MPa

Common rail fuel pressure Equivalent to rating <By models>

MPa

Low idle Fuel injection timing comHigh idle mand Equivalent to rating <By models>

—

Boost pressure

Equivalent to rating <By models>

kPa

—

Engine coolant temperature

Low idle

°C

—

Fuel temperature

Low idle

°C

—

Unit

Standard value (Reference value)

Check of reduced cylinder mode operation (Engine speed) Func tion

5 *10

Reduced cylinder

Checking condition

Measured Good NG value

No. 1 cylinder

Low idle

rpm

—

No. 2 cylinder

Low idle

rpm

—

No. 3 cylinder

Low idle

rpm

—

No. 4 cylinder

Low idle

rpm

—

No. 5 cylinder

Low idle

rpm

—

No. 6 cylinder

Low idle

rpm

—

12V140E-3 Series

40 Troubleshooting

C. Check of fuel circuit pressure 6

Fuel low-pressure circuit pressure

SEN00318-03

Checking condition

High idle

Unit

Standard value (Reference value)

MPa {kg/cm2}

Min. 0.15 {Min. 1.5}

Measured Good NG value

D. Check of strainers and filters 7

Visual check of strainers

Visual check of gauze filter

Visual check of fuel filter

Good NG

10 Visual check of bypass valve

Unit

Standard value (Reference value)

11 Leakage through pressure limiter No load, at rated output

cc/min

Max. 10

Equivalent to rating <By models> 1,600 rpm

cc/min

960

Equivalent to rating <By models> 1,700 rpm

cc/min

1,020

Equivalent to rating <By models> 1,800 rpm

cc/min

1,080

Equivalent to rating <By models> 1,900 rpm

cc/min

1,140

Equivalent to rating <By models> 2,000 rpm

cc/min

1,200

E. Check of leakage and return rate

12 Return rate from injector

Checking condition

Measured Good NG value

Speed:

Return rate:

*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

SEN00318-03

40 Troubleshooting

E-67 Code [559/CB559] Rail Press. Low Error 1 (RH bank) Error code

Failure code

559

CB559

Trouble

Supply pump no-pressure feed error 1 (RH bank)

Contents of trouble

• Supply pump does not feed fuel (level 1).

Action of controller

• Limits common rail pressure.

Phenomenon that appears on • Output drops. machine Related information Causes 1 Defective related system

If another failure code is indicated, carry out troubleshooting for it.

2 Use of improper fuel

Improper fuel may be used. Check fuel used directly.

Loosening of fuel pipe and leaked fuel

Fuel pipe may be loosened or fuel may be leaked. Check fuel pipe directly.

4 Clogging of filter/strainer

a For contents of troubleshooting, see Note 2.

Clogging of fuel tank air 5 breather

Fuel tank air breather may be clogged. Clean air breather and check the hose directly.

Possible causes and standard value in normal state

Standard value in normal state/Remarks on troubleshooting

Supply pump PCV may have electric trouble. Carry out troubleDefective supply pump PCV shooting for following codes [271/CB271] (E-31), [272/CB272] (Eelectrical system 33), [273/CB273] (E-35), [274/CB274] (E-37).

Defective low-pressure circuit device

a For contents of troubleshooting, see Note 1. For checking of fuel low-pressure circuit, see Testing and adjusting, Testing fuel pressure. Pressure in fuel low-pressure circuit

a For testing of return (spill) limit from injector, see Testing and adjusting, Testing leakage from pressure limiter and return rate from injector.

8 Defective injector

9 Defective pressure limiter

Speed at rated operation

Return (Spill) limit from injector

1,600 rpm

960 cc/min

1,700 rpm

1,020 cc/min

1,800 rpm

1,080 cc/min

1,900 rpm

1,140 cc/min

2,000 rpm

1,200 cc/min

a For testing of leakage from pressure limiter, see Testing and adjusting, Testing leakage from pressure limiter and return rate from injector. Leakage from pressure limiter

10 Defective supply pump

Max. 0.15 – 0.29 MPa {Max. 1.5 – 3.0 kg/cm2}

Max. 10 cc/min (at rated output)

If causes 1 – 9 are not detected, supply pump may be defective.

12V140E-3 Series

40 Troubleshooting

SEN00318-03

12V140E-3 Series

SEN00318-03

40 Troubleshooting

Check sheet for no-pressure feed Model Machine serial No.

Work No. #

Date of check

Engine Engine serial No.

Service meter #

Worker's name

A. Visual check 1

Fuel leakage to outside

Clogging of fuel tank breather

Good NG

B. Check with machine monitor (Fault history function, monitoring function, and reduced cylinder mode function) 3

Check of error/failure code

Good NG

Unit

Standard value (Reference value)

Measured Good NG value

Low idle

rpm

High idle

rpm

Equivalent to rating <By models>

rpm

Low idle

High idle

100

—

Check of monitoring information Code

Displayed item

Engine speed

Checking condition

Throttle opening

Fuel injection command

Equivalent to rating <By models>

mm3

Common rail pressure command

Equivalent to rating <By models>

MPa

Common rail fuel pressure Equivalent to rating <By models>

MPa

Low idle Fuel injection timing comHigh idle mand Equivalent to rating <By models>

—

Boost pressure

Equivalent to rating <By models>

kPa

—

Engine coolant temperature

Low idle

°C

—

Fuel temperature

Low idle

°C

—

Unit

Standard value (Reference value)

Check of reduced cylinder mode operation (Engine speed) Func tion

5 *10

Reduced cylinder

Checking condition

Measured Good NG value

No. 1 cylinder

Low idle

rpm

—

No. 2 cylinder

Low idle

rpm

—

No. 3 cylinder

Low idle

rpm

—

No. 4 cylinder

Low idle

rpm

—

No. 5 cylinder

Low idle

rpm

—

No. 6 cylinder

Low idle

rpm

—

12V140E-3 Series

40 Troubleshooting

C. Check of fuel circuit pressure 6

Fuel low-pressure circuit pressure

SEN00318-03

Checking condition

High idle

Unit

Standard value (Reference value)

MPa {kg/cm2}

Min. 0.15 {Min. 1.5}

Measured Good NG value

D. Check of strainers and filters 7

Visual check of strainers

Visual check of gauze filter

Visual check of fuel filter

Good NG

10 Visual check of bypass valve

Unit

Standard value (Reference value)

11 Leakage through pressure limiter No load, at rated output

cc/min

Max. 10

Equivalent to rating <By models> 1,600 rpm

cc/min

960

Equivalent to rating <By models> 1,700 rpm

cc/min

1,020

Equivalent to rating <By models> 1,800 rpm

cc/min

1,080

Equivalent to rating <By models> 1,900 rpm

cc/min

1,140

Equivalent to rating <By models> 2,000 rpm

cc/min

1,200

E. Check of leakage and return rate

12 Return rate from injector

Checking condition

Measured Good NG value

Speed:

Return rate:

12V140E-3 Series

SEN00318-03

40 Troubleshooting

E-68 Code [689/CA689] Eng. Ne Speed Sensor Error (LH bank) Error code

Failure code

689

CA689

Trouble

Engine Ne Speed Sensor detected abnormality (LH bank)

Contents of trouble

• Abnormality occurred in engine Ne speed sensor circuit.

Action of controller

• Controls Ne speed sensor with signals of G (Bkup) speed sensor.

Phenomenon • Running engine stops (when G (Bkup) speed sensor is also abnormal). that appears on • Stopped engine cannot be started (when G (Bkup) speed sensor is also abnormal). machine Related information

• Different machine models may have different connector Nos.

Causes 1

Standard value in normal state/Remarks on troubleshooting

Defective sensor power sup- If code [238/CA238] is indicated, carry out troubleshooting for it ply system first. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Disconnection in wiring harness 2 (Disconnection in wiring or defective contact in connector)

Wiring harness between LH J1 (female) (16) – Ne (female) (1)

Resistance

Max. 1 z

Wiring harness between LH J1 (female) (48) – Ne (female) (2)

Resistance

Max. 1 z

Wiring harness between LH J1 (female) (27) – Ne (female) (3)

Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harness 3 (Short circuit with GND circuit) Possible causes and standard value in normal state

Wiring harness between LH J1 (female) (16) – Ne (female) (1) and chassis ground

Resistance

Min. 1 Mz

Wiring harness between LH J1 (female) (48) – Ne (female) (2) and chassis ground

Resistance

Min. 1 Mz

Wiring harness between LH J1 (female) (27) – Ne (female) (3) and chassis ground

Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Short circuit in wiring harness 4 (With another wiring harness)

Wiring harness between LH J1 (female) (16) – Ne (female) (1) and LH J1 (female) (48) – Ne (female) (2)

Resistance

Min. 1 Mz

Wiring harness between LH J1 (female) (16) – Ne (female) (1) and LH J1 (female) (48) – Ne (female) (2)

Resistance

Min. 1 Mz

Wiring harness between LH J1 (female) (48) – Ne (female) (2) and LH J1 (female) (27) – Ne (female) (3)

Resistance

Min. 1 Mz

Defective mount of sensor or Check Ne speed sensor directly for defective mount (defective 5 defective rotation sensing clearance) or check rotation sensing part (flywheel) directly for part defect. Defective engine Ne speed sensor

If causes 1 – 5 are not detected, engine Ne speed sensor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)

7 Defective engine controller

If causes 1 – 6 are not detected, engine controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)

12V140E-3 Series

40 Troubleshooting

SEN00318-03

Circuit diagram related to engine Ne speed sensor

12V140E-3 Series

SEN00318-03

40 Troubleshooting

E-69 Code [689/CB689] Eng. Ne Speed Sensor Error (RH bank) Error code

Failure code

689

CB689

Trouble

Engine Ne Speed Sensor detected abnormality (RH bank)

Contents of trouble

• Abnormality occurred in engine Ne speed sensor circuit.

Action of controller

• Controls Ne speed sensor with signals of G (Bkup) speed sensor.

• Different machine models may have different connector Nos.

Causes 1

Standard value in normal state/Remarks on troubleshooting

Defective sensor power sup- If code [238/CB238] is indicated, carry out troubleshooting for it ply system first. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Disconnection in wiring harness 2 (Disconnection in wiring or defective contact in connector)

Wiring harness between LH J1 (female) (16) – Ne (female) (1)

Resistance

Max. 1 z

Wiring harness between RH J1 (female) (48) – Ne (female) (2)

Resistance

Max. 1 z

Wiring harness between RH J1 (female) (27) – Ne (female) (3)

Resistance

Max. 1 z

Wiring harness between LH J1 (female) (16) – Ne (female) (1) and chassis ground

Resistance

Min. 1 Mz

Wiring harness between RH J1 (female) (48) – Ne (female) (2) and chassis ground

Resistance

Min. 1 Mz

Wiring harness between RH J1 (female) (27) – Ne (female) (3) and chassis ground

Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Short circuit in wiring harness 4 (With another wiring harness)

Wiring harness between LH J1 (female) (16) – Ne (female) (1) and RH J1 (female) (48) – Ne (female) (2)

Resistance

Min. 1 Mz

Wiring harness between LH J1 (female) (16) – Ne (female) (1) and RH J1(female) (27) – Ne (female) (3)

Resistance

Min. 1 Mz

Wiring harness between RH J1 (female) (48) – Ne (female) (2) and RH J1 (female) (27) – Ne (female) (3)

Resistance

Min. 1 Mz

If causes 1 – 5 are not detected, engine Ne speed sensor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)

7 Defective engine controller

If causes 1 – 6 are not detected, engine controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)

12V140E-3 Series

40 Troubleshooting

SEN00318-03

Circuit diagram related to engine Ne speed sensor

12V140E-3 Series

SEN00318-03

40 Troubleshooting

E-70 Code [691/CA691] Intake Air Temp Sensor High Error (LH bank only) Error code

Failure code

691

CA691

Trouble

Intake air temperature sensor detected abnormally high temperature (LH bank)

Contents of trouble

• Intake air temperature sensor circuit detected abnormally high temperature.

Action of controller

• Fixes intake air temperature at (25 °C) and continues operation.

Phenomenon that appears on machine Related information Causes

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Defective charge tempera1 ture sensor (Internal trouble)

Possible causes and standard value in normal state

TAM1

Intake air temperature

Resistance

Between (A) – (B)

10 – 100 °C

0.5 – 20 kz

Between (A) – chassis ground

All range

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshootDisconnection in wiring haring without turning starting switch ON. ness Wiring harness between LH J1 (female) (43) Resis2 (Disconnection in wiring or Max. 1 z – TAM1 (female) (A) tance defective contact in connecWiring harness between LH J1 (female) (47) Resistor) Max. 1 z – TAM1 (female) (B) tance Ground fault in wiring harness 3 (Short circuit with GND circuit)

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between LH J1 (female) (43) – TAM1 (female) (A) and chassis ground

Resistance

Max. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4 Defective engine controller

TAM1 (male)

Intake air temperature

Resistance

Between (43) – (47)

10 – 100 °C

0.5 – 20 kz

12V140E-3 Series

40 Troubleshooting

SEN00318-03

Circuit diagram related to intake air temperature sensor

12V140E-3 Series

SEN00318-03

40 Troubleshooting

E-71 Code [692/CA692] Intake Air Temp Sensor Low Error (LH bank only) Error code

Failure code

692

CA692

Trouble

Intake air temperature sensor detected abnormally low temperature (LH bank only)

Contents of trouble

• Intake air temperature sensor circuit detected abnormally low temperature.

Action of controller

• Fixes intake air temperature at (25 °C) and continues operation.

Phenomenon that appears on machine Related information Possible causes and standard value in normal state

Causes

Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for E-70 Code [691/CA691].

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

731

CA731

Trouble

Engine G (Bkup) speed sensor abnormal phase (LH bank)

Contents of trouble

• Engine G (Bkup) sensor circuit detected abnormality in phase.

Action of controller

• Controls with signals of engine Ne speed sensor.

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

Possible causes and standard value in normal state

Causes

Standard value in normal state/Remarks on troubleshooting

Defective engine Ne speed sensor system

Engine Ne speed sensor may be defective. Carry out troubleshooting for [689/CA689] (E-68).

Defective G (Bkup) speed sensor system

Common rail pressure sensor may have electric trouble. Carry out troubleshooting for code [778/CA778] (E-76).

E-73 Code [731/CB731] Eng. G (Bkup) Speed Sensor Phase Error (RH bank) 1 Error code

Failure code

731

CB731

Trouble

Engine G (Bkup) speed sensor abnormal phase (RH bank)

Contents of trouble

• Engine G (Bkup) sensor circuit detected abnormality in phase.

Action of controller

• Controls with signals of engine Ne speed sensor.

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

Possible causes and standard value in normal state

Causes Defective engine Ne speed 1 sensor system 2

12V140E-3 Series

Defective G (Bkup) speed sensor system

Standard value in normal state/Remarks on troubleshooting Engine Ne speed sensor may be defective. Carry out troubleshooting for [689/CB689] (E-69). Common rail pressure sensor may have electric trouble. Carry out troubleshooting for code [778/CB778] (E-77).

SEN00318-03

40 Troubleshooting

E-74 Code [757/CA757] All Continuous Data Lost Error (LH bank) Error code

Failure code

757

CA757

Trouble

All Engine Controller Data Lost Error (LH bank)

Contents of trouble

• All data in engine controller are lost.

Action of controller

• None in particular.

Phenomenon that appears on • Engine continues operation normally, but it may stop during operation or may not be able to start. machine Related information Possible causes and standard value in normal state

Causes

Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for E-1 Code [111/CA111].

E-75 Code [757/CB757] All Continuous Data Lost Error (RH bank) Error code

Failure code

757

CB757

Trouble

All Engine Controller Data Lost Error (RH bank)

Contents of trouble

• All data in engine controller are lost.

Action of c ontroller

• None in particular.

Causes

Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for E-2 Code [111/CB111].

12V140E-3 Series

40 Troubleshooting

12V140E-3 Series

SEN00318-03

40 Troubleshooting

E-76 Code [778/CA778] Eng. G (Bkup) Speed Sensor Error (LH bank) 1 Error code

Failure code

778

CA778

Trouble

Engine G (Bkup) speed sensor abnormal (LH bank)

Contents of trouble

• Abnormality occurred in engine G (Bkup) speed sensor circuit.

Action of controller

• Controls with signals of Ne speed sensor.

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

• Different machine models may have different connector Nos.

Causes 1

Standard value in normal state/Remarks on troubleshooting

Defective sensor power sup- If code [187/CA187] or [227/CA227] is indicated, carry out troubleply system shooting for it first. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Disconnection in wiring harness 2 (Disconnection in wiring or defective contact in connector)

Wiring harness between LH J1 (female) (37) – LH G (female) (1)

Resistance

Max. 1 z

Wiring harness between LH J1 (female) (47) – LH G (female) (2)

Resistance

Max. 1 z

Wiring harness between LH J1 (female) (26) – LH G (female) (3)

Resistance

Max. 1 z

Wiring harness between LH J1 (female) (37) – LH G (female) (1) and chassis ground

Resistance

Min. 1 Mz

Wiring harness between LH J1 (female) (47) – LH G (female) (2) and chassis ground

Resistance

Min. 1 Mz

Wiring harness between LH J1 (female) (26) – LH G (female) (3) and chassis ground

Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Short circuit in wiring harness 4 (With another wiring harness)

Wiring harness between LH J1 (female) (37) – LH G (female) (1) and LH J1 (female) (47) – LH G (female) (2)

Resistance

Min. 1 Mz

Wiring harness between LH J1 (female) (37) – LH G (female) (1) and LH J1 (female) (26) – LH G (female) (3)

Resistance

Min. 1 Mz

Wiring harness between LH J1 (female) (47) – LH G (female) (2) and LH J1 (female) (26) – LH G (female) (3)

Resistance

Min. 1 Mz

Defective mount of sensor or Check G (Bkup) speed sensor directly for defective mount (defec5 defective rotation sensing tive clearance) or check rotation sensing part (in supply pump) part directly for defect. Defective G (Bkup) speed sensor system

If causes 1 – 5 are not detected, engine G (Bkup) speed sensor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)

7 Defective engine controller

If causes 1 – 6 are not detected, engine controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)

12V140E-3 Series

40 Troubleshooting

SEN00318-03

Circuit diagram related to engine G (Bkup) speed sensor system

12V140E-3 Series

SEN00318-03

40 Troubleshooting

E-77 Code [778/CB778] Eng. G (Bkup) Speed Sensor Error (RH bank) 1 Error code 778 Contents of • trouble Action of • controller Phenomenon • that appears on • machine Related • information

Failure code CB778

Engine G (Bkup) speed sensor abnormal (RH bank)

Abnormality occurred in engine G (Bkup) speed sensor circuit. Controls with signals of Ne speed sensor. Running engine stops (when Ne speed sensor is also abnormal). Stopped engine cannot be started (when Ne speed sensor is also abnormal). Different machine models may have different connector Nos.

Possible causes and standard value in normal state

Trouble

Causes Standard value in normal state/Remarks on troubleshooting Defective sensor power sup- If code [187/CB187] or [227/CB227] is indicated, carry out troubleply system shooting for it first. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring har- Wiring harness between RH J1 (female) ResisMax. 1 z ness (37) – RH G (female) (1) tance (Disconnection in wiring or Wiring harness between RH J1 (female) Resisdefective contact in connecMax. 1 z (47) – RH G (female) (2) tance tor) Wiring harness between RH J1 (female) ResisMax. 1 z (26) – RH G (female) (3) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between RH J1 (female) Resis(37) – RH G (female) (1) and chassis Min. 1 Mz tance Ground fault in wiring harground ness Wiring harness between RH J1 (female) (Short circuit with GND cirResis(47) – RH G (female) (2) and chassis Min. 1 Mz cuit) tance ground Wiring harness between RH J1 (female) Resis(26) – RH G (female) (3) and chassis Min. 1 Mz tance ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between RH J1 (female) Resis(37) – R G (female) (1) and RH J1 Min. 1 Mz tance Short circuit in wiring har(female) (47) – RH G (female) (2) ness Wiring harness between RH J1 (female) (With another wiring harResis(37) – R G (female) (1) and RH J1 Min. 1 Mz ness) tance (female) (26) – RH G (female) (3) Wiring harness between RH J1 (female) Resis(47) – R G (female) (2) and RH J1 Min. 1 Mz tance (female) (26) – RH G (female) (3) Defective mount of sensor or Check G (Bkup) speed sensor directly for defective mount (defecdefective rotation sensing tive clearance) or check rotation sensing part (in supply pump) part directly for defect. If causes 1 – 5 are not detected, engine G (Bkup) speed sensor Defective G (Bkup) speed may be defective. (Since trouble is in system, troubleshooting cansensor system not be carried out.) If causes 1 – 6 are not detected, engine controller may be defecDefective engine controller tive. (Since trouble is in system, troubleshooting cannot be carried out.)

12V140E-3 Series

40 Troubleshooting

SEN00318-03

Circuit diagram related to engine G (Bkup) speed sensor system

12V140E-3 Series

SEN00318-03

40 Troubleshooting

E-78 Code [781/CA781] Inter Multi-controller Communication Error (LH bank) 1 Error code

Failure code

781

CA781

Trouble

Inter multi-controller communication error (LH bank)

Contents of trouble

• Communication error occurred between engine controllers (LH bank)

Action of controller

• None in particular.

Phenomenon • Single-bank operation that appears on • Engine cannot be started with the key ON machine Related information

• Different machine models may have different connector Nos.

Causes

Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshootDisconnection in wiring haring without turning starting switch ON. ness Wiring harness between LH J1 (female) (8) Resis1 (Disconnection in wiring or Max. 1 z – RH J1 (female) (8) tance defective contact in connecWiring harness between LH J1 (female) (6) Resistor) Max. 1 z – RH J1 (female) (6) tance Possible causes and standard value in normal state

Ground fault in wiring harness 2 (Short circuit with GND circuit)

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between LH J1 (female) (8) – RH J1 (female) (8) and chassis ground

Resistance

Min. 1 Mz

Wiring harness between LH J1 (female) (6) – RH J1 (female) (6) and chassis ground

Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3 Defective engine controller

LH J1 (female)

Resistance

Between (8) – (6)

54 – 66 z

Between (8), (6) – chassis ground

Min. 1 Mz

12V140E-3 Series

40 Troubleshooting

SEN00318-03

Circuit diagram related to inter multi-controller communication

12V140E-3 Series

SEN00318-03

40 Troubleshooting

E-79 Code [781/CB781] Inter Multi-controller Communication Error (RH bank) 1 Error code

Failure code

781

CB781

Trouble

Inter multi-controller communication error (RH bank)

Contents of trouble

• Communication error occurred between engine controllers (LH bank)

Action of controller

• None in particular.

Phenomenon • Single-bank operation that appears on • Engine cannot be started with the key ON machine Related information Possible causes and standard value in normal state

• Different machine models may have different connector Nos.

Causes

Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for E-78 Code [781/CA781].

12V140E-3 Series

40 Troubleshooting

SEN00318-03

E-80 Code [1117/CA1117] Persistent Data Lost Error (LH bank) Error code

Failure code

1117

CA1117

Trouble

Engine Controller Data Lost Error (LH bank)

Contents of trouble

• All data in engine controller are lost.

Action of controller

• None in particular.

Phenomenon that appears on machine Related information Possible causes and standard value in normal state

Causes

Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for E-1 Code [111/CA111].

E-81 Code [1117/CB1117] Persistent Data Lost Error (RH bank) Error code

Failure code

1117

CB1117

Trouble

Engine Controller Data Lost Error (RH bank)

Contents of trouble

• All data in engine controller are lost.

Action of controller

• None in particular.

Phenomenon that appears on machine Related information Possible causes and standard value in normal state

12V140E-3 Series

Causes

Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for E-2 Code [111/CB111].

SEN00318-03

40 Troubleshooting

E-82 Code [1257/CA1257] Harness Key error (LH bank) Error code

Failure code

1257

CA1257

Trouble

Multi-controller identification harness key error (LH bank)

Contents of trouble

• Collation of identification harness between respective bank controllers fail (LH bank)

Action of controller

• Stops operation

Phenomenon that appears on • Engine cannot be started with the key ON machine Related information

• Different machine models may have different connector Nos.

Causes

Standard value in normal state/Remarks on troubleshooting

Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ness 1 (Disconnection in wiring or Resisdefective contact in connec- Wiring harness between OEM L (female) (7) Max. 1 z – OEM L (female) (34) tance tor) Possible causes and standard value in normal state

Ground fault in wiring harness 2 (Short circuit with GND circuit)

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between wiring harness OEM L (female) (8) and chassis ground

Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3 Defective engine controller

Between wiring harness OEM L (7) and chassis ground

Resistance

Max. 1 z

Between wiring harness OEM L (8) and chassis ground

Resistance

Min. 1 Mz

Circuit diagram related to multi-controller identification harness key

12V140E-3 Series

40 Troubleshooting

SEN00318-03

E-83 Code [1257/CB1257] Harness Key error (RH bank) Error code

Failure code

1257

CB1257

Trouble

Multi-controller identification harness key error (RH bank)

Contents of trouble

• Collation of identification harness between respective bank controllers fail (RH bank)

Action of controller

• Stops operation

Phenomenon that appears on • Engine cannot be started with the key ON machine Related information

• Different machine models may have different connector Nos.

Causes

Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wrong connection of harness 1 Connector connection error Between OEM R (female) (7) – OEM R ResisMin. 1 Mz (female) (34) terminals tance Possible causes and standard value in normal state

Ground fault in wiring harness 2 (Short circuit with GND circuit)

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between wiring harness OEM R (female) (8) and chassis ground

Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3 Defective engine controller

Between wiring harness OEM R (7) and chassis ground

Resistance

Min. 1 Mz

Between wiring harness OEM R (8) and chassis ground

Resistance

Min. 1 Mz

Circuit diagram related to multi-controller identification harness key

12V140E-3 Series

SEN00318-03

40 Troubleshooting

E-84 Code [1548/CB1548] Injector #7 (R/B #1) System Open/Short Error (RH bank) 1 Error code

Failure code

1548

CB1548

Trouble

Disconnection or short circuit in injector #7 (R/B #1) system (RH bank)

Contents of trouble

• There is disconnection or short circuit in injector #7 circuit.

Action of controller

• None in particular.

Phenomenon • Output drops. that appears on • Idle speed is unstable. machine Related information

• Different machine models may have different connector Nos.

Causes

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Possible causes and standard value in normal state

Defective injector #7 (Internal trouble)

RH CN1 (male)

Resistance

Between (1) – (2)

0.4 – 1.1 z

Between (1), (2) – chassis ground

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshootDisconnection in wiring haring without turning starting switch ON. ness Wiring harness between RH J1 (female) Resis2 (Disconnection in wiring or Max. 1 z (45) – RH CN1 (female) (1) tance defective contact in connecWiring harness between RH J1 (female) Resistor) Max. 1 z (53) – RH CN1 (female) (2) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harness 3 (Short circuit with GND circuit)

Wiring harness between RH J1 (female) (45) – RH CN1 (female) (1) and chassis ground

Resistance

Min. 1 Mz

Wiring harness between RH J1 (female) (53) – RH CN1 (female) (2) and chassis ground

Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4 Defective engine controller

RH J1 (female)

Resistance

Between (45) – (53)

0.4 – 1.1 z

Between (45), (53) – chassis ground

Min. 1 Mz

12V140E-3 Series

40 Troubleshooting

SEN00318-03

Circuit diagram related to injector #7 (R/B #1) system

12V140E-3 Series

SEN00318-03

40 Troubleshooting

E-85 Code [1549/CB1549] Injector #8 (R/B #2) System Open/Short Error (RH bank) 1 Error code

Failure code

1549

CB1549

Trouble

Disconnection or short circuit in injector #8 (R/B #2) system (RH bank)

Contents of trouble

• There is disconnection or short circuit in injector #8 circuit.

Action of controller

• None in particular.

Phenomenon • Output drops. that appears on • Idle speed is unstable. machine Related information

• Different machine models may have different connector Nos.

Causes

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Possible causes and standard value in normal state

Defective injector #8 (Internal trouble)

RH CN2 (male)

Resistance

Between (1) – (2)

0.4 – 1.1 z

Between (1), (2) – chassis ground

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshootDisconnection in wiring haring without turning starting switch ON. ness Wiring harness between RH J1 (female) Resis2 (Disconnection in wiring or Max. 1 z (54) – RH CN2 (female) (1) tance defective contact in connecWiring harness between RH J1 (female) Resistor) Max. 1 z (51) – RH CN2 (female) (2) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harness 3 (Short circuit with GND circuit)

Wiring harness between RH J1 (female) (54) – RH CN2 (female) (1) and chassis ground

Resistance

Min. 1 Mz

Wiring harness between RH J1 (female) (51) – RH CN2 (female) (2) and chassis ground

Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4 Defective engine controller

RH J1 (female)

Resistance

Between (54) – (51)

0.4 – 1.1 z

Between (54), (51) – chassis ground

Min. 1 Mz

12V140E-3 Series

40 Troubleshooting

SEN00318-03

Circuit diagram related to injector #8 (R/B #2) system

12V140E-3 Series

SEN00318-03

40 Troubleshooting

E-86 Code [1551/CB1551] Injector #10 (R/B #4) System Open/Short Error (RH bank) Error code

Failure code

1551

CB1551

Trouble

Disconnection or short circuit in injector #10 (R/B #4) system (RH bank)

Contents of trouble

• There is disconnection or short circuit in injector #10 circuit.

Action of controller

• None in particular.

Phenomenon • Output drops. that appears on • Idle speed is unstable. machine Related information

• Different machine models may have different connector Nos.

Causes

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Possible causes and standard value in normal state

Defective injector #10 (Internal trouble)

RH CN4 (male)

Resistance

Between (1) – (2)

0.4 – 1.1 z

Between (1), (2) – chassis ground

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshootDisconnection in wiring haring without turning starting switch ON. ness Wiring harness between RH J1 (female) Resis2 (Disconnection in wiring or Max. 1 z (56) – RH CN4 (female) (1) tance defective contact in connecWiring harness between RH J1 (female) Resistor) Max. 1 z (58) – RH CN4 (female) (2) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harness 3 (Short circuit with GND circuit)

Wiring harness between RH J1 (female) (56) – RH CN4 (female) (1) and chassis ground

Resistance

Min. 1 Mz

Wiring harness between RH J1 (female) (58) – RH CN4 (female) (2) and chassis ground

Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4 Defective engine controller

RH J1 (female)

Resistance

Between (56) – (58)

0.4 – 1.1 z

Between (56), (58) – chassis ground

Min. 1 Mz

12V140E-3 Series

40 Troubleshooting

SEN00318-03

Circuit diagram related to injector #10 (R/B #4) system

12V140E-3 Series

SEN00318-03

40 Troubleshooting

E-87 Code [1552/CB1552] Injector #11 (R/B #5) System Open/Short Error (RH bank) Error code

Failure code

1552

CB1552

Trouble

Disconnection or short circuit in injector #11 (R/B #5) system (RH bank)

Contents of trouble

• There is disconnection or short circuit in injector #11 circuit.

Action of controller

• None in particular.

Phenomenon • Output drops. that appears on • Idle speed is unstable. machine Related information

• Different machine models may have different connector Nos.

Causes

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Possible causes and standard value in normal state

Defective injector #11 (Internal trouble)

RH CN5 (male)

Resistance

Between (1) – (2)

0.4 – 1.1 z

Between (1), (2) – chassis ground

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshootDisconnection in wiring haring without turning starting switch ON. ness Wiring harness between RH J1 (female) Resis2 (Disconnection in wiring or Max. 1 z (46) – RH CN5 (female) (1) tance defective contact in connecWiring harness between RH J1 (female) Resistor) Max. 1 z (60) – RH CN5 (female) (2) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harness 3 (Short circuit with GND circuit)

Wiring harness between RH J1 (female) (46) – RH CN5 (female) (1) and chassis ground

Resistance

Min. 1 Mz

Wiring harness between RH J1 (female) (60) – RH CN5 (female) (2) and chassis ground

Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4 Defective engine controller

RH J1 (female)

Resistance

Between (46) – (60)

0.4 – 1.1 z

Between (46), (60) – chassis ground

Min. 1 Mz

12V140E-3 Series

40 Troubleshooting

SEN00318-03

Circuit diagram related to injector #11 (R/B #5) system

12V140E-3 Series

SEN00318-03

40 Troubleshooting

E-88 Code [1553/CB1553] Injector #12 (R/B #6) System Open/Short Error (RH bank) Error code

Failure code

1553

CB1553

Trouble

Disconnection or short circuit in injector #12 (R/B #6) system (RH bank)

Contents of trouble

• There is disconnection or short circuit in injector #12 circuit.

Action of controller

• None in particular.

Phenomenon • Output drops. that appears on • Idle speed is unstable. machine Related information

• Different machine models may have different connector Nos.

Causes

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Possible causes and standard value in normal state

Defective injector #12 (Internal trouble)

RH CN6 (male)

Resistance

Between (1) – (2)

0.4 – 1.1 z

Between (1), (2) – chassis ground

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshootDisconnection in wiring haring without turning starting switch ON. ness Wiring harness between RH J1 (female) Resis2 (Disconnection in wiring or Max. 1 z (57) – RH CN6 (female) (1) tance defective contact in connecWiring harness between RH J1 (female) Resistor) Max. 1 z (59) – RH CN6 (female) (2) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harness 3 (Short circuit with GND circuit)

Wiring harness between RH J1 (female) (57) – RH CN6 (female) (1) and chassis ground

Resistance

Min. 1 Mz

Wiring harness between RH J1 (female) (59) – RH CN6 (female) (2) and chassis ground

Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4 Defective engine controller

RH J1 (female)

Resistance

Between (57) – (59)

0.4 – 1.1 z

Between (57), (59) – chassis ground

Min. 1 Mz

12V140E-3 Series

40 Troubleshooting

SEN00318-03

Circuit diagram related to injector #12 (R/B #6) system

12V140E-3 Series

SEN00318-03

40 Troubleshooting

E-89 Code [1622/CB1622] Injector #9 (R/B #3) System Open/Short Error (RH bank) 1 Error code

Failure code

1622

CB1622

Trouble

Disconnection or short circuit in injector #9 (R/B #3) system (RH bank)

Contents of trouble

• There is disconnection or short circuit in injector #9 circuit.

Action of controller

• None in particular.

Phenomenon • Output drops. that appears on • Idle speed is unstable. machine Related information

• Different machine models may have different connector Nos.

Causes

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Possible causes and standard value in normal state

Defective injector #9 (Internal trouble)

RH CN3 (male)

Resistance

Between (1) – (2)

0.4 – 1.1 z

Between (1), (2) – chassis ground

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshootDisconnection in wiring haring without turning starting switch ON. ness Wiring harness between RH J1 (female) Resis2 (Disconnection in wiring or Max. 1 z (55) – RH CN3 (female) (1) tance defective contact in connecWiring harness between RH J1 (female) Resistor) Max. 1 z (52) – RH CN3 (female) (2) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harness 3 (Short circuit with GND circuit)

Wiring harness between RH J1 (female) (55) – RH CN3 (female) (1) and chassis ground

Resistance

Min. 1 Mz

Wiring harness between RH J1 (female) (52) – RH CN3 (female) (2) and chassis ground

Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4 Defective engine controller

RH J1 (female)

Resistance

Between (55) – (52)

0.4 – 1.1 z

Between (55), (52) – chassis ground

Min. 1 Mz

12V140E-3 Series

40 Troubleshooting

SEN00318-03

Circuit diagram related to injector #9 (R/B #3) system

12V140E-3 Series

SEN00318-03

40 Troubleshooting

E-90 Code [1633/CA1633] KOMNET Datalink Timeout Error (LH bank) 1 Error code

Failure code

1633

CA1633

Trouble

KOMNET error (LH bank)

Contents of trouble

• Abnormality occurred in circuit of KOMNET communication with machine (LH bank).

Action of controller

• Normal control (communication function disabled)

Phenomenon that appears on • Different problems occur on different machine models. machine Related information

• Different machine models may have different connector Nos.

Causes

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Disconnection in wiring harness 1 (Disconnection in wiring or defective contact in connector)

Possible causes and standard value in normal state

Wiring harness between OEM L (female) (46) – OEM R (female) (46)

Resistance

Max. 1 z

Wiring harness between OEM L (female) (47) – OEM R (female) (47)

Resistance

Max. 1 z

Wiring harness between OEM L (female) (46) – OEM L (female) (47)

Resistance

108 – 132 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harness 2 (Short circuit with GND circuit)

Wiring harness between OEM L (female) (46) – OEM R (female) (46) and chassis ground

Resistance

Min. 1 Mz

Wiring harness between OEM L (female) (47) – OEM R (female) (47) and chassis ground

Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3 Defective engine controller

Wiring harness between OEM L (female) (46) – OEM L (female) (47)

Resistance

108 – 132z

Wiring harness between OEM R (female) (46) – OEM R (female) (47)

Resistance

108 – 132 z

12V140E-3 Series

40 Troubleshooting

SEN00318-03

KOMNET-related circuit diagram

12V140E-3 Series

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

2185

CA2185

Trouble

Throttle sensor detection of abnormally high supply voltage (LH bank only)

Contents of trouble

• High voltage abnormality occurred to throttle sensor power supply (5 V) circuit.

Action of controller

• Sets throttle angle with signal other than throttle sensor signal and continues operation. (depending on each model)

Phenomenon that appears on • Depends on machine model. machine Related information

• Different machine models may have different connector Nos.

Causes

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.

Defective deceleration sen1 sor (Internal trouble)

Possible causes and standard value in normal state

Decelerator sensor

DEC connector

a Prepare with starting switch OFF, then carry out troubleshootDisconnection in wiring haring without turning starting switch ON. ness Wiring harness between OEM L (female) Resis2 (Disconnection in wiring or Max. 1 z (22) – DEC (female) (A) tance defective contact in connecWiring harness between OEM L (female) Resistor) Max. 1 z (23) – DEC (female) (C) tance Ground fault in wiring harness 3 (Short circuit with GND circuit)

Short circuit in wiring harness 4 (With another wiring harness)

5 Defective engine controller

Disconnect devices at right in order. If error code disappears subsequently, that device has a defect in it.

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between OEM L (female) (22) – DEC (female) (A) and chassis ground

Resistance

Min. 1 Mz

Wiring harness between OEM L (female) (23) – DEC (female) (C) and chassis ground

Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between OEM L (female) (22) – DEC (female) (A) and OEM L (female) (23) – DEC (female) (C)

Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. OEM L

Voltage

Between (22) – (23)

4.75 – 5.25 V

12V140E-3 Series

40 Troubleshooting

SEN00318-03

Circuit diagram related to deceleration pedal type throttle sensor (Case of D475-5)

12V140E-3 Series

SEN00318-03

40 Troubleshooting

E-92 Code [2186/CA2186] Throttle Sens. Sup. Volt. Low Error (LH bank only) 1 Error code

Failure code

2186

CA2186

Trouble

Throttle sensor detected abnormally low supply voltage (LH bank only)

Contents of trouble

• Low-voltage abnormality occurred to throttle sensor power supply (5V) circuit.

Action of controller

• Sets throttle angle with signal other than throttle sensor signal and continues operation. (depending on each model)

Phenomenon that appears on • Depends on machine model. machine Related information Possible causes and standard value in normal state

Causes

Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for E-91 Code [2185/CA2185].

12V140E-3 Series

40 Troubleshooting

SEN00318-03

E-93 Code [2249/CA2249] Rail Press. Very Low Error (LH bank) Error code

Failure code

2249

CA2249

Trouble

Supply pump no-pressure feed error 2 (LH bank)

Contents of trouble

• Supply pump does not feed fuel (level 2).

Action of controller

• Limits common rail pressure.

Phenomenon that appears on • Output drops. machine Related information Possible causes and standard value in normal state

Causes

Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for E-66 Code [559/CA559].

E-94 Code [2249/CB2249] Rail Press. Very Low Error (RH bank) Error code

Failure code

2249

CB2249

Contents of trouble

Trouble

Supply pump no-pressure feed error 2 (RH bank)

• Supply pump does not feed fuel (level 2).

Action of ontrol• Limits common rail pressure. ler Phenomenon that appears on • Output drops. machine Related information Possible causes and standard value in normal state

12V140E-3 Series

Causes

Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for E-67 Code [559/CB559].

SEN00318-03

40 Troubleshooting

E-95 Code [– –*1/–] Eng. Overheat (LH bank only) Error code

Failure code

– –*1

–

Trouble

Engine overheat (LH bank only)

Contents of trouble

• Engine coolant temperature is above operating range.

Action of controller

• Limits output and continues operation.

Phenomenon that appears on • Output drops. machine Related information

Possible causes and standard value in normal state

Causes

Standard value in normal state/Remarks on troubleshooting

This defective phenomenon is indicated only on the installed Carry out troubleshooting on machine when it was detected. 1 machine side Accordingly, contents of troubleshooting differ by the machine model. See Shop manual for machine.

E-96 Code [– –*2/–] Eng. Oil Press. Low Speed Derate (LH bank only) 1 Error code

Failure code

– –*2

–

Trouble

Engine oil pressure low and speed derate (LH bank only)

Contents of trouble

• Engine oil pressure is below operating range.

Action of controller

• Limits output and continues operation (Limits fuel injection rate and engine speed).

Phenomenon that appears on • Output drops. machine Related information

Possible causes and standard value in normal state

Causes

Standard value in normal state/Remarks on troubleshooting

12V140E-3 Series

40 Troubleshooting

SEN00318-03

E-97 Code [– –*3/–] Press. Low Torque Derate (LH bank only) Error code

Failure code

– –*3

–

Trouble

Engine oil pressure low and torque derate (LH bank only)

Contents of trouble

• Engine oil pressure is below operating range.

Action of controller

• Limits output and continues operation (Limits fuel injection rate and engine speed).

Phenomenon that appears on • Output drops. machine Related information

Possible causes and standard value in normal state

Causes

Standard value in normal state/Remarks on troubleshooting

12V140E-3 Series

SEN00318-03

40 Troubleshooting

KOMATSU 12V140E-3 Series engine Form No. SEN00318-03

12V140E-3 Series

SEN00320-03

ENGINE 1SHOP MANUAL

12V140E-3 Series

50 Disassembly and assembly General information on disassembly and assembly How to read this manual ................................................................................................................................. 2 Coating materials list....................................................................................................................................... 4 Special tool list ................................................................................................................................................ 7 Sketches of special tools ................................................................................................................................ 9

12V140E-3 Series

SEN00320-03

50 Disassembly and assembly

How to read this manual 1.

(Rev. 2009.01) 1

Removal and installation of assemblies Special tools q Special tools which are necessary for r e m o v a l o r i n s ta l l a t i o n o f pa r ts a r e described as A1,•••X1 etc. and their parts numbers, part names and quantities are described in the special tool list. q Also the following information is described in the special tool list. 1) 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 available on the market 2) Distinction of new and existing special tools N: Tools newly developed for this model. They have a new part number respectively. 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 modification. 3) Circle mark Q in sketch column: q The sketch of the special tool is presented in the section of "Sketches of special tools". q Part No. of special tools starting with 79*T-***-****: means that they are not available from Komatsu Ltd. (i.e. tools to be made locally).

Removal q In "Removal" section, the work procedures, precautions and know-how to do the work, and the amount of oil and coolant to be drained are described. q Common tools that are necessary for removal are described as [1], [2] ••• etc. and their part numbers, part names and quantities are not described. q Various symbols used in "Removal" section are explained and listed below. k :

Precautions related to work safety

a: Guidance or precautions for the work [*1] : This mark shows that instructions or precautions for parts installation work are given in "Installation" section. 6 :

Amount of oil or coolant to be drained

Weight of part or component

Installation q Unless otherwise instructed, installation of parts is to be done in the reverse order to removal. q Instructions and precautions for parts installation is shown with the mark ([*1], [*2]...) which corresponds to the mark in "Removal" section. q Common tools that are necessary for installation are described as [1], [2] ••• etc. and their part numbers, part names and quantities are not described. q Marks shown in the "Installation" section stand for the following. k :

Precautions related to work safety

a: Guidance or precautions for the work 2 : Type of coating material 3 : Tightening torque 5

: Amount of oil or coolant to be replenished

Sketches of special tools q Various special tools are illustrated for the local manufacture.

12V140E-3 Series

50 Disassembly and assembly

SEN00320-03

Disassembly and assembly of assemblies Special tools q Special tools which are necessary for disassembly and assembly of parts are described as A1,•••X1 etc. and their part numbers, part names and quantities are described in the special tool list. q Also the following information is described in the special tool list. 1) 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 available on the market. 2) Distinction of new and existing special tools N : Tools newly developed for this model. They have a new part number respectively. 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 modification. 3) Circle mark Q in sketch column: q The sketch of the special tool is presented in the section of "Sketches of special tools". q Part No. of special tools starting with 79*T-***-****: means that they are not available from Komatsu Ltd. (i.e. tools to be made locally).

Disassembly q In "Disassembly" section, the work procedures, precautions and know-how to do the work, and the amount of oil and coolant to be drained are described. q Common tools that are necessary for disassembly are described as [1], [2] ••• etc. and their part numbers, part names and quantities are not described. q The meanings of the symbols used in "Disassembly" section are as follows. k :

Precautions related to work safety

a: Guidance or precautions for the work 6: Amount of oil or coolant drained

Assembly q In "Assembly" section, the work procedures, precautions and know-how to do the work, and the amount of oil and coolant to be replenished are described. q Common tools that are necessary for assembly are described as [1], [2] ••• etc. and their part numbers, part names and quantities are not described. q The meanings of the symbols used in "Assembly" section are as follows. k :

Precautions related to work safety

a: Guidance or precautions for the work 2 : Type of coating material 3 : Tightening torque 5

: Amount of oil or coolant to be replenished

Sketches of special tools q Various special tools are illustrated for the local manufacture.

12V140E-3 Series

SEN00320-03

50 Disassembly and assembly

Coating materials list

(Rev. 2009.02) 1

a The recommended coating materials such as adhesives, gasket sealants, and greases used for disassembly and assembly are listed below. a For coating materials not listed below, use the equivalent of products shown in this manual.

Adhesive

Category

Komatsu code

Part number

Q'ty

Container

Main features and applications

LT-1A

790-129-9030

150 g

Tube

• Used to prevent rubber gaskets, rubber cushions, and cork plugs from coming out.

LT-1B

790-129-9050

20 g (2 pcs.)

• Used for plastic (except polyethylene, polypropylene, tetrafluoroethylene and vinyl Polyethylene chloride), rubber, metal, and non-metal parts container which require immediate and strong adhesion.

LT-2

09940-00030

50 g

Polyethylene • Features: Resistance to heat and chemicals. container • Used to fix and seal bolts and plugs.

LT-3

790-129-9060 Adhesive: 1 kg (Set of adhesive Hardener: 500 g and hardener)

LT-4

790-129-9040

250 g

Holtz MH 705

790-129-9120

75 g

ThreeBond 1735

Gasket sealant

• Used to stick and seal metal, glass, and plastics.

Polyethylene • Used to seal plugs. container Tube

• Heat-resistant seal used to repair engines.

50 g

• Quick-setting adhesive. Polyethylene • Setting time: Within 5 sec. to 3 min. container • Used mainly to stick metals, rubbers, plastics, and woods.

Aron-alpha 201

790-129-9130

• Quick-setting adhesive. • Quick-setting type. Polyethylene (max. strength is obtained after 30 minutes) container • Used mainly to stick rubbers, plastics, and metals.

Loctite 648-50

79A-129-9110

50 cc

• Features: Resistance to heat and chemicals. Polyethylene • Used for fitted portions used at high temperacontainer tures.

1 kg

• Used to seal various threaded portions, pipe Polyethylene joints, and flanges. container • Used to seal tapered plugs, elbows, and nipples of hydraulic piping.

LG-5

790-129-9080

LG-6

790-129-9160

200 g

Tube

• Features: Silicon-based heat and cold-resistant sealant. • Used to seal flange surfaces and threaded portions. • Used to seal oil pan, final drive case, etc.

LG-7

790-129-9170

1 kg

Tube

• Features: Silicon-based quick-setting sealant. • Used to seal flywheel housing, intake manifold, oil pan, thermostat housing, etc.

Tube

• Features: Silicon-based, heat and cold-resistant, vibration-resistant, impact-resistant sealant. • Used to seal transfer case, etc.

Tube

• Used for rough surfaces such as the circle gear top seal which does not need to be clamped, water resistance of the clearance at the welded area, etc. • Can be coated with paint.

LG-8 ThreeBond 1207B

LG-9 ThreeBond 1206D

790-129-9140

Can

419-15-18131

790-129-9310

100 g

200 g

12V140E-3 Series

50 Disassembly and assembly

Gasket sealant

CateKomatsu code gory

Part number

Q'ty

Container

LG-10 ThreeBond 1206E

790-129-9320

200 g

Tube

• Used as lubricant/sealant when the radiator hoses are inserted. • Can be coated with paint.

LG-11 ThreeBond 1121

790-129-9330

200 g

Tube

• Feature: Can be used together with gaskets. • Used for covers of the transmission case and steering case etc.

ThreeBond 1211

790-129-9090

100 g

Tube

• Gasket sealant used to repair engine.

Tube

• Used to prevent scuffing and seizure of press-fitted portions, shrink-fitted portions, and threaded portions. • Used to lubricate linkages, bearings, etc.

Can

• Spray type • Thin molybdenum disulphide films are made on metal surfaces to prevent the metals from scuffing each other. • Applicable for the propeller shaft splines, needle bearings, pins and bolts of various links, etc.

—

Can

• Feature: Seizure and scuffing prevention compound with metallic super-fine-grain, etc. • Used for the mounting bolt in the high temperature area of the exhaust manifold and the turbocharger, etc.

SYG2-400LI SYG2-350LI SYG2-400LI-A G2-LI SYG2-160LI G0-LI SYGA-160CNLI *: For cold district SYG0-400LI-A (*) SYG0-160CNLI (*)

Various

• Feature: Lithium grease with extreme pressure lubrication performance. • General purpose type.

Molybdenum SYG2-400M disulfide grease SYG2-400M-A LM-G (G2-M) SYGA-16CNM

• Used for parts under heavy load. Caution: 400 g x 10 Bellows-type • Do not apply grease to rolling bearings like 400 g x 20 container swing circle bearings, etc. and spline. • The grease should be applied to work equipment 16 kg Can pins at their assembly only, not applied for greasing afterwards.

Seizure prevention compound

Molybdenum disulfide lubricant

LM-P

Grease

SEN00320-03

—

LC-G NEVER-SEEZ

09940-00040

09995-00250

—

SYG2-400T-A SYG2-16CNT SYG0-400T-A (*) *: For cold district SYG0-16CNT (*)

Hyper White Grease G2-T, G0-T (*)

SYG2-400B Biogrease G2-B, G2-BT (*) SYGA-16CNB *: For use at high SYG2-400BT (*) temperature and SYGA-16CNBT under high load (*) G2-S ThreeBond 1855

G2-U-S ENS grease

12V140E-3 Series

—

427-12-11871

200 g

190 g

400 g 16 kg

200 g

2 kg

Main features and applications

• Bellows-type container • Can

Seizure resistance, heat resistance and water resistance higher than molybdenum disulfide grease. Not conspicuous on machine since color is white.

Bellows-type • Since this grease is decomposed by natural baccontainer teria in short period, it has less effects on microorganisms, animals, and plants. Can

Tube

• Feature: Silicone grease with wide using temperature range, high resistance to thermal-oxidative degradation and performance to prevent deterioration of rubber and plastic parts. • Used for oil seals of the transmission, etc.

Can

• Feature: Urea (organic system) grease with heat resistance and long life. Enclosed type. • Used for rubber, bearing and oil seal in damper. Caution: Do not mix with lithium grease.

SEN00320-03

Part number

SUNSTAR PAINT PRIMER 580 SUPER

SUNSTAR PAINT PRIMER 435-95

Container

Main features and applications

20 ml

Glass container

• Used as primer for cab side. (Using limit: 4 months after date of manufacture)

20 ml

Glass container

• Used as primer for glass side. (Using limit: 4 months after date of manufacture)

20 ml

Glass container

417-926-3910

22M-54-27230

• Used as primer for painted surface on cab side. (Using limit: 4 months after date of manufacture) • Used as primer for black ceramic-coated surface on glass side and for hard polycarbonate-coated surface. (Using limit: 4 months after date of manufacture)

SUNSTAR GLASS PRIMER 435-41

22M-54-27240

150 ml

Can

SUNSTAR SASH PRIMER GP-402

22M-54-27250

20 ml

Glass container

• Used as primer for sash (Almite). (Using limit: 4 months after date of manufacture)

SUNSTAR PENGUINE SEAL 580 SUPER “S” or “W”

417-926-3910

320 ml

Polyethylene container

• “S” is used for high-temperature season and “W” for low-temperature season as adhesive for glass. (Using limit: 4 months after date of manufacture)

Sika Japan, Sikaflex 256HV

20Y-54-39850

310 ml

Polyethylene container

• Used as adhesive for glass. (Using limit: 6 months after date of manufacture)

SUNSTAR PENGUINE SUPER 560

22M-54-27210

320 ml

Ecocart (Special container)

SUNSTAR PENGUINE SEAL No. 2505

417-926-3920

320 ml

Polyethylene container

SEKISUI SILICONE SEALANT

20Y-54-55130

333 ml

Polyethylene container

• Used to seal front window. (Using limit: 6 months after date of manufacture)

Cartridge

• Used to seal joint of glasses. Translucent white seal. (Using limit: 12 months after date of manufacture)

GE TOSHIBA SILICONES TOSSEAL 381

22M-54-27220

333 ml

Adhesive for cab glass

Caulking material

Adhesive

Primer

SUNSTAR GLASS PRIMER 580 SUPER

Q'ty

Adhesive for cab glass

CateKomatsu code gory

50 Disassembly and assembly

• Used as adhesive for glass. (Using limit: 6 months after date of manufacture) • Used to seal joints of glass parts. (Using limit: 4 months after date of manufacture)

12V140E-3 Series

50 Disassembly and assembly

SEN00320-03

Special tool list

(Rev. 2009.01) 1

Part No.

Engine repair stand

t 1

790-901-1800

Bracket assembly

t 1

790-901-1810

Bracket

t 1

790-901-1820

Bracket

t 1

790-901-1830

Bracket

t 1

790-901-1840

Bracket

t 1

790-901-1510

Plate

t 4

02100-01038

Bolt

t 36

01252-11050

Bolt

t 16

01643-31645

Washer

t 12

01643-31032

Washer

t 16

01602-21648

Washer

t 24

795-102-2102

Spring pusher

t 1

795-102-2110

Handle

t 1

795-102-2120

Bracket

t 1

795-102-4210

Bracket

t 1

01016-50830

Bolt

t 1

01580-10806

Nut

t 1

01144-31270

Stud

t 1

01580-11210

Nut

t 1

790-501-4000

Disassembly and assembly of engine assembly

Disassembly and assembly of cylinder head

Part name

Q'ty

Symbol

Removal and installation of piston ring

795-100-1191

Piston ring tool

t 1

Measurement of cylinder liner projection

795-502-1121

Holder

t 1

Removal of cylinder liner

795-236-1000

Liner puller

t 1

Installation of cylinder liner

795-230-5472

Liner driver

t 1

Angle tightening of bolt

795-331-1110

Wrench

t 1

Installation of piston

795-236-1500

Piston holder

t 1

12V140E-3 Series

New/Remodel Sketches

Work item

Necessity

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 available on the market a New/Remodel: N. . . . . . Tools newly developed for this model. They have a new part number respectively. : 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 modification. a Tools marked with Q in the sketch column are presented in the sketches of the special tools (See "Sketches of special tools")

Remarks

Installation of rear oil seal

New/Remodel Sketches

Installation of front oil seal

Symbol

795T-621-1430

Plate

t 1

795T-621-1441

Push tool

t 1

01050-32280

• Bolt

t 3

01582-02218

• Nut

t 3

01640-22232

• Washer

t 3

795T-621-1531

Push tool

t 1

01050-32050

Bolt

t 5

01640-02032

Washer

t 5

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

Push tool

t 1

Thickness gauge

q 1

Seal puller

q 1

Part No.

Press fitting of valve stem seal

795-130-1720

Adjusting valve clearance

Commercially available

Removal of front and rear oil seal

795-931-1100

Part name

Necessity

Work item

50 Disassembly and assembly

Q'ty

SEN00320-03

Remarks

IN: 0.35 mm, EX: 0.57 mm

12V140E-3 Series

50 Disassembly and assembly

Sketches of special tools

SEN00320-03

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches. J Plate

J Push tool

12V140E-3 Series

SEN00320-03

50 Disassembly and assembly

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches. K Push tool

K Push tool (For PC2000-8)

12V140E-3 Series

50 Disassembly and assembly

12V140E-3 Series

SEN00320-03

50 Disassembly and assembly

KOMATSU 12V140E-3 Series engine Form No. SEN00320-03

12V140E-3 Series

SEN00321-01

ENGINE 1SHOP MANUAL

12V140E-3 Series

50 Disassembly and assembly Disassembly and assembly, Part 1 Disassembly and assembly, Part 1 ................................................................................................................. 2 General disassembly of engine ............................................................................................................ 2

12V140E-3 Series

SEN00321-01

50 Disassembly and assembly

Disassembly and assembly, Part 1

General disassembly of engine 1 a a

The shapes, quantity, locations, etc. of the parts depend on each applicable machine. Take care. When a part is provided on both sides of the bank, one side alone is shown as an example. Except where otherwise specified, contents of the work shall be the same on both sides of the bank. 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 assembly. a Before cleaning the engine, carefully seal or remove the openings, electric parts, and wiring connectors so that water will not enter them.

Starting motor assembly Remove engine harness (1) and then remove starting motor assemblies (2) and (3). a Remove the assembly at the top first being followed by that at the bottom.

Alternator 1) Remove auxiliary equipment belt (1). 2) Remove alternator (2).

Installation to engine repair stand 1) Install the engine assembly (1) to tool A. 4 Engine assembly: Approx. 3,800 kg

Drain the engine coolant and engine oil. a Quantity of the engine oil depends on the applicable machines. 6 Engine oil: Approx. 130 l

Engine wiring harness Disconnect the connector and terminal and then remove engine harness (1) from the engine assembly.

12V140E-3 Series

50 Disassembly and assembly

SEN00321-01

Fuel filter and filter head assembly, and priming pump 1) Remove fuel tubes (1) and (2). 2) Remove fuel filter and filter head assembly (3). 3) Remove priming pump (4).

Air intake connector 1) Remove air intake connector (1).

Engine controller and controller cooler 1) Remove engine controller (1). 2) Remove fuel hoses (2) and (3). 3) Remove controller cooler (4).

10. Spill tube Remove spill tube (1).

Air inlet pipe 1) Remove the clamp and then remove air inlet pipe (1). 2) Remove bracket (2). 3) Remove bracket (3). a Remove bracket (3) on the right side bank alone. 11. High-pressure pipe (between supply pump – common rail) 1) Apply a marking to the installation positions of clamps (1) – (3) using paint. 2) Remove bracket (4). 3) Remove clamps (1) – (3). 4) Remove high-pressure pipes (5) and (6).

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12. High-pressure pipe (between common rail – fuel injector) 1) Remove bracket (1).

Apply a marking to every installation positions of clamps (2) and (3) using paint.

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3) 4) 5)

13. Air intake manifold assembly 1) Remove support (1).

2) 3)

Remove bracket. Remove all clamps (2) and (3). Remove 6 high-pressure pipes (4).

Lift air intake manifold (2) temporarily and then remove the mounting bolts. Lift off air intake manifold assembly (2). 4 Air intake manifold assembly: 45 kg

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16. Exhaust manifold assembly 1) Remove instation plates (1), muffler bracket (2), water pipes (3) and bracket (4).

14. Exhaust connector Remove exhaust connectors (1) and (2).

2) 3)

15. Turbocharger assembly 1) Remove 2 water pipes and 2 oil pipes. a When the air-cooled turbocharger is used, the oil pipes alone are provided. 2) Lift turbocharger assembly (1) temporarily and then remove the mounting bolts. 3) Lift off turbocharger assembly (1). 4 Turbocharger assembly: 35 kg

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Lift exhaust manifold assembly (5) temporarily and then remove the mounting bolts. Lift off exhaust manifold assembly (5). 4 Exhaust manifold assembly: 25 kg

17. Common rail 1) Remove fuel tube (1). 2) Remove common rail (2). 3) Remove bracket (3).

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18. Supply pump assembly 1) Remove oil tube (1) 2) Remove supply pump assembly mounting bolt (2). 3) Remove supply pump assembly (3).

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Remove water pump assembly (3).

Remove housing (5) from water pump (4).

19. Corrosion resister and filter head assembly Remove corrosion resister and filter head assembly (1).

21. Oil cooler (rear side) 1) Remove oil manifold (1). 2) Remove oil cooler (2) a Remove the oil cooler (front side) after removing the supply pump drive case. 20. Water pump assembly 1) Remove block (1) 2) Remove water connector (2).

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22. Plate and block Remove plates (1) and (2) and block (3).

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25. Head cover Remove head cover (1). a Repeat the same procedure on every cylinder up to removal of the cylinder head assembly.

23. Fuel tube 1) Remove fuel tube (1). 26. Rocker arm assembly 1) Loosen locknuts (1) and then loosen adjustment screws (2) fully. a Make sure that the valve tension is not applied to the rocker arm and thus it is free to move. 2) Remove rocker arm assembly (3). a Record the parts installation positions using a tag to avoid confusion in the later assembly.

24. Oil level gauge and oil filler tube 1) Remove bracket (1) and then remove oil filler tube (2). 2) Loosen the sleeve nut at the base and then remove oil level gauge (3). 3) Remove bracket (4).

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Remove air intake rocker arm (4), spacer (5) and exhaust rocker arm (6) from rocker shaft (7).

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27. Push rod Remove push rod (1).

28. Injector harness 1) Remove injector terminal mounting nut (1) and clamp mounting bolt (2). 2) Push connector (3) into the cylinder head and remove injector harness (4).

29. Fuel injector 1) Remove holder mounting bolt (1).

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Insert a small L-bar [1] under the fuel connector and pry out fuel injector (2) slowly. a Do not grip the solenoid valve at the top of the injector to pull off the injector.

30. Crosshead Remove crosshead (1).

31. Cylinder head assembly 1) Remove the water tube. 2) Lift off cylinder head assembly (1). 4 Cylinder head assembly: 25 kg

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50 Disassembly and assembly a

3) 4)

When removing the cylinder head assembly without removing the fuel injector, be sure to prevent its interference with the floor surface since the injector tip protrudes through the bottom of the cylinder head.

Remove the cylinder head gasket. Disassemble the cylinder head assembly according to the following procedure. 1] Using tool B, compress the valve spring to remove cotter (2). 2] Remove upper seat (3), outer spring (4), and inner spring (5).

3] 4]

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Remove lower seat (6). Raise the cylinder head and remove valve (7).

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32. Oil pan 1) Support the front and rear side of oil pan (1) with block [1]. 2) Remove all oil pan mounting bolts. 3) Separate the gasket sealant. 4) Lift the engine and then remove oil pan (1). 4 Oil pan: 90 kg

33. Suction pie and under plate 1) Fix under plate (1) temporarily using several oil pan mounting bolts. 2) Remove stay (2) and then remove suction pipe (3).

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3) 4)

Support under plate (1) using jack [1]. Remove the bolts used for temporary fixing and then lower the jack carefully to remove under plate (1). 4 Under plate: 25 kg

34. Relief valve 1) Remove relief valve (1).

Install the engine again to tool A.

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36. Breather Remove breather (1), blowby pipe (2) and plate (3). a Remove the plate on the left bank alone.

37. Thermostat case 1) Remove water outlets (1). 2) Remove thermostat case (2).

Remove thermostat (3) from thermostat case (2).

35. Alternator bracket Remove alternator bracket (1).

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38. Front engine hanger Remove front engine hanger (1).

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2] 3] 4]

39. Thermostat housing 1) Remove coolant temperature sensor (1). 2) Remove thermostat housing (2).

Remove shaft (5), thrust plate (6) and gear (7) as a unit. Remove gear (7) from shaft (5). Pull off oil seal (9) and bushing (10) from housing (8).

41. Flywheel assembly 1) Lift and secure flywheel assembly (1). 2) Remove the mounting bolt. 3) Separate the bolt from the crankshaft using forcing screw [1]. 4) Lift off flywheel assembly (1). 4 Flywheel assembly: 130 kg

40. Accessory drive 1) Remove pulley (1). 2) Remove accessory drive (2).

Disassemble the accessory drive according to the following procedure. 1] Pull off hub (3) and then remove thrust plate (4).

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42. Flywheel housing 1) Remove burring tool (1) and Ne speed sensor (2).

Remove engine speed sensor (3).

Lift flywheel housing (4) temporarily and then remove the mounting bolt. Lift off the flywheel housing (4). 4 Flywheel housing: 230 kg

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43. Rear oil seal Remove rear oil seal (1) from the flywheel housing.

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 assembly: 75 kg

45. Front support Remove front support (1) using puller [1].

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46. Gear case cover Lift off gear case cover (1). a As a cover for carrying a unit is put on the machine in the figure below, the shape of actual machine is partially different from it. 4 Gear case cover:75 kg

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Remove thrust plate (4) from the shaft. a A indicates the oil channel.

47. Front oil seal Remove front oil seal (1) from the gear case cover.

49. Supply pump gear 1) Remove the mounting nut. 2) Remove supply pump gear (1) using puller [1]. a After removing the supply pump gear, remove the key from the shaft and maintain so that it may not be lost.

48. Idler gear (Large) 1) Remove plate (1). 2) Remove idler gears (large) (2) and (3).

50. Idler gear (Small) 1) Remove plate (1). 2) Remove idler gear (small) (2).

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51. Oil pump assembly Remove oil pump assembly (1).

Remove cam follower assembly (3).

Disassemble the cam follower assembly according to the following procedure. 1] Remove snap rings (4) 2] Remove cam followers (5) from shaft (6). 3] Remove snap rings (7) from shaft (6).

52. Supply pump drive case 1) Remove oil tube (1) a Remove the oil tube on the left bank alone. 2) Remove supply pump drive case (2).

53. Oil cooler (Front side) Remove oil cooler (front side) (1)

54. Cam follower assembly 1) Remove plate (1) and cam follower cover (2).

55. Camshaft assembly 1) Turn cam gear (1) to remove mounting bolt (2) through lightening hole.

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SEN00321-01 a a

Pull off cam shaft assembly (3) along with the cam gear. a Turn the cam shaft carefully when removing it so that the bushing may not be damaged.

Be sure to remove the piston cooling nozzle before removing the piston connecting rod assembly. When removing the nozzle, turn it 90° so that it may not hit the piston.

58. Piston and connecting rod assembly 1) Prior to the removal, measure the side clearance of the connecting rod using dial gauge [1] in order to use it as a rough standard in the assembly. a Check the stamped No. of the connecting rod cap. q Make sure that the cap No. and cylinder No. are the same. q The No. must be stamped on the cam side. a If the cylinder No. is not stamped, write it using an electric pen prior to the removal (it is not acceptable to stamp the number).

56. Timing gear case 1) Lift timing gear case (1) temporarily and then remove the mounting bolt. 2) Lift off timing gear case (1). 4 Gear case cover: 55 kg

Rotate the crankshaft in order to drive the piston to be removed to the bottom dead center. Loosen connecting rod bolt (1) by 5 to 6 turns.

57. Piston cooling nozzle Remove piston cooling nozzle (1).

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5) 6)

Hit the connecting rod head lightly using a plastic hammer to loosen the connecting rod cap and connecting rod. Scrub the carbon off the top wall of the liner using fine sandpaper. Turn the crankshaft until the piston comes to the top dead center and then remove the connecting rod cap (2).

Push in and piston and connecting rod assembly using pushing bar [1] from the oil pan side and then remove the assembly while supporting piston (3) from the cylinder head side. a Take care not to damage the inside of the cylinder with a corner of the connecting rod. Remove other piston and connecting rod assemblies according to the above procedure. a Keep the sliding portion and bearing of the piston in a safe place to protect them from damage. a Assemble the connecting rod and cap temporarily and keep them along with the connecting rod bearing on a cylinder to cylinder basis.

50 Disassembly and assembly

Disassemble the piston and connecting rod assembly according to the following procedure. 1] Remove snap ring (4) 2] Support connecting rod (5) with hand and then remove piston pin (6) to disconnect piston (7) from the connecting 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.

4] 5]

Using tool C, remove piston ring (8). Remove oil ring expander (9) a Keep the piston, connecting rod, connecting rod bearing, piston ring, and piston pin on a cylinder to cylinder basis.

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50 Disassembly and assembly

59. Crankshaft 1) Before removing crankshaft, measure the end play of the crankshaft using dial gauge [1] in order to use it as a rough standard in the assembly.

2) 3)

Remove mounting bolts (2) of main cap (1). Insert the bolts in the bolt hole of the main cap (1) and remove the cap, while shaking it.

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Lift off crankshaft (4). a Use care in lifting the crankshaft so that it may not hit and get damage from the cylinder block. 4 Crankshaft: 210 kg

Remove upper thrust bearing (5) from No.7 journal. Remove upper bearing (6). a Apply marking to the assembly positions of the main cap, main bearing and thrust bearing using paint or tags and then keep them on a cap to cap basis.

Lower thrust bearing (3) is assembled to No. 7 main cap. Record its assembly position after removal.

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60. Cylinder liner 1) Before removing cylinder liner (1), measure its projection using tool D and dial gauge [1]. a Before measuring projection of the liner, tighten the liner with plate [2] so that it may not be lifted by the O-ring. 3 Plate mounting bolt: 69 – 98 Nm {7 – 10 kgm}

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61. Cylinder block Lift off the cylinder block from tool A. 4 Cylinder block: 850 kg

Using tool E, remove cylinder liner (1).

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KOMATSU 12V140E-3 Series engine Form No. SEN00321-01

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ENGINE 1SHOP MANUAL

12V140E-3 Series

50 Disassembly and assembly Disassembly and assembly, Part 2 General assembly of engine ........................................................................................................................... 2

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50 Disassembly and assembly

General assembly of engine a a

The shapes, quantity, locations, etc. of the parts depend on each applicable machine. Take care. When a part is provided on both sides of the banks, one side alone will be shown as an example. Except where otherwise noted, the same work procedure shall be employed for the both banks. Clean each part carefully, and check it for bruise, flaw, cavity, etc. Make sure each oil or coolant path is through.

Tightening bolts by plastic-region turning angle method a Bolts tightened by plastic-region turning angle method q Cylinder head mounting bolt q Main cap mounting bolt q Connecting rod cap mounting bolt a If the plastic-region turning angle method is applied, the tightened bolts have permanent strain. Accordingly, the allowable number of using times of each bolt is limited. Observe the following precautions. q Check each mounting bolt head for punch marks. If there were punch marks more than the specified numbers, replace the bolt. 1.

Cylinder block 1) Lift the cylinder block and then set it on tool A. 4 Cylinder block: 850 kg 2) Before inserting the cylinder liners, prepare the cylinder block according to the following procedure. 1] Remove the rust and scales from faces A and B with sandpaper, etc. until the machined surfaces are exposed. 2] Polish parts B, R and r with sandpap e r o f a b o u t No . 2 0 0 un t i l t h e y become smooth. If part R is sharpened or burrs are present there, finish it with a scraper or sandpaper. F i n i s h t h i s s u r f a c e pa r t i c u l a r l y smoothly so that it will not damage the O-ring. 3] If face R is so pitted that it cannot be repaired, replace the cylinder block. 4] If faces A and parts R and r are pitted, finish them smoothly.

Check the counterbored part and remove burrs. If chips or dust is on face C, the liner does not fit and coolant may leak and the projection of the liner may become improper consequently. a If the counterbored part is drooping, corroded, or pitted, repair it.

Cylinder liner a Replace the O-ring and clevis seal with new ones. 1) Check that the cylinder liner O-ring groove and periphery of the liner are not roughened because of rusting or pitting. If those parts are roughened, replace the cylinder liner. 2) Install clevis seal (1), O-rings (2) and (3) to the cylinder liner. a Check that there is not a burr, dust, etc. in the groove of the liner. a Fit the clevis seal with the chamfered side down. When fitting it, press it against the seal groove all round so that it will not be twisted. a When installing O-rings (2) and (3), refer to the following. q O-ring (2): Black q O-ring (3): Orange 2 Clevis seal and O-ring: Rubber lubricant (RF-1) a RF-1: DAIDO CHEMICAL INDUSTRY CO., LTD. If RF-1 is not available, apply clean engine oil (EO30). a Since the clevis seal and O-ring are swollen and deteriorated by oil, apply a small amount of oil to them thinly with a brush just before fitting them.

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50 Disassembly and assembly

After fitting the liner O-ring, check it for twist. If it is twisted, correct it with a smooth rod (about 10 mm in diameter).

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Gasket sealant application diameter: ø0.8 – 1.6 mm

When applying the gasket sealant, make sure overlapping b between the coating at start and the end complies with the following dimension. Gasket sealant overlapping dimension b: 6 ± 6 mm

Install the cylinder liner according to the following procedure. 1] Using cloth, wipe dirt and oil completely off the contact faces between the counterbored part of the cylinder block and liner flange. 2] Apply silicon-based gasket sealant to the counterbored mating parts a of the cylinder block and cylinder liner. 2 Cylinder block: Gasket sealant (LG-6)

12V140E-3 Series

After applying the gasket sealant, finish the cylinder liner installation within 50 minutes. When the bottom contact face of the counterbored liner flange is modified and shim (2) is used.

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50 Disassembly and assembly

Immediately before press-fitting of the liner, apply a small amount of engine oil to the liner O-ring, crevice seal and contact face of the cylinder block. 2 Clevis seal, O-ring and cylinder block: Engine oil (EO30) a Apply the engine oil, using hands, uniformly on the entire contact face of the cylinder block.

Direct stamping "T" on the top face of the liner toward the engine front side and then insert cylinder liner (1) to the cylinder block while taking care so that the O-ring may not be damaged. Push in cylinder liner keeping weight on both hands. a If the liner does not enter the cylinder block smoothly when pushed with weight on both hands, stop the work since the O-ring is potentially damaged. In this case, check the cylinder block for burrs.

Coat the bottom side of shim (2) with a small amount of gasket sealant LG-6 and then assemble the shim. Then apply gasket sealant LG-6 according to the same procedure as that employed when the shim is not used.

Using tool F, press-fit cylinder liner (1) to the cylinder block.

To prevent the gasket sealant from projecting through the clearance between the block and liner after the cylinder head is tightened, tighten the cylinder head tempo r a r i l y wi t h th e u s e d h ea d g a s k e t inserted. a At this time, observe the following tightening torque and tightening order. 3 Temporary tightening torque: 137 – 157 Nm {14 – 16 kgm} a Installation of No. 7 bolt is not necessary.

10) Remove the cylinder head and wipe off the gasket sealant projected from the counterbored part. a Be sure to perform steps 9) and 10) above since the projected gasket sealant can deform the grommet of the head gasket. 11) After press-fitting the cylinder liner, measure its projection using tool D. a Before measuring projection of the liner, tighten it with plate [1] so that it may not be lifted by the O-ring. q Measuring position: 4 positions at a, b, c and d.

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50 Disassembly and assembly

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3 Plate mounting bolt:

a a a

686 – 980 Nm {7 – 10 kgm} Standard cylinder projection: 0.07 – 0.15 mm If the projection is out of the standard, correct it according to the maintenance standard. If the gasket sealant is projected from the fitting parts of the cylinder block and cylinder liner up to the top of the cylinder block, wipe it off.

3) 3.

Crankshaft 1) Fit upper main bearing (6) to the cylinder block, matching the projection of the former to the notch of the latter.

Drive in the roll pin in such that its projection from the block end face may become 2.7 – 3.4 mm and then install upper thrust bearing (5). a Install the thrust bearing with the grooved surface on the crankshaft side. 2 Thrust bearing sliding surface: Engine oil (EO30) Before assembling crankshaft, confirm the following items. q Presence/absence of abnormality in the front and rear threaded portions. (Make sure the bolt can be smoothly screwed in with hand.) q Presence/absence of scratches or dents on the pin and main journal. q Presence/absence of dusts in the oil hole.

a a

Upper bearing: With oil hole A No. 4 bearing is wider than others. Thus, care must be taken to prevent an assembly error. a Bearing with a No. 4 bearing: 52 mm Bearings other than No. 4: 48 mm a Before fitting the bearing, make sure that its back side is free from foreign matter. 2 Bearing inner surface: Engine oil (EO30) a Don't apply the engine oil to the bearing backside. 12V140E-3 Series

Lift crankshaft (4) and then install it on the cylinder block. a When installing the crankshaft, take care not to hit its sliding surfaces against the cylinder block. 4 Crank shaft: 210 kg 2 Cylinder block journal: Engine oil (EO30)

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Install the projection of lower bearing (7) locating it to the notch of main cap (1) and install. a Before fitting the bearing, make sure that its back side is free from foreign matter. 2 Inside of bearing: Engine oil (EO30) a Don't apply the engine oil to the bearing backside.

50 Disassembly and assembly

a a a

Lower bearing: Without oil hole No. 4 bearing is wider than others. Thus, care must be used to prevent an assembly error. Bearing with a No. 4 bearing: 52 mm Bearings other than No. 4: 48 mm

Drive the roll pin of cap No. 7 so that it will be projected by 2.7 – 3.4 mm from the cap end and then install lower thrust bearings (3) to both sides. a Install the thrust bearing with the grooved surface on the crankshaft side. 2 Thrust bearing sliding surface: Engine oil (EO30) 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. 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)

Tighten main cap mounting bolts (2) according to the following procedure. a Tighten the bolts from the center one to the outer ones in order. 12V140E-3 Series

50 Disassembly and assembly

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2 Threaded portion of mounting bolt

and washer: Engine oil (EO30)

3 Main cap mounting bolt

1st time: 284 ± 15 Nm {29 ± 1.5 kgm} 2nd time: 569 ± 10 Nm {58 ± 1.0 kgm} 3rd time: Using tool G, retighten the bolt by 90° (+30°/0°).

When tool G is not used, apply marking b to the main cap and bolt with paint, and then retighten the bolt by 90° (+30°/0°). 10) Make punch mark c on the mounting bolt head. a When a new bolt is used, do not make a punch mark on its head.

Piston and connecting rod assembly 1) Assemble the piston and connecting rod according to the following procedure. 1] Fit in oil ring expander (9) to the oil ring groove. 2] Using tool C, assemble the oil ring, second ring and top ring, in this order.

a a a 11) Check that the crankshaft turns smoothly. a Standard crankshaft starting torque: Max. 147 Nm {15 kgm} 12) Measure the end play of the crankshaft with dial gauge [1]. a End play standard value: 0.140 – 0.320 mm a If the end play is out of the standard, correct it. For details, see "Structure, function and maintenance standard".

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Assemble respective piston rings as shown in the figure. When assembling the respective rings to the piston, direct their stamped side upward. Take the expander out of the oil ring and fit it to the piston first and then assemble the oil ring. At this time, make sure that the expander is fitted to the ring groove perfectly. Make sure that the coil butt joint of the expander is situated in a position 180° to the oil ring abutment joint.

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Install snap ring (10) to one side of piston (7).

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. 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) 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 ring groove. a Also make sure that the connecting rod moves lightly.

50 Disassembly and assembly

Install the projection of connecting 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 connecting rod, check the connecting rod oil hole for settled dusts. 2 Connecting rod bearing inner surface: Engine oil (EO30)

Install the projection of connecting rod lower bearing (12) locating it to the notch of the connecting rod cap. 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.

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50 Disassembly and assembly

Apply the engine oil to the cylinder liner. a Apply the engine oil uniformly on the entire circumference with hands. 2 Cylinder liner: Engine oil (EO30)

Turn the crankshaft to drive the pin journal of the target cylinder of insertion to the top dead center position. After confirming No. of the piston and connecting rod assembly, insert the assembly to the cylinder block directing it in the direction shown in the figure. a Set the direction of the cylinder block in such that the cylinder may face sideways. This process is needed to prevent sudden insertion of the piston and connecting rod assembly to the cylinder. a On each bank, install notch A for the piston cooling nozzle and chamfered side B of the connecting rod. In this case, their positional relation with front direction F of the engine must be as shown in the figure.

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Align the abutment joint of respective piston rings as well as the piston to the position shown in the figure.

Make sure that the coil butt joint of the oil ring is situated in a position 180° to the abutment joint 2 Piston ring, piston and crank journal: Engine oil (EO30) 6) Using tool H, compress the piston ring and then push in the piston head with a wooden bar and the like.

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Using the connecting rod puller [1] shown in the figure, pull the connecting rod until it is closely contacted against the pin journal. a Make sure the connecting rod bearing is not displaced. a The connecting rod puller [1] is made by welding bar b to unnecessary connecting rod bolt a. a Total length of connecting rod puller l: Approx. 500 mm. 2 Crank pin journal: Engine oil (EO30)

50 Disassembly and assembly

When assembling a new connecting rod, record its cylinder No. on the connecting rod cap using a electric pen (stamping is not acceptable). It is strictly prohibited to change the combination of the connecting rod and cap through this operation.

11) Apply the engine oil to the threaded portion and washer of the connecting rod. 2 Connecting rod bolt and washer Engine oil (EO30)

Turn the crankshaft 180° while pulling the connecting rod. 9) Install connecting rod lower bearing (12) to connecting rod cap (2). 2 Connecting rod lower bearing: Engine oil (EO30) 10) Install connecting rod cap (2) aligning it to the dowel pin on the connecting. a Check the cylinder No.

12) Tighten connecting rod bolts (1) alternately until the connecting rod cap is closely contacted.

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SEN00322-05 a

13) Turn the crankshaft 180° and insert the piston and connecting rod assembly on one bank according to the steps 1) – 12). 14) Tighten the mounting bolts in the order indicated in the figure according to the following procedure. 3 Connecting rod bolt: 1st time: 69 – 78 Nm {7 – 8 kgm} 2nd time: 69 – 78 Nm {7 – 8 kgm} (again) 3rd time: Using tool G, retighten the bolt by 90° (+30°/0°).

After assembling the connecting rod, make sure that the crankshaft rotates normally. 16) Measure the side clearance of the connecting rod with dial gauge [1]. q Standard side clearance: 0.3 – 0.454 mm a When the side clearance is out of the standard, remove the connecting rod cap and check the connecting rod for assembly errors, presence of burrs or pinching of foreign substances.

12V140E-3 Series

When tool G is not used, apply marking b to the connecting rod, connecting rod cap and bolt with paint and then retighten the bolt by 90° (+30°/0°). 15) After tightening the bolt, make a punch mark c on its head. a When a new bolt is used, do not make a punch mark on its head.

Piston cooling nozzle 1) Install piston cooling nozzle (1). a After completely inserting the spigot joint portion to the block side mounting hole, tighten the mounting bolt. 3 Piston cooling nozzle mounting bolt: 54 ± 20 Nm {5.5 ± 2.0 kgm} a Prior to the installation, check the nozzle for damages or internal clogging .

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Make sure prior to the installation that the notch for preventing interference of the piston cooling nozzle is provided on the piston skirt portion.

50 Disassembly and assembly

Camshaft assembly 1) Insert the camshaft assembly (3) to the cylinder block along with the cam gear. a Install it carefully turning the cam shaft so that the cam bushing may not be damaged. a Use care when inserting the cam shaft so that your fingers may not be pinched. 2 Camshaft: Engine oil (EO30)

Turn the crankshaft slowly to make sure that interference is not observed between piston cooling nozzle (1) and piston (2) or connecting rod (3).

Timing gear case Lift and install timing gear case (1). a Prior to the installation, fix several portions on the gasket temporarily using the gasket sealant so that it may not be displaced. 4 Gear case cover: 55 kg

Turn the cam gear (1) and tighten mounting bolt (2) through the lightening hole a Replace the current mounting bolt with a new one. 3 Cam shaft mounting bolt: 88 ± 34 Nm {9.0 ± 3.5 kgm}

Cam follower assembly 1) Assemble the cam follower according to the following procedure. 1] Install snap ring (7) to shaft (6). 2] Install cam follower (5) to shaft (6). 2 Cam follower bushing inner surface: Engine oil (EO30) 3] Install snap rings (4).

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50 Disassembly and assembly

Install cam follower assembly (3). 3 Cam follower assembly mounting bolt: 44.1 – 58.8 Nm {4.5 – 6.0 kgm}

Install cam follower cover (2) and then tighten it along with plate (1) using the mounting bolt. a The plate between No. 3 and No. 4 cylinders is longer than those used in other sections. 3 Cam follower cover mounting bolt: 34.3 – 44.1 Nm {3.5 – 4.5 kgm}

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10. Supply pump drive case 1) Install supply pump drive case (2). 2) Install oil tube (1). 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}

11. Oil pump assembly Install oil pump assembly (1). 3 Oil pump mounting bolt: 54 ± 20 Nm {5.5 ± 2.0 kgm}

Oil cooler (front side) Install oil cooler (front side) (1)

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50 Disassembly and assembly 3 Supply pump gear mounting nut

12. Idler gear (small) 1) Install idler gear (small) (2). a When installing the idler gear, align the counter mark "D" to that of the cam gear (3) for the right bank. 2 Idler gear bushing inner surface: Engine oil (EO30) 2) Install plate (1) and then tighten the mounting bolt. 2 Plate sliding surface: Engine oil (EO30) 3 Idler gear (small) mounting bolt: 98.0 – 122.5 Nm {10.0 – 12.5 kgm}

13. Supply pump gear 1) Install key (2) to the shaft.

Size before repair is M20: 176 – 196 Nm {18 – 20 kgm} Size after repair is M22: 225 – 274 Nm {23 – 28 kgm}

14. Idler gear (large) 1) Set No. 1 cylinder on the right bank to the top dead center position. a It is referenced as the standard position when adjusting respective gears. 2) Install thrust plate (4) to the shaft. a Install the plate in such that oil groove A may be set on the idler gear side. 2 Thrust plate: Engine oil (EO30)

3) 2)

Install supply pump gear (1). a After installing all timing gears, tighten mounting nut (3) and washer (4) while fixing the crankshaft. a Install the washer (4). This work is p er for med onl y for th e r epai r ed engine. a Or tighten the nut while retaining the lightening hole with a general purpose retention tool and fixing the supply pump gear.

Install idler gears (large) (2) and (3). 2 Idler gear bushing inner surface: Engine oil (EO30)

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Install water pump assembly (2) temporarily.

Measure the backlash and end play of each gear with the dial gauge. a Symbols in the figure correspond to "Position" field in the following table.

Install idler gears (large) (2) and (3) in such that their counter marks as well as that of respective gears may come to the positions shown in the figure.

Install plate (1) and then tighten the mounting bolt. a Install the plate setting its "OUT" marking on the outside. 2 Plate sliding surface: Engine oil (EO30) 3 Idler gear (large) mounting bolt: 98.0 – 122.5 Nm {10.0 – 12.5 kgm}

15. Check of timing gear for backlash and end play 1) Attach gear (1) to the compressor and then install them temporarily. (When the engine is equipped with the compressor)

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Backlash of each gear

(mm) Standard Position Measuring points value Right idler gear (small) and 0.130 – 0.390 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 acces0.085 – 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

When cover (2) was removed, apply the gasket sealant in the position shown in the figure before installing it again. 2 Cover: Gasket sealant (LG-7) q Application diameter: ø2.0 mm

End play of each gear

Position Gear name 1 Idler gear (large) end play 2 Idler gear (small) end play 3 Supply pump gear end play 4 Oil pump gear end play Accessory drive gear end 5 play 6 Crank gear end play 7 Cam gear end play

(mm) Standard value 0.07 – 0.18 0.07 – 0.18 0.07 – 0.20 0.03 – 0.088 0.1 – 0.4 0.14 – 0.32 0.10 – 0.25

16. Gear case cover Lift and install gear case cover (1). a As a cover for carrying a unit is put on the machine in the figure below, the shape of actual machine is partially different from it. 4 Gear case cover: 75 kg

17. Front oil seal 1) Clean, degrease and then dry the contact surface between the front cover and front seal. 2) Using a clean cloth, remove foreign matter deposited on the crankshaft flange. a Clean foreign matter deposited on the seal lip surface (surface around the crankshaft) and then degrease and dry the surface.

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Check the crankshaft end face corner and lip siding surface for scratches due to the housing, burrs or rusts. When installing front oil seal (2), do not apply oil or grease to the shaft and seal lip. Wipe off the oil from the shaft. 2 Inner circumference of front oil seal: Gasket sealant (LG-7 or equivalent) 1] The surface having the parts number (PN) marking must face to the outside of engine.

18. Front support Install front support (1). a Prior to the installation, fill the oil hole with grease. a Volume of grease filled: 20 cc 2 Front support: Grease (G2-LI)

Tighten nuts [1] using the tool J (plate), and press oil seal (8) to the crank shaft end surface.

19. Damper and crank pulley assembly 1) When the damper and crank pulley are separated, assemble them again by tightening the mounting bolts in the order indicated in the figure. 2 Damper mounting bolt and washer: Engine oil (EO30) 3 Damper mounting bolt: 98 – 122 Nm {10 – 12.5 kgm} 3]

Tighten nuts [1] using the tool J (push tool), press oil seal (8) in the front case until it becomes the dimension (a) as shown in the figure. a Oil seal press fit dimensions (a): 17 mm (from crank shaft end surface) (b): 25.1 mm (from front cover end surface)

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Lift and install damper and crank pulley assembly (1). a Install the assembly aligning it to the dowel pin of the crankshaft. 4 Damper and crank pulley assembly: 75 kg

Tighten the mounting bolts in 3 steps according to the order indicated in the figure. 2 Flywheel housing mounting bolt: Engine oil (EO30) 3 Flywheel housing mounting bolt: 1st time: 343 ± 49 Nm {35 ± 5 kgm} 2nd time: Loosen it fully 3rd time: 411.6 ± 19.6 Nm {42 ± 2 kgm}

Tighten the mounting bolts in 3 steps according to the order indicated in the figure. 2 Damper and crank pulley pump assembly mounting bolt and washer: Engine oil (EO30) 3 Damper and crank pulley assembly mounting bolt 1st time: 73.5 ± 19.6 Nm {7.5 ± 2 kgm} 2nd time: 245 ± 19.6 Nm {25 ± 2 kgm} 3rd time: 744.8 ± 19.6 Nm {76 ± 2 kgm}

After the installation, cut off the gasket projecting from the oil pan mounting surface to make height of the gasket and mounting surface even. Install burring tool (1) and Ne speed sensor (2).

20. Flywheel housing 1) Lift and install flywheel housing (4). 4 Flywheel housing: 230 kg

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21. Rear oil seal 1) Clean, degrease and then dry the contact surface between the flywheel housing and rear seal. 2) Using a clean cloth, remove foreign matter deposited on the crankshaft flange. a Clean foreign matter deposited on the seal lip surface (surface around the crankshaft) and then degrease and dry the surface. a Check the crankshaft end face corner and lip siding surface for scratches due to the housing, burrs or rusts. 3) When installing rear oil seal (3), do not apply oil or grease to the shaft and seal lip. Wipe off the oil from the shaft. 1] The surface having the parts number (PN) marking must face to the outside of engine.

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PC2000-8 a Check the Teflon seal (Laydown lip seal) by checking the wear of the shaft and replace it with the “Standard seal”.

a a

Clean, degrease and then dry the contact surface between the flywheel housing and rear seal. Clean foreign matter deposited on the seal lip surface (surface around the crankshaft) and then degrease and dry the surface. Check the crankshaft end face corner and lip siding surface for scratches due to the housing, burrs or rusts.

Using the K (push tool), press oil seal (3) in the flywheel housing until it becomes the dimension (a) or (B) as shown in the figure. a Oil seal press fit dimensions (a): 5 mm (from flywheel housing end surface)

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Installation procedure of standard seal a Do not apply any grease, oil and others to the seal lip surface (a). a Never remove inside plastic cylinder (3) of the standard spare seal before installing the seal.

5] 1]

Set the large inside diameter side (b) of plastic inside cylinder (3) to the end of crankshaft (4). a Extremely take care not to mistake the direction of the plastic inside cylinder.

7] 2] 3]

Hold the metal ring of rear oil seal (1) with both hands and push it in firmly. After pushing in the rear oil seal, remove plastic inside cylinder (3). a When removing the inside cylinder, take care not to damage the seal lip.

Apply rear seal (2) on the end of crankshaft (4). a Install the rear seal in the correct direction. Manually push the metal ring of rear seal (2) evenly, and insert in its position. Using the tool K, further press and insert rear seal (2) evenly.

Using the tool K, press rear seal (2) by tightening bolts equally. a Press rear seal (2) until tool K reaches crankshaft (4). q Press fit method of oil seal (from flywheel housing end surface) (a): 13.5 mm q Press fit method of oil seal (from crankshaft end surface) (b): 25.7 mm a After having pressed the rear seal, remove the red sealant form outer edge.

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Tighten the mounting bolts in the following order. 2 Flywheel assembly mounting bolt: Engine oil (EO30) 3 Flywheel mounting bolt 1st time: 98 ± 19.6 Nm {10 ± 2 kgm} 2nd time: 294 ± 19.6 Nm {30 ± 2 kgm} 3rd time: 539 ± 19.6 Nm {55 ± 2 kgm}

22. Flywheel assembly 1) Lift and install flywheel assembly (1). a Install the assembly aligning it to the dowel pin of the crankshaft. 4 Flywheel assembly: 130 kg

After installing the flywheel, inspect its facial runout and radial runout using dial gauge [2]. Standard facial runout: Max. 0.25 mm Standard radial runout: Max. 0.25 mm

When tightening the mounting bolt, fix the space flywheel and flywheel housing using plate [1] in order to prevent the crankshaft from turning.

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Install engine speed sensor (3). a Tighten the locknut until the sensor tip is contacted against the ring gear tooth tip of the flywheel. Return the sensor 3/4 - 1 turn from above position and then tighten the locknut. 3 Engine speed sensor locknut: 49 – 68.6 Nm {5 – 7 kgm}

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2) 3)

Install accessory drive (2). Install pulley (1).

24. Thermostat housing 1) Install thermostat housing (2). 2) Install water temperature sensor (1).

23. Accessory drive assembly 1) Assemble the accessory drive. 1] Pull off bushing (10) and oil seal (9) to housing (8). a Press-fit the bushing 2 mm deeper from the end face. 2 Bushing inner surface: Engine oil (EO30) a Press-fit the oil seal 1.5 mm deeper from the end face. 2 Seal lip: Grease (G2-LI) a Fill 50 – 80% of the lip open space with the grease. 2] Press-fit gear to (7) to shaft (5). 3] Assemble thrust plate (6) to the shaft and gear assembly and then insert the housing from the rear side. 4] Assemble thrust plate (4) to the shaft and then press-fit hub (3). a Use care in above operation so that the seal lip may not be damaged.

25. Front engine hanger Install front engine hanger (1).

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26. Thermostat case 1) Install thermostat (3) to thermostat case (2).

2) 3)

Install thermostat case (2). Install water outlet (1).

27. Breather Install breather (1), blow-by pipe (2) and plate (3). 3 Breather mounting bolt: 24.5 – 29.4 Nm {2.5 – 3.0 kgm} a Install plate (3) to the left side bank alone.

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28. Alternator bracket Install alternator bracket (1).

29. Relief valve 1) Remove engine assembly (1) from tool A and then support it using block [1]. a Make sure the engine is supported stably. 2) Install relief valve (1).

30. Suction pie and under plate 1) Using jack [1], install under plate (1) and then fix it temporarily using the oil pan mounting bolt. 4 Under plate: 25 kg

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Install suction pipe (3) and stay (2).

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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-pressure pipe is needed when installing the fuel injector. 3 Common rail mounting bolt: 59 – 74 Nm {4 – 5 kgm}

31. Oil pan 1) Install oil pan (1). 4 Oil pan: 75 kg

34. Cylinder head assembly 1) Assemble the cylinder head assembly according to the following procedure. 1] Install valve (7). 2] Install lower seat (6).

Install the engine assembly to tool A again.

32. Oil level gauge and oil filler tube 1) Install bracket (4). 2) Install oil level gauge (3) and then tighten the sleeve nut at the base. 3) Install oil filler tube (2). 4) Install bracket (1). 3]

Using tool L, install stem seal (8). a Drive in tool L until its lower end a is contacted against lower seat (6).

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4] 5]

2) 3)

Install inner spring (5), outer spring (4) and upper seat (3). Using tool B, compress the valve spring to install cotter (2). a After the installation, hit the valve stem lightly with the plastic hammer to make sure the cotter is installed stably.

Install the cylinder head gasket. Lift and install cylinder head assembly (1). 4 Cylinder head assembly: 30 kg

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Tighten the mounting bolts according to the following procedure. 1] Tighten mounting bolts (No. 1 – 7) temporarily. 2] Tighten the mounting bolts (No. 1 – 6) in 3 steps according to the order indicated in the figure. a When a bolt with 5 punch marks, which indicates the tightening frequency up to today, in its head is found, replace it with a new one. 2 Cylinder head assembly mounting bolt: Molybdenum disulfide lubricant (LM-P) 3 Cylinder head assembly mounting bolt (No. 1 – 6) 1st time: 137 – 157 Nm {14 – 16 kgm} 2nd time: 284 – 294 Nm {29 – 30 kgm} 3rd time: 90 (+30/0)°

When tool G is not used in tightening of the 3rd time, check the rotating angle after applying marking b to the cylinder head and bolt head using paint.

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Tighten the mounting bolt (No. 7) with the following torque. 2 Cylinder head assembly mounting bolt: Molybdenum disulfide lubricant (LM-P) 3 Cylinder head assembly mounting bolt (No. 7): 66.2 ± 7.4 Nm {6.75 ± 0.75 kgm} After the tightening, stamping punch mark a to the head of mounting bolts (No. 1 – 6).

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Insert fuel injector (2) to the cylinder head along with holder (3).

Install spherical washer (7) and then tighten holder mounting bolt (1) temporarily. 2 Special washer: Engine oil (EO30) Tighten sleeve nut (5) of the high-pressure pipe temporarily. a Also tighten the sleeve nut on the common rail side temporarily to proceed with the positioning. a See "High-pressure pipe" for precautions on this operation. Tighten holder mounting bolt (1) with the specified torque. 3 Holder mounting bolt: 58.8 – 73.5 Nm {6 – 7.5 kgm} a Leave sleeve nut (5) being tightened temporarily in above operation as is. This nut is to be tightened with the specified torque in the next step.

Install the water tube. Water tube joint bolt: 9.8 – 12.7 Nm {1.0 – 1.3 kgm}

35. Fuel injector a Check that the inside of the injector sleeve is free from dirt. 1) Install O-rings (4) and (5) and gasket (6) to the fuel injector. 2 O-ring: Engine oil (EO30)

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36. High-pressure pipe (between common rail fuel injector) k Install the high-pressure pipe and clamp paying attention to the following points. q It is strictly prohibited to reuse a highpressure 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 connecting 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. 2) 3)

4) 5)

After installing fuel injector (5) and common rail (6) temporarily to high-pressure pipe (4), tighten the sleeve nut with the specified torque. a Control the torque by using a spanner type torque wrench (commercially available) for the tightening. 3 High-pressure pipe sleeve nut (injector side): 39.2 – 49 Nm {4 -– 5 kgm} 3 High-pressure pipe sleeve nut (common rail side): 39.2 -– 49 Nm {4 – 5 kgm}

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After the tightening, make sure the Oring is not projecting from the sleeve nut.

Manually tighten and install temporarily the stay and top and bottom clamps of high-pressure pipe clamp (7). Tighten the top and bottom clamps permanently. a Before tightening the stay permanently, deflect the rubber fist. 3 Top and bottom clamp bolt: 9.8 ± 1 Nm {1 ± 0.1 kgm} Tighten the stay permanently. Manually tighten and install temporarily the stay and top and bottom clamps of the high-pressure pipe. Install the high-pressure pipe clamp and gate type frame temporarily. a First tighten the high-pressure pipe clamp permanently, and then tighten the gate type frame permanently to the common rail mounting bolt. 3 Gate type frame mounting bolt: 9.8 ± 1 Nm {1 ± 0.1 kgm} Tighten the high-pressure pipe clamp permanently. 3 High pressure pipe clamp bolt: 9.8 ± 1 Nm {1 ± 0.1 kgm}

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Tighten the clamp stay permanently. a Tighten the clamp of the air intake manifold after installing the manifold.

Install the rubber cover to the sleeve nut on the high-pressure pipe. a Direct the slit downward when installing the rubber cover. q Injector side (8): Bottom q Common rail side (9): Cylinder block side

37. Crosshead 1) Install crosshead (1). 2 Crosshead sliding portion: Engine oil (EO30)

When installing the high-pressure pipe without removing the fuel injector (for example, when replacing only the high-pressure pipe with new one), follow the procedure below. q Tighten sleeve nut (10) by 2 turns with the hand into the threads of the fuel injector and then tighten it with the spanner. a If sleeve nut (10) does not catch the threads, it will help to turn the spanner while pressing sleeve nut (8) end with a small rod, etc. toward the injector.

Adjust the crosshead according to the following procedure. 1] Loosen locknut (2) and then loosen adjustment screw (3) to a position where it does not valve stem (4). 2] Maintain the contact with valve stem (5) on the push rod side by pressing the contact face against the rocker arm using a finger. 3] Tighten adjustment screw (3) to confirm the position where adjustment screw (3) is contacted against valve stem (4). 4] Drive in adjustment screw (3) further by 20° from the contacting position against valve stem (4). 5] Tighten locknut (2) while suppressing move of adjustment screw (3). 3 Locknut: 58.8 ± 5.9 Nm {6.0 ± 0.6 kgm}

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38. Injector harness 1) Push connector (3) out of the cylinder head and then install injector harness (4) in the cylinder head. 2) Tighten injector terminal mounting nut (1) and clamp mounting bolt (2). a Alternately tighten injector terminal mounting nuts (1). 3 Injector terminal mounting nut: 2 ± 0.2 Nm {0.2 ± 0.02 kgm} a After tighten the injector terminal mounting nut, push the harnes s against the injector body to eliminate sagging.

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40. Rocker arm assembly 1) Assemble the rocker arm assembly according to the following procedure. 1] Install adjustment screw (2) on rocker arms (4) and (6), and then install lock nut (1). a Screw in adjustment screw (2) until its spherical part touches rocker arms (4) and (6).

Install exhaust rocker arm (4), spacer (5) and air intake rocker arm (6) to rocker arm shaft (7). 2 Rocker arm shaft: Engine oil (EO30)

39. Push rod Install push rod (1). a Make sure that the push rod end is securely fitted to the cam follower socket. 2 Both ends of push rod: Engine oil (EO30)

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Install rocker arm assembly (3). a Make sure that the ball of adjustment screw (2) is securely fitted to the push rod socket. a When tightening the mounting bolt, make sure adjustment screw (2) is not pushing the push rod. 2 Rocker arm: Engine oil (EO30) 3 Rocker arm assembly mounting bolt: 93 – 103 Nm {9.5 – 10.5 kgm} a Tighten locknut (1) after adjustment of the valve clearance is completed. 2)

41. Adjusting valve clearance 1) Rotate the crankshaft forward and drive right No.1 cylinder to the compression top dead center, while watching move of the intake valve on right No. 6 cylinder. Then locate the stamped line of R1.6 TOP of vibration damper (1) to pointer (2). a Crank the engine using the burring tool (B) being provided in the front right side of the flywheel housing. a The intake valve of right No. 6 cylinder will start moving as right No. 1 cyli nder i s dri ve n to vi ci nity of the compression top dead center. (Open) a Figure shows the cylinder No. and their firing order (circled numbers indicate the firing order).

Loosen locknut (6) of adjustment screw (5) of the right No. 1 cylinder and then in se r t c l ear a nc e ga ug e M , whi c h is adjusted to the specified thickness, between crosshead (4) and rocker arm (3). Then using the adjustment screw, adjust the clearance to a degree that allows only slight move of the gauge. a Standard valve clearance: q Intake valve: 0.35 ± 0.02 mm q Exhaust valve: 0.57 ± 0.02 mm Tighten locknut (6) to secure adjustment screw (5). 3 Locknut tightening torque: 52.9 – 64.7 Nm {5.4 – 6.6 kgm} a After tightening the locknut, check the valve clearance again. Repeat the same procedure for other engines, too, in the order of firing. Namely, crank the engine and then locate the stamped of the damper to the pointer to adjust the valve clearance of respective cylinders. a Firing order R1 - L1 - R5 - L5 - R3 - L3 - R6 - L6 R2 - L2 - R4 - L4

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42. Head cover Install head cover (1). 3 Head cover mounting bolt: 14.7 – 34.3 Nm {1.5 – 3.5 kgm}

43. Fuel tube Install fuel tube (1). 3 Fuel tube joint bolt: 9.8 – 12.7 Nm {1.0 – 1.3 kgm}

44. Plate and block Install block (3) and plates (2) and (1).

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45. Oil cooler (rear side) 1) Install oil cooler (2). 2) Install oil manifold (1).

46. Water pump assembly 1) Install housing (5) to water pump (4).

Install water pump assembly (3).

Install water connector (2).

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Install block (1).

47. Corrosion resister and filter head assembly Install corrosion resister and filter head assembly (1).

48. Exhaust manifold assembly 1) Install the gasket. a Install the gasket directing its "OUT" marking to the exhaust manifold side. 2) Lift and install exhaust manifold assembly (5). 4 Exhaust manifold assembly: 25 kg

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Tighten the mounting bolts in the following order. a Tighten it once and then tighten again with the same torque. 2 Exhaust manifold assembly mounting bolt: Molybdenum disulfide lubricant (LM-P) 3 Exhaust manifold assembly mounting bolt: 44.1 – 53.9 Nm {4.5 – 5.5 kgm}

Turbocharger assembly: 35 kg assembly mounting bolt and nut: Molybdenum disulfide lubricant (LM-P) 3 Turbocharger assembly mounting bolt: 44.1 – 53.9 Nm {4.5 – 5.5 kgm} 2 Turbocharger

Install bracket (4), water pipe (3), muffler bracket (2) and insulating plate (1).

49. Turbocharger assembly 1) Lift and install turbocharger assembly (1). a Tighten turbocharger assembly mounting bolt according to the procedure below. 1] Tighten mounting bolts at each connecting portion temporarily for positioning. 2] Tighten turbocharger assembly mounting bolts in the following order. 1st time: [1],[2],[3] and [4] 2nd time: [1],[3],[2]and [4]

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Install water pipes (2) and (3) and oil pipes (4) and (5). a As for the air-cooled turbocharger, install the oil pipes alone. 3 Water connector (Block side): 78.5 – 103 Nm {8 – 10.5 kgm} 3 Water pipe flare nut (Water connector side): 24.5 – 59 Nm {2.5 – 6 kgm} 3 Water pipe joint bolt (Turbocharger side): 24.5 – 34.3 Nm {2.5 – 3.5 kgm} 3 Water connector (Turbocharger side): 29.4 – 39.2 Nm {3 – 4 kgm} 3 Water pipe flare nut (Water connector side): 29.4 – 39.2 Nm {3 – 4 kgm}

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50. Exhaust connector Install exhaust connectors (1) and (2).

51. Air intake manifold assembly 1) Install the gasket. a Install the gasket setting its "UP" marking upward and also directing this side to the intake manifold. 2) Lift and install air intake manifold assembly (2). 4 Intake manifold assembly: 45 kg

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Install support (1).

52. High-pressure pipe clamp Install brackets (1) and (2) to the exhaust manifold and then tighten high-pressure pipe clamp bolt (3). 3 High pressure pipe clamp bolt: 9.8 ± 1 Nm {1 ± 0.1 kgm}

Tighten the mounting bolts in the following order. 3 Intake manifold assembly mounting bolt: 58.8 – 73.5 Nm {6 – 7.5 kgm}

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53. Spill tube Install spill tube (1). 3 Spill tube joint bolt Cylinder head side: 9.8 – 12.7 Nm {1.0 – 1.3 kgm} Intake manifold side: 19.6 – 29.4 Nm {2.0 – 3.0 kgm}

Tighten mounting bolt (2) with the 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)

54. Supply pump assembly and high-pressure pipe (between supply pump - common rail) k Install the high-pressure pipe and clamp paying attention to the following points. q It is strictly prohibited to reuse a highpressure 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. 1) Install supply pump assembly (1) temporarily. a Align and insert the unequal spline portion of the supply pump side to unequal spline portion A of the supply pump drive case side. a When it is difficult to insert the supply pump , turn the crankshaft to change position of unequal spline portion A.

3) 4)

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After installing high-pressure pipes (4) and (5) to supply pump (1) and common rail (3) temporarily, tighten the sleeve nut with the specified torque. a Control the torque by using a spanner type torque wrench (commercially available part) for the tightening. 3 High-pressure pipe sleeve nut (supply pump side): 39.2 – 49 Nm {4 – 5 kgm} 3 High-pressure pipe sleeve nut (common rail side): 39.2 – 58.8 Nm {4 – 6 kgm} Tighten supply pump assembly mounting bolt (2). Tighten the mounting bolt across the supply pump assembly bottom face and bracket. 3 Supply pump mounting bolt (Bottom side): 19.6 – 29.4 Nm {2.0 – 3.0 kgm} Install oil tube (6). 3 Oil tube joint bolt: 9.8 – 12.7 Nm {1.0 – 1.3 kgm}

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50 Disassembly and assembly

55. Fuel pipe 1) Install priming pump (4). a If the air bleeding plug is removed, tighten the pump with the following torque. 3 Air bleeding plug: 24.5 – 34.3 Nm {2.5 – 3.5 kgm} 2) Install fuel pipes (1) – (3). 3 Fuel pipe joint bolt (Common rail side): 17.7 – 22.6 Nm {1.8 – 2.3 kgm} 3 Fuel pipe joint bolt (Supply pump side): 14.8 – 19.6 Nm {1.5 – 2.0 kgm} 6)

Install high-pressure pipe clamp (7) according to the following procedure. 1] Manually tighten and install temporarily the stay and top and bottom clamps of the high-pressure pipe clamp. 2] Tighten the top and bottom clamps permanently. a Before tightening the stay permanently, deflect the rubber fist. a Use care in the tightening so that e xc e s si v e fo r c e ma y n ot b e applied to the supply pump side install position. 3 Top and bottom clamp bolt: 9.8 ± 1 Nm {1 ± 0.1 kgm} 3] Tighten respective stays permanently. Install the rubber cover to the sleeve nut on the high-pressure pipe. a Direct the slit downward when installing the rubber cover. q Supply pump side (8): Bottom q Common rail side (9): Facing inward (Opposed)

56. Air intake connector Install air intake connector (1).

12V140E-3 Series

50 Disassembly and assembly

57. Air inlet pipe 1) Install bracket (3). a Install bracket (3) to the right side bank alone. 2) Install bracket (2). 3) Install air inlet pipe (1) and then fix it with the clamp. 3 Clamping nut: 29.4 – 44.1 Nm {3.0 – 4.5 kgm} 4 Air inlet pipe: 35 kg

58. Engine controller and controller cooler 1) Install controller cooler (4). 2) Install fuel hoses (2) and (3). 3) Install engine controller (1). 3 Engine controller mounting bolt: 23.5 Nm {2.4 kgm}

12V140E-3 Series

SEN00322-05

59. Fuel filter and filter head assembly 1) Install fuel filter and filter head assembly (3). 2) Install fuel tubes (1) and (2). 3 Fuel tube joint bolt: 24.5 – 34.3 Nm {2.5 – 3.5 kgm}

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}

SEN00322-05

50 Disassembly and assembly

61. Starting motor assembly Install staring motor assemblies (3) and (2) and then connect wiring harness (1) to them. a Install the top assembly first being followed by the bottom one. 3 Starting motor B terminal nut: 19.6 – 25.5 Nm {2 – 2.6 kgm}

2) 62. Engine wiring harness Install engine wiring harness (1) on the engine assembly and then connect the connector and terminal.

4) 5)

6) 7) 63. Checking for fuel leakage a When removal and installation of fuel supply pump (1), common rail (2), or highpressure pipes (3) and (4) were conducted, check fuel leakage according to the following procedure after assembling the engine. a Here, high-pressure pipes (3) and (4) denote every fuel pipe (the figure shows an example).

Clean and degrease the engine and the parts around it in advance so that you can test it easily for fuel leakage. Spray color checker (developer) over the fuel supply pump, common rail, fuel injector, and joints of the high-pressure piping. Run the engine at speed below 1,000 rpm and stop it after its speed is stabilized. Check the fuel piping and devices for fuel leakage. a Check mainly around the high-pressure circuit parts coated with the color checker for fuel leakage. a If any fuel leakage is detected, repair it and check again from step 1). Run the engine at low idle. Check the fuel piping and devices for fuel leakage. a Check mainly around the high-pressure circuit parts coated with the color checker for fuel leakage. a If any fuel leakage is detected, repair it and check again from step 1). Run the engine at high idle. Check the fuel piping and devices for fuel leakage. a Check mainly around the high-pressure circuit parts coated with the color checker for fuel leakage. a If any fuel leakage is detected, repair it and check again from step 1). Run the engine at high idle and load it. a When checking while the components to be checked are mounted on the machine, stall the torque converter or relieve the hydraulic pump. Check the fuel piping and devices for fuel leakage. a Check mainly around the high-pressure circuit parts coated with the color checker for fuel leakage.

12V140E-3 Series

50 Disassembly and assembly a a

SEN00322-05

If any fuel leakage is detected, repair it and check again from step 1). If no fuel leakage is detected, check is completed.

12V140E-3 Series

SEN00322-05

50 Disassembly and assembly

KOMATSU 12V140E-3 Series engine Form No. SEN00322-05

12V140E-3 Series

SEN00876-03

ENGINE 1SHOP MANUAL

12V140E-3 Series

50 Disassembly and assembly Disassembly and assembly, Part 3 Removal and installation fuel supply pump unit .............................................................................................. 2 Removal and installation oil seal unit .............................................................................................................. 5

12V140E-3 Series

SEN00876-03

Removal and installation fuel supply pump unit a

50 Disassembly and assembly

Figure shows an example of the left side bank. Except where otherwise noted, the same work procedure shall be employed for the both banks.

Removal 1. 2.

Remove the connectors (in 3 places). 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 removed.

6. 7.

3. 4.

Remove fuel tube (5) between priming pump (4) and supply pump (2). [*2] Remove fuel tube and hose assembly (7) between supply pump (2) and controller cooler (6).

Remove oil tube (9) between supply pump (2) and the cylinder block. [*4] Disconnect fuel tube (10) between the fuel filter and supply pump (2) from the supply pump side. [*5]

Remove supply pump mounting bracket (11). [*6]

Remove 2 high-pressure pipes (8) between supply pump (2) and common rail (1). [*3]

12V140E-3 Series

50 Disassembly and assembly

Remove 4 mounting bolts (12) and then remove supply pump assembly (2). [*7]

SEN00876-03

Installation q Carry out installation in the reverse order to removal. [*1]

3 Fuel return hose (3) joint bolt (Common rail

side): 17.7 – 22.6 Nm {1.8 – 2.3 kgm} [*2]

3 Fuel tube (5) joint bolt:

24.5 – 34.3 Nm {2.5 – 3.5 kgm}

10. Remove nut (12), coupling (13) and key (14) from supply pump assembly (2). [*8]

[*3], [*7] Install the supply pump and high-pressure pipe by finalizing their position the following procedure. 1) Install supply pump assembly (2) temporarily. a Align the unequal spline portion of the supply pump side to unequal spline portion A of the supply pump drive case side and then insert the supply pump.. a When it is difficult to insert the supply pump , turn the crankshaft to change position of unequal spline portion A.

Tighten mounting bolt (12) with the 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)

12V140E-3 Series

SEN00876-03

50 Disassembly and assembly

After installing high-pressure pipes (8) on supply pump (2) and common rail (1) temporarily, 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): 39.2 – 49 Nm {4 – 5 kgm} 3 High-pressure pipe sleeve nut (Common rail side): 39.2 – 58.8 Nm {4 – 6 kgm} Install the clamp of the high-pressure pipe according to the following procedure. 1] Manually tighten and install temporarily the stay and top and bottom clamps of the high-pressure pipe. 2] Tighten the top and bottom clamps permanently. a Before tightening the stay permanently, deflect the rubber fist. a Take care in the tightening so that excessive force may not be applied to the supply pump side install position. 3 Top and bottom clamp bolt: 9.8 ± 1 Nm {1 ± 0.1 kgm} 3] Tighten respective stays permanently. Install the rubber cover to the sleeve nut on the high-pressure pipe. a Direct the slit downward when installing the rubber cover. 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} [*8]

3 Nut (12):

176 – 196 Nm {18 – 20 kgm}

12V140E-3 Series

50 Disassembly and assembly

Removal and installation oil seal unit 1

SEN00876-03 a

CS: Crankshaft

Rear oil seal a For the work up to removal of the flywheel, see the shop manual for the applicable machine. 1.

Remove rear seal (3).

Take care in the removal not to damage the seal installation position on the flywheel housing and the seal contact face on the crankshaft. Before removing, slightly drive the seal in once to free it from fixation. 1) Replace the tip of tool N with the hook type one. 2) Hitch the hook to the hoop of rear seal (3). 3) Remove rear seal with impact of slide hammer (SH). Tool N

12V140E-3 Series

SEN00876-03

50 Disassembly and assembly

Installation 1. Clean, degrease and then dry the contact surface between the flywheel housing and rear seal. 2.

Using a clean cloth, remove foreign matter deposited on the crankshaft flange. a Clean foreign matter deposited on the seal lip surface (surface around the crankshaft) and then degrease and dry the surface. a Check the crankshaft end face corner and lip siding surface for scratches due to the housing, burrs or rusts.

When installing rear oil seal (3), do not apply oil or grease to the shaft and seal lip. Wipe off the oil from the shaft. 1) The surface having the parts number (PN) marking must face to the outside of engine.

Using the K (push tool), press oil seal (3) in the flywheel housing until it becomes the dimension (a) or (b) as shown in the figure. a Oil seal press fit dimensions (a): 5 mm (from flywheel housing end surface)

Carry out the following work in the shop manual of the applicable machine.

12V140E-3 Series

50 Disassembly and assembly

Removal (PC2000-8) a For the work up to removal of the flywheel, see the shop manual for the applicable machine. 1.

Remove rear seal (2). a Take care in the removal not to damage the seal installation position on the flywheel housing and the seal contact face on the crankshaft. a Before removing, slightly drive the seal in once to free it from fixation. a When rear seal (2) is fixed too hard to the flywheel housing (FWH), carry out the following procedure. 1) Replace the tip of tool N with the drill type one. 2) Drill through a hole of approx. 3 mm dia. on rear seal (2). 3) Insert the top end of tool N into the drilled hole, and remove the rear seal by the impact of slide hammer (SH). (Apply the slide hammer evenly not to tilt the rear seal.) a Remove the metal powders completely. a Take care not to damage crankshaft (4).

SEN00876-03

Installation a Check the Teflon seal (Laydown lip seal) by checking the wear of the shaft and replace it with the “Standard seal”.

a a a

Tool A3

12V140E-3 Series

SEN00876-03

50 Disassembly and assembly

5) 6)

2) 3)

Set the large inside diameter side (b) of plastic inside cylinder (3) to the end of crankshaft (4). a Extremely take care not to mistake the direction of the plastic inside cylinder.

Carry out the following work in the shop manual of the applicable machine.

12V140E-3 Series

50 Disassembly and assembly

Front oil seal Removal a For the work up to removal of the damper, see the shop manual for the applicable machine. 1. Remove front oil seal (1) according to the following procedures.

SEN00876-03

Installation 1. Clean, degrease and then dry the contact surface between the front cover and front seal. 2.

When installing front oil seal (2), do not apply oil or grease to the shaft and seal lip. Wipe off the oil from the shaft. 2 Inner circumference of front oil seal:

Gasket sealant (LG-7 or equivalent)

1) 2) 3)

The surface having the parts number (PN) marking must face to the outside of engine.

Tighten nuts [1] using the tool J (plate), and press oil seal (8) to the crank shaft end surface.

Replace the tip of tool N with the hook type one. Hitch the hook to the hoop of front seal (2). Remove front seal with impact of slide hammer (SH). Tool A3

CS: Crankshaft

12V140E-3 Series

50 Disassembly and assembly

SEN00876-03

Carry out the following work in the shop manual of the applicable machine.

12V140E-3 Series

50 Disassembly and assembly

12V140E-3 Series

SEN00876-03

50 Disassembly and assembly

KOMATSU 12V140E-3 Series engine Form No. SEN00876-03

12V140E-3 Series

SEN05155-00

ENGINE 1SHOP MANUAL 2 3

12V140E-3 Series

90 Repair and replacement of parts 1 Information related to repair and replacement Flowchart ........................................................................................................................................................ 2 Special tool table............................................................................................................................................. 4

12V140E-3 Series

SEN05155-00

Flowchart

90 Repair and replacement of parts

Repair of cylinder block top and counterbore by grinding

a a

For removal, installation, disassembly and assembly of the engine, see the Shop Manual, "Disassembly and assembly". If the judgment of No. 9 is NO, examine A. If the result is NO again, examine B.

12V140E-3 Series

90 Repair and replacement of parts

12V140E-3 Series

SEN05155-00

90 Repair and replacement of parts

Special tool table Replacement/Repair item

1 Symbol

Q'ty 1

79A-471-1050 Pump assembly

795-100-1522 Push tool

795-411-1310 Push tool

795-100-4801 Seat puller

For valve seat insert

790-101-5001 Push tool kit

KIT

E 2

790-101-5081 Plate

For intake valve

790-101-5071 Plate

For exhaust valve

795-100-3005 Seat cutter

KIT

795-100-3100 Body assembly

795-100-3200 Micrometer

795-100-3300 Gauge

795-100-3401 Tool head

795-100-3601 Head support

795-100-3710 Cutter

For oversize machining

795-100-3720 Cutter

For 30°

795-100-3730 Cutter

For 45°

795-100-4211 Pilot

ø10.000 mm

795-100-4221 Pilot

ø10.010 mm

795-100-4231 Pilot

ø10.020 mm

795-100-4241 Pilot

ø10.030 mm

795-140-6410 Guide puller

795-130-1310 Guide driver

1 Replacement of valve seat insert F

Repair of valve by grinding

Commercially Valve refacer available

Check of main bearing mounting hole inside diameter

Commercially Alignment bar available

790-101-2800 Bearing puller

790-101-2300 Push puller

795-240-6401 Push tool

795-240-6411 Push tool

795-240-6420 Push tool

795-240-6431 Block

795-240-6440 Nut

795-213-1200 Push tool

795-213-1250 Bar

795-213-1210 Push tool

M 3

795-213-1240 Collar

795-213-1230 Guide

792-103-0400 Grip

Replacement of crankshaft gear

K L

Replacement of connecting rod small end bushing

Replacement of cam bushing

Remarks

795-611-1300 Coolant tester

Replacement of crosshead guide

Part name

Pressure test of cylinder head Replacement of valve guide

Part No.

KIT

12V140E-3 Series

90 Repair and replacement of parts

Replacement/Repair item

Repair of counterbore portion

12V140E-3 Series

Symbol

SEN05155-00

Part No.

Part name

Q'ty

Remarks

79A-513-1710 Basic machine

79A-513-1780 Guide plate

79A-513-1820 Cutter plate

79A-513-1860 Cutter

79A-513-1940 Cutter set gauge

79A-513-1950 Micrometer

79A-513-1960 Driver plate

79A-513-2090 Driver shaft

79A-513-2110 Driver handle

10 79A-513-2120 Service package

11 79A-513-2130 Case

12 79A-513-2140 Basic machine

13 79A-513-2160 Cutter plate

14 79A-513-2230 Cutter

15 79A-513-2240 Remover pin

16 79A-513-2250 Case

17 79A-513-2260 Service package

18 79A-513-2270 Compound

LOCTITE

19 79A-513-2280 Primer

LOCTITE

20 79A-513-2320 Bushing

SEN05155-00

90 Repair and replacement of parts

KOMATSU 12V140E-3 Series engine Form No. SEN05155-00

12V140E-3 Series

SEN05156-01

ENGINE 1SHOP MANUAL 2 3

12V140E-3 Series

90 Repair and replacement of parts 1 Parts related to cylinder head Part names related to cylinder head ............................................................................................................... 2 Testing and inspection of cylinder head .......................................................................................................... 3 Pressure test of cylinder head ........................................................................................................................ 5 Replacement of valve guide............................................................................................................................ 5 Replacement of valve seat insert.................................................................................................................... 6 Replacement of crosshead guide ................................................................................................................. 13 Repair of cylinder head mounting face by grinding ....................................................................................... 14 Repair of valve by grinding ........................................................................................................................... 15

12V140E-3 Series

SEN05156-01

Part names related to cylinder head

1. 2. 3. 4. 5. 6. 7.

90 Repair and replacement of parts

Cylinder head Crosshead guide Valve guide Valve seat insert (intake side) Valve (intake valve) Valve (exhaust valve) Valve seat insert (exhaust side)

12V140E-3 Series

90 Repair and replacement of parts

SEN05156-01

Testing and inspection of cylinder head

1 Unit: mm

Inspection item

Criteria

Remedy

• Presence of crack (External dye check) • Presence of water leakage during air pressure test (0.29 – Water leakage from and crack 0.34 MPa {3.0 – 3.5 kg/cm2}, 30 sec) of cylinder head • Water pressure test (0.34 – 0.39 MPa {3.5 – 4.0 kg/cm2}, 10 min) Distortion of cylinder head top and bottom

Tolerance

Repair limit

0 – 0.06

0.09

Repair by welding or replace cylinder head Repair by grinding or replace cylinder head

Projection of injector nozzle

a See Fig. A Allowable range of projection (a): 2.3 – 2.9

Replace copper gasket, injector or cylinder head

Damage of valve contact surface of valve seat insert or looseness of valve seat insert

• • • •

Repair valve seat insert contact surface or replace valve seat insert

Valve sinking quantity (both intake and exhaust valves)

Presence of dent on valve seat insert contact surface Check of valve seat insert contact surface Airtightness test Hit cylinder head lightly to check for looseness

a See Fig. B Sink (b) Standard value

Repair limit

0 ± 0.1

0.7

Replace valve or valve seat insert

a See Fig. C Valve head thickness (d)

Valve head thickness

Valve

Standard value

Repair limit

Intake

2.4

1.9

Exhaust

2.15

1.6

Valve seat contact surface angle (c) Intake valve: 30° Exhaust valve: 45°

Abnormality in valve

• • • • •

Replace valve

Deformation of head into dish shape Presence of crack or dent on seat contact surface of valve Airtightness test Play when new cotter pin is inserted in cotter groove Uneven wear or bend of valve stem Repair valve stem

• Presence of dent at valve stem end Valve Outside diameter of valve stem

Projection of valve guide Outside diameter of crosshead guide Projection of crosshead guide

12V140E-3 Series

Repair limit

Intake

9.940 – 9.955

—

Exhaust

9.911 – 9.926

—

Valve Inside diameter of valve guide

Standard size Standard value

Replace valve

Repair limit

Intake

9.989 – 10.011

—

Exhaust

9.989 – 10.011

—

Replace valve guide

a See Fig. D Allowable range of projection (e): 22 ± 0.2 Standard size

Standard value

Repair limit

11.000 – 11.011

10.95

a See Fig. E Allowable range of projection (f): 49 ± 0.25

Replace crosshead guide Repair crosshead guide

SEN05156-01

90 Repair and replacement of parts

Illustrations related to testing and inspection table Fig. A

Fig. D

a: 1. 2. 3.

Projection Injector Copper gasket Cylinder head

Projection

Fig. E

Fig. B

f: 1. 2. b:

Projection Crosshead guide Cylinder head

Sink

Fig. C

c: d:

Valve seat contact surface angle Valve head thickness

12V140E-3 Series

90 Repair and replacement of parts

Pressure test of cylinder head a

SEN05156-01

Replacement of valve guide a

Pressure test tools

Symbol

Part No.

Part name

790-553-1601

79A-471-1050 Pump assembly

Valve guide replacement tools

Symbol

Coolant tester

Part No.

Part name

795-100-1522

Push tool

795-411-1310

Push tool

Pulling out of valve guide q

If the cylinder head parts were repaired, perform the test according to the following procedure.

Water pressure test 1.

Combine tools A and B and connect the hose to the cylinder head.

Apply water pressure (0.34 – 0.39 MPa {3.5 – 4.0 kg/cm2}) for about 10 minutes and check around the cylinder head for leakage.

Warm the whole cylinder head and then perform the test with hot water at 80 – 95 °C. k Pay fully attention to handling the cylinder head and water whose temperature are high, and take care not to get burnt.

Using tool C1, pull out the valve guide.

Press fitting of valve guide 1.

Machine the valve guide hole of the cylinder head to the dimension below. q Inside diameter: 17(+0.011/0) mm

Press fit the valve guide until the tool C2 end touches the cylinder head.

Check that the projection of the valve guide is within the standard value. Projection tolerance of valve guide: 22 ± 0.2 mm

Air pressure test 1.

Connect the air compressor hose to the cylinder head.

Put the cylinder head in a water tub, apply air pressure (0.29 – 0.34 MPa {3.0 – 3.5 kg/cm2} for about 30 seconds, and check for air leakage.

If any crack is detected in the cylinder head by the above tests, replace the cylinder head.

12V140E-3 Series

SEN05156-01

90 Repair and replacement of parts

Replacement of valve seat insert 1 a

Valve seat insert replacement tools

Symbol

Part No.

795-100-4801

Part name Seat puller

790-101-5001

Push tool kit

790-101-5081

Plate

790-101-5071

Plate

795-100-3005

Seat cutter

795-100-3710

Cutter

795-100-3720

Cutter

795-100-3730

Cutter

795-100-4211

Pilot

Pulling out of valve seat insert k Keep the air pressure at 0.5 – 0.6 MPa {5 – 6

kg/cm2} during the work. k When replacing the grinding stone, stop the air. k Before starting the grinding work, perform a trial operation of the grinder for 1 minute and ensure that the grinder is normal. a After replacing the grinding stone, perform a trial operation for 3 minutes. k Ensure that the grinding stone is free from damage and install it to the grinder shaft with no play. k When using the grinder, put on safety glasses. When pulling out with seat puller of tool D 1. Install grinding stone (4) to grinder (1). 2.

While matching the groove of sleeve (2), insert the grinder in holder (3). (Adjust the grinder position with set screw (5).)

Adjust the position of grinder (1) so that the center of grinding stone (4) will be at the center of valve seat insert (a) and then tighten set screw (5) to fix grinder (1).

Rotate grinding stone (4) and move it slowly until it touches valve seat insert (a).

While lightly pressing grinding stone (4) against the inside surface of valve seat insert (a), make a groove about 1 mm deep all around the inside surface of valve seat insert (a).

12V140E-3 Series

90 Repair and replacement of parts

Push in 3 claws (10) of puller head (9) of tool D with the hand and put them in valve seat insert (a).

Tighten screw (12) to press 3 claws (10) against the inside groove of valve seat insert (a). a If screw (12) is tightened too strongly, the insert will be broken and become difficult to pull out. Accordingly, stop tightening when 3 claws (10) reach the groove fully.

Put bridge (8) in the outside of puller head (9), place plates (11) and (7) on the bridge, and tighten nut (6) to pull out valve seat insert (a).

12V140E-3 Series

SEN05156-01

When pulling out valve seat insert (a) by welding a bar to it 1. Weld bar (b) (Length: 0.1 – 0.5 mm shorter than valve seat inside diameter, Diameter: Approx. 10 mm) to the inside of valve seat insert (a). a Take care that welding spatters will not stick to the head. 2.

After the temperature of the welded parts has decreased to around the ambient temperature, insert an unnecessary valve (c) in the reverse direction and hit its head with a small hammer to pull out valve seat insert (a). a If a large impact is given, the welded parts may come off. Take care.

SEN05156-01

90 Repair and replacement of parts

Press fitting of valve seat insert When press fitting hole for valve seat insert (a) is not repaired by cutting 1. Using tools E1 and E2 or tools E1 and E3, press fit standard valve seat insert (a) with press (d). a Do not press fit with a hammer. a Press fitting force of valve seat insert (a) Intake side: Approx. 14.7 kN {Approx. 1.5 ton} Exhaust side: Approx. 14.7 kN {Approx. 1.5 ton}

Measure sinking quantity (f) of valve seat insert (a) from cylinder head bottom (e). a Sinking quantity (f) of valve seat insert (a) Intake side: 2.2 mm Exhaust side: 2.4 mm

12V140E-3 Series

90 Repair and replacement of parts

12V140E-3 Series

SEN05156-01

90 Repair and replacement of parts

Oversize machining of valve seat insert mounting hole q

Using tool F1 and attached cutter F2, increase the valve seat insert mounting hole to the next oversize.

Limit the increase of the mounting hole diameter to 1.0 mm. If the hole diameter needs to be increased more than 1.0 mm, replace the cylinder head.

Machining dimensions of valve seat insert and mounting hole Intake valve side Unit: mm Valve seat insert

Valve seat insert size

Valve seat insert mounting hole c1

Standard

55.0

+0.111 +0.086

8.8

–0 –0.1

55.0

+0.019 +0

58.00 ± 0.2

–0 –0.1

0.25 OS

55.25 +0.111 +0.086

8.8

–0 –0.1

55.25 +0.019 +0

58.25 ± 0.2

–0 –0.1

0.50 OS

55.5

+0.111 +0.086

8.92 –0 –0.1

55.5

+0.019 +0

58.50 ± 0.2

11.12 –0 –0.1

0.75 OS

55.75 +0.111 +0.086

9.05 –0 –0.1

55.75 +0.019 +0

58.75 ± 0.2

11.25 –0 –0.1

1.00 OS

56.0

+0.111 +0.086

9.18 –0 –0.1

56.0

+0.019 +0

59.00 ± 0.2

11.38 –0 –0.1

OS: Oversize

Exhaust valve side Unit: mm Valve seat insert

Valve seat insert size

Valve seat insert mounting hole c1

Standard

52.0

+0.080 +0.070

8.6

–0 –0.1

52.0

+0.019 +0

55.00 ± 0.2

–0 –0.1

0.25 OS

52.25 +0.080 +0.070

8.6

–0 –0.1

52.25 +0.019 +0

55.25 ± 0.2

–0 –0.1

0.50 OS

52.5

+0.080 +0.070

8.72 –0 –0.1

52.5

+0.019 +0

55.50 ± 0.2

11.12 –0 –0.1

0.75 OS

52.75 +0.080 +0.070

8.85 –0 –0.1

52.75 +0.019 +0

55.75 ± 0.2

11.25 –0 –0.1

1.00 OS

53.0

+0.080 +0.070

8.98 –0 –0.1

53.0

+0.019 +0

56.00 ± 0.2

11.38 –0 –0.1

OS: Oversize

12V140E-3 Series

90 Repair and replacement of parts

Valve seat insert

SEN05156-01

Finish machining of valve contact surface of valve seat insert 1. a

Using tool F1 and attached cutters F3 and F4, machine the valve contact surface of the valve seat insert to the following dimensions. Select tool F5 which will be inserted in the valve guide with no clearance.

Valve seat insert mounting hole

Cylinder head bottom

a a

Inside finished surface roughness: Max. 12.5 S Mounting hole bottom surface roughness: Max. 12.5 S Concentricity of valve guide hole and valve seat insert hole: Max. 0.07 mm (TIR) Squareness of valve guide hole to valve seat insert hole bottom: Max. 0.03 mm (TIR) TIR is an abbreviation for Total Indicator Reading, which is the difference between the maximum and minimum readings in runout. measurement.

a a a

12V140E-3 Series

EV: Exhaust valve IV: Intake valve h: Finish machining width

SEN05156-01

Fit the contact surface of the valve seat insert to the valve by using compound. 1) Thinly apply rough compound mixed with oil to the seat surface of a valve and insert that valve in the valve guide. 2) Install the fitting rod to the valve head and lightly hit valve against the valve seat while rotating it with both hands to fit the it to the valve seat. 3) After the valve and valve seat are fitted and their surfaces become smooth, wipe off the compound. 4) Apply fine compound and fit the valve and valve seat again similarly to the above until they are fitted to each other without breakage.

90 Repair and replacement of parts

Final inspection q

q q

Thinly apply red lead to the valve seat insert contact surface of a new valve and insert that valve in the valve guide. Lightly press the valve against the valve seat insert and rotate it 10°. Check the valve seat insert contact surface of the valve and ensure that the contact is even and is not broken. Or , make marks (m) (about 20 places) on the valve seat insert contact surface of a new valve with a pencil and insert that valve in the valve guide. Lightly press the valve against the valve seat insert and rotate it 10°. Ensure that all the pencil marks (m) have been erased evenly.

When master valve is used

EV: Exhaust valve IV: Intake valve j: Cylinder head bottom k: Contact width against valve a a

Concentricity of contact surfaces of valve guide and valve seat insert: Max. 0.07 mm (TIR) TIR is an abbreviation for Total Indicator Reading, which is the difference between the maxim u m an d m i n i m u m r e a d i n g s i n r u n o u t . measurement.

12V140E-3 Series

90 Repair and replacement of parts

Replacement of crosshead guide1 a

Crosshead guide replacement tools

Symbol G

Part No.

SEN05156-01

Press fitting of crosshead guide q

Part name

795-140-6410

Guide puller

795-130-1310

Guide driver

a a

Pulling out of crosshead guide q

Using tool G2, insert crosshead guide (a) in cylinder head (b) and press fit it with a copper or plastic hammer until the projection is within the tolerance. Projection tolerance of crosshead guide: 49 ± 0.25 mm Diameter of cylinder head crosshead guide hoe: ø11 –0.027/–0.054 mm

Using tool G1, pull out crosshead guide (a) from cylinder head (b). Hold crosshead guide (a) with collet (4) of the puller.

Tighten collet (4) with bolt (1) to lock sleeve (2).

Rotate nut (3) and pull out the crosshead guide.

Remove burrs and fins from and clean the crosshead guide mounting portion.

12V140E-3 Series

SEN05156-01

90 Repair and replacement of parts

Repair of cylinder head mounting face by grinding 1 Grinding 1.

Remove the valve seat insert. q For the removal procedure, see "Replacement of valve seat insert".

Remove the distortion and corrosion of the cylinder head by grinding within the tolerance of cylinder head height (a). q Stamp "R" on the left side of the cylinder head.

Standard cylinder head height (a): 140 ± 0.05 mm Limit after grinding: 139.65 mm Grinding depth by 1 grinding: 0.10 – 0.15 mm Ground surface roughness: Max. 8S Flatness (Distortion): Max. 0.05 mm Grinding depth limit: 0.3 mm Difference in head height (a) for 1 unit: Max. 0.15 mm

a a a a a a

Press fit the valve seat insert of the next oversize. q For the press fitting procedure, see "Replacement of valve seat insert".

Check after repair by grinding q

Measure the sinking quantity of the valve and projection of the injector and ensure that they are within the standard values and then adjust if necessary. Valve sinking quantity Standard: 0 ± 0.1 mm

12V140E-3 Series

90 Repair and replacement of parts

Repair of valve by grinding a

SEN05156-01

Valve grinding tool

Symbol

Part No.

Commercially available

Part name Valve refacer

Grinding of seat contact surface of valve q

Using tool H, grind the seat contact surface of the valve.

Seat contact surface angle of valve (a) Intake valve: 30° ± 0°15' Exhaust valve: 45° ± 0°15'

Check after grinding q

Apply dial gauge (1) to the facial runout measuring point of seat contact surface (c) of the valve and rotate the valve to measure its facial runout while pressing it toward left (d). Intake valve: Max. 0.045 mm (TIR) Exhaust valve: Max. 0.030 mm (TIR) TIR is an abbreviation for Total Indicator Reading, which is the difference between the maximum and minimum readings in runout. measurement.

Measure the valve head thickness, sinking quantity of the valve, and contact of the seat contact surface of the valve, and ensure that they are within the standard values. Allowable limit of valve head thickness (b) Intake valve: Min. 1.9 mm (Standard size: 2.4 mm) Exhaust valve: Min. 1.6 mm (Standard size: 2.15 mm) Valve sinking quantity Standard: 0 ± 0.1 mm Allowable limit: 0.7 mm

12V140E-3 Series

Block

Check the contact of the seat contact surface of the valve by either of the following methods. Thinly apply red lead to the seat contact surface of the ground valve and insert that valve in the valve guide. Lightly press the valve against the valve seat insert and rotate it 10°. Check the valve seat insert contact surface of the valve and ensure that the contact is even and is not broken. Make marks (f) (about 20 places) on the seat contact surface of the ground valve with a pencil and insert that valve in the valve guide. Lightly press the valve against the valve seat insert and rotate it 10°. Ensure that all the pencil marks (f) have been erased evenly.

q q

SEN05156-01

90 Repair and replacement of parts

KOMATSU 12V140E-3 Series engine Form No. SEN05156-01

12V140E-3 Series

SEN05157-01

ENGINE 1SHOP MANUAL 2 3

12V140E-3 Series

90 Repair and replacement of parts 1 Parts related to cylinder block Part names related to cylinder block............................................................................................................... 3 Testing and inspection of cylinder block.......................................................................................................... 4 Part names related to crankshaft .................................................................................................................... 7 Testing and inspection of crankshaft............................................................................................................... 8 Part names related to connecting rod ............................................................................................................. 9 Testing and inspection of connecting rod...................................................................................................... 10 Replacement of flywheel ring gear.................................................................................................................11 Replacement of crankshaft gear ................................................................................................................... 12 Replacement of camshaft gear ..................................................................................................................... 13 Replacement of main bearing metal cap ...................................................................................................... 14 Replacement of connecting rod small end bushing ...................................................................................... 16 Replacement of cam bushing ....................................................................................................................... 17 Repair of cylinder block top by grinding ........................................................................................................ 19

12V140E-3 Series

SEN05157-01

90 Repair and replacement of parts

Repair of counterbore by grinding................................................................................................................. 20 Check and identification after repair by grinding ........................................................................................... 22 Gasket sealant application procedure........................................................................................................... 23 Repair standard for cylinder liner O-ring ....................................................................................................... 25 Repair of crankshaft by grinding ................................................................................................................... 26 Improvement of surface roughness of crankshaft journal ............................................................................. 32

12V140E-3 Series

90 Repair and replacement of parts

Part names related to cylinder block

1. 2. 3. 4. 5. 6. 7.

SEN05157-01

Cylinder liner Clevis seal Cylinder liner O-ring Cylinder block Main bearing metal cap bolt Main bearing metal cap (No. 1, 2, 3, 5 and 6 are same) Camshaft bushing

12V140E-3 Series

SEN05157-01

90 Repair and replacement of parts

Testing and inspection of cylinder block

1 Unit: mm

Inspection item

Criteria

Remedy

Crack

Presence of crack (External dye check) Cylinder head bolt hole etc.

Repair of contact of packing

a See Fig. A Water leakage caused by corrosion

Replace cylinder block

a See Fig. B Standard value Clearance to cylinder liner

Standard size

Bore of cylinder block

Outside diameter of cylinder liner

Standard clearance

158.00 – 158.04

157.897 – 157.927

0.073 – 0.143

158.00 Inside diameter of camshaft bushing

Projection of cylinder liner

Depth and bottom corrosion counterbore

Inside diameter Standard size

Standard value

Repair limit

65.00 – 65.06

65.10

a See Fig. D Presence of corrosion Standard size

Standard value

11.00 – 11.05 Tolerance

Repair limit

Max. 0.09 Max. 0.05

0.135 0.100

a See Fig. E Main bearing mounting hole diameter Standard size Standard value • Tighten main bearing metal 156.990 – cap bolt to specified torque 157 157.025 • Measure in rage of 10° on General concentricity upper and lower sides of main bearing metal cap Concentricity of adjacent holes

Repair by cutting and add shim

Repair by cutting

Repair limit — Max. 0.020

Replace cylinder block

Max. 0.013

a See Fig. F Fit of main bearing metal cap and cylinder block (Interference)

Replace camshaft bushing Replace cylinder liner or repair cylinder block

a See Fig. C Allowable range: 0.07 – 0.15

Distortion and wear of cylinder All cylinder block head mounting face top of 1 cylinder

Replace cylinder liner or cylinder block

Journal

Standard fit (Interference)

No. 1 – 6

0.083 – 0.144

—

No. 7

0.038 – 0.099

—

Allowable clearance

a See Fig. G Cylinder liner Standard size Standard value

Inside diameter of counterbore and outside diameter of cylinder liner flange

Upper section

170.2

170.10 – 170.20

Lower section

161.2

161.25 – 161.29

— —

Replace cylinder liner

Cylinder block Standard size Standard value

Repair limit

Upper section

170.2

170.200 – 170.263

Lower section

161.2

161.170 – 161.230

Repair limit — —

Repair cylinder block and sleeve

12V140E-3 Series

90 Repair and replacement of parts

SEN05157-01

Illustrations related to testing and inspection table Fig. A

Fig. D

Packing portion

Depth of counterbore

Fig. B

Fig. E

Clearance

Inside diameter

Fig. C

Fig. F

c: d: e:

Cylinder liner Cylinder block Projection

12V140E-3 Series

Fit

SEN05157-01

Fig. G

90 Repair and replacement of parts

Method of checking main bearing metal inside diameter with alignment bar q

When checking the main bearing metal inside diameter with tool J (alignment bar), follow the procedure below. Unit: mm Specified dimension

i: j:

Diameter

157 –0.014 –0.039

Roundness

0.005

Straightness

0.010

Length

Min. 1,300

Upper section Lower section 1.

Set the cylinder block on the stand with the main bearing metal cap side up.

Apply engine oil to the inside of the main bearing metal hole of the cylinder block. a Leave the main bearing metal cap removed.

Set tool J (alignment bar) to the main bearing metal hole of the cylinder block.

Install the main bearing metal cap and tighten it to the following torque.

Check that tool J (alignment bar) moves smoothly.

12V140E-3 Series

90 Repair and replacement of parts

SEN05157-01

Part names related to crankshaft 1

1. 2. 3. 4.

Crankshaft Main bearing metal (upper) (All other than No. 4 are the same) Main bearing metal (lower) (All other than No. 4 are the same) Thrust metal (All of upper x 1 and lower x 2 are the same)

12V140E-3 Series

SEN05157-01

90 Repair and replacement of parts

Testing and inspection of crankshaft

1 Unit: mm

Inspection item

Criteria

Remedy

Crack

Check for crack by magnaflux inspection

Replace camshaft

Damage

• Flaw Presence of damage in journal • Seizure • Discoloration

If damaged slightly, repair with oilstone or by lapping. If seized, replace crankshaft

Damage of tap holes at front and rear ends

Repair or replace crankshaft

Clogging of oil hole End play of crankshaft

Thrust metal thickness

Outside diameter of crankpin journal

Presence of clogged oil hole Repair limit

0.140 – 0.320

0.50

Size

Standard size

Standard

4.000

0.25 OS

4.125

Outside diameter of crank main journal

Roundness of crank main journal Clearance in crank main journal

Bend of crankshaft (Total indicator reading)

Tolerance

Replace thrust metal or replace with oversize parts

Repair limit 3.79 3.92

–0.07 –0.12

0.50 OS

4.250

0.75 OS

4.375

1.00 OS

4.500

Size

Standard size

Standard

100.00

99.88

0.25 OS

99.75

99.63

0.50 OS

99.50

0.75 OS

99.25

1.00 OS

99.00

4.04

Replace thrust metal or replace with oversize crankshaft

4.17 4.29

Tolerance

Repair limit

–0.030 –0.030

99.38 99.13

Replace with undersize parts or replace crankshaft

98.88

Standard

Repair limit

0 – 0.010

0.010

0.046 – 0.116

0.260

Roundness of crankpin journal

Clearance in crankpin journal

Repair

Standard value

Size

Standard size

Standard

148.00

0.25 OS

147.75

0.50 OS

147.50

0.75 OS

147.25

1.00 OS

147.00

Tolerance

Replace with undersize parts or replace connecting rod bearing metal

Repair limit 147.97 147.72

–0.030 –0.030

147.47 147.22

Replace with undersize parts or replace crankshaft

146.97

Standard

Repair limit

0 – 0.010

0.010

No. 4 only

0.130 – 0.195

0.250

Other than No. 4

0.100 – 0.165

0.220

Replace with undersize parts or replace main bearing metal

Standard

Repair limit

Concentricity of all main journals

Max. 0.15

0.15

Concentricity of adjacent journals

Max. 0.07

0.07

Replace camshaft

a OS: Oversize

12V140E-3 Series

90 Repair and replacement of parts

Part names related to connecting rod

1. 2. 3. 4. 5. 6. 7. 8.

SEN05157-01

Connecting rod bolt Washer Cap Dowel pin Bearing metal (lower) Bearing metal (upper) Rod Small end bushing

12V140E-3 Series

SEN05157-01

90 Repair and replacement of parts

Testing and inspection of connecting rod

1 Unit: mm

Inspection item

Criteria

Remedy

Crack

Check for crack by dye check or magnaflux inspection a See Fig. H Parallelism and twist of small Presence of bend (after small end bushing is installed) and large end holes of Parallelism: 0.10 connecting rod Twist: 0.25 Tolerance Standard Standard Allowable Clearance between connecting size clearance clearance Shaft Hole rod small end bushing and pis–0.006 +0.049 0.030 – ton pin 52 0.11 –0.006 +0.030 0.055 Standard Tolerance • Large end hole diameter size • Without bearing metal. +0.026 • Inside surface roughness of large 106 –0.004 end hole: Max. 3.2 S Connecting rod large end hole • Clearance to crankshaft bearing Standard Allowable (with bearing metal) diameter clearance clearance • Wave of large end hole: Max. 0.004 0.046 – 0.26 (All width) 0.126

Replace connecting rod Replace small end bushing Surface roughness of inside of small end bushing: Max. 3.2S

Replace bearing metal or connecting rod

Even if dimensions of each part are within allowable limits, if any clearance exceeds allowable clearance, replace parts (bearing metal etc.)

Bearing metal thickness

Size Standard 0.125 US 0.250 US 0.375 US 0.500 US

Standard size 3.000 3.125 3.250 3.375 3.500

Tolerance

–0.025 –0.035

Repair limit 2.91 3.04 3.16 3.29 3.40

Replace bearing metal and connecting rod

Flaw on inside of or seizure of Presence of flaw and seizure bearing metal Distance between large and end small end holes

Standard size 305

Replace bearing metal

Tolerance –0.05 –0.05

a See Fig. J • Presence of lateral grinding mark Streak and bruise on H-portion • Presence of lateral streak of connecting rod

Replace connecting rod Replace connecting rod If there is bruise, replace connecting rod regardless of size of bruise

Presence of fretting on mating face • Mating face roughness: Max. 6.3 S • Fitted area of mating face: Min. 70% Scuffing on cap bolt seat surface Scuffing on bolt seat surface Scuffing on washer surface

Repair with oilstone Replace bolt Replace washer

Deformation of dowel pin

• Presence of deformation of dowel pin • Presence of deformation of dowel pin hole

Replace connecting rod

Damage of bolt

• Presence of crack and damage on threaded portion of bolt • Presence of bend of bolt

Replace bolt

Weight of connecting rod assembly

• 5.39 ± 0.077 kg

Replace connecting rod

Fretting on cap mating face

Scuffing on bolt seat surface

a a a a

If fretting is felt with nail, replace connecting rod

US: Undersize 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. 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. 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.

12V140E-3 Series

90 Repair and replacement of parts

Fig. H

SEN05157-01

Replacement of flywheel ring gear1

k Take care not to throw down the flywheel

and get hurt by mistake. Removal of gear Make a notch at the tooth bottom of the gear with a grinder and break the gear to remove with a chisel.

k Take

care in handling the grinder and chisel.

Measured value

Fig. J

b: c: d:

Press fitting of gear 1. Check the gear mounting face. If there is a flaw, repair with an oilstone. 2.

Heat the gear at the specified shrink fit temperature for a certain time. a Gear shrink fit temperature: Max. 200 °C Heating time: Min. 50 min

Press fit the gear with the chamfered side directed toward the flywheel until its side is fitted with the flywheel.

Inspection range Streaks Lengthwise direction

12V140E-3 Series

SEN05157-01

90 Repair and replacement of parts

Replacement of crankshaft gear 1 a

Crankshaft gear replacement tools

Symbol K

Part No.

Part name

790-101-2800

Bearing puller

790-101-2300

Push puller

Using the drive tool, press fit the gear with the timing mark out until its side is fitted with the crankshaft flange. a Press fit the gear quickly before it cools down.

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 copper rod etc. a Take care not to damage the crankshaft.

Press fitting of gear 1. Check the gear mounting face, key way, flange surface, etc. If there is a flaw, repair with an oilstone.

Drive a new key into the key way of the crankshaft.

Heat the gear at the specified shrink fit temperature for a certain time. a Gear shrink fit temperature: 200 °C Heating time: Min. 30 min

12V140E-3 Series

90 Repair and replacement of parts

Replacement of camshaft gear

SEN05157-01

k When setting the camshaft assembly on the

press stand, take care not to catch your fingers between the press stand and the gear. Removal of gear Set the camshaft assembly on the press stand and press the camshaft to pull out the gear.

Press fitting of gear 1. Check the gear mounting face, key way, flange surface, etc. If there is a flaw, repair with an oilstone. 2.

Drive a new key into the key way of the camshaft.

Install the thrust plate.

Heat the gear at the specified shrink fit temperature for a certain time. a Gear shrink fit temperature: 220 – 240 °C Heating time: Min. 30 min

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

SEN05157-01

90 Repair and replacement of parts

Replacement of main bearing metal cap a

Repair parts Part name

6215-99-4160 No. 1, 2, 3, 5, 6 main bearing metal cap 6215-99-4170 No. 4 main bearing metal cap 6215-99-4180 No. 7 main bearing metal cap

Inside machining of main bearing metal cap 1. Remove the cylinder liner. 2.

Apply dial gauges to the inside of the 2 main bearing metal caps at the longest pitch among the caps to be used to center the arbor of the boring machine.

While checking the inside diameter of main bearing metal cap (1), cut little by little. a Cut to the degree that the boring bar tool almost touches the inside of cylinder block (2). a Inside diameter of main bearing metal cap q Machining dimension Tolerance: 157 +0.025/0 mm q After machining, remove the main bearing metal cap, assemble it again, and check its inside diameter. Tolerance: 157 +0.025/–0.010 mm (Range to upper and lower 10° from mating face of main bearing metal cap) a Finished surface roughness: Max. 10 S a Do not cut the inside surface of the cylinder block.

When replacing the main bearing metal cap, work on the semi-finished cap according to the following procedure and install it.

Part No.

Install the replacement main bearing metal cap to the cylinder block and tighten it to the specified torque. a Match the notches of the cylinder block and main bearing metal cap to each other. 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

Range

1st time

284 {29}

270 – 299 {27.5 – 30.5}

2nd time

569 {58}

559 – 579 {57.0 – 59.0}

3rd time

90° tightening

90° +30° +00

Set the cylinder block mounting jig on the table of the horizontal boring machine and install the cylinder block by fitting its cylinder liner mounting hole to the datum line of the jig.

Target

The cylinder block in the illustration has 6 cylinders.

12V140E-3 Series

90 Repair and replacement of parts

SEN05157-01

Side machining of main bearing metal cap (Machine only No. 7 main bearing metal cap) 1. Insert cast iron bushing (3) and pass arbor (4) through it. 2.

Install facing tool (5) to the arbor.

Cut main bearing metal cap (1) to the degree that facing tool almost touches the cylinder block surface.

Cut the opposite side similarly. a Thrust metal mounting surface roughness: Max. 12.5 S a Do not cut the cylinder block. a Tolerance of main bearing metal cap width: 51 0/–0.030 mm

12V140E-3 Series

SEN05157-01

90 Repair and replacement of parts

Replacement of connecting rod small end bushing 1

Press fitting of bushing 1. Set the connecting rod to block (3) of tool L.

Install the bushing to push tool (1), set push tool (4), and fix them with nut (2). a Match the oil holes of the bushing and connecting rod to each other.

Drive push tool (1) with the press to press fit the bushing. a Since the bushing is semi-finished, its inside diameter is small and the piston pin does not go through it. After press fitting the bushing, machine its inside with a reamer or a honing machine according to the maintenance standard. 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.

Connecting rod small end bushing replacement tool

Symbol

Part No.

795-240-6401

Part name Push tool (KIT)

Pulling out of bushing 1. Set the connecting rod to block (3) of tool L. 2.

Using push tool (1) and nut, drive out the busing with the press. a After removing the bushing, remove sharp edges and burrs from and clean the bushing mounting hole.

12V140E-3 Series

90 Repair and replacement of parts

Replacement of cam bushing a

Pulling out of No. 3, No. 4 and No. 5 bushings 1) Assemble bar (1), push tool (2), collar (3) and guide (4) . 2) While hitting bar (1), drive out the bushing from the cylinder block.

After removing the bushing, remove burrs and foreign matter from and clean the bushing mounting hole.

Cam bushing replacement tools

Symbol

Part No.

795-213-1200

SEN05157-01

Part name Push tool (KIT)

Before replacing the cam bushing, remove the plug at the rear of the cylinder block.

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.

Pulling out of No. 2 and No. 6 bushings 1) Assemble bar (1), push tool (2), collar (3) and guide (4) . 2) While hitting bar (1), drive out the bushing from the cylinder block.

12V140E-3 Series

SEN05157-01

Installation a Cam bushing installation drawing a Press fit the cam bushing, while checking its direction so that its mating part will be on the upper side of its center after installed.

Press fitting of No. 3, No. 4 and No. 5 bushings 1) Install bar (1), push tool (2), collar (3) and guide (4) to the bushing. 2) Press fit the bushing until the oil holes of th e c y l i n d e r b l o c k a n d b u s h i n g a r e matched to each other.

90 Repair and replacement of parts

Press fitting of No. 1 and No. 7 bushings 1) Install bar (1), push tool (2) and collar (3) to the bushing. 2) Press fit the bushing until the oil holes of t h e c y l i n d e r b l o c k a nd b u s h i n g ar e matched to each other.

Measurement after bushing is press fitted 1) Using dial inside gauge (a), measure the inside diameter of the bushing.

2) 2.

Press fitting of No. 2 and No. 6 bushings 1) Install bar (1), push tool (2), collar (3) and guide (4) to the bushing. 2) Press fit the bushing until the oil holes of th e c y l i n d e r b l o c k a n d b u s h i n g a r e matched to each other.

Measure the clearance between the bushing and shaft. If it is out of the allowable range or the shaft does not go through smoothly, repair the inside of the bushing with a reamer. a After repairing the inside of the bushing with a reamer, remove all the chips from the oil hole and oil groove. a Inside diameter of cam bushing: ø65 +0.06/0 mm a Clearance to camshaft journal: 0.016 – 0.096 mm

12V140E-3 Series

90 Repair and replacement of parts

Repair of cylinder block top by grinding

SEN05157-01

Repair by grinding If there is distortion or corrosion on the cylinder block top, remove it by grinding. a If the cylinder liner contact surface of counterbore portion (b) is blackened and grained (particularly in the forward and backward directions of the cylinder block) more than a half of the contact surface or the cylinder block top needs to be ground, repair the counterbore portion. a Rough criteria for repairing cylinder block top by grinding q The cylinder block top is worn and corroded in the shape of the trace of the head gasket. q Quantity (a) of the above wear is 0.15 mm or more.

Grinding of top q Measure the wear quantity and distortion of the cylinder block top. If the measured value is larger than the allowable limit, repair the cylinder block top by grinding within the allowable limit of cylinder block height (H). Unit: mm Standard size

Repair limit

Flatness of cylinder block top (per cylinder)

Max. 0.05

0.10

Cylinder block height (H)

471.5 ± 0.04

471.06

Cylinder block top surface roughness

12V140E-3 Series

Max. 12.5S

When repairing with grinding stone (Reference) Grinding speed: 1,650 – 1,950 m/min Table speed: 15 – 30 m/min Grinding depth by 1 grinding: 0.025 mm Cross feed for 1 grinding: 1 – 2 mm Grinding stone: A461 V Grinding fluid: Water soluble grinding fluid

SEN05157-01

90 Repair and replacement of parts

Repair of counterbore by grinding 1

Counterbore grinding tool

Symbol

a q q

Part No.

Part name

79A-513-1710 Basic machine

79A-513-1780 Guide plate

79A-513-1820 Cutter plate

79A-513-1860 Cutter

79A-513-1940 Cutter set gauge

79A-513-1950 Micrometer

79A-513-1960 Driver plate

79A-513-2090 Driver shaft

79A-513-2110

79A-513-2120 Service package

79A-513-2130 Case

79A-513-2140 Basic machine

79A-513-2160 Cutter plate

79A-513-2230 Cutter

79A-513-2240 Remover pin

79A-513-2250 Case

79A-513-2260 Service package

79A-513-2270 Compound

79A-513-2280 Primer

79A-513-2320 Bushing

q q

Machine only the hatched part of counterbore portion depth (e). Set the machining margin of counterbore portion depth (e) so that cylinder liner projection (f) will be within the standard value. If counterbore portion depth (e) exceeds the standard dimension and the counterbore portion needs to be ground within the allowable limit, set the machining margin so that 1 shim shown below will be used for 1 cylinder. Remove burrs and sharp edges from the tapered portion etc. (g) is a line parallel with the cylinder center.

Driver handle

After repairing the top of cylinder block (a) by grinding, measure the counterbore portion depth and repair the counterbore by grinding within the allowable limit of counterbore depth (e) if necessary. Rough criteria for repairing counterbore portion by grinding A dimension is out of the standard dimension. The cylinder liner contact surface (a) of the counterbore portion is blackened and grained (particularly in the forward and backward directions) more than a half of the whole area. If counterbore portion depth (e) after the repair is 11.05 – 12.525 mm, adjust cylinder liner projection (f) to 0.07 – 0.15 mm with shims. Unit: mm

Counterbore portion depth (e) Cylinder liner projection (f) Counterbore surface roughness Grinding shape

Standard size

Repair limit

11 +0.05 +0

12.525

—

0.07 – 0.15

Max. 12.5S See figure below

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Shims for adjusting counterbore depth (reference) Unit: mm Part No.

Weight (kg)

6210-29-2260

1.50

0.025

0.023

6210-29-2250

0.80

0.025

0.012

6210-29-2240

0.50

0.025

0.008

6210-29-2230

0.26

0.025

0.004

6210-29-2220

0.20

0.020

0.003

6210-29-2210

0.16

0.016

0.002

a q q

When grinding the counterbore portion, use tool N.

Remarks

Outside diameter (i) and inside diameter (j) of shim (1) i: 169 ± 0.15 mm j: 161.3 + 0.030/0 mm

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Check and identification after repair by grinding

After repairing by grinding, check the flat portions around the water and oil holes on the cylinder block top for flaw. Remove all burrs and sharp edges. After grinding the top, if cylinder block height (H) is larger than the standard dimension and within allowable limit (471.06 – 471.45 mm), be sure to use the oversize head gasket.

q q

Unit: mm

Spare parts used

Head gasket

Part No.

Plate thickness

Standard

6210-17-1814

2.0

Oversize

6210-19-1814

2.4

The 2 letters of "OS" are stamped on the plate for identification. After repairing, stamp the contents of repair on the cylinder block top (rear of the left bank) (a). Stamp method is shown in the following table. Oversize head gasket

Shim

Stamp

—

Unnecessary

—

(Stamp letter size shall be 5 – 10 mm)

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90 Repair and replacement of parts

Gasket sealant application procedure q

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When press fitting the cylinder liner again after pulling it out, apply gasket sealant (LG-6) to the cylinder block top deck (cylinder liner flange contact surface of the cylinder block) according to the following procedure. When using shim for the deck, apply the gasket sealant similarly.

Wipe off dirt, oil etc. from cylinder block top (c) and the cylinder liner flange contact surface with cloths.

Apply LG-6 to gasket sealant application area (a). q String diameter: 2 – 3 mm q Overlap length of starting and ending points (b): 6 ± 6 mm a When using shim for the deck q Thinly apply LG-6 to the underside (e) of shim (1) and fit the shim to the cylinder block deck. q Then, apply LG-6 as when no shim is used.

Press fit cylinder liner to the cylinder block. At this time, apply a little amount of rubber lubricant (RF-1) to cylinder block contact surface (d) of the O-ring and seal of the cylinder liner. a Apply the engine oil just before press fitting the cylinder liner. a RF-1: Product of DAIDO CHEMICAL INDUSTRY CO., LTD. If RF-1 cannot be obtained, apply clean engine oil SAE No. 30. a Since the clevis seal and O-ring are swelled and deteriorated with oil, apply a little amount of oil with a brush just before installing.

12V140E-3 Series

Set the cylinder liner to the cylinder block, install the used head gasket, and tighten the cylinder head temporarily. At this time, tighten the bolts in the following order. 3 Tightening torque: 147 ± 10 Nm {15 ± 1 kgm}

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90 Repair and replacement of parts

Loosen the cylinder head mounting bolts, remove the cylinder head, and wipe off the excessive gasket sealant projected from the counterbore portion. a If the gasket sealant sticks to grommet (1) of the head gasket, it deforms the grommet into a heart shape and can cause coolant leakage into water hole (2). Accordingly, wipe off the gasket sealant thoroughly. a When installing the cylinder head after performing step "4.5", use a new head gasket.

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90 Repair and replacement of parts

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Repair standard for cylinder liner O-ring 1 After repairing the bushing at the cylinder liner Oring portion of the cylinder block, finish to the following dimensions. a Concentricity of (6) to standard (A): Max. 0.05 mm Unit: mm No.

Finish dimension

ø167

ø161.45 ± 0.25

ø160.67 ± 0.064

176 ± 0.25

184.94 ± 0.18

ø158 +0.040 +0

ø159.03 (Gauge diameter)

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Repair of crankshaft by grinding 1 q

When the crankshaft is worn, seized or damaged slightly and needs to be repaired, grind it to one of the following undersizes. Undersizes: 0.25, 0.50, 0.75, 1.00 mm If the crankshaft is bent or worn unevenly, it should not be repaired but should be replaced. (Repairing the crankshaft requires high technologies) Finish fillet portion (R), shoulder portion (r) and area (R) around the hole of the crankshaft with extreme care.

Finish the oil holes of the main journal and pin journal to the dimensions shown below.

Main journal portion

Finish dimensions of fillet portion

Pin journal portion (a)

Finish dimension

Unit: mm Surface roughness

4 +0.4 +0

3.2S

—

3.5 –0 –0.5

3.2S

—

Main journal (b)

12V140E-3 Series

90 Repair and replacement of parts

Pin journal portion

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Inspection before repair by grinding Visual check Check for crack, damage, discoloration by seizure, wear, etc. and judge if the crankshaft can be repaired by grinding. Hardness check of journal surface Standard value: 63 – 69 Hs If the hardness is below the allowable limit, discard the crankshaft. Check during and after repair by grinding Check of fillet R portion q Check that each fillet R portion is connected to the journal shoulder smoothly. q Using the fillet R gauges, check that the R dimension is between the minimum value gauge and maximum value gauge. q (a) is the contact point of minimum value gauge. q (b) is the contact point of maximum value gauge. Unit: mm Fillet R

The outside surface roughness of the pin journal and main journal must be maximum of 0.8 S.

Equipment necessary for grinding q Magnaflux inspection machine q Shore hardness tester q Etching kit q Crankshaft grinding machine q Crankshaft grinding polishing machine q Surface roughness gauge q Fillet R gauge

12V140E-3 Series

Min. radius

Max. radius

Pin journal

4.0

4.4

Main journal

3.0

3.5

Check for seizure mark by etching After repairing by grinding, check that there is no grinding seizure mark by etching inspection. q If any seizure mark is detected, grind about 0.02 mm again to the next undersize dimension. q After checking, neutralize and clean the checked surface and apply rust preventive oil. q

Magnaflux inspection Before using the repaired crankshaft, check it by magnaflux inspection to ensure that it has no crack. q Extremely closely check journal fillet portion (c) which is in each dangerous area of the crankshaft shown in the figure. q After the magnaflux inspection, be sure to demagnetize the crankshaft. q

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Measurement of bend (Measurement of alignment) q Measure the bend of the ground crankshaft and ensure that it is within the standard value. q Measure the bend (alignment) at the following 4 places. Tolerance of overall length alignment: Max. 0.15 mm Tolerance of adjacent alignment: Max. 0.07 mm Tolerance of front end alignment: Max. 0.03 mm Tolerance of rear end alignment: Max. 0.03 mm

Grinding of main journal a Grind all the main journals to the same undersize. a When grinding, leave the polish finishing margin of 0.007 – 0.008 mm. a Stamp undersize dimension (a) on the ground crankshaft as shown in the figure to prevent installation of bearing metals of a different size.

90 Repair and replacement of parts

Undersize dimensions of main journal Unit: mm

a q

q q

Size

Standard size

Standard

148.00

0.25 US

147.75

0.50 US

147.50

0.75 US

147.25

1.00 US

147.00

Tolerance

–0 –0.030

US: Undersize Roundness, cylindricality (TIR) and surface roughness of main journal Tolerance: Max. 0.010 mm Allowable limit: 0.010 mm Surface roughness: Max. 0.8 µm

M: Main journal P: Crankpin journal

Grinding of thrust surface a It is not always required to grind the thrust surfaces of front (b) and rear (c) to the same undersize dimension. a Stamp the undersize dimension on the ground crankshaft as shown in the figure to prevent installation of a wrong thrust metal. a If thrust surface (a) was repaired by grinding, ensure that the end play of the crankshaft is within the allowable range. (See Disassembly and assembly, "General assembly")

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90 Repair and replacement of parts

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Oversize dimensions of thrust surface Unit: mm Rear thrust surface

Front thrust surface

Standard

0.125 OS

0.25 OS

0.375 OS

0.50 OS

a q

Standard

0.125 OS

0.25 OS

0.375 OS

Standard size

+0.050 59.000 +0

+0.050 59.125 +0

+0.050 59.250 +0

+0.050 59.375 +0

Repair limit

59.060

59.185

59.310

59.435

Standard size

59.125 +0

59.250 +0

59.375 +0

59.500 +0

59.625 +0

Repair limit

59.185

59.310

59.435

59.560

59.685

Standard size

59.250 +0

59.375 +0

59.500 +0

59.625 +0

59.750 +0

Repair limit

59.310

59.435

59.560

59.685

59.810

Standard size

59.375 +0

59.500 +0

59.625 +0

59.750 +0

59.875 +0

Repair limit

59.435

59.560

59.685

59.810

59.935

Standard size

59.500 +0

59.625 +0

59.750 +0

59.875 +0

60.000 +0

Repair limit

59.560

59.685

59.810

59.935

60.060

+0.050

0.50 OS +0.050

59.500 +0

59.560 +0.050

+0.050

OS: Oversize Squareness of thrust surface (TIR) Tolerance: 0.02 mm Allowable limit: 0.02 mm TIR is an abbreviation for Total Indicator Reading, which is the difference between the maxim 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.

Grinding of pin journal a Grind all the pin journals to the same undersize. a When grinding, leave the polish finishing margin of 0.007 – 0.008 mm. a Stamp undersize dimension (a) on the ground crankshaft as shown in the figure to prevent installation of bearing metals of a different size. Undersize dimensions of pin journal Unit: mm

a q

Size

Standard size

Tolerance

Standard

100.000

0.25 US

99.750

0.50 US

99.500

0.75 US

99.250

1.00 US

99.000

M: Main journal P: Crankpin journal

–0 –0.030

US: Undersize 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

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Grinding of sides of main journal and pin journal q When repairing the worn surfaces of the main journal and pin journal, limit the grinding quantity to the minimum. q Width of crankshaft main journal #1 standard: 57 +0.1/0 mm #2, 3, 5, 6 standard: 55 +0.1/0 mm #4 standard: 59 +0.1/0 mm #7 standard: 59 +0.05/0 mm q Width of crankshaft pin journal Standard: 92 +0.054/0 mm

Dressing of grinding stone Dress the grinding stone for each journal. q Adjust the grinding stone edge to the arc of the fillet with the grinding stone modifying device. q Test and correct the grinding stone edge by grinding a piece of wood on trial, while checking with ball gauges. q

90 Repair and replacement of parts

Work after repair by grinding q Ensure again that each dimension is as specified. q Clean each part thoroughly and apply rust-preventive oil. q When storing the crankshaft for a long period, support it on 3 points or keep it erected with a sling. Balancing (Reference) Avoid performing repair that may affect the crankshaft 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) Distance between holes: Thickness must be at least 5 mm. a TIR is an abbreviation for Total Indicator Reading, which is the difference between the maxim 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 . measurement.

Prevention of grinding seizure q Apply the plunge grinding method. q Use all the width of the grinding stone. q Avoid grinding the boss surface as much as possible. q Apply cooling oil sufficiently. q Set the standard peripheral speed of the grinding stone to 2,000 m/min when the crankshaft rotation speed is 40 rpm. Finishing of surface See "Improvement of surface roughness of crankshaft 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 portions of pin and main journals: Max. 3.2S q Polish finishing margin: 0.007 – 0.008 mm

12V140E-3 Series

90 Repair and replacement of parts

Measuring procedure for bend and outside diameter of journal portion 1. Support both end centers of the crankshaft with a lathe. Apply the dial gauge probe to the central journal (No. 4) perpendicularly from side so that deflection caused by the own weight of the crankshaft will not affect the measurement and then set the gauge to 0 at the top. Rotate the crankshaft 1 turn and read the minimum and maximum values. a If a lathe is not available, support the No. 1 and No. 7 journals on V-blocks.

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Measuring points of journal Pin journal: 5 places in directions X and Y Main journal: 3 places in directions X and Y

Measure the outside diameters of the main journal and pin journal with a micrometer or an air micrometer.

12V140E-3 Series

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Improvement of surface roughness of crankshaft journal 1 q

If the surface roughness of the journal portions of the crankshaft is out of the standard or the journal surface has a flaw, bruise or rust which can be removed, improve the surface roughness.

Cleaning and blowing air Before starting grinding, brush the oil holes and blow air into them.

90 Repair and replacement of parts

Check the surface roughness with the standard piece. a Measure the surface roughness of the journal by comparing it with the standard piece. Surface roughness standard (Pin journal and main journal) Journal surface: Max. 0.8S Round part: Max. 3.2S

If the surface roughness does not satisfy the standard, make round polishing with the sandpaper (#500) again between both ends. a After improving the surface roughness, be sure to brush the oil holes and blow air into them. a Ensure that the there is no flaw or bruise on the journal portion and the round part of each fillet. If there is any flaw or bruise, polish again from step 1.

Improvement of surface roughness of journal portions

When improving with special polishing machine q Use the special polishing machine shown below.

Set the rotation speed of the polishing machine to 40 – 50 rpm. Improve the surface roughness by making round polishing with sandpaper (belt type) between both ends of each journal. a Use sandpaper (belt type) of #320. a Move the sandpaper smoothly without stopping at a place. a Do not use honing oil.

Replace the sandpaper with one of #500. Apply honing oil to the journal surface. Make round polishing with the sandpaper between both ends of the journal, while operating handle (1) to move the sandpaper by the play. a Move the sandpaper smoothly without stopping at a place.

If the special polishing machine is not available, use the following clamp jig for polishing to improve the surface roughness.

Using the crankshaft grinding machine, rotate the crankshaft to polish. q Sandpaper: #800 q Grinding oil: Honing oil (Diesel fuel oil may be used) q Rotation speed of crankshaft: 40 rpm

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90 Repair and replacement of parts

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While moving the polishing jig in the axial direction by the play of the journal width (approx. 5 mm), polish the journal. a Finish polishing each journal in about 6 minutes. Each time honing of 1 journal is finished, replace the sandpaper with new one. a When honing the pin journal, set it to the center of rotation.

Assembly and using procedure of clamp jig for polishing 1. Assemble the clamp jigs for the pin journal and main journal as shown in the following figure.

Cut off sandpaper (#800) (a, b) to the shapes shown below. q (a) is for the pin journal and its size is as follows; L: 200 mm, W:108 mm q (b) is for the main journal and its size is as follows. L: 170 mm, W: 70 mm a Make slits (c) 20 mm long on both sides of the sandpaper at intervals of 10 mm and cut off one part at each end (d).

12V140E-3 Series

Insert 2 pieces of upper and lower sandpapers (a) or (b) in slit (e) and fix the ends with tape (f).

Fold slit portion (d) of the sandpaper along the round part of the clamp.

Hold the journal with the clamp and fix the lever ends with rubber tube (g) etc.

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90 Repair and replacement of parts

Clamp jig for polishing a Make the polishing jig according to the following drawings. Clamp jig for polishing (for pin journal) Plate 1 (Use 2 pieces for 1 jig)

Lever 2 (Use 2 pieces for 1 jig)

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90 Repair and replacement of parts

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Clamp jig for polishing (for main journal) Plate 1 (Use 2 pieces for 1 jig)

Lever 2 (Use 2 pieces for 1 jig)

12V140E-3 Series

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KOMATSU 12V140E-3 Series engine Form No. SEN05157-01

12V140E-3 Series