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Manual Motor 475,785-7, PC2000 y WA900-3Eo Series 12V140-3 PDF
Manual Motor 475,785-7, PC2000 y WA900-3Eo Series 12V140-3 PDF
Shop
Manual
12V140E-3 SERIES
ENGINE
This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in
accordance with written authorization from Komatsu America Corp.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to
make changes or improvements at any time without incurring any obligation to install such changes on products
sold previously.
Due to this continuous program of research and development, revisions may be made to this publication. It is
recommended that customers contact their distributor for information on the latest revision.
12V140E-3 Series
12V140E-3 Series 1
SEN00294-04 00 Index and foreword
01 Specification SEN00301-02
Specification and technical data SEN00303-02 q
40 Troubleshooting SEN00314-00
General information on troubleshooting SEN00315-00
Troubleshooting of mechanical system (S-mode) SEN00316-00
Troubleshooting of electrical system (E-mode), Part 1 SEN00317-00
Troubleshooting of electrical system (E-mode), Part 2 SEN00318-00
2 12V140E-3 Series
00 Index and foreword SEN00294-04
Table of contents 1
00 Index and foreword
Index SEN00294-04
Composition of shop manual ................................................................................................... 2
Table of contents ..................................................................................................................... 3
01 Specification
Specification and technical data SEN00303-02
Outline ..................................................................................................................................... 2
Specifications........................................................................................................................... 4
General view............................................................................................................................ 10
Weight table............................................................................................................................. 19
Engine performance curves..................................................................................................... 20
12V140E-3 Series 3
SEN00294-04 00 Index and foreword
40 Troubleshooting
General information on troubleshooting SEN00315-00
General information on troubleshooting ...................................................................................... 2
Points to remember when troubleshooting .............................................................................. 2
4 12V140E-3 Series
00 Index and foreword SEN00294-04
12V140E-3 Series 5
SEN00294-04 00 Index and foreword
6 12V140E-3 Series
00 Index and foreword SEN00294-04
E-89 Code [1622/CB1622] Injector #9 (R/B #3) System Open/Short Error (RH bank) ........... 50
E-90 Code [1633/CA1633] KOMNET Datalink Timeout Error (LH bank) ................................ 52
E-91 Code [2185/CA2185] Throttle Sens. Sup. Volt. High Error (LH bank only)..................... 54
E-92 Code [2186/CA2186] Throttle Sens. Sup. Volt. Low Error (LH bank only)...................... 56
E-93 Code [2249/CA2249] Rail Press. Very Low Error (LH bank) .......................................... 57
E-94 Code [2249/CB2249] Rail Press. Very Low Error (RH bank) .......................................... 57
E-95 Code [– –*1/–] Eng. Overheat (LH bank only) ................................................................ 58
E-96 Code [– –*2/–] Eng. Oil Press. Low Speed Derate (LH bank only) ................................. 58
E-97 Code [– –*3/–] Press. Low Torque Derate (LH bank only) .............................................. 59
12V140E-3 Series 7
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© 2007 KOMATSU
All Rights Reserved
8 12V140E-3 Series
SEN00296-02
12V140E-3 Series
12V140E-3 Series 1
SEN00296-02 00 Index and foreword
2 12V140E-3 Series
00 Index and foreword SEN00296-02
3) When disassembling or assembling, sup- 8) When removing piping, stop the fuel or oil
port the machine with blocks, jacks, or from spilling out. If any fuel or oil drips
stands before starting work. onto the floor, wipe it up immediately. Fuel
4) Remove all mud and oil from the steps or or oil on the floor can cause you to slip
other places used to get on and off the and can even start fires.
machine. Always use the handrails, lad- 9) As a general rule, do not use gasoline to
ders or steps when getting on or off the wash parts. Do not use it to clean electri-
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 cal parts, in particular.
machine. If it is impossible to use the 10) Be sure to assemble all parts again in their
handrails, ladders or steps, use a stand to original places. Replace any damaged
provide safe footing. parts and parts which must not be reused
with new parts. When installing hoses and
3. Precautions during work wires, be sure that they will not be dam-
1) Before disconnecting or removing compo- aged by contact with other parts when the
nents of the oil, water, or air circuits, first machine is operated.
release the pressure completely from the 11) When installing high pressure hoses,
circuit. When removing the oil filler cap, a make sure that they are not twisted. Dam-
drain plug, or an oil pressure pickup plug, aged tubes are dangerous, so be
loosen it slowly to prevent the oil from extremely careful when installing tubes for
spurting out. high pressure circuits. In addition, check
2) The coolant and oil in the circuits are hot 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
when the engine is stopped, so be careful installed.
not to get scalded. Wait for the oil and 12) When assembling or installing parts,
coolant to cool before carrying out any always tighten them to the specified
work on the oil or water circuits. torques. When installing protective parts
3) Before starting work, stop the engine. such as guards, or parts which vibrate vio-
When working on or around a rotating lently or rotate at high speed, be particu-
part, in particular, stop the engine. When l 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
checking the machine without stopping installed correctly.
the engine (measuring oil pressure, 13) When aligning 2 holes, never insert your
revolving speed, temperature, etc.), take fingers or hand. Be careful not to get your
extreme care not to get rolled or caught in fingers caught in a hole.
rotating parts or moving parts. 14) When measuring hydraulic pressure,
4) Before starting work, remove the leads check that the measuring tools are cor-
from the battery. Always remove the lead rectly assembled.
from the negative (–) terminal first. 15) Take care when removing or installing the
5) When raising a heavy component (heavier tracks of track-type machines. When
than 25 kg), use a hoist or crane. Before removing the track, the track separates
starting work, check that the slings (wire suddenly, so never let anyone stand at
ropes, chains, and hooks) are free from either end of the track.
damage. Always use slings which have 16) If the engine is operated for a long time in
ample capacity and install them to proper a place which is not ventilated well, you
places. Operate the hoist or crane slowly may suffer from gas poisoning. Accord-
to prevent the component from hitting any ingly, open the windows and doors to ven-
other part. Do not work with any part still tilate well.
raised by the hoist or crane.
6) 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 wir-
ing. Damaged wiring may cause electrical
fires.
12V140E-3 Series 3
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4 12V140E-3 Series
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q If the load is unstable or the wire rope 13) If the hoist stops because of a power fail-
or chains are twisted, lower the load ure, turn the power switch OFF. When
and lift it up again. turning on a switch which was turned OFF
q Do not lift up the load slantingly. by the electric shock prevention earth
13) When lifting down a load, observe the fol- leakage breaker, check that the devices
lowing. related to that switch are not in operation
q When lifting down a load, stop it tem- state.
porarily at 30 cm above the floor, and 14) If you find an obstacle around the hoist,
then lower it slowly. stop the operation.
q Check that the load is stable, and 15) After finishing the work, stop the hoist at
then remove the sling. the specified position and raise the hook
q Remove kinks and dirt from the wire to at least 2 m above the floor. Do not
ropes and chains used for the sling leave the sling installed to the hook.
work, and put them in the specified
place. 7. Selecting wire ropes
1) Select adequate ropes depending on the
5. Precautions for using mobile crane weight of parts to be hoisted, referring to
a Read the Operation and Maintenance the table below.
Manual of the crane carefully in advance
and operate the crane safely. Wire ropes
(Standard “Z” twist ropes without galvanizing)
6. Precautions for using overhead hoist crane (JIS G3525, No. 6, Type 6X37-A)
k When raising a heavy part (heavier Nominal
Allowable load
than 25 kg), use a hoist, etc. In Disas- diameter of rope
sembly and assembly, the weight of a mm kN ton
part heavier than 25 kg is indicated 10 8.8 0.9
after the mark of 4. 12 12.7 1.3
1) Before starting work, inspect the wire 14 17.3 1.7
ropes, brake, clutch, controller, rails, over
16 22.6 2.3
wind stop device, electric shock preven-
18 28.6 2.9
tion earth leakage breaker, crane collision
20 35.3 3.6
prevention device, and power application
warning lamp, and check safety. 25 55.3 5.6
2) Observe the signs for sling work. 30 79.6 8.1
3) Operate the hoist at a safe place. 40 141.6 14.4
4) Check the direction indicator plates (east, 50 221.6 22.6
west, south, and north) and the directions 60 318.3 32.4
of the control buttons without fail.
5) Do not sling a load slantingly. Do not move a The allowable load is one-sixth of the
the crane while the slung load is swinging. breaking strength of the rope used
6) Do not raise or lower a load while the (Safety coefficient: 6).
crane is moving longitudinally or laterally.
7) Do not drag a sling.
8) When lifting up a load, stop it just after it
leaves the ground and check safety, and
then lift it up.
9) Consider the travel route in advance and
lift up a load to a safe height.
10) Place the control switch on a position
where it will not be an obstacle to work
and passage.
11) After operating the hoist, do not swing the
control switch.
12) Remember the position of the main switch
so that you can turn off the power immedi-
ately in an emergency.
12V140E-3 Series 5
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2) Connection
1] When installing the air conditioner cir-
cuit hoses and tubes, take care that
dirt, dust, water, etc. will not enter
them.
2] When connecting the air conditioner
hoses and tubes, check that O-rings
(1) are fitted to their joints.
3] Check that each O-ring is not dam-
aged or deteriorated.
4] When connecting the refrigerant pip-
ing, apply compressor oil for refriger-
ant (R134a) (DENSO: ND-OIL8,
ZEXEL: ZXL100PG (equivalent to
PAG46)) to its O-rings.
6 12V140E-3 Series
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q Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one
of them is required, consult KOMATSU distributors.
q Materials and specifications are subject to change without notice.
q Shop manuals are divided into the “Chassis volume” and “Engine volume”. For the engine unit, see the
engine volume of the engine model mounted on the machine.
01. Specification
This section explains the specifications of the machine.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is
divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also
explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
12V140E-3 Series 7
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3. Filing method
File by the brochures in the correct order of the form number printed in the shop manual composition
table.
q Revisions
Revised brochures are shown in the shop manual composition table.
4. Symbols
Important safety and quality portions are marked with the following symbols so that the shop manual will
be used practically.
4
Weight of parts of component or parts. Caution necessary when
Weight
selecting hoisting wire, or when working posture is important, etc.
3
Tightening Places that require special attention for tightening torque during
torque assembly.
5
Oil, coolant Places where oil, etc. must be added, and capacity.
6
Drain Places where oil, etc. must be drained, and quantity to be drained.
5. Units
In this shop manual, the units are indicated with International System of units (SI). For reference, con-
ventionally used Gravitational System of units is indicated in parentheses { }.
8 12V140E-3 Series
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Example:
Standard size Tolerance
–0.022
120
–0.126
Example:
Tolerance
Standard size
Shaft Hole
–0.030 +0.046
60
–0.076 +0
12V140E-3 Series 9
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10 12V140E-3 Series
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12V140E-3 Series 11
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3) Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with
a crane with the wiring still connected, or a
heavy object hits the wiring, the crimping
of the connector may separate, or the sol-
dering may be damaged, or the wiring
may be broken.
12 12V140E-3 Series
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12V140E-3 Series 13
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2) Connecting connectors
1] Check the connector visually.
Check that there is no oil, dirt, or
water stuck to the connector pins
(mating portion).
Check that there is no deformation,
defective contact, corrosion, or dam-
age to the connector pins.
Check that there is no damage or
breakage to the outside of the con-
nector.
a If there is any oil, water, or dirt
stuck to the connector, wipe it off
with a dry cloth. If any water has
got inside the connector, warm
the inside of the wiring with a
dryer, but be careful not to make
it too hot as this will cause short
circuits.
a If there is any damage or break-
age, replace the connector.
2] Fix the connector securely.
Align the position of the connector
correctly, and then insert it securely.
For connectors with the lock stopper,
push in the connector until the stop-
per clicks into position.
3] Correct any protrusion of the boot and
any misalignment of the wiring har-
ness.
For connectors fitted with boots, cor-
rect any protrusion of the boot. In
addition, if the wiring harness is mis-
aligned, or the clamp is out of posi-
tion, adjust it to its correct position.
a If the connector cannot be cor-
rected easily, remove the clamp
and adjust the position.
q If the connector clamp has been
removed, be sure to return it to
its original position. Check also
that there are no loose clamps.
14 12V140E-3 Series
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3) Heavy duty wire connector (DT 8-pole, 12- q Disconnection q Connection (Example of
pole) incomplete setting of (a))
Disconnection (Left of figure)
While pressing both sides of locks (a)
and (b), pull out female connector (2).
Connection (Right of figure)
1] Push in female connector (2) horizon-
tally until the lock clicks.
Arrow: 1)
2] Since locks (a) and (b) may not be set
completely, push in female connector
(2) while moving it up and down until
the locks are set normally.
Arrow: 1), 2), 3)
a Right of figure: Lock (a) is pulled
down (not set completely) and
lock (b) is set completely.
(1): Male connector
(2): Female connector
(a), (b): Locks
12V140E-3 Series 15
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16 12V140E-3 Series
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4. Handling controller
1) The controller contains a microcomputer
and electronic control circuits. These con-
trol all of the electronic circuits on the
machine, so be extremely careful when
handling the controller.
2) Do not place objects on top of the control-
ler.
3) Cover the control connectors with tape or
a vinyl bag. Never touch the connector
contacts with your hand.
4) During rainy weather, do not leave the
controller in a place where it is exposed to
rain.
5) Do not place the controller on oil, water, or
soil, or in any hot place, even for a short
time. (Place it on a suitable dry stand).
6) Precautions when carrying out arc welding
When carrying out arc welding on the
body, disconnect all wiring harness con-
nectors connected to the controller. Fit an
arc welding ground close to the welding
point.
12V140E-3 Series 17
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3. Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from
entering. If the opening is left open or is
blocked with a rag, there is danger of dirt
entering or of the surrounding area being
made dirty by leaking oil so never do this. Do
not simply drain oil out onto the ground, but
collect it and ask the customer to dispose of it,
or take it back with you for disposal.
18 12V140E-3 Series
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6. Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit. Normally, flushing is
carried out twice: primary flushing is carried
out with flushing oil, and secondary flushing is
carried out with the specified hydraulic oil.
7. Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the
machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil cir-
cuit. The oil cleaning equipment is used to
remove the ultra fine (about 3 m) particles that
the filter built in the hydraulic equipment can-
not remove, so it is an extremely effective
device.
12V140E-3 Series 19
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20 12V140E-3 Series
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q 114 engine
q 107 engine
12V140E-3 Series 21
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Example)
Injection pressure control valve of fuel
supply pump: PCV (SUMITOMO-2)
Example)
Speed sensor of fuel supply pump:
G (SUMITOMO-3)
a Pull the connector straight up.
22 12V140E-3 Series
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In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by sym-
bols. The electric wire code is helpful in understanding the electric circuit diagram.
Example: AEX 0.85 L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nomi-
nal No. of 0.85
Indicates color of wire by color code.
Color codes are shown in Table 3.
(Table 1)
Using
Sym-
Type Material temperature Example of use
bol
range (°C)
Low-voltage Conduc- Annealed copper for elec-
General wiring
wire for AV tor tric appliance
(Nominal No. 5 and above)
automobile Insulator Soft polyvinyl chloride
Thin-cover Conduc- Annealed copper for elec- –30 to +60
low-voltage tor tric appliance General wiring
AVS
wire for (Nominal No. 3 and below)
automobile Insulator Soft polyvinyl chloride
Heat-resis- Conduc- Annealed copper for elec-
General wiring in extremely
tant low-volt- tor tric appliance
AEX –50 to +110 cold district, wiring at high-tem-
age wire for Heat-resistant crosslinked
Insulator perature place
automobile polyethylene
12V140E-3 Series 23
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2. Dimensions
(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5
Number of
strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32
eter of strand
Conductor
Sectional
0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
area (mm2)
d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0
AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 –
Cov-
AV Standard – – – – – – – 4.6
er D
AEX Standard 2.0 2.2 2.7 3.0 3.1 – 3.8 4.6
24 12V140E-3 Series
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(Table 3)
Color Code Color of wire Color Code Color of wire
B Black LgW Light green & White
Br Brown LgY Light green & Yellow
BrB Brown & Black LR Blue & Red
BrR Brown & Red LW Blue & White
BrW Brown & White LY Blue & Yellow
BrY Brown & Yellow O Orange
Ch Charcoal P Pink
Dg Dark green R Red
G Green RB Red & Black
GB Green & Black RG Red & Green
GL Green & Blue RL Red & Blue
Gr Gray RW Red & White
GR Green & Red RY Red & Yellow
GW Green & White Sb Sky Blue
GY Green & Yellow Y Yellow
L Blue YB Yellow & Black
LB Blue & Black YG Yellow &Green
Lg Light green YL Yellow & Blue
LgB Light green & Black YR Yellow & Red
LgR Light green & Red YW Yellow & White
Remarks: In a color code consisting of 2 colors, the first color is the color of the background and
the second color is the color of the marking.
Example: “GW” means that the background is Green and marking is White.
(Table 4)
Type of wire AVS or AV AEX
Charge R WG – – – – R –
Ground B – – – – – B –
Start R – – – – – R –
Light RW RB RY RG RL – D –
Instrument Y YR YB YG YL YW Y Gr
Signal G GW GR GY GB GL G Br
L LW LR LY LB – L –
Type of
Br BrW BrR BrY BrB – – –
circuit
Lg LgR LgY LgB LgW – – –
O – – – – – – –
Others Gr – – – – – – –
P – – – – – – –
Sb – – – – – – –
Dg – – – – – – –
Ch – – – – – – –
12V140E-3 Series 25
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3) If the part is not under hydraulic pressure, the following corks can be used.
Nominal Dimensions
Part Number
number D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34
26 12V140E-3 Series
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a When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other
hydraulic equipment removed for repair, always bleed the air as follows:
1) Start the engine and run at low idle.
2) Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times, stopping the
cylinder 100 mm from the end of its stroke.
3) Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke.
4) After doing this, run the engine at normal speed.
a When using the machine for the first time after repair or long storage, follow the same procedure.
12V140E-3 Series 27
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28 12V140E-3 Series
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Type 1
1. Disconnection
1) Hold adapter (1) and push hose joint (2)
into mating adapter (3). (Fig. 1)
a The adapter can be pushed in about
3.5 mm.
a Do not hold rubber cap portion (4).
2) After hose joint (2) is pushed into adapter
(3), press rubber cap portion (4) against
adapter (3) until it clicks. (Fig. 2)
3) Hold hose adapter (1) or hose (5) and pull
it out. (Fig. 3)
a Since some hydraulic oil flows out,
prepare an oil receiving container.
2. Connection
1) Hold hose adapter (1) or hose (5) and
insert it in mating adapter (3), aligning
them with each other. (Fig. 4)
a Do not hold rubber cap portion (4).
2) After inserting the hose in the mating
adapter perfectly, pull it back to check its
connecting condition. (Fig. 5)
a When the hose is pulled back, the
rubber cap portion moves toward the
hose about 3.5 mm. This does not
indicate abnormality, however.
12V140E-3 Series 29
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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 hexag-
onal portion at the male end. (Fig. 6)
2) While holding the condition of Step 1), turn
lever (8) to the right (clockwise). (Fig. 7)
3) While holding the condition of Steps 1)
and 2), pull out whole body (7) to discon-
nect it. (Fig. 8)
2. Connection
q Hold the tightening portion and push body
(7) straight until sliding prevention ring (6)
contacts contact surface (a) of the hexag-
onal portion at the male end. (Fig. 9)
30 12V140E-3 Series
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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 hexag-
onal portion at the male end. (Fig. 10)
2) While holding the condition of Step 1),
push cover (10) straight until it contacts
contact surface (b) of the hexagonal por-
tion at the male end. (Fig. 11)
3) While holding the condition of Steps 1)
and 2), pull out whole body (9) to discon-
nect it. (Fig. 12)
2. Connection
q Hold the tightening portion and push body
(9) straight until the sliding prevention ring
contacts contact surface (b) of the hexag-
onal portion at the male end. (Fig. 13)
12V140E-3 Series 31
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a Fig. A a Fig. B
32 12V140E-3 Series
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12V140E-3 Series 33
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5. Table of tightening torques for hoses (taper seal type and face seal type)
a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the
torque below.
a Apply the following torque when the threads are coated (wet) with engine oil.
6. Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts)
a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114
engine series to the torque below.
Tightening torque
Thread size
Bolts and nuts
mm Nm kgm
6 10 ± 2 1.02 ± 0.20
8 24 ± 4 2.45 ± 0.41
10 43 ± 6 4.38 ± 0.61
12 77 ± 12 7.85 ± 1.22
14 — —
7. 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.
34 12V140E-3 Series
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8. 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.
12V140E-3 Series 35
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Conversion table 1
Method of using the conversion table
The conversion table in this section is provided to enable simple conversion of figures. For details of the
method of using the conversion table, see the example given below.
Example: Method of using the conversion table to convert from millimeters to inches
36 12V140E-3 Series
00 Index and foreword SEN00296-02
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
12V140E-3 Series 37
SEN00296-02 00 Index and foreword
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
kgm to ft.lb
1 kgm = 7.233 ft.lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
38 12V140E-3 Series
00 Index and foreword SEN00296-02
kg/cm2 to lb/in2
1 kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1,010 1,024 1,038 1,053 1,067 1,081 1,095 1,109 1,124
80 1,138 1,152 1,166 1,181 1,195 1,209 1,223 1,237 1,252 1,266
90 1,280 1,294 1,309 1,323 1,337 1,351 1,365 1,380 1,394 1,408
100 1,422 1,437 1,451 1,465 1,479 1,493 1,508 1,522 1,536 1,550
110 1,565 1,579 1,593 1,607 1,621 1,636 1,650 1,664 1,678 1,693
120 1,707 1,721 1,735 1,749 1,764 1,778 1,792 1,806 1,821 1,835
130 1,849 1,863 1,877 1,892 1,906 1,920 1,934 1,949 1,963 1,977
140 1,991 2,005 2,020 2,034 2,048 2,062 2,077 2,091 2,105 2,119
150 2,134 2,148 2,162 2,176 2,190 2,205 2,219 2,233 2,247 2,262
160 2,276 2,290 2,304 2,318 2,333 2,347 2,361 2,375 2,389 2,404
170 2,418 2,432 2,446 2,460 2,475 2,489 2,503 2,518 2,532 2,546
180 2,560 2,574 2,589 2,603 2,617 2,631 2,646 2,660 2,674 2,688
190 2,702 2,717 2,731 2,745 2,759 2,773 2,788 2,802 2,816 2,830
200 2,845 2,859 2,873 2,887 2,901 2,916 2,930 2,944 2,958 2,973
210 2,987 3,001 3,015 3,030 3,044 3,058 3,072 3,086 3,101 3,115
220 3,129 3,143 3,158 3,172 3,186 3,200 3,214 3,229 3,243 3,257
230 3,271 3,286 3,300 3,314 3,328 3,343 3,357 3,371 3,385 3,399
240 3,414 3,428 3,442 3,456 3,470 3,485 3,499 3,513 3,527 3,542
12V140E-3 Series 39
SEN00296-02 00 Index and foreword
Temperature
Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centi-
grade temperature reading or vice versa is to enter the accompanying table in the center (boldface column)
of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahren-
heit temperatures and read the corresponding Centigrade temperature in the column at the left.
When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centi-
grade values, and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
–40.4 –40 –40.0 –11.7 11 51.8 7.8 46 114.8 27.2 81 177.8
–37.2 –35 –31.0 –11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
–34.4 –30 –22.0 –10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
–31.7 –25 –13.0 –10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
–28.9 –20 –4.0 –9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
40 12V140E-3 Series
00 Index and foreword SEN00296-02
12V140E-3 Series 41
SEN00296-02 00 Index and foreword
© 2007 KOMATSU
All Rights Reserved
42 12V140E-3 Series
SEN00303-02
12V140E-3 Series
01 Specification 1
Specification and technical data
Outline.................................................................................................................................................. 2
Specifications ....................................................................................................................................... 4
General view ...................................................................................................................................... 10
Weight table ....................................................................................................................................... 19
Engine performance curves ............................................................................................................... 20
12V140E-3 Series 1
SEN00303-02 01 Specification
Outline 1
1. Applicable machine
2 12V140E-3 Series
01 Specification SEN00303-02
2. Outline of engine
q The 12V140E-3 engine is a high-performance are added: mounting of a recirculation port for
and high-efficiency engine which provides low surging control at the compressor side and a
fuel consumption, low noise, and improved design to improve efficiency of the turbine. As
exhaust gas color, and improved acceleration a result, high performance is attained in a wide
performance, and it cleared the strict exhaust range from the low-speed range to the high-
gas regulation (USA: EPA regulations for speed range, and high performance and low
2006). Accordingly, this newly developed fuel consumption are also obtained.
engine is suitable as a power source of
c o n s t r u c t i o n m a c h i n e r y, a n d i n d u s t r i a l 5) The piston cooling nozzle of 12V140-1 is
machinery used for various purposes. reviewed in regard to oil flow. As a result,
durability of the piston is improved and
q It is the successor of conventional 12V140-1 temperature of the rear surface of the piston is
engine which introduces various kinds of new reduced to prevent deterioration of the piston
technologies while adhering fundamentally to due to exposure of lubricating oil on the
the configuration of V12-cylinder, water- surface to high temperature. Since the high-
cooled, direct injection, and 4-stroke diesel pressure fuel injection system controlled
engine. electronically is employed, less-soot
combustion is attained and the draining
1) High-pressure fuel injection system controlled interval of the oil is lengthened.
electronically
The conventional one is a jerk in-line fuel 6) The high-pressure pump to create high
injection pump-based engine mechanically pressure in the common rail injection system is
controlled by a governor, while in all series of one-third of the conventional in-line fuel
the new one, an electronic control system- and injection pump, and in addition, it is connected
high-pressure injection system-based common compact to the timing gear case as a flange
rail injection system is adopted. This system mount rather than a saddle mount. As a result,
provides high pressure fuel of 118 MPa {1,200 sound radiation is reduced to provide low
kg/cm2} level from the low-speed range to the noise.
high-speed range. In addition, it can control
the form of injection most properly by the 7) Capacity of the lubrication pump is increased
electronic control system according to the by 10% over the conventional engine to
speed and load. As a result, clean exhaust contribute to the reliability and durability.
g a s , c l e a n e x h a u s t g a s c o l o r, l o w f u e l
consumption, and low noise are attained 8) The air cleaner is changed from the
simultaneously. conventional end surface seal type to radial
seal type to prevent the entry of dust due to
2) It adopts a re-entrant piston combustion deformation into the clean side. In addition, the
chamber which has been used since air cleaner clogging sensor for 5 clogging level
introduction into the 6D140E-2 engine and also indication is provided to inform users of a
uses a quality cast iron piston with less thermal precise cleaning time.
expansion and shaker cooling gallery. As a
result, clean exhaust gas, clean exhaust gas 9) A high performance and high efficiency
color, and low fuel consumption are attained combination filter is adopted as an oil filter, and
simultaneously, and also high durability and a filter system to collect small dirts as well as
high reliability are also obtained. large dirts is adopted for all specifications.
3) It also provides a higher compression ratio 10) The fuel filter system includes a high efficiency
than the conventional one to improve main filter and prefilter as standard features to
combustion efficiency and reduce the white allow use of low-grade fuel in the market
exhaust smoke when starting the engine in (corresponding to NAS13 level). In addition,
cold climate areas. In addition, by using the the delivery of the priming pump used to
above-mentioned high-pressure fuel injection replace the filters is increased for higher
system controlled electronically and setting the serviceability.
injection characteristics most properly to
improve the startability and reduce the white 11) In addition, since the engine controller is
exhaust smoke when the temperature is low. mounted on the engine and equipped with the
automatic high-altitude compensation function,
4) It is equipped with an improved turbocharger it can be operated at high altitude without
KOMATSU KTR110 of which high reliability replacing the controller. As a result, the
and high performance have been proven in the serviceability is improved.
12V140-1 engine. The following improvements
12V140E-3 Series 3
SEN00303-02 01 Specification
Specifications 1
671 {899}/2,000
Rated output kW{HP}/rpm
(Gross)
3,825 {390}/1,400
Max. torque Nm{kgm}/rpm
(Gross)
Performance
g/kW·h
Fuel consumption ratio at rated output 210 {156.7}
{g/HP·h}
4 12V140E-3 Series
01 Specification SEN00303-02
895 {1,200}/1,900
Rated output kW{HP}/rpm
(Gross)
5,076 {518}/1,350
Max. torque Nm{kgm}/rpm
(Gross)
Performance
g/kW·h
Fuel consumption ratio at rated output 207 {154}
{g/HP·h}
12V140E-3 Series 5
SEN00303-02 01 Specification
728 {976}/1,800
Rated output kW{HP}/rpm
(Gross)
4,488 {458}/1,350
Max. torque Nm{kgm}/rpm
(Gross)
Performance
g/kW·h
Fuel consumption ratio at rated output 207 {154}
{g/HP·h}
6 12V140E-3 Series
01 Specification SEN00303-02
636 {853}/2,000
Rated output kW{HP}/rpm
(Gross)
3,802 {388}/1,400
Max. torque Nm{kgm}/rpm
(Gross)
Performance
g/kW·h
Fuel consumption ratio at rated output 215 {160}
{g/HP·h}
12V140E-3 Series 7
SEN00303-02 01 Specification
672 {900}/2,050
Rated output kW{HP}/rpm
(Gross)
4,159 {424}/1,300
Max. torque Nm{kgm}/rpm
(Gross)
Performance
g/kW·h
Fuel consumption ratio at rated output 215 {160}
{g/HP·h}
8 12V140E-3 Series
01 Specification SEN00303-02
12V140E-3 Series 9
SEN00303-02 01 Specification
General view 1
SAA12V140E-3 (Left side view of engine)
Machine model: D475A-5E0
1. Center of crankshaft
2. Rear face of flywheel housing
10 12V140E-3 Series
01 Specification SEN00303-02
1. Center of crankshaft
2. Center of engine
12V140E-3 Series 11
SEN00303-02 01 Specification
1. Center of crankshaft
2. Rear face of flywheel housing
12 12V140E-3 Series
01 Specification SEN00303-02
1. Center of crankshaft
2. Center of engine
12V140E-3 Series 13
SEN00303-02 01 Specification
1. Center of crankshaft
2. Rear face of flywheel housing
14 12V140E-3 Series
01 Specification SEN00303-02
1. Center of crankshaft
2. Center of engine
12V140E-3 Series 15
SEN00303-02 01 Specification
1. Center of crankshaft
2. Rear face of flywheel housing
16 12V140E-3 Series
01 Specification SEN00303-02
1. Center of crankshaft
2. Center of engine
12V140E-3 Series 17
SEN00303-02 01 Specification
Dimensions table
Unit: mm
Dimensions of each part
Engine Machine model
A B C D E F G
D475A-5E0 287 1,582 1,772 2,171.5 726 507 507
HD785-7 230 1,585.8 2,046.5 1,745.3 715 210 210
SAA12V140E-3
PC2000-8 353 1,574.8 1,807.7 1,734.3 726 600 600
WA800-3E0, WA900-3E0 230 1,585.8 2,123 1,940 715.2 210 210
a These dimensions are given for reference when the engine is set on a test bench.
18 12V140E-3 Series
01 Specification SEN00303-02
Weight table 1
Unit: kg
No. Item Main parts SAA12V140E-3
1 Turbocharger KOMATSU KTR110L (Water-cooled) 25 x 2
Cylinder head, valve,
2 Cylinder head assembly 22.5 x 12
rocker arm, valve spring
Cylinder block, bearing cap,
3 Cylinder block assembly 810
cylinder liner
4 Gear case 72
5 Gear case 52
D475A-5E0
HD785-7
88.4
6 Oil pan Integral-type WA800-3E0,
WA900-3E0
PC2000-8 89.2
D475A-5E0 127.6
HD785-7 72.5
7 Flywheel assembly Flywheel, ring gear PC2000-8
WA800-3E0, 88.7
WA900-3E0
8 Flywheel housing assembly 133.5
9 Crankshaft assembly Crankshaft, crank gear 210
Camshaft, cam gear L 20
10 Camshaft assembly
thrust plate R 20
Piston, piston ring,
11 Piston and connecting rod assembly 10.5 x 12
piston pin, connecting rod
12 Oil pump 9
13 Fuel supply pump 13
14 Water pump 22
15 Alternator 24V, 90A 12
D475A-5E0
HD785-7
24V, 7.5kW
16 Starting motor WA800-3E0, 18 x 2
WA900-3E0
24V, 11kW PC2000-8
D475A-5E0 35 x 2
HD785-7 33 x 2
17 Aftercooler assembly PC2000-8 43 x 2
WA800-3E0,
40 x 2
WA900-3E0
12V140E-3 Series 19
SEN00303-02 01 Specification
20 12V140E-3 Series
01 Specification SEN00303-02
12V140E-3 Series 21
SEN00303-02 01 Specification
22 12V140E-3 Series
01 Specification SEN00303-02
12V140E-3 Series 23
SEN00303-02 01 Specification
24 12V140E-3 Series
01 Specification SEN00303-02
12V140E-3 Series 25
SEN00303-02 01 Specification
© 2007 KOMATSU
All Rights Reserved
26 12V140E-3 Series
SEN00307-02
12V140E-3 Series
12V140E-3 Series 1
SEN00307-02 10 Structure, function and maintenance standard
Crankshaft........................................................................................................................................... 26
Camshaft............................................................................................................................................. 28
Cam follower, 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
2 12V140E-3 Series
10 Structure, function and maintenance standard SEN00307-02
12V140E-3 Series 3
SEN00307-02 10 Structure, function and maintenance standard
Air cleaner 1
ERB type
[Air cleaner of automatic exhaust gas discharge type (Radial seal type)]
A: Air inlet
B: To turbocharger (Intake air)
C: To muffler (Dust)
1. Pre-cleaner
2. Air cleaner casing
3. Outer element
4. Inner element
4 12V140E-3 Series
10 Structure, function and maintenance standard SEN00307-02
FRG type
[Air cleaner of cyclone pack type with evacuator valve (Radial seal type)]
Number of
Engine Machine model Type Evacuator valve
elements
1 Inner element,
SAA12V140E-3 HD785-7 FRG (Radial seal type) Automatic discharge
1 Outer element
Structure Operation
q The size of the body is reduced from the con- q Air containing dust is sucked in vertically
ventional type without changing the diameter through inlet (1) and the dust is separated by
of the element. the centrifugal effect of guide vane (3).
q Since the inlet is set in the tangential direction, q More than 99.9% of the dust is removed by pri-
air is given sufficient centrifugal force by the mary element (4) and clean air is sucked in the
simple spiral guide vane, not by the guide engine through safety element (5) and outlet
plate. (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 dis-
charged out automatically.
12V140E-3 Series 5
SEN00307-02 10 Structure, function and maintenance standard
Turbocharger 1
Water-cooled type
Type: KTR110L
6 12V140E-3 Series
10 Structure, function and maintenance standard SEN00307-02
1. Blower housing
2. V-band
3. Diffuser plate
4. Center housing
5. Shroud
6. Turbine housing
7. Blower impeller
8. Seal ring
9. Thrust metal
10. Journal bearing
11. Seal ring
12. Turbine impeller
Specifications
Model: KOMATSU KTR110L (Water-cooled)
Overall length: 308 mm
Overall width: 305 mm
Overall height: 287 mm
Weight: 25 kg
12V140E-3 Series 7
SEN00307-02 10 Structure, function and maintenance standard
Model: KTR110L
8 12V140E-3 Series
10 Structure, function and maintenance standard SEN00307-02
Unit: mm
No. Check item Criteria Remedy
Standard Repair limit Replace thrust
1 End play (Play in axial direction)
0.08 – 0.13 0.18 parts
Replace
2 Radial play (Play in radial direction) 0.43 – 0.68 0.84
bearing parts
Clearance between blower housing Replace
3 Clearance limit (Min.): 0.14
and impeller bearing parts
12V140E-3 Series 9
SEN00307-02 10 Structure, function and maintenance standard
Turbocharger mounting
1. Exhaust manifold
2. Turbocharger
10 12V140E-3 Series
10 Structure, function and maintenance standard SEN00307-02
Aftercooler 1
Air-cooled type
1. Upper tank
2. Core
3. Lower tank
4. Fin
5. Tube
12V140E-3 Series 11
SEN00307-02 10 Structure, function and maintenance standard
Muffler 1
1. Turbocharger
2. Muffler
12 12V140E-3 Series
10 Structure, function and maintenance standard SEN00307-02
12V140E-3 Series 13
SEN00307-02 10 Structure, function and maintenance standard
Engine unit 1
Cylinder head 1
14 12V140E-3 Series
10 Structure, function and maintenance standard SEN00307-02
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 15
SEN00307-02 10 Structure, function and maintenance standard
Unit: mm
No. Check item Criteria Remedy
Strain of cylinder head Tolerance Repair limit Repair by grind-
1
mounting face 0 – 0.06 0.09 ing or replace
Engine Standard Replace nozzle
2 Projection of nozzle
SAA12V140E-3 2.3 – 2.9 or gasket
Bolt No. Procedure Target (Nm{kgm}) Range (Nm{kgm})
Tightening torque for cyl- Tighten in order
inder head mounting bolt 1st phase 147 {15} 137 – 157 {14 – 16} shown above. If
3 (Apply molybdenum dis- [1] – [6] 2nd phase 216 {22} 284 – 294 {29 – 30} there are 5 punch
ulfied or engine oil to 3rd phase Retighten by 90° 90(+30/0)° marks, replace
threaded part) the bolt.
[7] — 68.6 {7} 58.8 – 73.5 {6 – 7.5}
Tightening torque for Target (Nm {kgm}) Range (Nm {kgm})
4 injector holder mounting
bolt 66.7 {6.8} 58.8 – 73.5 {6 – 7.5}
16 12V140E-3 Series
10 Structure, function and maintenance standard SEN00307-02
12V140E-3 Series 17
SEN00307-02 10 Structure, function and maintenance standard
Cylinder block 1
1. Cylinder block
2. Cylinder liner
3. Clevis seal
4. O-ring
5. O-ring
6. Main bearing metal cap bolt
7. Main bearing metal cap
8. Main bearing metal
9. Piston cooling nozzle
10. Thrust bearing metal
18 12V140E-3 Series
10 Structure, function and maintenance standard SEN00307-02
Piston cooling
With piston cooling nozzle
Cylinder liner
Wet type
Machining on inside: Plateau honing and
Tufftride
12V140E-3 Series 19
SEN00307-02 10 Structure, function and maintenance standard
20 12V140E-3 Series
10 Structure, function and maintenance standard SEN00307-02
Unit: mm
No. Check item Criteria Remedy
Tolerance Repair limit Repair by
Strain of cylinder head mount-
1 grinding or
ing face 0 – 0.09 0.135 replace
Standard size Tolerance Replace or cor-
Inside diameter of main bear-
+0.025 rect main bear-
ing metal mounting hole 157
–0.010 ing metal cap
Surface roughness of main
10S or less
bearing metal mounting hole Correct
2
Roundness of mounting hole Repair limit: 0.005
–0.050
No.4 only 4.5
Thickness of main –0.060
bearing metal Other –0.065
4.5
than No.4 –0.075
Replace bear-
Inside diameter of Standard size Tolerance Repair limit
ing metal
main bearing metal +0.175
No.4 only 148 148.23
3 (When tightening +0.130
bolt with specified Other +0.145
torque) 148 148.20
than No.4 +0.100
Standard size Tolerance
Inside diameter of cam bush- Correct or
4 +0.025
ing mounting hole 69 replace block
+0.025
Standard size Tolerance Repair limit
Inside diameter of cam bush- Replace
5 +0.040
ing 65 65.15 cam bushing
+0.025
Procedure Target (Nm {kgm}) Range (Nm {kgm})
Tightening torque for main
bearing cap 1st time 284 {29} 270 – 299{27.5 – 30.5}
6
(Apply engine oil to threaded 2nd time 569 {58} 559 – 579{57.0 – 59.0}
portion and washer) Retighten
3rd time Retighten by 90° 90(+30/0)°
Tightening torque for oil pan
— — 65.7 {6.7} 58.8 – 73.6 {6 – 7.5}
mounting bolt
Level difference between
— under surfaces of cylinder Repair limit: 0.14 Reassemble
block and front cover
12V140E-3 Series 21
SEN00307-02 10 Structure, function and maintenance standard
Cylinder liner 1
Unit: mm
No. Check item Criteria Remedy
1 Projection of cylinder liner Repair limit: 0.07 – 0.15 Replace cylinder liner
or cylinder block
Rank Standard size Tolerance Repair limit
+0.020
Inside diameter of cylinder S 140 +0.020 140.12
liner
2 L 140 +0.040 140.14
+0.021 Replace cylinder liner
(Refilling is allowed
Roundness of cylinder liner Repair limit: 0.02 only for L)
Cylindricality of cylinder liner Repair limit: 0.02
Standard size Tolerance
Outside diameter of cylinder
liner (Counterbore portion) 170.2 –0.10
3 –0.10
Clearance between cylinder
liner and block Standard clearance: 0 – 0.163 Replace cylinder liner
(counterbore portion) or block
22 12V140E-3 Series
10 Structure, function and maintenance standard SEN00307-02
12V140E-3 Series 23
SEN00307-02 10 Structure, function and maintenance standard
24 12V140E-3 Series
10 Structure, function and maintenance standard SEN00307-02
Crankshaft
Closed die forging
Journal, filet: Induction hardening
Piston
Special thin ductile cast iron
FCD piston
Re-entrant piston
Connecting rod
Closed die forging
With lubricating oil hole
Cap bolt is screw type, installed by plastic-region Top ring (1) : Double-side keystone, inner cut,
tightening. ba rr e l f ac e, har d ch ro mi um-
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
12V140E-3 Series 25
SEN00307-02 10 Structure, function and maintenance standard
Crankshaft 1
26 12V140E-3 Series
10 Structure, function and maintenance standard SEN00307-02
Unit: mm
No. Check item Criteria Remedy
Standard value Repair limit Replace thrust bearing
1 End play metal or use oversize
0.140 – 0.315 0.50 metal
Rank Standard size Tolerance Repair limit
S.T.D. 148 147.98
Outside diameter of main 0.25 U.S. 147.75 147.73
journal –0.020 Use undersize journal
0.50 U.S. 147.50 147.48
–0.020 or replace
0.75 U.S. 147.25 147.23
2
1.00 U.S. 147.00 146.98
Roundness of main journal Repair limit: 0.010
Journal Standard clearance Clearance limit
Use undersize journal
Clearance of main journal No.4 only 0.130 – 0.195 0.25
or replace main metal
Other than No.4 0.100 – 0.165 0.22
Correct surface rough-
Surface roughness of main
0.8S (Surface roughness of R portion: 3.2S) ness of crankshaft
journal
journal
Rank Standard size Tolerance Repair limit
S.T.D. 100 89.88
Outside diameter of crank 0.25 U.S. 99.75 89.63
pin journal –0.020 Use undersize journal
0.50 U.S. 89.50 89.38
–0.020 or replace
0.75 U.S. 99.25 89.13
3 1.00 U.S. 99.00 88.88
Roundness of pin journal Repair limit: 0.010
Clearance of Standard clearance Clearance limit
crank pin journal 0.046 – 0.116 0.17 Replace connecting
Surface roughness of rod bearing metal
0.8S (Surface roughness of R portion: 3.2S)
crankpin journal
Standard Repair limit
Coaxiality of all main journals:
0.09
4 Bend of crankshaft 0.09 or less Replace
Coaxiality of adjacent main journals:
0.05
0.05 or less
Procedure Target (Nm {kgm}) Range (Nm {kgm})
Tightening torque for 1st time 74 {7.5} 54 – 93 {5.5 – 9.5}
5
adapter mounting bolt 2nd time 245 {25} 226 – 265 {23 – 27}
Retighten
3rd time 745 {76} 725 – 765 {74 – 78}
Tightening torque for
6 108 ± 10 Nm {11 ± 1.0 kgm}
damper mounting bolt
12V140E-3 Series 27
SEN00307-02 10 Structure, function and maintenance standard
Camshaft 1
Unit: mm
No. Check item Criteria Remedy
Standard Repair limit
1 End play Replace thrust plate
0.1 – 0.25 0.36
Standard size Tolerance
Outside diameter of cam-
–0.016 Replace
shaft journal 65
2 –0.036
Clearance of Standard clearance Clearance limit
Replace cam bushing
camshaft journal 0.016 – 0.096 0.15
3 Bend of camshaft Repair limit: 0.04 (Overall swing of indicator)
Cam Standard size Tolerance Repair limit
Replace
4 Height of cam Intake 55.48 ± 0.1 55.08
Exhaust 55.75 ± 0.1 55.35
28 12V140E-3 Series
10 Structure, function and maintenance standard SEN00307-02
Unit: mm
No. Check item Criteria Remedy
Standard size Tolerance Repair limit
Outside diameter of cam
follower shaft –0.021
1 22 –0.034 21.92
12V140E-3 Series 29
SEN00307-02 10 Structure, function and maintenance standard
30 12V140E-3 Series
10 Structure, function and maintenance standard SEN00307-02
Unit: mm
No. Check item Criteria Remedy
Rank Standard size Tolerance Repair limit
–0.120
S 140 139.830
1 Outside diameter of piston –0.135 Replace piston
–0.105
L 140 139.845
–0.120
No. Measuring point Standard size Tolerance
–0.015
2 No.1 ring 2.9
–0.035
Replace piston
Thickness of piston ring –0.010
3 No.2 ring 2.41 ring
–0.035
–0.010
4 Oil ring 4
–0.030
2 No.1 ring
Check with group wear gauge
3 No.2 ring
Width of piston ring groove Replace piston
+0.040
4 Oil ring 4
+0.025
No. Measuring point Standard clearance Clearance limit
2 No.1 ring Replace piston
2 – 4 Clearance between piston Check with group wear gauge
ring and piston ring groove 3 No.2 ring or piston ring
4 Oil ring 0.035 – 0.060 0.14
0.42 – 0.57
(Tension:
2 No.1 ring 2.0
16.5 – 23.5 N
{1.68 – 2.40 kg})
0.65 – 0.80
No.2 ring Replace piston
(Tension:
Closed gap of piston ring 3 (Identification 1.5 ring or cylinder
16.2 – 24.2 N
2RN white mark) liner
{1.65 – 2.47 kg})
0.30 – 0.50
(Tension:
4 Oil ring 1.0
70.1 – 94.6 N
{7.15 – 9.65 kg})
Standard size Tolerance
Outside diameter of piston Replace piston
pin –0.006 pin
52
–0.006
5 Inside diameter of piston pin +0.045
52 Replace piston
hole +0.035
Clearance between piston Standard clearance Clearance limit Replace piston
pin and piston 0.035 – 0.051 0.10 or piston pin
12V140E-3 Series 31
SEN00307-02 10 Structure, function and maintenance standard
Connecting rod 1
32 12V140E-3 Series
10 Structure, function and maintenance standard SEN00307-02
Unit: mm
No. Check item Criteria Remedy
Standard size Tolerance Repair limit Replace bushing
Inside diameter of connecting
+0.049 (Refilled part is
rod small end bushing 52 52.09
+0.030 semi-finished part)
1
Clearance between connect- Standard clearance Clearance limit
Replace bushing
ing rod small end bushing and
0.030 – 0.055 0.11 or piston pin
piston pin
Inside diameter of connecting Standard size Tolerance Replace connect-
2 rod small end bushing mount- +0.030 ing rod (Correction
ing hole 57.4 not allowed)
+0.030
Inside diameter of connecting Standard size Tolerance Repair limit
Replace bearing
3 rod large end bearing metal +0.096
100 100.15 metal
(Crankpin journal) +0.046
Inside diameter of connecting +0.026
106 — Replace connect-
rod large end hole –0.004
4 ing rod (Correction
(Without bearing metal, X, Y,
and Z directions) • Tighten connecting rod cap with specified torque and measure not allowed)
a Do not use a connecting rod cap mounting bolt more than 5 times.
Each time the bolt is used, make a punch mark on its head.
12V140E-3 Series 33
SEN00307-02 10 Structure, function and maintenance standard
Unit: mm
No. Check item Criteria Remedy
Facial runout of
1 Repair limit: 0.25
flywheel housing
Radial runout of
2 Repair limit: 0.25 Reassemble
flywheel housing
34 12V140E-3 Series
10 Structure, function and maintenance standard SEN00307-02
Vibration damper 1
1. Vibration damper
2. Pin (between adapter and vibration damper)
3. Adapter
4. Pin (between adapter and crankshaft)
5. Bolt (between adapter and crankshaft)
6. Bolt (between adapter and vibration damper)
12V140E-3 Series 35
SEN00307-02 10 Structure, function and maintenance standard
Timing gear 1
36 12V140E-3 Series
10 Structure, function and maintenance standard SEN00307-02
Unit: mm
No. Check item Criteria Remedy
Posi-
Measuring point Standard Repair limit
tion
Crank gear and
a 0.141 – 0.425
right main idler gear (Large)
Right main idler gear (Small) and
b 0.130 – 0.390
right sub idler gear
Right sub idler gear and
c 0.129 – 0.391
right cam gear
Right cam gear and
d 0.085 – 0.492
accessory drive gear
Right main idler gear (Small) and
— Backlash of each gear e 0.051 – 0.469 Replace
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
h 0.141 – 0.425
left main idler 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
Standard Tolerance Standard Clearance
Clearance between main size clearance limit
Shaft Hole
1 idler gear bushing and shaft
(Both right and left banks) –0.016 +0.034 Replace
56 0.025 – 0.063 0.20 bushing
–0.029 +0.009
Clearance between sub –0.016 +0.055
2 56 0.016 – 0.084 0.20
idler gear bushing and shaft –0.029 +0.055
Standard Repair limit
3 End play of main idler gear
0.09 – 0.26 0.4
12V140E-3 Series 37
SEN00307-02 10 Structure, function and maintenance standard
Valve system 1
38 12V140E-3 Series
10 Structure, function and maintenance standard SEN00307-02
Specifications
Camshaft
Drawn steel bar (Machining)
Journal and cam sections: Induction hardening
12V140E-3 Series 39
SEN00307-02 10 Structure, function and maintenance standard
40 12V140E-3 Series
10 Structure, function and maintenance standard SEN00307-02
Unit: mm
No. Check item Criteria Remedy
Valve Standard size Tolerance Repair limit
Replace valve or
1 Sinking distance of valve Intake 0 ± 0.10 0.70
valve seat
Exhaust 0 ± 0.10 0.70
Valve Standard size Repair limit
2 Thickness of valve lip Intake 2.4 1.9 Replace valve
Exhaust 2.15 1.75
Valve Standard size Tolerance
Correct or replace
3 Valve seat angle Intake 30° ± 15'
valve or valve seat
Exhaust 45° ± 15'
–0.045
Intake 10
Outside diameter of valve –0.060
Replace valve
stem –0.074
Exhaust 10
–0.089
Before head is +0.019
10
press fitted +0.001
Standard size Tolerance
Inside diameter of valve Press Not press Replace valve guide
4 guide After head is fitted fitted
press fitted 10 portion portion
+0.008 +0.011
–0.009 –0.009
Valve Standard clearance Clearance limit
Clearance between valve Replace valve or
Intake 0.034 – 0.071 0.22
guide and stem valve guide
Exhaust 0.063 – 0.100 0.24
Bend of valve stem Repair limit: 0.02 (Total runout of indicator, per 100) Replace valve
Standard Tolerance
5 Driving height of valve guide Correct
22.0 ± 0.2
Spring Standard size Repair limit
Free length of valve spring Outer 81.7 —
Inner 72.0 —
Installed Standard installed Allowable installed
Spring
length load (N {kg}) load (N {kg}) Replace valve
6 424.3 ± 21.6 377.3 spring
Installed load of valve spring Outer 51.0
{43.3 ± 2.2} {38.5}
215.6 ± 10.8 192.1
Inner 46.0
{22.0 ± 1.1} {19.6}
Perpendicularity of valve
Repair limit: 2° (Both ends)
spring
12V140E-3 Series 41
SEN00307-02 10 Structure, function and maintenance standard
Unit: mm
No. Check item Criteria Remedy
Outside diameter of rocker Standard size Tolerance Replace rocker arm
arm shaft 32.0 ± 0.0065 shaft
Inside diameter of rocker +0.087
1 32.0 Replace rocker arm
arm bushing +0.035
Clearance between rocker Standard clearance Clearance limit Replace rocker arm
arm shaft and rocker arm 0.0285 – 0.0935 0.13 shaft or rocker arm
Valve Standard Tolerance
Valve clearance
2 Intake 0.35 ± 0.02 Adjust
(When cold)
Exhaust 0.57 ± 0.02
Tightening torque Target (Nm {kgm}) Range (Nm {kgm})
3 for locknut of rocker arm Tighten
adjustment screw 58.8 {6} 52.9 – 64.7 {5.4 – 6.6}
42 12V140E-3 Series
10 Structure, function and maintenance standard SEN00307-02
Unit: mm
No. Check item Criteria Remedy
Standard size Tolerance Repair limit
Depth of crosshead stem
1 +0.3
receiver 6.2 6.61
+0.3
Inside diameter of cross- Replace
11.04 ± 0.02 11.17
head
2
Outside diameter of cross- +0.011
11 10.95
head guide +0.011
Projection of crosshead
3 49.0 ± 0.25 — Correct
guide
12V140E-3 Series 43
SEN00307-02 10 Structure, function and maintenance standard
© 2007 KOMATSU
All Rights Reserved
44 12V140E-3 Series
SEN00309-02
12V140E-3 Series
12V140E-3 Series 1
SEN00309-02 10 Structure, function and maintenance standard
2 12V140E-3 Series
10 Structure, function and maintenance standard SEN00309-02
12V140E-3 Series 3
SEN00309-02 10 Structure, function and maintenance standard
Lubrication system 1
Lubrication system diagram 1
4 12V140E-3 Series
10 Structure, function and maintenance standard SEN00309-02
W: Coolant
1. Oil pan
2. Strainer
3. Oil pump (Triple gear pump)
4. Main relief valve
5. Oil cooler
6. Regulator valve
7. Oil cooler bypass valve
8. Oil filter
9. Oil filter safety valve
10. Main gallery
11. Crankshaft
12. Camshaft
13. Rocker arm
14. Cam follower
15. Intake valve and exhaust valve
16. Piston
17. Piston cooling nozzle
18. Timing gear
19. Turbocharger
20. Fuel supply pump
12V140E-3 Series 5
SEN00309-02 10 Structure, function and maintenance standard
Oil pump 1
6 12V140E-3 Series
10 Structure, function and maintenance standard SEN00309-02
Oil cooler 1
12V140E-3 Series 7
SEN00309-02 10 Structure, function and maintenance standard
Oil filter 1
8 12V140E-3 Series
10 Structure, function and maintenance standard SEN00309-02
Unit: mm
No. Check item Criteria Remedy
Tolerance
Standard
Standard size Outside diam- Inside diame-
Clearance between main relief clearance Replace valve or
4 eter of valve ter of body
valve and body body
–0.040 –0.016
33 0.040 – 0.076
–0.060 –0.016
Installed Installed load Allowable load
Free length
5 Main relief valve spring length (N {kg}) (N {kg}) Replace spring
12V140E-3 Series 9
SEN00309-02 10 Structure, function and maintenance standard
10 12V140E-3 Series
10 Structure, function and maintenance standard SEN00309-02
Unit: mm
No. Check item Criteria Remedy
Tolerance
Standard
Standard size Outside diam- Inside diame-
Clearance between regulator clearance Replace valve or
1 eter of valve ter of body
valve and body body
–0.020 +0.033
22 0.020 – 0.074
–0.041 +0.033
Installed Installed load Allowable load
Free length
2 Regulator valve spring length (N {kg}) (N {kg}) Replace spring
12V140E-3 Series 11
SEN00309-02 10 Structure, function and maintenance standard
Fuel system 1
CRI system diagram 1
12 12V140E-3 Series
10 Structure, function and maintenance standard SEN00309-02
1. NE speed sensor
2. Engine controller
3. Injector
4. Fuel tank
5. Pre-fuel filter
6. Main fuel filter
7. Overflow valve
8. Fuel supply pump assembly
9. PCV
10. High-pressure pump
11. Feed pump
12. Relief valve
13. G speed sensor
14. Common rail
15. Flow damper
16. Pressure limiter
17. High-pressure injection pipe
18. Priming pump (Main)
12V140E-3 Series 13
SEN00309-02 10 Structure, function and maintenance standard
Configuration
q The CRI system is divided by the function into
the fuel system and control system.
14 12V140E-3 Series
10 Structure, function and maintenance standard SEN00309-02
2. Control system
12V140E-3 Series 15
SEN00309-02 10 Structure, function and maintenance standard
q The CRI system consists of fuel supply pump, q If the TWV is turned ON (energized), the fuel
common rail, injector, ECU which controls circuit is changed so that the high-pressure
these 3 units, and sensors. fuel in the control chamber will flow through the
q The fuel supply pump generates fuel pressure orifice. As a result, the needle valve is raised
in the common rail. The fuel pressure is con- to start fuel injection by the nozzle cracking
trolled by the fuel discharge rate of the supply pressure of the high-pressure fuel on the noz-
pump. zle side.
q The fuel discharge rate is controlled by turning q If the TWV is turned OFF (de-energized), the
on and off the PCV (Fuel injection pressure fuel circuit is changed so that the high-pres-
control valve) of the fuel supply pump accord- sure fuel will flow to the control chamber
ing to the electric signals from the ECU. through the orifice. As a result, the needle
q The common rail receives the pressurized fuel valve lowers to finish fuel injection.
from the fuel supply pump and distributes it to q Accordingly, the fuel injection timing and fuel
the cylinders. injection rate are controlled respectively by the
q The fuel pressure is sensed by the common timing to turn on the TWV and the length of the
rail fuel pressure sensor installed to the com- turn-on time of the TWV.
mon rail.
q A feedback control is applied so that the actual
fuel pressure will match to the command pres-
sure set according to the engine speed and the
load on the engine.
q The fuel pressure in the common rail is applied
to the nozzle side of the injector and to the
control chamber through the fuel injection pipe
of each cylinder.
q The injector controls the fuel injection rate and
fuel injection timing by turning ON and OFF the
TWV (2-way solenoid valve).
16 12V140E-3 Series
10 Structure, function and maintenance standard SEN00309-02
12V140E-3 Series 17
SEN00309-02 10 Structure, function and maintenance standard
Operation
18 12V140E-3 Series
10 Structure, function and maintenance standard SEN00309-02
12V140E-3 Series 19
SEN00309-02 10 Structure, function and maintenance standard
2. Common rail
Structure
q Common rail (4) distributes the high-pressure
fuel from the high-pressure pump to the injec-
tors of the cylinders.
q Common rail (4) is equipped with common rail
fuel pressure sensor (2), flow dampers (1), and
pressure limiter (3).
q The fuel injection pipes are connected to flow
dampers (1) to send the high-pressure fuel to
the injectors.
q The piping of the pressure limiter (3) is
returned to the fuel tank.
1) Flow damper
Function
q The flow dampers damp the pressure pulses in 2) Pressure limiter
the high pressure piping and supply the fuel to q If abnormally high pressure is generated, the
the injectors with stable pressure. pressure limiter opens to release that pres-
q If excessive fuel flows out, the flow dampers sure.
block the fuel passage to prevent abnormal q If the common rail fuel pressure reaches about
outflow of the fuel. 140 MPa {1,430 kg/cm2}, the pressure limiter
q If the fuel flows out abnormally, high pressure operates (Opens).
is applied to the piston, which moves to the q If the common rail fuel pressure lowers to 30
right until it reaches the seat to stop the fuel. MPa {310 kg/cm2}, the pressure limiter resets
itself (close) to maintain the pressure.
20 12V140E-3 Series
10 Structure, function and maintenance standard SEN00309-02
12V140E-3 Series 21
SEN00309-02 10 Structure, function and maintenance standard
3. Injector
Outline
q The function of the injector is to inject the high
pressure fuel from the common rail into each
combustion chamber of the engine in the opti-
mum timing, by the optimum quantity, at the
optimum injection rate, and under the optimum
spray condition.
q The TWV (2-way solenoid valve) controls the
start and finish of fuel injection by controlling
the pressure in the control chamber.
q The orifice limits the opening speed of the noz-
zle and controls the fuel injection rate.
q The hydraulic piston transmits the force gener-
ated by the pressure in the control chamber to
the needle valve of the nozzle.
q The nozzle sprays the fuel.
22 12V140E-3 Series
10 Structure, function and maintenance standard SEN00309-02
Structure
12V140E-3 Series 23
SEN00309-02 10 Structure, function and maintenance standard
Operation
1) No fuel injection (A) 3) Finish of fuel injection (C)
q While solenoid (6) is not energized, valve body q If solenoid (6) is de-energized, valve body (5)
(5) is pressed down by spring (7). is lowered by spring (7) and the fuel passage is
q Since the high-pressure fuel is applied from closed.
the common rail to pressure control chamber q Since the high-pressure fuel in the common
(8), nozzle (1) is closed and the fuel is not rail is applied to pressure control chamber (8)
injected. suddenly at this time, nozzle (1) is closed
quickly and fuel injection is finished sharply.
2) Start of fuel injection (B)
q If solenoid (6) is energized, valve body (5) is
raised by electromagnetic power to open the
fuel passage.
q Since the fuel in pressure control chamber (8)
flows out through orifices (3) and (4), nozzle
(1) rises and the fuel injection pump starts.
q The fuel injection rate is increased gradually by
the function of orifices (3) and (4).
q Continuing energization to solenoid (6) pro-
vides the maximum fuel injection rate.
24 12V140E-3 Series
10 Structure, function and maintenance standard SEN00309-02
12V140E-3 Series 25
SEN00309-02 10 Structure, function and maintenance standard
26 12V140E-3 Series
10 Structure, function and maintenance standard SEN00309-02
A: Pressure inlet
B: Mounting screw: M5
Tightening torque:
4.5 ± 0.5 Nm {0.46 ± 0.05 kgm}
q The following graph shows the output charac-
teristics of the atmospheric pressure sensor.
12V140E-3 Series 27
SEN00309-02 10 Structure, function and maintenance standard
A: Mounting screw: M6
Tightening torque:
5.5 ± 0.5 Nm {0.56 ± 0.05 kgm}
1. Sensor
2. O-ring
28 12V140E-3 Series
10 Structure, function and maintenance standard SEN00309-02
12V140E-3 Series 29
SEN00309-02 10 Structure, function and maintenance standard
Various controls
30 12V140E-3 Series
10 Structure, function and maintenance standard SEN00309-02
12V140E-3 Series 31
SEN00309-02 10 Structure, function and maintenance standard
Fuel piping 1
Left bank
32 12V140E-3 Series
10 Structure, function and maintenance standard SEN00309-02
12V140E-3 Series 33
SEN00309-02 10 Structure, function and maintenance standard
Right bank
34 12V140E-3 Series
10 Structure, function and maintenance standard SEN00309-02
12V140E-3 Series 35
SEN00309-02 10 Structure, function and maintenance standard
36 12V140E-3 Series
10 Structure, function and maintenance standard SEN00309-02
Fuel filter 1
A: Fuel inlet
B: Fuel outlet
Specifications
Filtration area: 1.0 m2
12V140E-3 Series 37
SEN00309-02 10 Structure, function and maintenance standard
Pre-fuel filter
A: Fuel inlet
B: Fuel outlet
Specifications
Filtration area: 2.12 m2
38 12V140E-3 Series
10 Structure, function and maintenance standard SEN00309-02
Priming pump 1
12V140E-3 Series 39
SEN00309-02 10 Structure, function and maintenance standard
Cooling system 1
Cooling system diagram 1
40 12V140E-3 Series
10 Structure, function and maintenance standard SEN00309-02
A: Lubricating oil
1. Radiator
2. Cooling fan
2A. Hydraulic fan motor
3. Water pump
4. Oil cooler (For engine)
5. Corrosion resistor
6. Thermostat housing
7. Oil cooler (For power train)
8. Oil cooler bypass circuit (For power train)
9. Air bleeding
10. Turbocharger
12V140E-3 Series 41
SEN00309-02 10 Structure, function and maintenance standard
Water pump 1
1. Pump shaft
2. Water seal
3. Pump body
4. Water pump drive gear (Number of teeth: 25)
5. Ball bearing
6. Oil seal
7. Impeller
8. Pump cover
Specifications
Water pump
Type: Centrifugal, gear-driven
Revolving speed: Engine speed x 1.80
42 12V140E-3 Series
10 Structure, function and maintenance standard SEN00309-02
1. Oil cooler
2. Thermostat housing
3. Water pump
12V140E-3 Series 43
SEN00309-02 10 Structure, function and maintenance standard
Thermostat 1
A: To radiator
B: To water pump (When bypassing)
C: To thermostat
1. Thermostat housing
2. Thermostat
3. Cylinder block
Specifications
Valve cracking temperature: 76.5 ± 2°C
Temperature at full opening: 90°C
Lift at full opening: Min. 10 mm
Q'ty: 3
Unit: mm
No. Check item Criteria Remedy
Lift of thermostat at full Min. 10 mm (Before checking, leave it in water tank of 90°C for 4
opening – 5 minutes)
2 Move valve in fully open condition (in water tank of 90°C) to water Replace
Opening/Closing of
tank of 71°C and keep it for 4 -–5 minutes.
thermostat
Valve must fully close.
44 12V140E-3 Series
10 Structure, function and maintenance standard SEN00309-02
Corrosion resistor 1
12V140E-3 Series 45
SEN00309-02 10 Structure, function and maintenance standard
46 12V140E-3 Series
10 Structure, function and maintenance standard SEN00309-02
1. Crankshaft pulley
2. Fan belt
3. Tension pulley
4. Adjustment bolt
5. Tension pulley bracket
6. Fan pulley
7. Fan
12V140E-3 Series 47
SEN00309-02 10 Structure, function and maintenance standard
Tension pulley
SAA12V140E-3 (HD785-7, WA800-3E0, WA900-3E0)
1. Tension shaft
2. Spring
3. Roller bearing
4. Tension bracket
5. Spacer
6. Tension pulley (outside diameter: 154 mm)
7. Ball bearing
8. Oil seal
9. Grease fitting
10. Grease fitting
48 12V140E-3 Series
10 Structure, function and maintenance standard SEN00309-02
The cooling fan is hydraulic motor-driven. For more information, refer to the shop
manual for the machine body.
12V140E-3 Series 49
SEN00309-02 10 Structure, function and maintenance standard
Electrical equipment 1
Alternator 1
Alternator with built-in regulator (Open type, 90A)
Pulley
Specifica- Outside Weight
Engine Machine model Type Number
tions diameter (kg)
of stages
(mm)
D475A-5E0
HD785-7 Open type (brushless) manu-
SAA12V140E-3 24V, 90A 2 95 19
PC2000-8 factured by NIKKO DENKI
WA800-3E0, WA900-3E0
50 12V140E-3 Series
10 Structure, function and maintenance standard SEN00309-02
Alternator mounting
1. Adjustment bolt
2. Alternator pulley
3. Alternator
4. Alternator drive belt
5. Accessory pulley
12V140E-3 Series 51
SEN00309-02 10 Structure, function and maintenance standard
Starting motor 1
For 7.5 kW
E: To chassis ground
R: To alternator terminal R
S: To starting switch terminal C
Number
Specifica- Weight Type of
Engine Machine model Type of pinion
tions (kg) connector
teeth
D475A-5E0 Water-resistant, oil-resistant
SAA12V140E-3 HD785-7 type manufactured by NIKKO 24V, 7.5 kW 11 18 DT
WA800-3E0, WA900-3E0 DENKI
52 12V140E-3 Series
10 Structure, function and maintenance standard SEN00309-02
For 11 kW
E: To chassis ground
R: To alternator terminal R
S: To starting switch terminal C
Number
Specifica- Weight Type of
Engine Machine model Type of pinion
tions (kg) connector
teeth
Water-resistant, oil-resistant type
SAA12V140E-3 PC2000-8 24V, 11 kW 11 18 DT
manufactured by NIKKO DENKI
12V140E-3 Series 53
SEN00309-02 10 Structure, function and maintenance standard
Starting aid 1
Electric heater
1. Body Specifications
2. Heater coil Type of heater: Electrical intake air heater
3. Terminal Rated voltage: 22 V (DC)
4. Connection diagram Load current: 175 A
54 12V140E-3 Series
10 Structure, function and maintenance standard SEN00309-02
Engine controller 1
Features
Mounting of engine controller on engine
q Since the engine controller is mounted on the engine, the operator can service it easily in the field.
q Vibrations are damped by the vibration-proof rubber.
12V140E-3 Series 55
SEN00309-02 10 Structure, function and maintenance standard
© 2007 KOMATSU
All Rights Reserved
56 12V140E-3 Series
SEN00311-03
12V140E-3 Series
12V140E-3 Series 1
SEN00311-03 20 Standard value table
Engine SAA12V140E-3
Machine model D475A-5E0
Category
Speed
Min. speed at no load rpm 660 ± 40 660 ± 40
Necessary At 0°C (without starting aid) rpm Min. 110 —
speed for
starting At –20°C (with starting aid) rpm Min. 100 —
Exhaust kPa
At rated output — —
pressure {mmHg}
Exhaust
Whole speed range (20°C ) °C Max. 680 750
temperature
Bosch
At sudden acceleration (Low to High) Max. 4.5 5.5
index
Exhaust gas Bosch
At rated output Max. 1.0 2.0
color index
Bosch
At high idle Max. 1.0 2.0
index
Intake valve mm 0.35 ± 0.02 0.35 ± 0.02
Valve clearance
Exhaust valve mm 0.57 ± 0.02 0.57 ± 0.02
Compression Engine oil temperature: 40 – 60°C MPa Min. 4.1 2.8
pressure Engine speed: 200 – 250 rpm {kg/cm2} {Min. 42} {29}
Body
Engine oil temperature: Min. 80°C SAE5W40E0S {kg/cm2} {3.0 – 4.5} {2.0}
Oil pressure SAE10W30DH
At low idle SAE15W40DH MPa Min. 0.08 0.04
Engine oil temperature: Min. 80°C SAE30DH {kg/cm2} {Min. 0.8} {0.4}
Oil temperature Whole speed range (Oil in oil pan) °C 90 – 110 120
Ratio to fuel consumption at continuous rated
Oil consumption % 0.15 0.3
output
Function of
Cooling system
kPa
radiator pres- Cracking pressure (Differential pressure) — —
{kg/cm2}
sure valve
Hydraulically Hydraulically
Fan speed At rated speed rpm driven on driven on
machine side machine side
Alternator belt
— Deflection under finger pressure of 59 N {6 kg} mm 20 20
tension
2 12V140E-3 Series
20 Standard value table SEN00311-03
Engine SAA12V140E-3
Machine model HD785-7
Category
Speed
Min. speed at no load rpm 650 ± 20 650 ± 20
Necessary At 0°C (without starting aid) rpm Min. 110 —
speed for
starting At –20°C (with starting aid) rpm Min. 100 —
Exhaust kPa
At rated output — —
pressure {mmHg}
Exhaust
Whole speed range (20°C ) °C Max. 700 750
temperature
Bosch
At sudden acceleration (Low to High) Max. 4.5 5.5
index
Exhaust gas Bosch
At rated output Max. 1.0 2.0
color index
Bosch
At high idle Max. 1.0 2.0
index
Intake valve mm 0.35 ± 0.02 0.35 ± 0.02
Valve clearance
Exhaust valve mm 0.57 ± 0.02 0.57 ± 0.02
Compression Engine oil temperature: 40 – 60°C MPa Min. 4.1 2.8
pressure Engine speed: 200 – 250 rpm {kg/cm2} {Min. 42} {29}
Body
Engine oil temperature: Min. 80°C SAE5W40E0S {kg/cm2} {3.0 – 4.5} {2.0}
Oil pressure SAE10W30DH
At low idle SAE15W40DH MPa Min. 0.08 0.04
Engine oil temperature: Min. 80°C SAE30DH {kg/cm2} {Min. 0.8} {0.4}
Oil temperature Whole speed range (Oil in oil pan) °C 90 – 110 120
Ratio to fuel consumption at continuous rated
Oil consumption % 0.15 0.3
output
Function of
Cooling system
kPa
radiator pres- Cracking pressure (Differential pressure) — —
{kg/cm2}
sure valve
Alternator belt
— Deflection under finger pressure of 59 N {6 kg} mm 20 20
tension
12V140E-3 Series 3
SEN00311-03 20 Standard value table
Engine SAA12V140E-3
Machine model PC2000-8
Category
Speed
Min. speed at no load rpm 825 ± 25 825 ± 25
Necessary At 0°C (without starting aid) rpm Min. 110 —
speed for
starting At –20°C (with starting aid) rpm Min. 100 —
Exhaust kPa
At rated output — —
pressure {mmHg}
Exhaust
Whole speed range (20°C ) °C Max. 700 750
temperature
Bosch
At sudden acceleration (Low to High) Max. 4.5 5.5
index
Exhaust gas Bosch
At rated output Max. 1.0 2.0
color index
Bosch
At high idle Max. 1.0 2.0
index
Intake valve mm 0.35 ± 0.02 0.35 ± 0.02
Valve clearance
Exhaust valve mm 0.57 ± 0.02 0.57 ± 0.02
Compression Engine oil temperature: 40 – 60°C MPa Min. 4.1 2.8
pressure Engine speed: 200 – 250 rpm {kg/cm2} {Min. 42} {29}
Body
Engine oil temperature: Min. 80°C SAE5W40E0S {kg/cm2} {3.0 – 4.5} {2.0}
Oil pressure SAE10W30DH
At low idle SAE15W40DH MPa Min. 0.08 0.06
Engine oil temperature: Min. 80°C SAE30DH {kg/cm2} {Min. 0.8} {0.6}
Oil temperature Whole speed range (Oil in oil pan) °C 90 – 110 120
Ratio to fuel consumption at continuous rated
Oil consumption % 0.15 0.3
output
Function of
Cooling system
kPa
radiator pres- Cracking pressure (Differential pressure) — —
{kg/cm2}
sure valve
Hydraulically Hydraulically
Fan speed At rated speed rpm driven on driven on
machine side machine side
Alternator belt
— Deflection under finger pressure of 59 N {6 kg} mm 20 20
tension
4 12V140E-3 Series
20 Standard value table SEN00311-03
Engine SAA12V140E-3
Machine model WA800-3E0
Category
Speed
Min. speed at no load rpm 680 (+50/0) 680 (+50/0)
Necessary At 0°C (without starting aid) rpm Min. 110 —
speed for
starting At –20°C (with starting aid) rpm Min. 100 —
Exhaust kPa
At rated output — —
pressure {mmHg}
Exhaust
Whole speed range (20°C ) °C Max. 680 750
temperature
Bosch
At sudden acceleration (Low to High) Max. 4.5 5.5
index
Exhaust gas Bosch
At rated output Max. 1.0 2.0
color index
Bosch
At high idle Max. 1.0 2.0
index
Intake valve mm 0.35 ± 0.02 0.35 ± 0.02
Valve clearance
Exhaust valve mm 0.57 ± 0.02 0.57 ± 0.02
Compression Engine oil temperature: 40 – 60°C MPa Min. 4.1 2.8
pressure Engine speed: 200 – 250 rpm {kg/cm2} {Min. 42} {29}
Body
Engine oil temperature: Min. 80°C SAE5W40E0S {kg/cm2} {3.0 – 4.5} {2.0}
Oil pressure SAE10W30DH
At low idle SAE15W40DH MPa Min. 0.08 0.04
Engine oil temperature: Min. 80°C SAE30DH {kg/cm2} {Min. 0.8} {0.4}
Oil temperature Whole speed range (Oil in oil pan) °C 90 – 110 120
Ratio to fuel consumption at continuous rated
Oil consumption % 0.15 0.3
output
Function of
Cooling system
kPa
radiator pres- Cracking pressure (Differential pressure) — —
{kg/cm2}
sure valve
Alternator belt
— Deflection under finger pressure of 59 N {6 kg} mm 20 20
tension
12V140E-3 Series 5
SEN00311-03 20 Standard value table
Engine SAA12V140E-3
Machine model WA900-3E0
Category
Speed
Min. speed at no load rpm 680 (+50/0) 680 (+50/0)
Necessary At 0°C (without starting aid) rpm Min. 110 —
speed for
starting At –20°C (with starting aid) rpm Min. 100 —
Exhaust kPa
At rated output — —
pressure {mmHg}
Exhaust
Whole speed range (20°C ) °C Max. 700 750
temperature
Bosch
At sudden acceleration (Low to High) Max. 4.5 5.5
index
Exhaust gas Bosch
At rated output Max. 1.0 2.0
color index
Bosch
At high idle Max. 1.0 2.0
index
Intake valve mm 0.35 ± 0.02 0.35 ± 0.02
Valve clearance
Exhaust valve mm 0.57 ± 0.02 0.57 ± 0.02
Compression Engine oil temperature: 40 – 60°C MPa Min. 4.1 2.8
pressure Engine speed: 200 – 250 rpm {kg/cm2} {Min. 42} {29}
Body
Engine oil temperature: Min. 80°C SAE5W40E0S {kg/cm2} {3.0 – 4.5} {2.0}
Oil pressure SAE10W30DH
At low idle SAE15W40DH MPa Min. 0.08 0.04
Engine oil temperature: Min. 80°C SAE30DH {kg/cm2} {Min. 0.8} {0.4}
Oil temperature Whole speed range (Oil in oil pan) °C 90 – 110 120
Ratio to fuel consumption at continuous rated
Oil consumption % 0.15 0.3
output
Function of
Cooling system
kPa
radiator pres- Cracking pressure (Differential pressure) — —
{kg/cm2}
sure valve
Alternator belt
— Deflection under finger pressure of 59 N {6 kg} mm 20 20
tension
6 12V140E-3 Series
20 Standard value table SEN00311-03
Engine SAA12V140E-3
Machine model D475A-5E0
Procedure
Item
1 2 3 4 5 6
Running time min. 5 15 5 5 20 10
Speed rpm 660 1,000 1,250 1,550 1,800 2,000
Dynamometer load N {kg} 0 {0} 568 {58} 1,127 {115} 2,254 {230} 3,381 {345} 4,508 {460}
Output kW {HP} 0 {0} 43 {57} 106 {142} 263 {352} 457 {612} 677 {907}
a This table shows the values when the fan is not installed.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Engine SAA12V140E-3
Machine model D475A-5E0
Max. speed at Min. speed at
Test item Rated output Max. torque
no load no load
Specification value 671 kW/2,000 rpm 3,825 Nm/1,400 rpm
— 2,150(+25/-50)rpm 660 ± 40 rpm
(Gross value) {899 HP/2,000 rpm} {390 kgm/1,400 rpm}
Speed rpm 2,000 ± 5 1,300 – 1,500 — —
N 4,341 – 4,596 5,174 – 5,498
Dynamometer load — —
{kg} {443 – 469} {528 – 561}
kW 651 – 691
Output (Gross value) — — —
{HP} {873 – 926}
Nm 3,704 – 3,940
Torque (Gross value) — — —
{kgm} {378 – 402}
Fuel consumption sec/1,000cc Min. 19.5 — — —
Coolant temperature °C 70 – 90 70 – 90 70 – 90 70 – 90
Lubricating oil
°C 90 – 110 90 – 110 90 – 110 90 – 110
temperature
Lubricating oil MPa 0.34 – 0.49 Min. 0.08
— —
pressure {kg/cm2} {3.0 – 4.5} {Min. 0.8}
Exhaust temperature °C Max. 650 Max. 680 — —
a This table shows the standard values obtained by using the JIS correction coefficients.
a Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.
a This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
a Use ASTM No.1 or No. 2 diesel fuel as fuel.
a Use SAE15W-40 as lubricating oil.
a Aftercooler outlet temperature must not exceed 50°C.
12V140E-3 Series 7
SEN00311-03 20 Standard value table
Running-in standard
Engine SAA12V140E-3
Machine model HD785-7
Procedure
Item
1 2 3 4 5 6
Running time min. 5 15 5 5 20 10
Speed rpm 650 1,000 1,250 1,550 1,800 1,900
Dynamometer load N {kg} 0 {0} 784 {80} 1,568 {160} 3,136 {320} 4,704 {480} 6,272 {640}
Output kW {HP} 0 {0} 59 {79} 147 {197} 365 {489} 635 {852} 894 {1,200}
a This table shows the values when the fan is not installed.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Engine SAA12V140E-3
Machine model HD785-7
Max. speed at Min. speed at
Test item Rated output Max. torque
no load no load
Specification value 895 kW/1,900 rpm 5,076 Nm/1,350 rpm
— 2,250 ± 25 rpm 650 ± 20 rpm
(Gross value) {1,200 HP/1,900 rpm} {518 kgm/1,350 rpm}
Speed rpm 1,900 ± 5 1,300 – 1,400 — —
N 6,086 – 6,468 6,870 – 7,311
Dynamometer load — —
{kg} {621 – 660} {701 – 746}
kW 868 – 922
Output (Gross value) — — —
{HP} {1,160 – 1,240}
Nm 4,920 – 5,233
Torque (Gross value) — — —
{kgm} {502 – 534}
Fuel consumption sec/1,000cc Min. 15.2 — — —
Coolant temperature °C 70 – 90 70 – 90 70 – 90 70 – 90
Lubricating oil
°C 90 – 110 90 – 110 90 – 110 90 – 110
temperature
Lubricating oil MPa 0.34 – 0.49 Min. 0.08
— —
pressure {kg/cm2} {3.0 – 4.5} {Min. 0.8}
Exhaust temperature °C Max. 650 Max. 700 — —
a This table shows the standard values obtained by using the JIS correction coefficients.
a Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.
a This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
a Use ASTM No.1 or No. 2 diesel fuel as fuel.
a Use SAE15W-40 as lubricating oil.
a Aftercooler outlet temperature must not exceed 50°C.
8 12V140E-3 Series
20 Standard value table SEN00311-03
Running-in standard
Engine SAA12V140E-3
Machine model PC2000-8
Procedure
Item
1 2 3 4 5 6
Running time min. 5 15 5 5 20 10
Speed rpm 825 1,000 1,250 1,550 1,800 1,800
Dynamometer load N {kg} 0 {0} 676 {69} 1,352 {138} 2,695 {275} 4,074 {413} 5,390 {550}
Output kW {HP} 0 {0} 51 {68} 127 {171} 313 {420} 546 {733} 728 {976}
a This table shows the values when the fan is not installed.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Engine SAA12V140E-3
Machine model PC2000-8
Max. speed at Min. speed at
Test item Rated output Max. torque
no load no load
Specification value 728 kW/1,800 rpm 4,488 Nm/1,350 rpm
— 1,980 ± 25 rpm 825 ± 25 rpm
(Gross value) {976 HP/1,800 rpm} {458 kgm/1,350 rpm}
Speed rpm 1,800 ± 5 1,300 – 1,400 — —
N 4,341 – 4,596 6,076 – 6,380
Dynamometer load — —
{kg} {534 – 567} {620 – 659}
kW 706 – 750
Output (Gross value) — — —
{HP} {947 – 1,010}
Nm 4,351 – 4,626
Torque (Gross value) — — —
{kgm} {444 – 472}
Fuel consumption sec/1,000cc Min. 18.6 — — —
Coolant temperature °C 70 – 90 70 – 90 70 – 90 70 – 90
Lubricating oil
°C 90 – 110 90 – 110 90 – 110 90 – 110
temperature
Lubricating oil MPa 0.34 – 0.49 Min. 0.08
— —
pressure {kg/cm2} {3.0 – 4.5} {Min. 0.8}
Exhaust temperature °C Max. 650 Max. 700 — —
a This table shows the standard values obtained by using the JIS correction coefficients.
a Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.
a This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
a Use ASTM No.1 or No. 2 diesel fuel as fuel.
a Use SAE15W-40 as lubricating oil.
a Aftercooler outlet temperature must not exceed 50°C.
12V140E-3 Series 9
SEN00311-03 20 Standard value table
Running-in standard
Engine SAA12V140E-3
Machine model WA800-3E0
Procedure
Item
1 2 3 4 5 6
Running time min. 5 15 5 5 20 10
Speed rpm 680 1,000 1,250 1,550 1,800 2,000
Dynamometer load N {kg} 0 {0} 529 {54} 1,058 {108} 2,107 {215} 3,156 {322} 4,214 {430}
Output kW {HP} 0 {0} 40 {53} 99 {133} 245 {328} 427 {572} 633 {848}
a This table shows the values when the fan is not installed.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Engine SAA12V140E-3
Machine model WA800-3E0
Max. speed at Min. speed at
Test item Rated output Max. torque
no load no load
Specification value 636 kW/2,000 rpm 3,802 Nm/1,400 rpm 2,200 (+10/-20)
— 680 (+50/0) rpm
(Gross value) {853 HP/2,000 rpm} {388 kgm/1,400 rpm} rpm
Speed rpm 2,000 ± 5 1,350 – 1,450 — —
N 4,116 – 4,371 5,155 – 5,468
Dynamometer load — —
{kg} {420 – 446} {526 – 558}
kW 617 – 655
Output (Gross value) — — —
{HP} {827 – 879}
Nm 3,685 – 3,920
Torque (Gross value) — — —
{kgm} {376 – 400}
Fuel consumption sec/1,000cc Min. 20.5 — — —
Coolant temperature °C 70 – 90 70 – 90 70 – 90 70 – 90
Lubricating oil
°C 90 – 110 90 – 110 90 – 110 90 – 110
temperature
Lubricating oil MPa 0.34 – 0.49 Min. 0.08
— —
pressure {kg/cm2} {3.0 – 4.5} {Min. 0.8}
Exhaust temperature °C Max. 650 Max. 680 — —
a This table shows the standard values obtained by using the JIS correction coefficients.
a Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.
a This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
a Use ASTM No.1 or No. 2 diesel fuel as fuel.
a Use SAE15W-40 as lubricating oil.
a Aftercooler outlet temperature must not exceed 50°C.
10 12V140E-3 Series
20 Standard value table SEN00311-03
Running-in standard
Engine SAA12V140E-3
Machine model WA900-3E0
Procedure
Item
1 2 3 4 5 6
Running time min. 5 15 5 5 20 10
Speed rpm 680 1,000 1,250 1,550 1,800 2,050
Dynamometer load N {kg} 0 {0} 549 {56} 1,088 {111} 2,185 {223} 3,273 {334} 4,361 {445}
Output kW {HP} 0 {0} 41 {55} 102 {137} 254 {341} 442 {593} 671 {899}
a This table shows the values when the fan is not installed.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Engine SAA12V140E-3
Machine model WA900-3E0
Max. speed at Min. speed at
Test item Rated output Max. torque
no load no load
Specification value 672 kW/2,050 rpm 4,159 Nm/1,300 rpm
— 2,200(+10/-20)rpm 680(+50/0)rpm
(Gross value) {900 HP/2,050 rpm} {424 kgm/1,300 rpm}
Speed rpm 2,050 ± 5 1,250 – 1,350 — —
N 4,234 – 4,488 5,625 – 5,978
Dynamometer load — —
{kg} {432 – 458} {574 – 610}
kW 652 – 691
Output (Gross value) — — —
{HP} {874 – 927}
Nm 4,028 – 4,283
Torque (Gross value) — — —
{kgm} {411 – 437}
Fuel consumption sec/1,000cc Min. 19.5 — — —
Coolant temperature °C 70 – 90 70 – 90 70 – 90 70 – 90
Lubricating oil
°C 90 – 110 90 – 110 90 – 110 90 – 110
temperature
Lubricating oil MPa 0.34 – 0.49 Min. 0.08
— —
pressure {kg/cm2} {3.0 – 4.5} {Min. 0.8}
Exhaust temperature °C Max. 650 Max. 700 — —
a This table shows the standard values obtained by using the JIS correction coefficients.
a Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.
a This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
a Use ASTM No.1 or No. 2 diesel fuel as fuel.
a Use SAE15W-40 as lubricating oil.
a Aftercooler outlet temperature must not exceed 50°C.
12V140E-3 Series 11
SEN00311-03 20 Standard value table
© 2007 KOMATSU
All Rights Reserved
12 12V140E-3 Series
SEN00313-00
12V140E-3 Series
12V140E-3 Series 1
SEN00313-00 30 Testing and adjusting
2 12V140E-3 Series
30 Testing and adjusting SEN00313-00
Sym-
Q'ty
Testing/Adjusting item Part No. Part name Remarks
bol
Testing air boost 799-201-2202 Boost gauge kit 1 -101 – 200 kPa {-760 – 1,500 mmHg}
A
pressure 799-401-2220 Hose 1
Testing exhaust
B 799-101-1502 Digital thermometer 1 - 99.9 – 1,299°C
temperature
Commercially Intake: 0.35 mm
Adjusting valve clearance C Thickness gauge 1
available Exhaust: 0.57 mm
1 795-502-1590 Compression gauge 1 0 – 6.9 MPa {0 – 70 kg/cm2}
Testing compression
D 795-471-1310 Adapter 1
pressure 2 For 140E-3, 5
6261-71-6150 Gasket 1
1 799-201-1590 Gauge 1 0 – 10 kPa {0 – 1,000 mmH2O}
2 799-201-1450 Adapter 2
Testing blow-by pressure E
3 799-201-1511 Nozzle 2
4 799-201-1571 Tube 1
Pressure gauge: 2.5, 6, 40, 60 MPa
799-101-5002 Hydraulic tester 1
1 {25.5, 61.2, 408, 612 kg/cm2}
Testing oil pressure F
799-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {612 kg/cm2}
2 799-401-2320 Gauge 1 Pressure gauge: 1 MPa {10 kg/cm2}
Pressure gauge: 2.5, 6, 40, 60 MPa
799-101-5002 Hydraulic tester 1
1 {25.5, 61.2, 408, 612 kg/cm2}
799-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {612 kg/cm2}
Testing fuel pressure G 2 (Setting) Adapter 1 8 x 1.25 (male) – PT1/8 (female)
799-101-5220 Nipple (10 x 1.25 mm) 1
3 Size: 10 x 1.25 mm
07002-11023 O-ring 1
4 799-401-2320 Gauge 1 Pressure gauge: 1 MPa {10 kg/cm2}
1 6151-51-8490 Spacer 1 ø 14
2 6141-71-1710 Joint 1 ø 10
Commercially
3 Hose 1 Inside diameter: Approx. 11 mm
available
Testing leakage through Commercially
4 Hose 1 Inside diameter: Approx. 17 mm
pressure limiter and H available
return rate from injector Commercially
5 Measuring cylinder 1
available
Commercially
6 Stopwatch 1
available
7 07376-70315 Plug 1 Size: 03
799-601-4130 T-adapter 1 For Ne sensor
799-601-4330 Socket 1 For G (Bkup) sensor
Controller • sensor 799-601-4240 Socket 1 For atmospheric pressure sensor
J
• Actuator diagnosis 799-601-4250 Socket 1 For boost pressure sensor
799-601-9420 T-adapter 1 For common rail pressure sensor
799-601-4150 T-adapter 1 For oil pressure sensor
12V140E-3 Series 3
SEN00313-00 30 Testing and adjusting
Sym-
Q'ty
Testing/Adjusting item Part No. Part name Remarks
bol
For boost temperature sensor
795-799-5540 Socket 1
For intake air sensor
For coolant temperature sensor
795-799-5530 Socket 1 For fuel temperature sensor
Oil temperature sensor
799-601-9430 Socket 1 For supply pump PCV
Controller • sensor 799-601-9020 T-adapter 1 For injector
J
• Actuator diagnosis 799-601-4260 T-adapter 1 For controller (4 - pole)
799-601-4211 T-adapter 1 For controller (50 - pole)
799-601-4220 T-adapter 1 For controller (60 - pole)
799-601-4350 T-box 1 For 60 - pole type
799-601-9320 T-box 1 For 24 - pole type
799-601-9310 Plate 1
4 12V140E-3 Series
30 Testing and adjusting SEN00313-00
12V140E-3 Series 5
SEN00313-00 30 Testing and adjusting
Testing exhaust temperature 1 3. Run the engine and test the exhaust tempera-
ture in the whole speed range.
a Testing tool for exhaust temperature
a When testing with the engine mounted on
Symbol Part No. Part name the machine, test on the condition
B 799-101-1502 Digital thermometer described in the shop manual for the
machine.
k Remove and install the testing tools after
the exhaust manifold temperature has low-
ered.
a The test point is subject to machine models.
6 12V140E-3 Series
30 Testing and adjusting SEN00313-00
Adjusting valve clearance 1 5. Hereafter crank the engine similar way in the
firing order. Match the stamped line of the
a Adjusting tool for valve clearance damper to the pointer and adjust the valve
Symbol Part No. Part name clearance of each cylinder.
a Firing order
Commercially
C
available
Clearance gauge R1 – L1 – R5 – L5 – R3 – L3 – R6 – L6 –
R2 – L2 – R4 – L4
12V140E-3 Series 7
SEN00313-00 30 Testing and adjusting
8 12V140E-3 Series
30 Testing and adjusting SEN00313-00
12V140E-3 Series 9
SEN00313-00 30 Testing and adjusting
10 12V140E-3 Series
30 Testing and adjusting SEN00313-00
Testing blow-by pressure 1 3. Run the engine at the rated output and test the
blow-by pressure.
a Testing tool for blow-by pressure
a When testing with the engine mounted on
Symbol Part No. Part name Q'ty the machine, test on the condition
1 799-201-1590 Gauge 1 described in the shop manual for the
machine.
2 799-201-1450 Adapter 2
E
3 799-201-1511 Nozzle 2
4 799-201-1571 Tube 1
2. Connect tube [4] and gauge [1] to either one of 4. After finishing testing, remove the testing tools
the nozzles.Close the tube connecting mate of and return the removed parts.
other nozzle with a piece of short cut tube, etc.
12V140E-3 Series 11
SEN00313-00 30 Testing and adjusting
12 12V140E-3 Series
30 Testing and adjusting SEN00313-00
Testing oil pressure 1 3. Run the engine at the rated output and low idle
and test the oil pressure.
a Testing tools for oil pressure a When testing with the engine mounted on
Symbol Part No. Part name the machine, test on the condition
described in the shop manual for the
799-101-5002 Hydraulic tester
1 machine.
F 790-261-1204 Digital hydraulic tester
2 799-401-2320 Hydraulic tester
12V140E-3 Series 13
SEN00313-00 30 Testing and adjusting
14 12V140E-3 Series
30 Testing and adjusting SEN00313-00
Testing fuel pressure 1 3. Run the engine at high idle and measure the
fuel pressure.
a Testing tools for fuel pressure a If the fuel pressure is in the following
Symbol Part No. Part name range, it is normal.
799-101-5002 Hydraulic tester Engine speed Fuel pressure
1
790-261-1204 Digital hydraulic tester 0.15 – 0.3 MPa
High idle
2 (Setting) Adapter {1.5 – 3 kg/cm2}
G
799-101-5220 Nipple
3
07002-11023 O-ring
4 799-401-2320 Gauge
1. Remove air bleeder plug (1) on the top of fuel 4. Since the fuel circuits on the LH and RH banks
filter. after the priming pump are independent, test
each circuit.
12V140E-3 Series 15
SEN00313-00 30 Testing and adjusting
16 12V140E-3 Series
30 Testing and adjusting SEN00313-00
a If the engine is of a type that returns the fuel a Prepare an oil pan of about 20 l to receive the
spilling from the injector from the return block fuel flowing out during the test.
installed to the front of intake manifold, check
the engine according to the following (the fig- 1. Preparatory work (case of the LH bank)
ure showing the LH bank for PC2000). 1) Remove tube (4) between common rail (3)
a Testing tools for pressure limiter leakage and and supply pump (5).
injector return rate 2) Insert spacer H1 on supply pump (5) side
Symbol Part No. Part name and tighten the removed joint bolt again.
1 6151-51-8490 Spacer
2 6141-71-1710 Joint
Commercially Inside diameter of the hose:
3
available Approx. 11 mm
Commercially Inside diameter of the hose:
4
H available Approx. 17 mm
Commercially
5 Measuring cylinder
available
Commercially
6 Stopwatch
available
7 07376-70315 Plug
12V140E-3 Series 17
SEN00313-00 30 Testing and adjusting
a Connect the return pipe to the fuel 2. Testing leakage from pressure limiter
tank again, too. 1) Lay test hose H3 so that it will not slacken
a Be sure to provide a gasket to both and put its end in the oil pan.
ends of the spacer. 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 lim-
iter is in the following range, it is nor-
mal.
Engine speed Leakage
(rpm) (cc/min)
3) Insert joint H2 on common rail (3) side and
1,600 Max. 10
tighten the removed joint bolt again.
a Be sure to fit the gaskets to both ends
of the joint.
4) 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.
18 12V140E-3 Series
30 Testing and adjusting SEN00313-00
12V140E-3 Series 19
SEN00313-00 30 Testing and adjusting
a If fuel is used up or if a fuel circuit part is a Don't fill fuel directly after removing main
removed and installed, bleed air from the fuel filter (1).
circuit according to the following procedure.
a The locations of the fuel circuit parts are sub-
ject to machine models (The figure showing
the LH bank for D475A-5).
20 12V140E-3 Series
30 Testing and adjusting SEN00313-00
12V140E-3 Series 21
SEN00313-00 30 Testing and adjusting
22 12V140E-3 Series
30 Testing and adjusting SEN00313-00
a If fuel is used up or if a fuel circuit part is a Don't fill fuel directly after removing main
removed and installed, bleed air from the fuel filter (1).
circuit according to the following procedure.
a The locations of the fuel circuit parts are sub-
ject to machine models (The figure showing
the LH bank for PC2000).
12V140E-3 Series 23
SEN00313-00 30 Testing and adjusting
24 12V140E-3 Series
30 Testing and adjusting SEN00313-00
Testing fuel system for leakage 1 9. Inspect the fuel piping and devices for fuel
k
leakage.
Very high pressure is generated in the high-
a Check mainly around the high-pressure
pressure circuit of the fuel system. If fuel
circuit parts coated with the color checker
leaks while the engine is running, it is dan-
for fuel leakage.
gerous since it can catch fire.
a If any fuel leakage is detected, repair it
After testing the fuel system or removing
and inspect again from step 1.
its parts, test it for fuel leakage according
a If no fuel leakage is detected, check is
to the following procedure.
completed.
a Clean and degrease the engine and the parts
around it in advance so that you can test it eas-
ily for fuel leakage.
12V140E-3 Series 25
SEN00313-00 30 Testing and adjusting
1. Remove speed sensor (1) and check that its tip Adjusting
is free from steel chips and flaws, and then a If the deflection is out of the standard range,
install it again temporarily. adjust it according to the following procedure.
2 Threads: Gasket sealant (LG-6)
26 12V140E-3 Series
30 Testing and adjusting SEN00313-00
12V140E-3 Series 27
SEN00313-00 30 Testing and adjusting
© 2006 KOMATSU
All Rights Reserved
28 12V140E-3 Series
SEN00315-00
12V140E-3 Series
40 Troubleshooting
General information on troubleshooting
General information on troubleshooting.......................................................................................................... 2
Points to remember when troubleshooting ........................................................................................... 2
Error codes and failure codes list ......................................................................................................... 3
12V140E-3 Series 1
SEN00315-00 40 Troubleshooting
2 12V140E-3 Series
40 Troubleshooting SEN00315-00
12V140E-3 Series 3
SEN00315-00 40 Troubleshooting
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)
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)
4 12V140E-3 Series
40 Troubleshooting SEN00315-00
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)
--*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)
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.
12V140E-3 Series 5
SEN00315-00 40 Troubleshooting
© 2006 KOMATSU
All Rights Reserved
6 12V140E-3 Series
SEN00316-00
12V140E-3 Series
40 Troubleshooting 1
Troubleshooting of mechanical system
(S-mode)
Troubleshooting of mechanical system (S-mode)........................................................................................... 3
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
12V140E-3 Series 1
SEN00316-00 40 Troubleshooting
2 12V140E-3 Series
40 Troubleshooting SEN00316-00
Items listed in the [Questions] and [Check items] and related to the [Causes] are marked with E, Q, or w.
E: Causes to be referred to for questions and check items
Q: Causes related to questions and check items
w: Causes highly probable among ones marked with Q
a When narrowing the "auses", apply the items marked with w before those marked with Q.
When narrowing the causes, do not apply the items marked with E. (If no items have other marks and
the causes cannot be narrowed, however, you may apply them.)
12V140E-3 Series 3
SEN00316-00 40 Troubleshooting
4 12V140E-3 Series
40 Troubleshooting SEN00316-00
If we look for the linkage of these three phenomena to possible causes, we find that they have causal rela-
tionship with five causes.
Let us explain here the method of using this causal relationship to pinpoint the most probable cause.
12V140E-3 Series 5
SEN00316-00 40 Troubleshooting
Defective injector
start until the crankshaft revolves 2 turns at maximum.
This phenomenon does not indicate a trouble, however.
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Clean
Clean
Clean
Clean
Remedy
6 12V140E-3 Series
40 Troubleshooting SEN00316-00
installed machine
When terminal B and terminal C of starting switch are connected,
Turn starting switch OFF,
engine starts q
connect cord, turn the
switch ON and carry out When terminal B and terminal C at safety relay outlet are connected,
troubleshooting engine starts q
When terminal B and terminal C at safety relay outlet are connected,
engine does not start q
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Remedy
—
12V140E-3 Series 7
SEN00316-00 40 Troubleshooting
Defective injector
Confirm recent repair history
Degree of
Operated for long period E E E
Questions
machine operation
Exhaust smoke suddenly stopped coming out (when starting again) w Q w w w E E
Non-specified fuel is being used w
Replacement of filters not carried out according to Operation and Maintenance
w w E E Q
Manual
When fuel tank is inspected, it is found to be empty w
Air breather hole of fuel tank cap is clogged Q w
Rust and water are found when fuel tank is drained Q Q Q Q Q
When fuel filter is removed, there is no fuel in it w Q w
w
Check items
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Clean
Remedy
Add
8 12V140E-3 Series
40 Troubleshooting SEN00316-00
c) Exhaust smoke comes out but engine does not start Causes
(fuel is being injected)
While engine is Fuel does not flow out if air bleeding plug of fuel filter is
removed Q Q w w
cranked with start-
ing motor, If spill hose from injector is disconnected, little fuel spills Q Q w
When exhaust manifold is touched immediately after starting engine, temperature of
some cylinders is low w
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Clean
Clean
Remedy
12V140E-3 Series 9
SEN00316-00 40 Troubleshooting
gas is Black w Q w w
When engine is cranked, abnormal sound is generated around cylinder head w
When engine is cranked, interference sound is emitted from around turbocharger w
High idle speed under no load is normal, but speed suddenly drops when load is applied Q w w
There is hunting from engine (rotation is irregular) Q Q w Q
Blow-by gas is excessive w
Replace
Replace
Replace
Replace
Correct
Correct
Remedy
Clean
Clean
Clean
Clean
10 12V140E-3 Series
40 Troubleshooting SEN00316-00
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Remedy
—
Add
12V140E-3 Series 11
SEN00316-00 40 Troubleshooting
Correct
Correct
Correct
Clean
Remedy
Add
12 12V140E-3 Series
40 Troubleshooting SEN00316-00
Suddenly
Power was lost
Gradually Q Q Q Q Q Q Q
Non-specified fuel is being used Q Q
Replacement of filters not carried out according to Operation and Mainte-
nance Manual w Q
Engine oil replenished more frequently Q Q Q
Dust indicator is red (if indicator is installed) w
Air breather hole of fuel tank cap is clogged w
Fuel is leaking from fuel piping w
Output becomes insufficient after short stop of operation w
Color of exhaust Black w w
gas Blue under light load w
When exhaust manifold is touched immediately after starting engine,
temperature of some cylinders is low w
w
Check items
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
Clean
Clean
Clean
12V140E-3 Series 13
SEN00316-00 40 Troubleshooting
14 12V140E-3 Series
40 Troubleshooting SEN00316-00
Color of exhaust
gas Gradually became black w Q Q
Blue under light load w
Non-specified fuel is being used Q Q
Oil replenished more frequently w
Suddenly w Q Q Q
Power was lost
Gradually Q Q Q Q
Dust indicator is red (if indicator is installed) w
Muffler is crushed w
Air leaks between turbocharger and cylinder head, and clamp is loosened w
Engine is operated in low-temperature mode at normal temperature Q Q Q
When exhaust manifold is touched immediately after starting engine, temperature
of some cylinders is low Q w
When engine is cranked, interference sound is emitted from around turbocharger w
Check items
Adjusting
Adjusting
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Remedy
Clean
12V140E-3 Series 15
SEN00316-00 40 Troubleshooting
Turbocharger 1
q Long-time operation of engine at low idle or high idle
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
16 12V140E-3 Series
40 Troubleshooting SEN00316-00
See S-7
Inspect oil cooler directly q
Inspect oil filter directly q
Spring of oil filter safety valve is hitched or broken q
Inspect turbocharger lubrication drain tube directly q
Replace
Replace
Replace
Replace
Replace
Clean
Clean
Remedy Clean
—
12V140E-3 Series 17
SEN00316-00 40 Troubleshooting
Carry out troubleshooting according to “No-pressure feed by supply pump error (*1)“ in E-mode q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change
change on some cylinders q
If spill hose from injector is disconnected and measured, much fuel spills q
Carry out troubleshooting according to “Abnormality in coolant temperature sensor (*2)“ in E-mode q
Confirm with INSITE or with monitoring function on installed machine side q q
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Remedy
18 12V140E-3 Series
40 Troubleshooting SEN00316-00
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)1
General causes why oil is mixed in coolant Causes
q Internal leakage in lubrication system
Broken hydraulic oil cooler or power train oil cooler on installed machine side
q Internal leakage in cooling system
operation
Suddenly increased Q Q Q
Oil level
Gradually increased Q Q
Hard water is being used as coolant Q Q
Oil level has risen and oil is milky Q Q w
There are excessive air bubbles in radiator, coolant spurts back w w
Check items
on installed machine
Remedy
—
12V140E-3 Series 19
SEN00316-00 40 Troubleshooting
Replace
Replace
Correct
Remedy
Clean
Clean
Clean
Clean
—
Add
20 12V140E-3 Series
40 Troubleshooting SEN00316-00
Clogged water pump drain hole (breather hole) and/or defective seal
q Fuel in oil (smells diluted diesel fuel)
a If oil is in coolant, carry out troubleshooting for "S-11 Oil is in cool-
Degree of
machine operation
Operated for long period E E E E
Fuel consumption increasing w w
Coolant replenished more frequently Q w
There is oil mixed in coolant Q Q Q w
Oil smells of diesel fuel w w
Oil is milky Q w
When engine is started, drops of water come from muffler Q
When radiator cap is removed and engine is run at low idle, an abnormal number of bubbles
appears, or coolant spurts back w Q
Check items
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
12V140E-3 Series 21
SEN00316-00 40 Troubleshooting
Sudden overheated Q w Q
Condition for
Persistent overheating Q w w Q
Coolant tempera- Rises quickly Q w
ture gauge
(if installed) Does not go down from red range w
Radiator coolant level monitor indicates drop of coolant level (if monitor is installed) w
Engine oil level has risen and oil is milky w Q
Fan belt tension is low w
Milky oil is floating on coolant w
There are excessive air bubbles in radiator and coolant spurts back w
When light bulb is held behind radiator core, no light passes through w
Radiator shroud, inside of underguard on applicable machine side are clogged with
Check items
dirt or mud w w
Coolant is leaking because of cracks in hose or loose clamps w
Coolant flows out from radiator overflow hose w
Fan belt whines under sudden acceleration w
Power train oil temperature gauge enters red range faster than engine coolant tem-
perature gauge (if oil temperature gauge and coolant temperature gauge are w
installed) on the installed machine side
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
—
Add
22 12V140E-3 Series
40 Troubleshooting SEN00316-00
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Remedy
12V140E-3 Series 23
SEN00316-00 40 Troubleshooting
Adjusting
Replace
Replace
Replace
Replace
Replace
Replace
Remedy
24 12V140E-3 Series
SEN00316-00 40 Troubleshooting
© 2006 KOMATSU
All Rights Reserved
26 12V140E-3 Series
SEN00317-00
12V140E-3 Series
40 Troubleshooting 1
Troubleshooting of electrical system
(E-mode), Part 1
Troubleshooting of electrical system (E-mode), Part 1 ................................................................................... 4
Information in troubleshooting table ..................................................................................................... 4
E-1 Code [111/CA111] ECM Critical Internal Failure (LH bank) ........................................................... 6
E-2 Code [111/CB111] ECM Critical Internal Failure (RH bank)........................................................... 8
E-3 Code [115/CA115] Eng. Ne and G (Bkup) Speed Sensor Error (LH bank).................................. 10
E-4 Code [115/CB115] Eng. Ne and G (Bkup) Speed Sensor Error (RH bank) ..................................11
E-5 Code [122/CA122] Charge Air Press. Sensor High Error (LH bank only) ................................... 12
E-6 Code [123/CA123] Charge Air Press. Sensor Low Error (LH bank only) .................................... 14
E-7 Code [131/CA131] Throttle Sensor High Error (LH bank only).................................................... 16
E-8 Code [132/CA132] Throttle Sensor Low Error (LH bank only) .................................................... 18
E-9 Code [135/CA135] Oil Press. Sensor High Error (LH bank only) ................................................ 20
E-10 Code [141/CA141] Oil Press. Sensor Low Error (LH bank only) ............................................... 22
E-11 Code [144/CA144] Coolant Temp. Sensor High Error (LH bank only) ....................................... 24
E-12 Code [145/CA145] Coolant Temp. Sensor Low Error (LH bank only) ....................................... 26
12V140E-3 Series 1
SEN00317-00 40 Troubleshooting
E-13 Code [153/CA153] Charge Air Temp. Sensor High Error (LH bank only) .................................. 28
E-14 Code [154/CA154] Charge Air Temp. Sensor Low Error (LH bank only)................................... 30
E-15 Code [187/CA187] Sensor Sup. 2 Volt. Low Error (LH bank) .................................................... 31
E-16 Code [187/CB187] Sensor Sup. 2 Volt. Low Error (RH bank) ................................................... 31
E-17 Code [212/CA212] Eng. Oil Temp.Sensor High Error (LH bank only) ....................................... 32
E-18 Code [213/CA213] Eng. Oil Temp.Sensor Low Error (LH bank only) ........................................ 34
E-19 Code [221/CA221] Ambient Air Press. Sensor High Error (LH bank only) ................................ 36
E-20 Code [222/CA222] Ambient Air Press. Sensor Low Error (LH bank only) ................................. 38
E-21 Code [227/CA227] Sensor Sup. 2 Volt. High Error (LH bank) ................................................... 40
E-22 Code [227/CB227] Sensor Sup. 2 Volt. High Error (RH bank)................................................... 42
E-23 Code [234/CA234] Eng. Overspeed (LH bank only).................................................................. 44
E-24 Code [238/CA238] Ne Speed Sensor Sup. Volt. Error (LH bank).............................................. 46
E-25 Code [238/CB238] Ne Speed Sensor Sup. Volt. Error (RH bank) ............................................. 48
E-26 Code [263/CA263] Fuel Temp. Sensor High Error (LH bank).................................................... 50
E-27 Code [263/CB263] Fuel Temp. Sensor High Error (RH bank) ................................................... 52
E-28 Code [265/CA265] Fuel Temp. Sensor Low Error (LH bank)..................................................... 54
E-29 Code [265/CB265] Fuel Temp. Sensor Low Error (RH bank) .................................................... 54
E-30 Code [271/CA271] PCV1 Short Error (LH bank) ....................................................................... 56
E-31 Code [271/CB271] PCV1 Short Error (RH bank)....................................................................... 58
E-32 Code [272/CA272] PCV1 Open Error (LH bank) ....................................................................... 60
E-33 Code [272/CB272] PCV1 Open Error (RH bank)....................................................................... 61
E-34 Code [273/CA273] PCV2 Short Error (LH bank) ....................................................................... 62
E-35 Code [273/CB273] PCV2 Short Error (RH bank)....................................................................... 64
E-36 Code [274/CA274] PCV2 Open Error (LH bank) ....................................................................... 66
E-37 Code [274/CB274] PCV2 Open Error (RH bank)....................................................................... 67
E-38 Code [322/CA322] Injector #1 (L/B #1) System Open/Short Error (LH bank) ........................... 68
E-39 Code [323/CA323] Injector #5 (L/B #5) System Open/Short Error (LH bank) ........................... 70
E-40 Code [324/CA324] Injector #3 (L/B #3) System Open/Short Error (LH bank) ........................... 72
E-41 Code [325/CA325] Injector #6 (L/B #6) System Open/Short Error (LH bank) ........................... 74
E-42 Code [331/CA331] Injector #2 (L/B #2) System Open/Short Error (LH bank) ........................... 76
E-43 Code [332/CA332] Injector #4 (L/B #4) System Open/Short Error (LH bank) ........................... 78
E-44 Code [342/CA342] Caribration Code Incompatibility (LH bank) ................................................ 80
E-45 Code [342/CB342] Caribration Code Incompatibility (RH bank) ................................................ 80
E-46 Code [351/CA351] INJ. Drive Circuit Error (LH bank) ............................................................... 82
E-47 Code [351/CB351] INJ. Drive Circuit Error (RH bank)............................................................... 84
E-48 Code [352/CA352] Sensor Sup. 1 Volt. Low Error (LH bank) .................................................... 86
E-49 Code [352/CB352] Sensor Sup. 1 Volt. Low Error (RH bank) ................................................... 86
E-50 Code [386/CA386] Sensor Sup. 1 Volt. High Error (LH bank) ................................................... 88
E-51 Code [386/CB386] Sensor Sup. 1 Volt. High Error (RH bank)................................................... 90
E-52 Code [441/CA441] Battery Voltage Low Error (LH bank) .......................................................... 92
E-53 Code [441/CB441] Battery Voltage Low Error (RH bank).......................................................... 92
E-54 Code [442/CA442] Battery Voltage High Error (LH bank).......................................................... 93
E-55 Code [442/CB442] Battery Voltage High Error (RH bank) ......................................................... 93
2 12V140E-3 Series
SEN00317-00 40 Troubleshooting
4 12V140E-3 Series
40 Troubleshooting SEN00317-00
12V140E-3 Series 5
SEN00317-00 40 Troubleshooting
6 12V140E-3 Series
40 Troubleshooting SEN00317-00
12V140E-3 Series 7
SEN00317-00 40 Troubleshooting
8 12V140E-3 Series
40 Troubleshooting SEN00317-00
12V140E-3 Series 9
SEN00317-00 40 Troubleshooting
10 12V140E-3 Series
40 Troubleshooting SEN00317-00
12V140E-3 Series 11
SEN00317-00 40 Troubleshooting
E-5 Code [122/CA122] Charge Air Press. Sensor High Error (LH bank
only) 1
Error code Failure code Sensor detection of abnormally high charge pressure
Trouble
122 CA122 (LH bank only)
Contents of
• Charge pressure sensor circuit detects abnormally high pressure.
trouble
Action of
• Sets charge pressure to fixed value (400 kPa) and continues operation.
controller
Phenomenon
that appears on • Acceleration performance of engine drops.
machine
Related
• Different machine models may have different connector Nos.
information
12 12V140E-3 Series
40 Troubleshooting SEN00317-00
12V140E-3 Series 13
SEN00317-00 40 Troubleshooting
E-6 Code [123/CA123] Charge Air Press. Sensor Low Error (LH bank
only) 1
Error code Failure code Sensor detection of abnormally low charge pressure
Trouble
123 CA123 (LH bank only)
Contents of
• Abnormally low pressure detected in charge pressure sensor circuit.
trouble
Action of
• Sets charge pressure to fixed value (400 kPa) and continues operation.
controller
Phenomenon
that appears on • Acceleration performance of engine drops.
machine
Related
information
14 12V140E-3 Series
SEN00317-00 40 Troubleshooting
E-7 Code [131/CA131] Throttle Sensor High Error (LH bank only) 1
Throttle sensor of decelerator pedal type (Case of D475-5)
Error code Failure code
Trouble Throttle sensor detection of abnormally high level (LH bank only)
131 CA131
Contents of
• Throttle sensor circuit detection of abnormally high level.
trouble
Action of • Sets throttle angle with signal other than throttle sensor signal and continues operation.
controller (depending on each model)
Phenomenon
that appears on • Depends on machine model.
machine
Related infor-
• Different machine models may have different connector Nos.
mation
16 12V140E-3 Series
40 Troubleshooting SEN00317-00
Circuit diagram related to deceleration pedal type throttle sensor (Case of D475–5)
12V140E-3 Series 17
SEN00317-00 40 Troubleshooting
E-8 Code [132/CA132] Throttle Sensor Low Error (LH bank only) 1
Throttle sensor of decelerator pedal type (Case of D475-5)
Error code Failure code
Trouble Throttle sensor detection of abnormally low level (LH bank only)
132 CA132
Contents of
• Signal voltage in throttle sensor circuit is abnormally low.
trouble
Action of • Sets throttle angle with signal other than throttle sensor signal and continues operation.
controller (depending on each model)
Phenomenon
that appears on • Varies by installed machine
machine
Related
information
18 12V140E-3 Series
SEN00317-00 40 Troubleshooting
E-9 Code [135/CA135] Oil Press. Sensor High Error (LH bank only) 1
Error code Failure code Oil pressure sensor detection of abnormally high pressure
Trouble
135 CA135 (LH bank only)
Contents of
• Signal voltage in oil pressure sensor circuit is abnormally high.
trouble
Action of
• Set oil pressure to default value (250 kPa) and continue operation.
controller
Phenomenon
that appears on
machine
Related
• Different machine models may have different connector Nos.
information
20 12V140E-3 Series
40 Troubleshooting SEN00317-00
12V140E-3 Series 21
SEN00317-00 40 Troubleshooting
E-10 Code [141/CA141] Oil Press. Sensor Low Error (LH bank only) 1
Error code Failure code Oil pressure sensor detection of abnormally low pressure
Trouble
141 CA141 (LH bank only)
Contents of
• Signal voltage in oil pressure sensor circuit is abnormally low.
trouble
Action of
• Sets oil pressure to default value (250 kPa) and continues operation.
controller
Phenomenon
that appears on
machine
Related
information
22 12V140E-3 Series
SEN00317-00 40 Troubleshooting
E-11 Code [144/CA144] Coolant Temp. Sensor High Error (LH bank
only) 1
Error code Failure code Coolant temperature sensor detection of abnormally high tempera-
Trouble
144 CA144 ture (LH bank only)
Contents of
• Signal voltage in coolant temperature sensor circuit is abnormally high.
trouble
Action of
• Fixes coolant temperature at (90 °C) and continues operation.
controller
Phenomenon
that appears on
machine
Related
• Different machine models may have different connector Nos.
information
24 12V140E-3 Series
40 Troubleshooting SEN00317-00
12V140E-3 Series 25
SEN00317-00 40 Troubleshooting
E-12 Code [145/CA145] Coolant Temp. Sensor Low Error (LH bank only)1
Error code Failure code Coolant temperature sensor detection of abnormally low tempera-
Trouble
145 CA145 ture (LH bank only)
Contents of
• Signal voltage in coolant temperature sensor circuit is abnormally low.
trouble
Action of
• Fixes coolant temperature at (90 °C) and continues operation.
controller
Phenomenon
that appears on
machine
Related
information
26 12V140E-3 Series
SEN00317-00 40 Troubleshooting
E-13 Code [153/CA153] Charge Air Temp. Sensor High Error (LH bank
only) 1
Error code Failure code Charge temperature sensor detection of abnormally high tempera-
Trouble
153 CA153 ture (LH bank only)
Contents of
• Signal voltage in charge temperature sensor circuit is abnormally high.
trouble
Action of
• Fixes charge temperature (intake air temperature) at (70 °C) and continues operation.
controller
Phenomenon
that appears on
machine
Related
• Different machine models may have different connector Nos.
information
28 12V140E-3 Series
40 Troubleshooting SEN00317-00
12V140E-3 Series 29
SEN00317-00 40 Troubleshooting
E-14 Code [154/CA154] Charge Air Temp. Sensor Low Error (LH bank
only) 1
Error code Failure code Charge temperature sensor detection of abnormally low charge
Trouble
154 CA154 temperature (LH bank only)
Contents of
• Signal voltage in charge temperature sensor circuit is abnormally low.
trouble
Action of
• Fixes charge temperature (intake air temperature) at (70 °C) and continues operation.
controller
Phenomenon
that appears on
machine
Related
information
30 12V140E-3 Series
40 Troubleshooting SEN00317-00
E-15 Code [187/CA187] Sensor Sup. 2 Volt. Low Error (LH bank) 1
Error code Failure code Power supply 2 sensor detection of abnormally low voltage
Trouble
187 CA187 (LH bank)
Contents of
• Signal voltage in sensor power supply 2 (5 V) circuit is abnormally low.
trouble
• Sets atmospheric pressure sensor to default value (52.44 kPa) and continues operation.
Action of • Sets oil pressure sensor to default value (250 kPa) and continues operation.
controller • Fixes charge pressure sensor value (400 kPa) and continues operation.
• Operates G (Bkup) sensor with signals of Ne speed sensor.
Phenomenon
that appears on • Output drops.
machine
Related
information
E-16 Code [187/CB187] Sensor Sup. 2 Volt. Low Error (RH bank) 1
Error code Failure code Power supply 2 sensor detection of abnormally low voltage
Trouble
187 CB187 (RH bank)
Contents of
• Signal voltage in sensor power supply 2(5 V) circuit is abnormally low.
trouble
Action of
• Operate G (Bkup) sensor with signals of Ne speed sensor.
controller
Phenomenon
that appears on • Output drops.
machine
Related
information
12V140E-3 Series 31
SEN00317-00 40 Troubleshooting
E-17 Code [212/CA212] Eng. Oil Temp.Sensor High Error (LH bank
only) 1
Error code Failure code Engine oil temperature sensor detection of abnormally high tem-
Trouble
212 CA212 perature (LH bank only)
Contents of
• Signal voltage in engine oil temperature sensor circuit is abnormally high.
trouble
Action of
• Sets oil pressure to default value (100 °C) and continues operation.
controller
Phenomenon
that appears on
machine
Related
• Different machine models may have different connector Nos.
information
32 12V140E-3 Series
40 Troubleshooting SEN00317-00
12V140E-3 Series 33
SEN00317-00 40 Troubleshooting
E-18 Code [213/CA213] Eng. Oil Temp.Sensor Low Error (LH bank
only) 1
Error code Failure code Engine oil temperature sensor detection of abnormally low temper-
Trouble
213 CA213 ature (LH bank only)
Contents of
• Signal voltage in engine oil temperature sensor circuit is abnormally low.
trouble
Action of
• Sets oil temperature to default value (100 °C) and continues operation.
controller
Phenomenon
that appears on
machine
Related
• Different machine models may have different connector Nos.
information
34 12V140E-3 Series
SEN00317-00 40 Troubleshooting
E-19 Code [221/CA221] Ambient Air Press. Sensor High Error (LH bank
only) 1
Error code Failure code Atmospheric pressure sensor detection of abnormally high pres-
Trouble
221 CA221 sure (LH bank only)
Contents of
• Signal voltage in atmospheric pressure sensor circuit is abnormally high.
trouble
Action of
• Sets atmospheric pressure to default value (52.44 kPa) and continues operation.
controller
Phenomenon
that appears on • Output drops.
machine
Related
• Different machine models may have different connector Nos.
information
36 12V140E-3 Series
40 Troubleshooting SEN00317-00
Possible causes a Prepare with starting switch OFF, then turn starting switch ON
and standard or start engine and carry out troubleshooting.
value in normal 6 Defective engine controller LH J1 Voltage
state Between (37) – (38) 4.75 – 5.25 V
Between (3) – (38) 0.5 – 4.5 V
12V140E-3 Series 37
SEN00317-00 40 Troubleshooting
E-20 Code [222/CA222] Ambient Air Press. Sensor Low Error (LH bank
only) 1
Error code Failure code Atmospheric pressure sensor detection of abnormally low pressure
Trouble
222 CA222 (LH bank only)
Contents of
• Signal voltage in atmospheric pressure sensor circuit is abnormally low.
trouble
Action of
• Sets atmospheric pressure to default value (52.44 kPa) and continues operation.
controller
Phenomenon
that appears on • Output drops.
machine
Related
information
38 12V140E-3 Series
SEN00317-00 40 Troubleshooting
E-21 Code [227/CA227] Sensor Sup. 2 Volt. High Error (LH bank) 1
Error code Failure code Power supply 2 sensor detection of abnormally high voltage
Trouble
227 CA227 (LH bank)
Contents of
• Signal voltage in sensor power supply 2(5 V) circuit is abnormally high.
trouble
• Sets atmospheric pressure sensor to default value (52.44 kPa) and continues operation.
Action of • Sets oil pressure sensor to default value (250 kPa) and continues operation.
controller • Fixes charge pressure sensor value (400 kPa) and continues operation.
• Operates G (Bkup) sensor with signals of Ne speed sensor.
Phenomenon
that appears on • Output drops.
machine
Related
• Different machine models may have different connector Nos.
information
40 12V140E-3 Series
40 Troubleshooting SEN00317-00
12V140E-3 Series 41
SEN00317-00 40 Troubleshooting
E-22 Code [227/CB227] Sensor Sup. 2 Volt. High Error (RH bank) 1
Error code Failure code Power supply 2 sensor detection of abnormally high voltage
Trouble
227 CB227 (RH bank)
Contents of
• Signal voltage in sensor power supply 2 (5 V) circuit is abnormally high.
trouble
Action of
• Operates G(Bkup) sensor with signals of Ne speed sensor.
controller
Phenomenon
that appears on • Output drops.
machine
Related
• Different machine models may have different connector Nos.
information
42 12V140E-3 Series
40 Troubleshooting SEN00317-00
12V140E-3 Series 43
SEN00317-00 40 Troubleshooting
44 12V140E-3 Series
SEN00317-00 40 Troubleshooting
E-24 Code [238/CA238] Ne Speed Sensor Sup. Volt. Error (LH bank) 1
Error code Failure code
Trouble Ne Speed Sensor Sup. Volt. Error (LH bank)
238 CA238
Contents of
• Abnormality occurred in Ne speed sensor power supply (5 V) circuit.
trouble
Action of
• Controls Ne speed sensor with signals of G (Bkup) speed sensor.
controller
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
• Different machine models may have different connector Nos.
information
46 12V140E-3 Series
40 Troubleshooting SEN00317-00
12V140E-3 Series 47
SEN00317-00 40 Troubleshooting
E-25 Code [238/CB238] Ne Speed Sensor Sup. Volt. Error (RH bank) 1
Error code Failure code
Trouble Ne Speed Sensor Sup. Volt. Error (RH bank)
238 CB238
Contents of
• Abnormality occurred in Ne speed sensor power supply (5 V) circuit.
trouble
Action of
• Controls Ne speed sensor with signals of G (Bkup) speed sensor.
controller
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
• Different machine models may have different connector Nos.
information
48 12V140E-3 Series
40 Troubleshooting SEN00317-00
12V140E-3 Series 49
SEN00317-00 40 Troubleshooting
E-26 Code [263/CA263] Fuel Temp. Sensor High Error (LH bank) 1
Error code Failure code Fuel temperature sensor detection of abnormally high temperature
Trouble
263 CA263 (LH bank only)
Contents of
• Signal voltage in fuel temperature sensor circuit is abnormally high.
trouble
Action of
• Fixes fuel temperature at (95 °C) and continues operation.
controller
Phenomenon
that appears on
machine
Related
• Different machine models may have different connector Nos.
information
50 12V140E-3 Series
40 Troubleshooting SEN00317-00
12V140E-3 Series 51
SEN00317-00 40 Troubleshooting
E-27 Code [263/CB263] Fuel Temp. Sensor High Error (RH bank) 1
Error code Failure code Fuel temperature sensor detection of abnormally high temperature
Trouble
263 CB263 (RH bank only)
Contents of
• Signal voltage in fuel temperature sensor circuit is abnormally high.
trouble
Action of
• Fixes fuel temperature at (95 °C) and continues operation.
controller
Phenomenon
that appears on
machine
Related
• Different machine models may have different connector Nos.
information
52 12V140E-3 Series
40 Troubleshooting SEN00317-00
12V140E-3 Series 53
SEN00317-00 40 Troubleshooting
E-28 Code [265/CA265] Fuel Temp. Sensor Low Error (LH bank) 1
Error code Failure code Fuel temperature sensor detection of abnormally low temperature
Trouble
265 CA265 (LH bank)
Contents of
• Signal voltage in fuel temperature sensor circuit is abnormally low.
trouble
• Substitutes with coolant temperature sensor. If coolant temperature sensor is also in abnormal
Action of
state.
controller
• Sets oil temperature to default value (95 °C) and continues operation.
Phenomenon
that appears on
machine
Related
information
E-29 Code [265/CB265] Fuel Temp. Sensor Low Error (RH bank) 1
Error code Failure code Fuel temperature sensor detection of abnormally low temperature
Trouble
265 CB265 (RH bank)
Contents of
• Signal voltage in fuel temperature sensor circuit is abnormally low.
trouble
• Substitutes with coolant temperature sensor. If coolant temperature sensor is also in abnormal
Action of
state.
controller
• Fixes fuel temperature at (95 °C) and continues operation.
Phenomenon
that appears on
machine
Related
information
54 12V140E-3 Series
SEN00317-00 40 Troubleshooting
56 12V140E-3 Series
40 Troubleshooting SEN00317-00
12V140E-3 Series 57
SEN00317-00 40 Troubleshooting
58 12V140E-3 Series
40 Troubleshooting SEN00317-00
12V140E-3 Series 59
SEN00317-00 40 Troubleshooting
60 12V140E-3 Series
40 Troubleshooting SEN00317-00
12V140E-3 Series 61
SEN00317-00 40 Troubleshooting
62 12V140E-3 Series
40 Troubleshooting SEN00317-00
12V140E-3 Series 63
SEN00317-00 40 Troubleshooting
64 12V140E-3 Series
40 Troubleshooting SEN00317-00
12V140E-3 Series 65
SEN00317-00 40 Troubleshooting
66 12V140E-3 Series
40 Troubleshooting SEN00317-00
12V140E-3 Series 67
SEN00317-00 40 Troubleshooting
68 12V140E-3 Series
40 Troubleshooting SEN00317-00
12V140E-3 Series 69
SEN00317-00 40 Troubleshooting
70 12V140E-3 Series
40 Troubleshooting SEN00317-00
12V140E-3 Series 71
SEN00317-00 40 Troubleshooting
72 12V140E-3 Series
40 Troubleshooting SEN00317-00
12V140E-3 Series 73
SEN00317-00 40 Troubleshooting
74 12V140E-3 Series
40 Troubleshooting SEN00317-00
12V140E-3 Series 75
SEN00317-00 40 Troubleshooting
76 12V140E-3 Series
40 Troubleshooting SEN00317-00
12V140E-3 Series 77
SEN00317-00 40 Troubleshooting
78 12V140E-3 Series
40 Troubleshooting SEN00317-00
12V140E-3 Series 79
SEN00317-00 40 Troubleshooting
80 12V140E-3 Series
SEN00317-00 40 Troubleshooting
82 12V140E-3 Series
40 Troubleshooting SEN00317-00
12V140E-3 Series 83
SEN00317-00 40 Troubleshooting
84 12V140E-3 Series
40 Troubleshooting SEN00317-00
12V140E-3 Series 85
SEN00317-00 40 Troubleshooting
E-48 Code [352/CA352] Sensor Sup. 1 Volt. Low Error (LH bank) 1
Error code Failure code Power supply 1 sensor detection of abnormally low voltage
Trouble
352 CA352 (LH bank)
Contents of
• Signal voltage in sensor power supply 1 (5 V) circuit is abnormally low.
trouble
Action of
• Sets atmospheric pressure sensor to default value (52.44 kPa) and continues operation.
controller
Phenomenon
that appears on • Output drops.
machine
Related
information
E-49 Code [352/CB352] Sensor Sup. 1 Volt. Low Error (RH bank) 1
Error code Failure code Power supply 1 sensor detection of abnormally low voltage
Trouble
352 CB352 (RH bank)
Contents of
• Signal voltage in sensor power supply 1 (5 V) circuit is abnormally low.
trouble
Action of
• Sets atmospheric pressure sensor to default value (52.44 kPa) and continues operation.
controller
Phenomenon
that appears on • Output drops.
machine
Related
information
86 12V140E-3 Series
SEN00317-00 40 Troubleshooting
E-50 Code [386/CA386] Sensor Sup. 1 Volt. High Error (LH bank) 1
Error code Failure code Power supply 1 sensor detection of abnormally high voltage
Trouble
386 CA386 (LH bank)
Contents of
• Signal voltage in sensor power supply 1 (5 V) circuit is abnormally high.
trouble
Action of
• Limits output and continues operation (Limits common rail pressure).
controller
Phenomenon
that appears on • Output drops.
machine
Related
• Different machine models may have different connector Nos.
information
88 12V140E-3 Series
40 Troubleshooting SEN00317-00
12V140E-3 Series 89
SEN00317-00 40 Troubleshooting
E-51 Code [386/CB386] Sensor Sup. 1 Volt. High Error (RH bank) 1
Error code Failure code Power supply 1 sensor detection of abnormally high voltage
Trouble
386 CB386 (RH bank)
Contents of
• Signal voltage in sensor power supply 1 (5 V) circuit is abnormally high.
trouble
Action of
• Limits output and continues operation (Limits common rail pressure).
controller
Phenomenon
that appears on • Output drops.
machine
Related
• Different machine models may have different connector Nos.
information
Possible causes a Prepare with starting switch OFF, then carry out troubleshoot-
and standard ing without turning starting switch ON.
value in normal Wiring harness between RH J1 (female)
Resis-
state (33) – RH PFUEL (female) (1) and chassis Min. 1 Mz
Ground fault in wiring har- tance
ground
ness
4 Wiring harness between RH J1 (female)
(Short circuit with GND cir- Resis-
cuit) (25) – RH PFUEL (female) (2) and chassis Min. 1 Mz
tance
ground
Wiring harness between RH J1 (female)
Resis-
(47) – RH PFUEL (female) (2) and chassis Min. 1 Mz
tance
ground
a Prepare with starting switch OFF, then carry out troubleshoot-
ing without turning starting switch ON.
Wiring harness between RH J1 (female)
Resis-
(33) – RH PFUEL (female) (1) and RH J1 Min. 1 Mz
tance
Short circuit in wiring har- (female) (25) – RH PFUEL (female) (2)
ness Wiring harness between wiring RH J1
5
(With another wiring har- (female) (33) – RH PFUEL (female) (1) and Resis-
ness) Min. 1 Mz
RH J1 (female) (47) – RH PFUEL (female) tance
(3)
Wiring harness between RH J1 (female)
Resis-
(25) – RH PFUEL (female) (2) and RH J1 Min. 1 Mz
tance
(female) (47) – RH PFUEL (female) (3)
90 12V140E-3 Series
40 Troubleshooting SEN00317-00
12V140E-3 Series 91
SEN00317-00 40 Troubleshooting
92 12V140E-3 Series
40 Troubleshooting SEN00317-00
12V140E-3 Series 93
SEN00317-00 40 Troubleshooting
© 2006 KOMATSU
All Rights Reserved
94 12V140E-3 Series
SEN00318-00
12V140E-3 Series
40 Troubleshooting 1
Troubleshooting of electrical system
(E-mode), Part 2
Troubleshooting of electrical system (E-mode), Part 2 ................................................................................... 3
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
12V140E-3 Series 1
SEN00318-00 40 Troubleshooting
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
E-76 Code [778/CA778] Eng. G (Bkup) Speed Sensor Error (LH bank) ............................................ 30
E-77 Code [778/CB778] Eng. G (Bkup) Speed Sensor Error (RH bank) ........................................... 32
E-78 Code [781/CA781] Inter Multi-controller Communication Error (LH bank)................................. 34
E-79 Code [781/CB781] Inter Multi-controller Communication Error (RH bank) ................................ 36
E-80 Code [1117/CA1117] Persistent Data Lost Error (LH bank) ....................................................... 37
E-81 Code [1117/CB1117] Persistent Data Lost Error (RH bank)....................................................... 37
E-82 Code [1257/CA1257] Harness Key error (LH bank) .................................................................. 38
E-83 Code [1257/CB1257] Harness Key error (RH bank).................................................................. 39
E-84 Code [1548/CB1548] Injector #7 (R/B #1) System Open/Short Error (RH bank) ...................... 40
E-85 Code [1549/CB1549] Injector #8 (R/B #2) System Open/Short Error (RH bank) ...................... 42
E-86 Code [1551/CB1551] Injector #10 (R/B #4) System Open/Short Error (RH bank) .................... 44
E-87 Code [1552/CB1552] Injector #11 (R/B #5) System Open/Short Error (RH bank) .................... 46
E-88 Code [1553/CB1553] Injector #12 (R/B #6) System Open/Short Error (RH bank) .................... 48
E-89 Code [1622/CB1622] Injector #9 (R/B #3) System Open/Short Error (RH bank) ...................... 50
E-90 Code [1633/CA1633] KOMNET Datalink Timeout Error (LH bank) ........................................... 52
E-91 Code [2185/CA2185] Throttle Sens. Sup. Volt. High Error (LH bank only)................................ 54
E-92 Code [2186/CA2186] Throttle Sens. Sup. Volt. Low Error (LH bank only) ................................ 56
E-93 Code [2249/CA2249] Rail Press. Very Low Error (LH bank) ..................................................... 57
E-94 Code [2249/CB2249] Rail Press. Very Low Error (RH bank)..................................................... 57
E-95 Code [– –*1/–] Eng. Overheat (LH bank only) ........................................................................... 58
E-96 Code [– –*2/–] Eng. Oil Press. Low Speed Derate (LH bank only)............................................ 58
E-97 Code [– –*3/–] Press. Low Torque Derate (LH bank only)......................................................... 59
2 12V140E-3 Series
40 Troubleshooting SEN00318-00
E-57 Code [449/CB449] Rail Press. Very High Error (RH bank) 1
Error code Failure code
Trouble Common rail pressure abnormally high Error 2 (RH bank)
449 CB449
Contents of
• Common rail pressure sensor circuit detected abnormally high pressure (level 2).
trouble
Action of
• Limits output and continues operation (Limits common rail pressure).
controller
Phenomenon
that appears on • Output drops.
machine
Related
information
12V140E-3 Series 3
SEN00318-00 40 Troubleshooting
E-58 Code [451/CA451] Rail Press. Sensor High Error (LH bank) 1
Error code Failure code Common rail pressure sensor detected abnormally high pressure
Trouble
451 CA451 (LH bank)
Contents of
• Signal voltage in common rail pressure sensor circuit is abnormally high.
trouble
Action of
• Limits output and continues operation (Limits common rail pressure).
controller
Phenomenon
that appears on • Output drops.
machine
Related
• Different machine models may have different connector Nos.
information
4 12V140E-3 Series
40 Troubleshooting SEN00318-00
12V140E-3 Series 5
SEN00318-00 40 Troubleshooting
E-59 Code [451/CB451] Rail Press. Sensor High Error (RH bank) 1
Error code Failure code Common rail pressure sensor detected abnormally high pressure
Trouble
451 CB451 (RH bank)
Contents of
• Signal voltage in common rail pressure sensor circuit is abnormally high.
trouble
Action of
• Limits output and continues operation (Limits common rail pressure).
controller
Phenomenon
that appears on • Output drops.
machine
Related
• Different machine models may have different connector Nos.
information
6 12V140E-3 Series
40 Troubleshooting SEN00318-00
12V140E-3 Series 7
SEN00318-00 40 Troubleshooting
E-60 Code [452/CA452] Rail Press. Sensor Low Error (LH bank) 1
Error code Failure code Common rail pressure sensor detected abnormally low pressure
Trouble
452 CA452 (LH bank)
Contents of
• Signal voltage in common rail pressure sensor circuit is abnormally low.
trouble
Action of
• Limits output and continues operation (Limits common rail pressure).
controller
Phenomenon
that appears on • Output drops.
machine
Related
information
E-61 Code [452/CB452] Rail Press. Sensor Low Error (RH bank) 1
Error code Failure code Common rail pressure sensor detected abnormally low pressure
Trouble
452 CA452 (RH bank)
Contents of
• Signal voltage in common rail pressure sensor circuit is abnormally low.
trouble
Action of
• Limits output and continues operation (Limits common rail pressure).
controller
Phenomenon
that appears on • Output drops.
machine
Related
information
8 12V140E-3 Series
40 Troubleshooting SEN00318-00
12V140E-3 Series 9
SEN00318-00 40 Troubleshooting
10 12V140E-3 Series
40 Troubleshooting SEN00318-00
E-64 Code [554/CA554] Rail Press. Sensor In Range Error (LH bank) 1
Error code Failure code Common rail pressure sensor detection of in range abnormality
Trouble
554 CA554 (LH bank)
Contents of
• In range error occurred in common rail pressure sensor circuit.
trouble
Action of
• Limits output and continues operation (Limits common rail pressure).
controller
Phenomenon
that appears on • Output drops.
machine
Related
information
E-65 Code [554/CB554] Rail Press. Sensor In Range Error (RH bank) 1
Error code Failure code Common rail pressure sensor detected In range abnormality
Trouble
554 CB554 (RH bank)
Contents of
• In range error occurred in common rail pressure sensor circuit.
trouble
Action of
• Limits output and continues operation (Limits common rail pressure).
controller
Phenomenon
that appears on • Output drops.
machine
Related
information
12V140E-3 Series 11
SEN00318-00 40 Troubleshooting
12 12V140E-3 Series
40 Troubleshooting SEN00318-00
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.
1) Gauze filter: Disassemble and check. If clogged, clean.
2) Upstream strainer of gauze filter: If the gauze filter is clogged, clean the upstream filter, too.
3) Fuel filter: If the trouble is not solved by performing 1) and 2) above, replace the fuel filter.
12V140E-3 Series 13
SEN00318-00 40 Troubleshooting
14 12V140E-3 Series
40 Troubleshooting SEN00318-00
Standard value
Measured
C. Check of fuel circuit pressure Checking condition Unit (Reference Good NG
value
value)
Fuel low-pressure circuit pres- MPa Min. 0.15
6 High idle
sure {kg/cm2} {Min. 1.5}
Standard value
E. Check of leakage and return Measured
Checking condition Unit (Reference Good NG
rate value)
value
*1 – *11:
When inspecting with INSITE (bench test tool), see Operation and Maintenance Manual (Testing
method).
When inspecting with the monitoring function of the machine, use the codes specified for each machine
model.
Equivalent to rating <By models>:
When inspecting the engine unit on the bench, operate it under a load equivalent to the rating. When
the engine is installed to the machine, however, the operation load equivalent to the rating depends on
the machine model.
12V140E-3 Series 15
SEN00318-00 40 Troubleshooting
16 12V140E-3 Series
40 Troubleshooting SEN00318-00
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.
1) Gauze filter: Disassemble and check. If clogged, clean.
2) Upstream strainer of gauze filter: If the gauze filter is clogged, clean the upstream filter, too.
3) Fuel filter: If the trouble is not solved by performing 1) and 2) above, replace the fuel filter.
12V140E-3 Series 17
SEN00318-00 40 Troubleshooting
18 12V140E-3 Series
40 Troubleshooting SEN00318-00
Standard value
Measured
C. Check of fuel circuit pressure Checking condition Unit (Reference Good NG
value
value)
Fuel low-pressure circuit pres- MPa Min. 0.15
6 High idle
sure {kg/cm2} {Min. 1.5}
Standard value
E. Check of leakage and return Measured
Checking condition Unit (Reference Good NG
rate value)
value
*1 – *11:
When inspecting with INSITE (bench test tool), see Operation and Maintenance Manual (Testing
method).
When inspecting with the monitoring function of the machine, use the codes specified for each machine
model.
Equivalent to rating <By models>:
When inspecting the engine unit on the bench, operate it under a load equivalent to the rating. When
the engine is installed to the machine, however, the operation load equivalent to the rating depends on
the machine model.
12V140E-3 Series 19
SEN00318-00 40 Troubleshooting
20 12V140E-3 Series
40 Troubleshooting SEN00318-00
12V140E-3 Series 21
SEN00318-00 40 Troubleshooting
22 12V140E-3 Series
40 Troubleshooting SEN00318-00
12V140E-3 Series 23
SEN00318-00 40 Troubleshooting
E-70 Code [691/CA691] Intake Air Temp Sensor High Error (LH bank
only) 1
Error code Failure code Intake air temperature sensor detected abnormally high tempera-
Trouble
691 CA691 ture (LH bank)
Contents of
• Intake air temperature sensor circuit detected abnormally high temperature.
trouble
Action of
• Fixes intake air temperature at (25 °C) and continues operation.
controller
Phenomenon
that appears on
machine
Related
information
24 12V140E-3 Series
40 Troubleshooting SEN00318-00
12V140E-3 Series 25
SEN00318-00 40 Troubleshooting
E-71 Code [692/CA692] Intake Air Temp Sensor Low Error (LH bank
only) 1
Error code Failure code Intake air temperature sensor detected abnormally low tempera-
Trouble
692 CA692 ture (LH bank only)
Contents of
• Intake air temperature sensor circuit detected abnormally low temperature.
trouble
Action of
• Fixes intake air temperature at (25 °C) and continues operation.
controller
Phenomenon
that appears on
machine
Related
information
26 12V140E-3 Series
40 Troubleshooting SEN00318-00
E-72 Code [731/CA731] Eng. G (Bkup) Speed Sensor Phase Error (LH
bank) 1
Error code Failure code
Trouble Engine G (Bkup) speed sensor abnormal phase (LH bank)
731 CA731
Contents of
• Engine G (Bkup) sensor circuit detected abnormality in phase.
trouble
Action of
• Controls with signals of engine Ne speed sensor.
controller
Phenomenon
• Running engine stops (when Ne speed sensor is also abnormal).
that appears on
• Stopped engine cannot be started (when Ne speed sensor is also abnormal).
machine
Related
information
E-73 Code [731/CB731] Eng. G (Bkup) Speed Sensor Phase Error (RH
bank) 1
Error code Failure code
Trouble Engine G (Bkup) speed sensor abnormal phase (RH bank)
731 CB731
Contents of
• Engine G (Bkup) sensor circuit detected abnormality in phase.
trouble
Action of
• Controls with signals of engine Ne speed sensor.
controller
Phenomenon
• Running engine stops (when Ne speed sensor is also abnormal).
that appears on
• Stopped engine cannot be started (when Ne speed sensor is also abnormal).
machine
Related
information
12V140E-3 Series 27
SEN00318-00 40 Troubleshooting
E-74 Code [757/CA757] All Continuous Data Lost Error (LH bank) 1
Error code Failure code
Trouble All Engine Controller Data Lost Error (LH bank)
757 CA757
Contents of
• All data in engine controller are lost.
trouble
Action of
• None in particular.
controller
Phenomenon
that appears on • Engine continues operation normally, but it may stop during operation or may not be able to start.
machine
Related
information
E-75 Code [757/CB757] All Continuous Data Lost Error (RH bank) 1
Error code Failure code
Trouble All Engine Controller Data Lost Error (RH bank)
757 CB757
Contents of
• All data in engine controller are lost.
trouble
Action of c
• None in particular.
ontroller
Phenomenon
that appears on • Engine continues operation normally, but it may stop during operation or may not be able to start.
machine
Related
information
28 12V140E-3 Series
SEN00318-00 40 Troubleshooting
E-76 Code [778/CA778] Eng. G (Bkup) Speed Sensor Error (LH bank) 1
Error code Failure code
Trouble Engine G (Bkup) speed sensor abnormal (LH bank)
778 CA778
Contents of
• Abnormality occurred in engine G (Bkup) speed sensor circuit.
trouble
Action of
• Controls with signals of Ne speed sensor.
controller
Phenomenon
• Running engine stops (when Ne speed sensor is also abnormal).
that appears on
• Stopped engine cannot be started (when Ne speed sensor is also abnormal).
machine
Related
• Different machine models may have different connector Nos.
information
30 12V140E-3 Series
40 Troubleshooting SEN00318-00
12V140E-3 Series 31
SEN00318-00 40 Troubleshooting
E-77 Code [778/CB778] Eng. G (Bkup) Speed Sensor Error (RH bank) 1
Error code Failure code
Trouble Engine G (Bkup) speed sensor abnormal (RH bank)
778 CB778
Contents of
• Abnormality occurred in engine G (Bkup) speed sensor circuit.
trouble
Action of
• Controls with signals of Ne speed sensor.
controller
Phenomenon
• Running engine stops (when Ne speed sensor is also abnormal).
that appears on
• Stopped engine cannot be started (when Ne speed sensor is also abnormal).
machine
Related
• Different machine models may have different connector Nos.
information
32 12V140E-3 Series
40 Troubleshooting SEN00318-00
12V140E-3 Series 33
SEN00318-00 40 Troubleshooting
34 12V140E-3 Series
40 Troubleshooting SEN00318-00
12V140E-3 Series 35
SEN00318-00 40 Troubleshooting
36 12V140E-3 Series
40 Troubleshooting SEN00318-00
12V140E-3 Series 37
SEN00318-00 40 Troubleshooting
Possible causes Ground fault in wiring har- a Prepare with starting switch OFF, then carry out troubleshoot-
and standard ness ing without turning starting switch ON.
2
value in normal (Short circuit with GND cir- Between wiring harness OEM L (female) (8) Resis-
cuit) Min. 1 Mz
state and chassis ground tance
a Prepare with starting switch OFF, then carry out troubleshoot-
ing without turning starting switch ON.
Between wiring harness OEM L (female) (7) Resis-
3 Defective engine controller Max. 1 z
and chassis ground tance
Between wiring harness OEM L (female) (8) Resis-
Min. 1 Mz
and chassis ground tance
38 12V140E-3 Series
40 Troubleshooting SEN00318-00
12V140E-3 Series 39
SEN00318-00 40 Troubleshooting
40 12V140E-3 Series
40 Troubleshooting SEN00318-00
12V140E-3 Series 41
SEN00318-00 40 Troubleshooting
42 12V140E-3 Series
40 Troubleshooting SEN00318-00
12V140E-3 Series 43
SEN00318-00 40 Troubleshooting
44 12V140E-3 Series
40 Troubleshooting SEN00318-00
12V140E-3 Series 45
SEN00318-00 40 Troubleshooting
46 12V140E-3 Series
40 Troubleshooting SEN00318-00
12V140E-3 Series 47
SEN00318-00 40 Troubleshooting
48 12V140E-3 Series
40 Troubleshooting SEN00318-00
12V140E-3 Series 49
SEN00318-00 40 Troubleshooting
50 12V140E-3 Series
40 Troubleshooting SEN00318-00
12V140E-3 Series 51
SEN00318-00 40 Troubleshooting
52 12V140E-3 Series
40 Troubleshooting SEN00318-00
12V140E-3 Series 53
SEN00318-00 40 Troubleshooting
E-91 Code [2185/CA2185] Throttle Sens. Sup. Volt. High Error (LH bank
only) 1
Throttle sensor of decelerator pedal type (Case of D475-5)
Error code Failure code Throttle sensor detection of abnormally high supply voltage
Trouble
2185 CA2185 (LH bank only)
Contents of
• High voltage abnormality occurred to throttle sensor power supply (5 V) circuit.
trouble
Action of • Sets throttle angle with signal other than throttle sensor signal and continues operation.
controller (depending on each model)
Phenomenon
that appears on • Depends on machine model.
machine
Related
• Different machine models may have different connector Nos.
information
54 12V140E-3 Series
40 Troubleshooting SEN00318-00
Circuit diagram related to deceleration pedal type throttle sensor (Case of D475-5)
12V140E-3 Series 55
SEN00318-00 40 Troubleshooting
E-92 Code [2186/CA2186] Throttle Sens. Sup. Volt. Low Error (LH bank
only) 1
Error code Failure code Throttle sensor detected abnormally low supply voltage
Trouble
2186 CA2186 (LH bank only)
Contents of
• Low-voltage abnormality occurred to throttle sensor power supply (5V) circuit.
trouble
Action of • Sets throttle angle with signal other than throttle sensor signal and continues operation.
controller (depending on each model)
Phenomenon
that appears on • Depends on machine model.
machine
Related
information
56 12V140E-3 Series
40 Troubleshooting SEN00318-00
E-93 Code [2249/CA2249] Rail Press. Very Low Error (LH bank) 1
Error code Failure code
Trouble Supply pump no-pressure feed error 2 (LH bank)
2249 CA2249
Contents of
• Supply pump does not feed fuel (level 2).
trouble
Action of
• Limits common rail pressure.
controller
Phenomenon
that appears on • Output drops.
machine
Related
information
E-94 Code [2249/CB2249] Rail Press. Very Low Error (RH bank) 1
Error code Failure code
Trouble Supply pump no-pressure feed error 2 (RH bank)
2249 CB2249
Contents of
• Supply pump does not feed fuel (level 2).
trouble
Action of ontrol-
• Limits common rail pressure.
ler
Phenomenon
that appears on • Output drops.
machine
Related
information
12V140E-3 Series 57
SEN00318-00 40 Troubleshooting
E-96 Code [– –*2/–] Eng. Oil Press. Low Speed Derate (LH bank only) 1
Error code Failure code
Trouble Engine oil pressure low and speed derate (LH bank only)
– –*2 –
Contents of
• Engine oil pressure is below operating range.
trouble
Action of
• Limits output and continues operation (Limits fuel injection rate and engine speed).
controller
Phenomenon
that appears on • Output drops.
machine
Related
information
58 12V140E-3 Series
40 Troubleshooting SEN00318-00
E-97 Code [– –*3/–] Press. Low Torque Derate (LH bank only) 1
Error code Failure code
Trouble Engine oil pressure low and torque derate (LH bank only)
– –*3 –
Contents of
• Engine oil pressure is below operating range.
trouble
Action of
• Limits output and continues operation (Limits fuel injection rate and engine speed).
controller
Phenomenon
that appears on • Output drops.
machine
Related
information
12V140E-3 Series 59
SEN00318-00 40 Troubleshooting
© 2006 KOMATSU
All Rights Reserved
60 12V140E-3 Series
SEN00320-00
12V140E-3 Series
12V140E-3 Series 1
SEN00320-00 50 Disassembly and assembly
Assembly
q In Assembly section, the work procedures, pre-
cautions and know-how for carrying out those
procedures, and quantity of the oil and coolant
added are described.
q The meanings of the symbols used in Assem-
bly section are as follows.
k : Precautions related to safety in execution
of work
a : Know-how or precautions for work
2 : Type of coating material
3 : Tightening torque
2 12V140E-3 Series
50 Disassembly and assembly SEN00320-00
Cate- Komatsu
Part No. Q'ty Container Main features and applications
gory code
• Used to prevent falling off of rubber gaskets, rubber
LT-1A 790-129-9030 150 g Tube
cushions, and cork plugs.
• Used for plastic (except polyethylene, polypropylene,
20 g Polyethylene tetrafluoroethylene and vinyl chloride), rubber, metal,
LT-1B 790-129-9050
(2 pcs.) container and non-metal parts which require immediate and
strong adhesion.
Polyethylene • Features: Resistant to heat and chemicals.
LT-2 09940-00030 50 g
container • Used to fix and seal bolts and plugs.
790-129-9060 Adhesive:
Set of 1 kg
LT-3 Can • Used to stick and seal metal, glass, and plastics.
adhesive and Hardener:
hardener 500 g
Adhesive
Polyethylene
LT-4 790-129-9040 250 g • Used to seal plugs for drilled holes.
container
Holtz
790-129-9120 75 g Tube • Heat-resistant sealant used to repair engines.
MH 705
• Quick-setting adhesive.
Three Bond Polyethylene • Setting time: Within 5 sec. to 3 min.
790-129-9140 50 g
1735 container • Used mainly to stick metals, rubbers, plastics, and
woods.
• Quick-setting adhesive.
Aron-alpha Polyethylene • Quick-hardening type. (max. strength is obtained after
790-129-9130 2g
201 container 30 minutes of application)
• Used mainly to stick rubbers, plastics, and metals.
Loctite Polyethylene • Features: Resistant to heat and chemicals.
79A-129-9110 50 cc
648-50 container • Used for fitted portions of high temperatures.
• Used to stick or seal gaskets and packings of power
LG-1 790-129-9010 200 g Tube
train case, etc.
• Used to seal various threaded portions, pipe joints,
Polyethylene and flanges.
LG-5 790-129-9080 1 kg
container • Used to seal tapered plugs, elbows, and nipples of
hydraulic pipes.
• Features: Silicon-based heat and cold-resistant seal-
Gasket sealant
ant.
LG-6 790-129-9020 200 g Tube
• Used to seal flanged surfaces and threaded portions.
• Used to seal oil pan, final drive case, etc.
• Features: Silicon-based quick-hardening sealant.
LG-7 790-129-9070 1 kg Tube • Used to seal flywheel housing, intake manifold, oil
pan, thermostat housing, etc.
Three Bond
790-129-9090 100 g Tube • Gasket sealant used to repair engine.
1211
• Features: Silicon-based, heat-resistant, vibration-
Three Bond
419-15-18131 100 g Tube resistant and impact-resistant sealant.
1207B
• Used to seal transfer case, etc.
12V140E-3 Series 3
SEN00320-00 50 Disassembly and assembly
Cate- Komatsu
Part No. Q'ty Container Main features and applications
gory code
• Used to lubricate sliding portions.
Molybdenum disulfide
SYG2-400LI
SYG2-350LI
G2-LI SYG2-400LI-A Various Various • General purpose type.
SYG2-160LI
SYGA-160CNLI
SYG2-400CA
SYG2-350CA
• Used for bearings used at normal temperature
G2-CA SYG2-400CA-A Various Various
under light load in contact with water or steam.
SYG2-160CA
SYGA-160CNCA
Molybdenum SYG2-400M 400 gx10 Bellows-type
disulfide grease SYG2-400M-A 400 gx20 container • Used for parts under heavy load.
Grease
SUPER
• Used as primer for painted surface on cab
SUNSTAR
Glass side.
Primer
4 12V140E-3 Series
50 Disassembly and assembly SEN00320-00
Cate- Komatsu
Part No. Q'ty Container Main features and applications
gory code
• "S" is used for high-temperature season
SUNSTAR
(April – October) and "W" for low-tempera-
PENGUINE Polyethyl-
ture season (November – April) as adhesive
SEAL 580 417-926-3910 320 ml ene con-
for glass.
SUPER "S" or tainer
(Using limit: 4 months after date of manufac-
"W"
Adhesive
ture)
Polyethyl- • Used as adhesive for glass.
Sika Japan,
20Y-54-39850 310 ml ene con- (Using limit: 6 months after date of manufac-
12V140E-3 Series 5
SEN00320-00 50 Disassembly and assembly
New/Remodel
Necessity
Sketches
Sym-
Q'ty
Work item Part No. Part name Remarks
bol
6 12V140E-3 Series
50 Disassembly and assembly SEN00320-00
New/Remodel
Necessity
Sketches
Sym-
Q'ty
Work item Part No. Part name Remarks
bol
12V140E-3 Series 7
SEN00320-00 50 Disassembly and assembly
© 2006 KOMATSU
All Rights Reserved
8 12V140E-3 Series
SEN00321-00
12V140E-3 Series
12V140E-3 Series 1
SEN00321-00 50 Disassembly and assembly
1. Preparation work
Before disassembling the engine, check its
parts for cracking, damage, etc. and clean the
entire engine carefully for accurate inspection
of its parts and quick disassembly and assem- 4. Starting motor assembly
bly. Remove engine harness (1) and then remove
a Before cleaning the engine, carefully seal starting motor assemblies (2) and (3).
or remove the openings, electric parts, a Remove the assembly at the top first
and wiring connectors so that water will being followed by that at the bottom.
not enter them.
5. Alternator
1) Remove auxiliary equipment belt (1).
2) Remove alternator (2).
2 12V140E-3 Series
50 Disassembly and assembly SEN00321-00
12V140E-3 Series 3
SEN00321-00 50 Disassembly and assembly
2) Apply a marking to every installation posi- 13. Air intake manifold assembly
tions of clamps (2) and (3) using paint. 1) Remove support (1).
4 12V140E-3 Series
50 Disassembly and assembly SEN00321-00
12V140E-3 Series 5
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6 12V140E-3 Series
50 Disassembly and assembly SEN00321-00
12V140E-3 Series 7
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27. Push rod 2) Insert a small L-bar [1] under the fuel con-
Remove push rod (1). nector and pry out fuel injector (2) slowly.
a Do not grip the solenoid valve at the
top of the injector to pull off the injec-
tor.
8 12V140E-3 Series
50 Disassembly and assembly SEN00321-00
12V140E-3 Series 9
SEN00321-00 50 Disassembly and assembly
2) Install the engine again to tool A. 3) Remove thermostat (3) from thermostat
case (2).
35. Alternator bracket
Remove alternator bracket (1).
10 12V140E-3 Series
50 Disassembly and assembly SEN00321-00
38. Front engine hanger 2] Remove shaft (5), thrust plate (6) and
Remove front engine hanger (1). gear (7) as a unit.
3] Remove gear (7) from shaft (5).
4] Pull off oil seal (9) and bushing (10)
from housing (8).
12V140E-3 Series 11
SEN00321-00 50 Disassembly and assembly
2) Remove engine speed sensor (3). 44. Damper and crank pulley assembly
1) Lift damper and crank pulley assembly (1)
temporarily and then remove the mounting
bolts.
2) Lift off damper and crank pulley assembly
(1).
4 Damper and crank pulley assem-
bly: 75 kg
12 12V140E-3 Series
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12V140E-3 Series 13
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14 12V140E-3 Series
50 Disassembly and assembly SEN00321-00
12V140E-3 Series 15
SEN00321-00 50 Disassembly and assembly
4) Hit the connecting rod head lightly using a 9) Disassemble the piston and connecting
plastic hammer to loosen the connecting rod assembly according to the following
rod cap and connecting rod. procedure.
5) Scrub the carbon off the top wall of the 1] Remove snap ring (4)
liner using fine sandpaper. 2] Support connecting rod (5) with hand
6) Turn the crankshaft until the piston comes and then remove piston pin (6) to dis-
to the top dead center and then remove connect piston (7) from the connect-
the connecting rod cap (2). ing rod.
a When the piston pin is firmly
fixed and unremovable, heat it
(roughly 5 minutes at 100°C)
using an industrial dryer.
3] Remove the snap ring on the other
side.
16 12V140E-3 Series
50 Disassembly and assembly SEN00321-00
2) Remove mounting bolts (2) of main cap 5) Remove upper thrust bearing (5) from
(1). No.7 journal.
3) Insert the bolts in the bolt hole of the main 6) Remove upper bearing (6).
cap (1) and remove the cap, while shaking a Apply marking to the assembly posi-
it. tions of the main cap, main bearing
and thrust bearing using paint or tags
and then keep them on a cap to cap
basis.
12V140E-3 Series 17
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18 12V140E-3 Series
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© 2006 KOMATSU
All Rights Reserved
20 12V140E-3 Series
SEN00322-00
12V140E-3 Series
12V140E-3 Series 1
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2 12V140E-3 Series
50 Disassembly and assembly SEN00322-00
12V140E-3 Series 3
SEN00322-00 50 Disassembly and assembly
1] Coat the bottom side of shim 8) Using tool F, press-fit cylinder liner (1) to
(2) with a small amount of the cylinder block.
gasket sealant LG-6 and
then assemble the shim.
2] Then apply gasket sealant
LG-6 according to the same
procedure as that employed
when the shim is not used.
4 12V140E-3 Series
50 Disassembly and assembly SEN00322-00
12V140E-3 Series 5
SEN00322-00 50 Disassembly and assembly
5) Install the projection of lower bearing (7) 6) Drive the roll pin of cap No. 7 so that it will
locating it to the notch of main cap (1) and be projected by 2.7 – 3.4 mm from the cap
install. end and then install lower thrust bearings
a Before fitting the bearing, make sure (3) to both sides.
that its back side is free from foreign a Install the thrust bearing with the
matter. grooved surface on the crankshaft
2 Inside of bearing: side.
Engine oil (EO30) 2 Thrust bearing sliding surface:
a Don't apply the engine oil to the bear- Engine oil (EO30)
ing backside. 7) Apply the engine oil to the surface of the
journal of the crankshaft. Then install the
main cap after making sure that the No.
being stamped on respective main caps
(1) is matching the cylinder block No.
2 Crankshaft journal:
Engine oil (EO30)
a When installing the main cap, direct
its cast part number side toward the
front of the engine.
8) Apply engine oil to the threaded portion of
the main cap mounting bolt and washer
and then drive in the bolts alternately until
the main cap is completely fitted.
2 Main cap mounting bolt:
Engine oil (EO30)
a Lower bearing: Without oil hole
a No. 4 bearing is wider than others. Thus, care
must be used to prevent an assembly error.
a Bearing with a
No. 4 bearing: 52 mm
Bearings other than No. 4: 48 mm
6 12V140E-3 Series
50 Disassembly and assembly SEN00322-00
12V140E-3 Series 7
SEN00322-00 50 Disassembly and assembly
3] Install snap ring (10) to one side of 7] Install the projection of connecting
piston (7). rod upper bearing (11) locating it to
the notch of the connecting rod.
a Before fitting the bearing, make
sure that its back side is free
from foreign matter.
a Don't apply the oil to the bearing
backside.
a Make sure that the connecting
rod small end bushing are large
end bearing hole are aligned with
the connecting rod oil hole.
a Before assembling the connect-
ing rod, check the connecting rod
oil hole for settled dusts.
2 Connecting rod bearing inner
surface: Engine oil (EO30)
4] Set the piston (7) and connecting rod
(5). Mate the cast letters "EX i F" on
the piston against the chamfered hole
side in the big end of the connecting
rod and then assemble them.
5] Apply engine oil to the piston pin boss
and inner surface of the connecting
rod bushing and then insert piston pin
(6) while directing the connecting rod
upward.
2 Piston pin: Engine oil (EO30)
6] Install snap ring (4) on the opposite
side.
a Turn the snap ring to make sure
that the left and right side snap
rings are completely fitted in the 8] Install the projection of connecting
ring groove. rod lower bearing (12) locating it to
a Also make sure that the connect- the notch of the connecting rod cap.
ing rod moves lightly. a Before fitting the bearing, make
sure that its back side is free
from foreign matter. Don't apply
the engine oil to the backside.
8 12V140E-3 Series
50 Disassembly and assembly SEN00322-00
2) Apply the engine oil to the cylinder liner. 5) Align the abutment joint of respective pis-
a Apply the engine oil uniformly on the ton rings as well as the piston to the posi-
entire circumference with hands. tion shown in the figure.
2 Cylinder liner: Engine oil (EO30)
12V140E-3 Series 9
SEN00322-00 50 Disassembly and assembly
7) Using the connecting rod puller [1] shown a When assembling a new connecting
in the figure, pull the connecting rod until it rod, record its cylinder No. on the
is closely contacted against the pin jour- connecting rod cap using a electric
nal. pen (stamping is not acceptable). It is
a Make sure the connecting rod bearing strictly prohibited to change the com-
is not displaced. bination of the connecting rod and
a The connecting rod puller [1] is made cap through this operation.
by welding bar b to unnecessary con-
necting rod bolt a.
a Total length of connecting rod puller l:
Approx. 500 mm.
2 Crank pin journal:
Engine oil (EO30)
10 12V140E-3 Series
50 Disassembly and assembly SEN00322-00
12V140E-3 Series 11
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12 12V140E-3 Series
50 Disassembly and assembly SEN00322-00
2) Install cam follower assembly (3). 10. Supply pump drive case
3 Cam follower assembly mounting 1) Install supply pump drive case (2).
bolt: 2) Install oil tube (1).
44.1 – 58.8 Nm {4.5 – 6.0 kgm}
a Install the oil tube on the left bank
alone.
3 Oil tube joint bolt:
7.9 – 12.7 Nm {0.8 – 1.3 kgm}
12V140E-3 Series 13
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14 12V140E-3 Series
50 Disassembly and assembly SEN00322-00
12V140E-3 Series 15
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1] Backlash of each gear a When cover (2) was removed, apply the
(mm) gasket sealant in the position shown in the
Standard figure before installing it again.
Position Measuring points
value 2 Cover: Gasket sealant (LG-7)
Right idler gear (small) and 0.130 – 0.390 q Application diameter: ø2.0 mm
A•A
right sub idler gear (0.125 – 0.363)
Right sub idler gear and right 0.051 – 0.469
B1•B1
supply pump gear (0.125 – 0.363)
Left sub idler gear and left 0.051 – 0.469
B2•B2
supply pump gear (0.125 – 0.363)
Left sub idler gear and left 0.129 – 0.391
C•C
cam gear (0.125 – 0.363)
Right idler gear (small) and 0.129 – 0.391
D•D
right cam gear (0.125 – 0.363)
Right idler gear (large) and
E•E 0.052 – 0.481
water pump drive gear
Right idler gear (large) and
F•F 0.137 – 0.421
oil pump gear
Left supply pump gear and 0.106 – 0.381
G•G
compressor gear (0.138 – 0.354)
Right cam gear and acces- 0.085 – 0.492
H•H
sory drive gear (0.138 – 0.354)
Crank gear and left idler gear
L•L 0.141 – 0.425
(large)
Crank gear and right idler
R•R 0.141 – 0.425
gear (large)
Note): The standard value enclosed in ( ) indicates
the backlash between spur gears
16 12V140E-3 Series
50 Disassembly and assembly SEN00322-00
12V140E-3 Series 17
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18 12V140E-3 Series
50 Disassembly and assembly SEN00322-00
18. Front support 2) Lift and install damper and crank pulley
Install front support (1). assembly (1).
a Prior to the installation, fill the oil hole with a Install the assembly aligning it to the
grease. dowel pin of the crankshaft.
a Volume of grease filled: 20 cc 4 Damper and crank pulley assem-
2 Front support: Grease (G2-LI) bly: 75 kg
12V140E-3 Series 19
SEN00322-00 50 Disassembly and assembly
20. Flywheel housing 2) After the installation, cut off the gasket
1) Lift and install flywheel housing (4). projecting from the oil pan mounting sur-
4 Flywheel housing: 230 kg face to make height of the gasket and
mounting surface even.
3) Install burring tool (1) and Ne speed sen-
sor (2).
20 12V140E-3 Series
50 Disassembly and assembly SEN00322-00
12V140E-3 Series 21
SEN00322-00 50 Disassembly and assembly
5) Using tool K, install rear oil seal (1). 2] When installing the oil seal after mod-
a Tighten the mounting bolts evenly. ifying its originally intended installa-
a Before assembling the oil seal, clean tion position.
periphery of the crankshaft and apply q Don't use a washer [1] between
all circumferences with the engine oil. tool K and crankshaft.
2 Crankshaft: Engine oil (EO30)
a Apply all circumferences of the oil
seal lip with the engine oil.
2 Oil seal lip: Engine oil (EO30)
2 Metal ring face in oil seal periphery:
Gasket sealant (LG-4)
a Use care in above operation so
tha t the s eal li p m ay not be
applied with the oil.
a When rubber is used in the periphery
of the oil seal (1), use rubber lubricat-
ing liquid (RF-1) or soap water for the
applying.
a Select one of the following 3 oil seal
press-fitting depths depending on the
condition of the crankshaft (2). 3] When sleeve (3) is provided for the
1] When a new crankshaft is used or crankshaft.
when wear is not recognized on the q Use 2 washers [1] between tool
contact surface of oil seal. K and crankshaft (2).
q Use 2 washers [1] between tool
K and crankshaft.
22 12V140E-3 Series
50 Disassembly and assembly SEN00322-00
12V140E-3 Series 23
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24 12V140E-3 Series
50 Disassembly and assembly SEN00322-00
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.
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
12V140E-3 Series 25
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26 12V140E-3 Series
50 Disassembly and assembly SEN00322-00
12V140E-3 Series 27
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28 12V140E-3 Series
50 Disassembly and assembly SEN00322-00
12V140E-3 Series 29
SEN00322-00 50 Disassembly and assembly
37. Crosshead
1) Install crosshead (1).
2 Crosshead sliding portion:
38. Injector harness
Engine oil (EO30)
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).
30 12V140E-3 Series
50 Disassembly and assembly SEN00322-00
12V140E-3 Series 31
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32 12V140E-3 Series
50 Disassembly and assembly SEN00322-00
12V140E-3 Series 33
SEN00322-00 50 Disassembly and assembly
3) Install water connector (2). a Tighten the mounting bolts in the fol-
4) Install block (1). lowing order.
a Tighten it once and then tighten again
with the same torque.
2 Exhaust manifold assembly mount-
ing bolt:
Molybdenum disulfide lubricant
(LM-P)
3 Exhaust manifold assembly mount-
ing bolt:
44.1 – 53.9 Nm {4.5 – 5.5 kgm}
34 12V140E-3 Series
50 Disassembly and assembly SEN00322-00
12V140E-3 Series 35
SEN00322-00 50 Disassembly and assembly
36 12V140E-3 Series
50 Disassembly and assembly SEN00322-00
a Tighten mounting bolt (2) with the 6) Install high-pressure pipe clamp (7)
specified torque after tightening the according to the following procedure.
sleeve nut of the high-pressure pipe 1] Manually tighten and install tempo-
(between supply pump and common rarily the stay and top and bottom
rail). clamps of the high-pressure pipe
2 Supply pump assembly mounting
clamp.
bolt: Adhesive (LT-2)
2] Tighten the top and bottom clamps
permanently.
a Before tightening the stay perma-
nently, deflect the rubber fist.
a Use care in the tightening so that
ex c e ss i v e fo r ce 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.
7) Install the rubber cover to the sleeve nut
on the high-pressure pipe.
a Direct the slit downward when install-
ing the rubber cover.
q Supply pump side (8): Bottom
2) After installing high-pressure pipes (4) and q Common rail side (9): Facing
(5) to supply pump (1) and common rail inward (Opposed)
(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}
3) Tighten supply pump assembly mounting
bolt (2).
4) Tighten the mounting bolt across the sup-
ply pump assembly bottom face and
bracket.
3 Supply pump mounting bolt (Bot- 55. Fuel pipe
tom side): 1) Install priming pump (4).
19.6 – 29.4 Nm {2.0 – 3.0 kgm} a If the air bleeding plug is removed,
5) Install oil tube (6). tighten the pump with the following
3 Oil tube joint bolt: torque.
9.8 – 12.7 Nm {1.0 – 1.3 kgm}
12V140E-3 Series 37
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38 12V140E-3 Series
50 Disassembly and assembly SEN00322-00
60. Alternator
1) Install alternator (2).
2) Install auxiliary equipment belt (1).
3) Adjust tension of the auxiliary equipment
belt.
a Adjust its deflection to 20 mm when
the pushing force of 58.8 Nm {6 kgm}
is applied to the belt center through a
finger.
3 Adjuster lock bolt:
53.9 – 122.6 Nm {5.5 – 12.5 kgm}
12V140E-3 Series 39
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40 12V140E-3 Series
SEN00322-00 50 Disassembly and assembly
© 2006 KOMATSU
All Rights Reserved
42 12V140E-3 Series
SEN00876-00
12V140E-3 Series
12V140E-3 Series 1
SEN00876-00 50 Disassembly and assembly
Removal
1. Remove the connectors (in 3 places).
2. Remove fuel return hose (3) between common
rail (1) and supply pump (2). [*1]
a A fuel return pipe is provided on the right
side bank. Since it does not allow removal
halfway, the whole set of the pipe must be 6. Remove oil tube (9) between supply pump (2)
removed. and the cylinder block. [*4]
7. Disconnect fuel tube (10) between the fuel fil-
ter and supply pump (2) from the supply pump
side. [*5]
2 12V140E-3 Series
50 Disassembly and assembly SEN00876-00
9. Remove 4 mounting bolts (12) and then a Tighten mounting bolt (12) with the
remove supply pump assembly (2). [*7] specified torque after tightening the
sleeve nut of the high-pressure pipe
(between supply pump and common
rail).
2 Supply pump assembly mounting
bolt: Adhesive (LT-2)
2) After installing high-pressure pipes (8) on
supply pump (2) and common rail (1) tem-
porarily, tighten the sleeve nut with the
specified torque.
a Use a spanner type torque wrench
(commercially available part) should
be used for the tightening to ensure
observance of the specified torque.
3 High-pressure pipe sleeve nut
(Supply pump side):
Installation 39.2 – 49 Nm {4 – 5 kgm}
3 High-pressure pipe sleeve nut
q Carry out installation in the reverse order to
removal. (Common rail side):
39.2 – 58.8 Nm {4 – 6 kgm}
[*1] 3) Install the clamp of the high-pressure pipe
3 Fuel return hose (3) joint bolt (Common rail according to the following procedure.
side): 17.7 – 22.6 Nm {1.8 – 2.3 kgm} 1] Manually tighten and install tempo-
rarily the stay and top and bottom
[*2] clamps of the high-pressure pipe.
3 Fuel tube (5) joint bolt: 2] Tighten the top and bottom clamps
24.5 – 34.3 Nm {2.5 – 3.5 kgm} permanently.
a Before tightening the stay perma-
[*3] [*7] nently, deflect the rubber fist.
Install the supply pump and high-pressure pipe by a Take care in the tightening so
finalizing their position the following procedure. that excessive force may not be
1) Install supply pump assembly (2) tempo- applied to the supply pump side
rarily. install position.
a Align the unequal spline portion of the 3 Top and bottom clamp bolt:
supply pump side to unequal spline 9.8 ± 1 Nm {1 ± 0.1 kgm}
portion A of the supply pump drive 3] Tighten respective stays permanently.
case side and then insert the supply 4) Install the rubber cover to the sleeve nut
pump.. on the high-pressure pipe.
a When it is difficult to insert the supply a Direct the slit downward when install-
pump , turn the crankshaft to change ing the rubber cover.
position of unequal spline portion A. q Supply pump side: Bottom side
q Common rail side:
Faced inward (Opposed)
[*4]
3 Oil tube (9) joint bolt:
9.8 – 12.7 Nm {1.0 – 1.3 kgm}
[*5]
3 Fuel tube (10) joint bolt:
24.5 – 34.3 Nm {2.5 -– 3.5 kgm}
[*6]
3 Supply pump mounting bolt (Pump bottom
side): 19.6 – 29.4 Nm {2.0 – 3.0 kgm}
12V140E-3 Series 3
SEN00876-00 50 Disassembly and assembly
Installation
a Check the Teflon seal (Laydown lip seal) by
checking the wear of the shaft and replace it
with the "Standard seal "or " Sleeved seal".
Removal of sleeved seal a If the shaft is worn to the degree of luster (If
1) Hitch the end of tool N to the metal ring of wear which you feel with your finger is less
seal (1) and pull out the seal with impacts than 10 m) and does not have any flaw,
of slide hammer [1]. install the standard seal.In other cases, install
a Before pulling out the seal, drive in it the sleeved seal.
a little to separate it from housing (2) a The left one in the following figure is the stan-
for the ease of removal. dard seal and the right one is the sleeved seal.
2) Cut and remove sleeve (3) with a chisel
and a hammer.
a When cutting the sleeve, take care
extremely not to damage crankshaft
(4).
a Remove all the chips.
a The left one in the following figure is
the standard seal and the right one is
the sleeved seal.
4 12V140E-3 Series
50 Disassembly and assembly SEN00876-00
Installation
Following remedial actions are needed when wear
is recognized on the contact face of the oil seal on
the crankshaft.
1) When a new crankshaft is used or when wear
is not recognized on the contact surface of oil
seal.
q Install the rear oil seal in such that the dimen-
sion from the flywheel housing end face may
conform to the standard dimension indicated in
the figure.
12V140E-3 Series 5
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6 12V140E-3 Series
50 Disassembly and assembly SEN00876-00
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).
12V140E-3 Series 7
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8 12V140E-3 Series
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12V140E-3 Series 9
SEN00876-00 50 Disassembly and assembly
© 2006 KOMATSU
All Rights Reserved
10 12V140E-3 Series