Engine Saa12v140e-3 HPCR Sen00291-00d

SEN00291-00
ENGINE
SEN00294-00
ENGINE
1SHOP MANUAL
12V140E-3 Series
00 Index and foreword
Index
Organization list of the shop manual.................................................................................................... 2
Table of contents .................................................................................................................................. 3
12V140E-3 Series
SEN00294-00
Organization list of the shop manual
The contents of this shop manual are shown together with Form No. in a list.
Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly.
The marks shown to the right of Form No. denote the following:
Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.)
Note 2: This shop manual can be supplied for each Form No.
Note 3: To file this shop manual in the special binder for management, handle it as follows:
Place a divider on the top of each section in the file after matching the Tub No. with No. indicated
next to each Section Name shown in the table below:
File overview and other materials in sections in the order shown below and utilize them accordingly.
Section Title
Form Number
Shop Manual, contents binder, binder label and tabs
SEN00291-00

Index
Foreword and general information
SEN00292-00
SEN00294-00
SEN00296-00
01 Specification
Specification and technical data
SEN00301-00
SEN00303-00
10 Structure, function and maintenance standard

Structure, function and maintenance standard, Part 1
SEN00304-00
SEN00307-00
SEN00309-00
20 Standard value table

Standard service value table
SEN00310-00
SEN00311-00
12V140E-3 Series
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Table of contents

Index
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Organization list of the shop manual .......................................................................................
2
Table of contents .....................................................................................................................
3
SEN00296-00
Safety notice............................................................................................................................
2
How to read the shop manual..................................................................................................
6
Explanation of terms for maintenance standard ......................................................................
8
Handling electric equipment and hydraulic component ........................................................... 10
How to read electric wire code ................................................................................................ 18
Method of disassembling and connecting push-pull type coupler ........................................... 21
Standard tightening torque table.............................................................................................. 24
Conversion table...................................................................................................................... 28
01 Specification
SEN00303-00
Outline .....................................................................................................................................
2
Specifications...........................................................................................................................
4
General view............................................................................................................................
5
Weight table.............................................................................................................................
8
Engine performance curves..................................................................................................... 10
SEN00307-00
Air intake and exhaust system ....................................................................................................
3
Air intake and exhaust unit ......................................................................................................
3
Air cleaner ...............................................................................................................................
4
Turbocharger ...........................................................................................................................
6
Aftercooler ............................................................................................................................... 11
Muffler...................................................................................................................................... 12
Engine unit .................................................................................................................................. 14
Cylinder head .......................................................................................................................... 14
Cylinder block .......................................................................................................................... 18
Cylinder liner............................................................................................................................ 22
Main moving parts ................................................................................................................... 24
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
SEN00309-00
Lubrication system ......................................................................................................................
4
Lubrication system diagram.....................................................................................................
4
Oil pump ..................................................................................................................................
6
Oil cooler .................................................................................................................................
7
12V140E-3 Series
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Oil filter.....................................................................................................................................
Main relief valve.......................................................................................................................
Oil cooler bypass valve and regulator valve ............................................................................
Fuel system .................................................................................................................................
CRI system diagram ................................................................................................................
Outline of CRI system..............................................................................................................
Fuel piping ...............................................................................................................................
Fuel filter ..................................................................................................................................
Priming pump...........................................................................................................................
Cooling system............................................................................................................................
Cooling system diagram ..........................................................................................................
Water pump .............................................................................................................................
Thermostat...............................................................................................................................
Corrosion resistor ....................................................................................................................
Cooling fan drive......................................................................................................................
Electrical equipment ....................................................................................................................
Alternator .................................................................................................................................
Starting motor ..........................................................................................................................
Starting aid...............................................................................................................................
Engine controller......................................................................................................................
8
9
10
12
12
14
32
37
39
40
40
42
44
45
47
48
48
50
51
52

SEN00311-00
Standard service value table .......................................................................................................
2
Standard service value table for testing, adjusting, and troubleshooting .................................
2
Running-in standard and performance test standard ..............................................................
3
12V140E-3 Series
12V140E-3 Series
SEN00294-00
SEN00294-00
KOMATSU 12V140E-3 Series engine

Form No. SEN00294-00
2005 KOMATSU
All Rights Reserved
Printed in Japan 11-05 (02)
12V140E-3 Series
SEN00296-00
ENGINE
1SHOP MANUAL
12V140E-3 Series

Foreword and general information .................................................................................................................. 2
Safety notice ........................................................................................................................................ 2
How to read the shop manual .............................................................................................................. 6
Explanation of terms for maintenance standard................................................................................... 8
Handling electric equipment and hydraulic component...................................................................... 10
How to read electric wire code ........................................................................................................... 18
Method of disassembling and connecting push-pull type coupler...................................................... 21
Standard tightening torque table ........................................................................................................ 24
Conversion table ................................................................................................................................ 28
12V140E-3 Series
SEN00296-00

Safety notice
(Rev. 2005/11)
Important safety notice

Proper service and repair are extremely important for safe machine operation. The service and repair
techniques recommended by Komatsu and described in this manual are both effective and safe.
Some of these techniques require the use of tools specially designed by Komatsu for the specific
purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The
cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with
the situation.
1.
General precautions
k Mistakes in operation are extremely
dangerous. Read the Operation and
Maintenance Manual carefully before
operating the machine.
1) Before carrying out any greasing or
repairs, read all the safety plates stuck to
the machine. For the locations of the
safety plates and detailed explanation of
precautions, see the Operation and Maintenance Manual.
2) Decide a place in the repair workshop to
keep tools and removed parts. Always
keep the tools and parts in their correct
places. Always keep the work area clean
and make sure that there is no dirt, water,
or oil on the floor. Smoke only in the areas
provided for smoking. Never smoke while
working.
3) When carrying out any operation, always
wear safety shoes and helmet. Do not
wear loose work clothes, or clothes with
buttons missing.
q
Always wear safety glasses when hitting parts with a hammer.
q
Always wear safety glasses when
grinding parts with a grinder, etc.
4) When carrying out any operation with 2 or
more workers, always agree on the operating procedure before starting. Always
inform your fellow workers before starting
any step of the operation. Before starting
work, hang UNDER REPAIR signs in the
operator's compartment.
5) Only qualified workers must carry out work
and operation which require license or
qualification.
6) Keep all tools in good condition, learn the
correct way to use them, and use the
proper ones of them. Before starting work,
thoroughly check the tools, machine, forklift, service car, etc.
7)
8)
If welding repairs are needed, always

have a trained and experienced welder
carry out the work. When carrying out
w eld in g wo rk , alw ay s wear wel din g
gloves, apron, shielding goggles, cap and
other clothes suited for welding work.
Before starting work, warm up your body
thoroughly to start work under good condition.
Safety points
1 Good arrangement
2 Correct work clothes
3 Following work standard
4 Making and checking signs
Prohibition of operation and handling by
5
unlicensed workers
6 Safety check before starting work
Wearing protective goggles
7
(for cleaning or grinding work)
Wearing shielding goggles and protectors
8
(for welding work)
9 Good physical condition and preparation
Precautions against work which you are
10
not used to or you are used to too much
2.
Preparations for work

1) Before adding oil or making any repairs,
park the machine on hard and level
ground, and apply the parking brake and
block the wheels or tracks to prevent the
machine from moving.
2) Before starting work, lower the work
equipment (blade, ripper, bucket, etc.) to
the ground. If this is not possible, insert
the lock pin or use blocks to prevent the
work equipment from falling. In addition,
be sure to lock all the control levers and
hang warning signs on them.
12V140E-3 Series
3)
4)
3.
When disassembling or assembling, support the machine with blocks, jacks, or

stands before starting work.
Remove all mud and oil from the steps or
other places used to get on and off the
machine. Always use the handrails, ladders or steps when getting on or off the
m a c h i n e . N e v e r j u m p o n o r o ff t h e
machine. If it is impossible to use the
handrails, ladders or steps, use a stand to
provide safe footing.
Precautions during work

1) Before disconnecting or removing components of the oil, water, or air circuits, first
release the pressure completely from the
circuit. When removing the oil filler cap, a
drain plug, or an oil pressure pickup plug,
loosen it slowly to prevent the oil from
spurting out.
2) The coolant and oil in the circuits are hot
when the engine is stopped, so be careful
not to get scalded. Wait for the oil and
coolant to cool before carrying out any
work on the oil or water circuits.
3) Before starting work, stop the engine.
When working on or around a rotating
part, in particular, stop the engine. When
checking the machine without stopping
the engine (measuring oil pressure,
revolving speed, temperature, etc.), take
extreme care not to get rolled or caught in
rotating parts or moving parts.
4) Before starting work, remove the leads
from the battery. Always remove the lead
from the negative () terminal first.
5) When raising a heavy component (heavier
than 25 kg), use a hoist or crane. Before
starting work, check that the slings (wire
ropes, chains, and hooks) are free from
damage. Always use slings which have
ample capacity and install them to proper
places. Operate the hoist or crane slowly
to prevent the component from hitting any
other part. Do not work with any part still
raised by the hoist or crane.
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 wiring. Damaged wiring may cause electrical
fires.
12V140E-3 Series
SEN00296-00
8)
9)
10)
11)
12)
13)
14)
15)
16)
When removing piping, stop the fuel or oil

from spilling out. If any fuel or oil drips
onto the floor, wipe it up immediately. Fuel
or oil on the floor can cause you to slip
and can even start fires.
As a general rule, do not use gasoline to
wash parts. Do not use it to clean electrical parts, in particular.
Be sure to assemble all parts again in their
original places. Replace any damaged
parts and parts which must not be reused
with new parts. When installing hoses and
wires, be sure that they will not be damaged by contact with other parts when the
machine is operated.
When installing high pressure hoses,
make sure that they are not twisted. Damaged tubes are dangerous, so be
extremely careful when installing tubes for
high pressure circuits. In addition, check
t h a t c o n n e c t i n g pa r ts a r e c o r r e c t l y
installed.
When assembling or installing parts,
always tighten them to the specified
torques. When installing protective parts
such as guards, or parts which vibrate violently or rotate at high speed, be particul a r l y c a r e fu l t o c he c k t h a t t h ey ar e
installed correctly.
When aligning 2 holes, never insert your
fingers or hand. Be careful not to get your
fingers caught in a hole.
When measuring hydraulic pressure,
check that the measuring tools are correctly assembled.
Take care when removing or installing the
tracks of track-type machines. When
removing the track, the track separates
suddenly, so never let anyone stand at
either end of the track.
If the engine is operated for a long time in
a place which is not ventilated well, you
may suffer from gas poisoning. Accordingly, open the windows and doors to ventilate well.
SEN00296-00
4.
Precautions for sling work and making

signs
1) Only one appointed worker must make
signs and co-workers must communicate
with each other frequently. The appointed
sign maker must make specified signs
clearly at a place where he is seen well
from the operator's seat and where he can
see the working condition easily. The sign
maker must always stand in front of the
load and guide the operator safely.
q
Do not stand under the load.
q
Do not step on the load.
2) Check the slings before starting sling
work.
3) Keep putting on gloves during sling work.
(Put on leather gloves, if available.)
4) Measure the weight of the load by the eye
and check its center of gravity.
5) Use proper sling according to the weight
of the load and method of slinging. If too
thick wire ropes are used to sling a light
load, the load may slip and fall.
6) Do not sling a load with 1 wire rope alone.
If it is slung so, it may rotate and may slip
out of the rope. Install 2 or more wire
ropes symmetrically.
k Slinging with one rope may cause
turning of the load during hoisting,
untwisting of the rope, or slipping
of the rope from its original winding position on the load, which can
result in a dangerous accident.
7) Limit the hanging angle to 60, as a rule.
Do not sling a heavy load with ropes forming a wide hanging angle from the hook.
When hoisting a load with 2 or more
ropes, the force subjected to each rope
will increase with the hanging angle. The
table below shows the variation of allowable load in kN {kg} when hoisting is made
with 2 ropes, each of which is allowed to
sling up to 9.8 kN {1,000 kg} vertically, at
various hanging angles. When the 2 ropes
sling a load vertically, up to 19.6 kN {2,000
kg} of total weight can be suspended.
This weight is reduced to 9.8 kN {1,000
kg} when the 2 ropes make a hanging
angle of 120. If the 2 ropes sling a 19.6
kN {2,000 kg} load at a lifting angle of
150, each of them is subjected to a force
as large as 39.2 kN {4,000 kg}.
8)
When installing wire ropes to an angular

load, apply pads to protect the wire ropes.
If the load is slippery, apply proper material to prevent the wire rope from slipping.
9) Use the specified eyebolts and fix wire
ropes, chains, etc. to them with shackles,
etc.
10) Apply wire ropes to the middle portion of
the hook.
q
Slinging near the tip of the hook may
cause the rope to slip off the hook
during hoisting. The hook has the
maximum strength at the middle portion.
11) Do not use twisted or kinked wire ropes.

12) When lifting up a load, observe the following.
q
Wind in the crane slowly until wire
ropes are stretched. When settling
the wire ropes with the hand, do not
grasp them but press them from
above. If you grasp them, your fingers
may be caught.
q
After the wire ropes are stretched,
stop the crane and check the condition of the slung load, wire ropes, and
pads.
12V140E-3 Series
If the load is unstable or the wire rope

or chains are twisted, lower the load
and lift it up again.
q
Do not lift up the load slantingly.
13) When lifting down a load, observe the following.
q
When lifting down a load, stop it temporarily at 30 cm above the floor, and
then lower it slowly.
q
Check that the load is stable, and
then remove the sling.
q
Remove kinks and dirt from the wire
ropes and chains used for the sling
work, and put them in the specified
place.
SEN00296-00
13) If the hoist stops because of a power failure, turn the power switch OFF. When
turning on a switch which was turned OFF
by the electric shock prevention earth
leakage breaker, check that the devices
related to that switch are not in operation
state.
14) If you find an obstacle around the hoist,
stop the operation.
15) After finishing the work, stop the hoist at
the specified position and raise the hook
to at least 2 m above the floor. Do not
leave the sling installed to the hook.
5.
6.
Precautions for using mobile crane

a Read the Operation and Maintenance
Manual of the crane carefully in advance
and operate the crane safely.
Precautions for using overhead hoist crane
k When raising a heavy part (heavier
than 25 kg), use a hoist, etc. In Disassembly and assembly, the weight of a
part heavier than 25 kg is indicated
after the mark of 4.
1) Before starting work, inspect the wire
ropes, brake, clutch, controller, rails, over
wind stop device, electric shock prevention earth leakage breaker, crane collision
prevention device, and power application
warning lamp, and check safety.
2) Observe the signs for sling work.
3) Operate the hoist at a safe place.
4) Check the direction indicator plates (east,
west, south, and north) and the directions
of the control buttons without fail.
5) Do not sling a load slantingly. Do not move
the crane while the slung load is swinging.
6) Do not raise or lower a load while the
crane is moving longitudinally or laterally.
7) Do not drag a sling.
8) When lifting up a load, stop it just after it
leaves the ground and check safety, and
then lift it up.
9) Consider the travel route in advance and
lift up a load to a safe height.
10) Place the control switch on a position
where it will not be an obstacle to work
and passage.
11) After operating the hoist, do not swing the
control switch.
12) Remember the position of the main switch
so that you can turn off the power immediately in an emergency.
12V140E-3 Series
7.
Selecting wire ropes

1) Select adequate ropes depending on the
weight of parts to be hoisted, referring to
the table below.
Wire ropes
(Standard Z twist ropes without galvanizing)
(JIS G3525, No. 6, Type 6X37-A)
Nominal
Allowable load
diameter of rope
mm
kN
ton
10
8.8
0.9
12
12.7
1.3
14
17.3
1.7
16
22.6
2.3
18
28.6
2.9
20
35.3
3.6
25
55.3
5.6
30
79.6
8.1
40
141.6
14.4
50
221.6
22.6
60
318.3
32.4
The allowable load is one-sixth of the

breaking strength of the rope used
(Safety coefficient: 6).
SEN00296-00
How to read the shop manual

q
q
q
1.
Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one
of them is required, consult KOMATSU distributors.
Materials and specifications are subject to change without notice.
Shop manuals are divided into the Chassis volume and Engine volume. For the engine unit, see the
engine volume of the engine model mounted on the machine.
Composition of shop manual

This shop manual contains the necessary technical information for services performed in a workshop.
For ease of understanding, the manual is divided into the following sections.
00. Index and foreword
This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard
This section explains the structure, function, and maintenance standard values of each component.
The structure and function sub-section explains the structure and function of each component. It
serves not only to give an understanding of the structure, but also serves as reference material for
troubleshooting. The maintenance standard sub-section explains the criteria and remedies for disassembly and service.
20. Standard value table
This section explains the standard values for new machine and judgement criteria for testing,
adjusting, and troubleshooting. This standard value table is used to check the standard values in
testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting
This section explains measuring instruments and measuring methods for testing and adjusting, and
method of adjusting each part. The standard values and judgement criteria for testing and adjusting
are explained in Testing and adjusting.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is
divided by failure modes. The S mode of the troubleshooting related to the engine may be also
explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly
This section explains the special tools and procedures for removing, installing, disassembling, and
assembling each component, as well as precautions for them. In addition, tightening torque and
quantity and weight of coating material, oil, grease, and coolant necessary for the work are also
explained.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
q
Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q
Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
2.
Revision and distribution

Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most
up-to-date information before you start any work.
12V140E-3 Series
3.
4.
Filing method
File by the brochures in the correct order of the form number printed in the shop manual composition
table.
q
Revised edition mark

When a manual is revised, the ones and tens digits of the form number of each brochure is
increased by 1. (Example: 00, 01, 02 )
Revisions
Revised brochures are shown in the shop manual composition table.
Symbols
Important safety and quality portions are marked with the following symbols so that the shop manual will
be used practically.
Symbol
Item
Safety
Caution
Weight
Tightening
torque
5.
SEN00296-00
Coat
Oil, coolant
Drain
Remarks
Special safety precautions are necessary when performing work.
Special technical precautions or other precautions for preserving standards are necessary when performing work.
Weight of parts of component or parts. Caution necessary when
selecting hoisting wire, or when working posture is important, etc.
Places that require special attention for tightening torque during
assembly.
Places to be coated with adhesives, etc. during assembly.
Places where oil, etc. must be added, and capacity.
Places where oil, etc. must be drained, and quantity to be drained.
Units
In this shop manual, the units are indicated with International System of units (SI). For reference, conventionally used Gravitational System of units is indicated in parentheses { }.
12V140E-3 Series
SEN00296-00
Explanation of terms for maintenance standard
The maintenance standard values necessary for judgment of products and parts are described by the following terms.
1.
Standard size and tolerance

To be accurate, the finishing size of parts
is a little different from one to another.
q
To specify a finishing size of a part, a temporary standard size is set and an allowable difference from that size is indicated.
q
The above size set temporarily is called
the standard size and the range of difference from the standard size is called the
tolerance.
q
The tolerance with the symbols of + or is
indicated on the right side of the standard
size.
q
Example:
Standard size
120
Tolerance
0.022
0.126
The tolerance may be indicated in the text

and a table as [standard size (upper limit
of tolerance/lower limit of tolerance)].
Example) 120 (0.022/0.126)
Usually, the size of a hole and the size of

the shaft to be fitted to that hole are indicated by the same standard size and different tolerances of the hole and shaft.
The tightness of fit is decided by the tolerance.
Indication of size of rotating shaft and hole
and relationship drawing of them
Example:
Standard size
60
Tolerance
Shaft
Hole
0.030
+0.046
0.076
+0
12V140E-3 Series
2.
Standard clearance and standard value

The clearance made when new parts are
assembled is called the standard clearance, which is indicated by the range
from the minimum clearance to the maximum clearance.
q
When some parts are repaired, the clearance is generally adjusted to the standard
clearance.
q
A value of performance and function of
new products or equivalent is called the
standard value, which is indicated by a
range or a target value.
q
When some parts are repaired, the value
of performance/function is set to the standard value.
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5.
3.
Standard interference
When the size of a hole is smaller than the
size of a shaft because of the standard
size and tolerance, the difference between
these sizes is called the interference.
q
The range (A B) from the difference (A)
between the minimum size of the shaft
and the maximum size of the hole to the
difference (B) between the maximum size
of the shaft and the minimum size of the
hole is the standard interference.
q
After repairing or replacing some parts,
measure the size of their hole and shaft
and check that the interference is in the
standard range.
q
4.
Clearance limit
Parts can be used until the clearance
between them is increased to a certain
limit. The limit at which those parts cannot
be used is called the clearance limit.
q
If the clearance between the parts
exceeds the clearance limit, they must be
replaced or repaired.
q
6.
Interference limit
The allowable maximum interference
between the hole of a part and the shaft of
another part to be assembled is called the
interference limit.
q
The interference limit shows the repair
limit of the part of smaller tolerance.
q
If the interference between the parts
exceeds the interference limit, they must
be replaced or repaired.
q
Repair limit and allowable value

The size of a part changes because of
wear and deformation while it is used. The
limit of changed size is called the repair
limit.
q
If a part is worn to the repair limit must be
replaced or repaired.
q
The performance and function of a product lowers while it is used. A value below
which the product can be used without
causing a problem is called the allowable
value.
q
If a product is worn to the allowable value,
it must be checked or repaired. Since the
permissible value is estimated from various tests or experiences in most cases,
however, it must be judged after considering the operating condition and customer's
requirement.
q
12V140E-3 Series
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Handling electric equipment and hydraulic component
To maintain the performance of the machine over a long period, and to prevent failures or other troubles
before they occur, correct operation, maintenance and inspection, troubleshooting, and repairs must
be carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at
improving the quality of repairs. For this purpose, it gives sections on Handling electric equipment and
Handling hydraulic equipment (particularly gear oil and hydraulic oil).
Points to remember when handling electric

equipment
1. Handling wiring harnesses and connectors
Wiring harnesses consist of wiring connecting
one component to another component, connectors used for connecting and disconnecting
one wire from another wire, and protectors or
tubes used for protecting the wiring.
Compared with other electrical components fitted in boxes or cases, wiring harnesses are
more likely to be affected by the direct effects
of rain, water, heat, or vibration. Furthermore,
during inspection and repair operations, they
are frequently removed and installed again, so
they are likely to suffer deformation or damage.
For this reason, it is necessary to be extremely
careful when handling wiring harnesses.
2.
Main failures occurring in wiring harness

1) Defective contact of connectors (defective contact between male and female)
Problems with defective contact are likely
to occur because the male connector is
not properly inserted into the female connector, or because one or both of the connectors is deformed or the position is not
correctly aligned, or because there is corrosion or oxidization of the contact surfaces.
2)
10
Defective crimping or soldering of connectors

The pins of the male and female connectors are in contact at the crimped terminal
or soldered portion, but if there is excessive force brought to bear on the wiring,
the plating at the joint will peel and cause
improper connection or breakage.
12V140E-3 Series
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 soldering may be damaged, or the wiring
may be broken.
4)
High-pressure water entering connector

The connector is designed to make it difficult for water to enter (drip-proof structure), but if high-pressure water is sprayed
directly on the connector, water may enter
the connector, depending on the direction
of the water jet. Accordingly, take care not
splash water over the connector. The connector is designed to prevent water from
entering, but at the same time, if water
does enter, it is difficult for it to be drained.
Therefore, if water should get into the connector, the pins will be short-circuited by
the water, so if any water gets in, immediately dry the connector or take other
appropriate action before passing electricity through it.
5)
Oil or dirt stuck to connector

If oil or grease are stuck to the connector
and an oil film is formed on the mating surface between the male and female pins,
the oil will not let the electricity pass, so
there will be defective contact. If there is
oil or grease stuck to the connector, wipe it
off with a dry cloth or blow it dry with compressed air and spray it with a contact
restorer.
a When wiping the mating portion of the
connector, be careful not to use
excessive force or deform the pins.
a If there is oil or water in the compressed air, the contacts will become
even dirtier, so remove the oil and
water from the compressed air completely before cleaning with compressed air.
12V140E-3 Series
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11
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3.
Removing, installing, and drying connectors and wiring harnesses

1) Disconnecting connectors
1] Hold the connectors when disconnecting.
When disconnecting the connectors,
hold the connectors. For connectors
held by a screw, loosen the screw
fully, then hold the male and female
connectors in each hand and pull
apart. For connectors which have a
lock stopper, press down the stopper
with your thumb and pull the connectors apart.
a Never pull with one hand.
2]
q
12
When removing from clips

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

clip, pull the connector in a parallel
direction to the clip for removing stoppers.
a If the connector is twisted up and
down or to the left or right, the
housing may break.
3]
Action to take after removing connectors

After removing any connector, cover it
with a vinyl bag to prevent any dust,
dirt, oil, or water from getting in the
connector portion.
a If the machine is left disassembled for a long time, it is particularly easy for improper contact to
occur, so always cover the connector.
12V140E-3 Series
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 damage to the connector pins.
Check that there is no damage or
breakage to the outside of the connector.
a If there is any oil, water, or dirt
stuck to the connector, wipe it off
with a dry cloth. If any water has
got inside the connector, warm
the inside of the wiring with a
dryer, but be careful not to make
it too hot as this will cause short
circuits.
a If there is any damage or breakage, replace the connector.
2] Fix the connector securely.
Align the position of the connector
correctly, and then insert it securely.
For connectors with lock stopper,
push in the connector until the stopper clicks into position.
3] Correct any protrusion of the boot and
any misalignment of the wiring harness.
For connectors fitted with boots, correct any protrusion of the boot. In
addition, if the wiring harness is misaligned, or the clamp is out of position, adjust it to its correct position.
a If the connector cannot be corrected easily, remove the clamp
and adjust the position.
q
If the connector clamp has been
removed, be sure to return it to
its original position. Check also
that there are no loose clamps.
3)
Connecting DT connectors
Since the DT 8-pin and 12-pin heavy duty
wire connectors have 2 latches respectively, push them in until they click 2 times.
1.
2.
q
q
SEN00296-00
Male connector
Female connector
Normal locking state (Horizontal): a,
b, d
Incomplete locking state (Diagonal): c
12V140E-3 Series
13
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4)
14
Drying wiring harness

If there is any oil or dirt on the wiring harness, wipe it off with a dry cloth. Avoid
washing it in water or using steam. If the
connector must be washed in water, do
not use high-pressure water or steam
directly on the wiring harness. If water
gets directly on the connector, do as follows.
1] Disconnect the connector and wipe
off the water with a dry cloth.
a If the connector is blown dry with
compressed air, there is the risk
that oil in the air may cause
defective contact, so remove all
oil and wa te r fr om the compressed air before blowing with
air.
2] Dry the inside of the connector with a
dryer.
If water gets inside the connector, use
a dryer to dry the connector.
a Hot air from the dryer can be
used, but regulate the time that
the hot air is used in order not to
make the connector or related
parts too hot, as this will cause
deformation or damage to the
connector.
3] Carry out a continuity test on the connector.
After drying, leave the wiring harness
disconnected and carry out a continuity test to check for any short circuits
between pins caused by water.
a After completely drying the conn e c t o r, b l o w i t w i t h c o n ta c t
restorer and reassemble.
12V140E-3 Series
4.
Handling controller
1) The controller contains a microcomputer
and electronic control circuits. These control all of the electronic circuits on the
machine, so be extremely careful when
handling the controller.
2) Do not place objects on top of the controller.
3) Cover the control connectors with tape or
a vinyl bag. Never touch the connector
contacts with your hand.
4) During rainy weather, do not leave the
controller in a place where it is exposed to
rain.
5) Do not place the controller on oil, water, or
soil, or in any hot place, even for a short
time. (Place it on a suitable dry stand).
6) Precautions when carrying out arc welding
When carrying out arc welding on the
body, disconnect all wiring harness connectors connected to the controller. Fit an
arc welding ground close to the welding
point.
5.
Points to remember when troubleshooting

electric circuits
1) Always turn the power OFF before disconnecting or connecting connectors.
2) Before carrying out troubleshooting, check
that all the related connectors are properly
inserted.
a Disconnect and connect the related
connectors several times to check.
3) Always connect any disconnected connectors before going on to the next step.
a If the power is turned ON with the
connectors still disconnected, unnecessary abnormality displays will be
generated.
4) When carrying out troubleshooting of circuits (measuring the voltage, resistance,
continuity, or current), move the related
wiring and connectors several times and
check that there is no change in the reading of the tester.
a If there is any change, there is probably defective contact in that circuit.
12V140E-3 Series
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15
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Points to remember when handling hydraulic equipment

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

Avoid adding hydraulic oil, replacing filters, or
repairing the machine in rain or high winds, or
places where there is a lot of dust.
2.
Disassembly and maintenance work in the

field
If disassembly or maintenance work is carried
out on hydraulic equipment in the field, there is
danger of dust entering the equipment. It is
also difficult to check the performance after
repairs, so it is desirable to use unit exchange.
Disassembly and maintenance of hydraulic
equipment should be carried out in a specially
prepared dustproof workshop, and the performance should be checked with special test
equipment.
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.
4.
Do not let any dirt or dust get in during

refilling operations
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers. If an oil cleaning device is used, it is possible to filter out the
dirt that has collected during storage, so this is
an even more effective method.
16
12V140E-3 Series
5.
Change hydraulic oil when the temperature

is high
When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be
drained out easily from the circuit together with
the oil, so it is best to change the oil when it is
still warm. When changing the oil, as much as
possible of the old hydraulic oil must be
drained out. (Drain the oil from the hydraulic
tank; also drain the oil from the filter and from
the drain plug in the circuit.) If any old oil is left,
the contaminants and sludge in it will mix with
the new oil and will shorten the life of the
hydraulic oil.
6.
Flushing operations
After disassembling and assembling the equipment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit. Normally, flushing is
carried out twice: primary flushing is carried
out with flushing oil, and secondary flushing is
carried out with the specified hydraulic oil.
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 circuit. The oil cleaning equipment is used to
remove the ultra fine (about 3 m) particles that
the filter built in the hydraulic equipment cannot remove, so it is an extremely effective
device.
12V140E-3 Series
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17
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How to read electric wire code

a
The information about the wires unique to each machine model is described in Troubleshooting section,
Relational information of troubleshooting.
In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by symbols. The electric wire code is helpful in understanding the electric circuit diagram.
Example: AEX
0.85
L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nominal No. of 0.85
Indicates color of wire by color code.
Color codes are shown in Table 3.
Indicates size of wire by nominal No.
Size (Nominal No.) is shown in Table 2.
Indicates type of wire by symbol.
Type, symbol, and material of wire are shown in Table 1.
(Since AV and AVS are classified by size (nominal No.), they are not indicated.)
1.
Type, symbol, and material

AV and AVS are different in only thickness and outside diameter of the cover. AEX is similar to AV in
thickness and outside diameter of AEX and different from AV and AVS in material of the cover.
(Table 1)
Type
Symbol
Low-voltage
wire for
automobile
AV
Thin-cover
low-voltage
wire for
automobile
AVS
Heat-resistant low-voltAEX
age wire for
automobile
18
Material
Conductor
Insulator
Conductor
Annealed copper for electric appliance

Soft polyvinyl chloride
Insulator
Soft polyvinyl chloride
Conductor

Heat-resistant crosslinked
polyethylene
Insulator
Using
temperature
range (C)
Example of use
General wiring
(Nominal No. 5 and above)
30 to +60
General wiring
(Nominal No. 3 and below)
General wiring in extremely
50 to +110 cold district, wiring at high-temperature place
12V140E-3 Series
2.
SEN00296-00
Dimensions
(Table 2)
Nominal No.
0.5f
(0.5)
0.75f
(0.85)
1.25f
(1.25)
2f
3f
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)
AVS
CovAV
er D
AEX
d (approx.)
Standard
Standard
Standard
Nominal No.
Number of
strands/Diameter of strand
Conductor
Sectional
area (mm2)
d (approx.)
AVS
Standard
CovAV
Standard
er D
AEX
Standard
1.0
2.0
2.0
1.2
2.2
2.2
1.5
2.5
2.7
1.9
2.9
3.0
50
1.9
2.9
3.1
2.3
3.5
60
2.4
3.6
3.8
85
3.0
4.6
4.6
15
20
30
40
100
50/0.45
84/0.45
41/0.80
70/0.80
85/0.80
7.95
13.36
20.61
35.19
42.73
54.29
63.84
84.96
109.1
3.7
5.5
5.3
4.8
7.0
7.0
6.0
8.2
8.2
8.0
10.8
10.8
8.6
11.4
11.4
9.8
13.0
13.0
10.4
13.6
13.6
12.0
16.0
16.0
13.6
17.6
17.6
108/0.80 127/0.80 169/0.80 217/0.80
f of nominal No. denotes flexible.
12V140E-3 Series
19
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3.
Color codes table
(Table 3)
Color Code
B
Br
BrB
BrR
BrW
BrY
Ch
Dg
G
GB
GL
Gr
GR
GW
GY
L
LB
Lg
LgB
LgR
Color of wire
Color Code
LgW
LgY
LR
LW
LY
O
P
R
RB
RG
RL
RW
RY
Sb
Y
YB
YG
YL
YR
YW
Black
Brown
Brown & Black
Brown & Red
Brown & White
Brown & Yellow
Charcoal
Dark green
Green
Green & Black
Green & Blue
Gray
Green & Red
Green & White
Green & Yellow
Blue
Blue & Black
Light green
Light green & Black
Light green & Red
Color of wire
Light green & White
Light green & Yellow
Blue & Red
Blue & White
Blue & Yellow
Orange
Pink
Red
Red & Black
Red & Green
Red & Blue
Red & White
Red & Yellow
Sky Blue
Yellow
Yellow & Black
Yellow &Green
Yellow & Blue
Yellow & Red
Yellow & White
Remarks: In a color code consisting of 2 colors, the first color is the color of the background and
the second color is the color of the marking.
Example: GW means that the background is Green and marking is White.
4.
Types of circuits and color codes
(Table 4)
Type of wire
Charge
Ground
Start
Light
Instrument
Signal
Type of
circuit
Others
20
AVS or AV
R
B
R
RW
Y
G
L
Br
Lg
O
Gr
P
Sb
Dg
Ch
AEX
WG
R
B
R
D
Y
G
L
RB
YR
GW
LW
BrW
LgR
RY
YB
GR
LR
BrR
LgY
RG
YG
GY
LY
BrY
LgB
RL
YL
GB
LB
BrB
LgW
YW
GL
Gr
Br
12V140E-3 Series
SEN00296-00
Method of disassembling and connecting push-pull type coupler

k
k
Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to
release the residual pressure from the hydraulic tank.
Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly, prepare an oil receiving container.
Type 1
1.
Disconnection
1) Hold adapter (1) and push hose joint (2)
into mating adapter (3). (Fig. 1)
a The adapter can be pushed in about
3.5 mm.
a Do not hold rubber cap portion (4).
2) After hose joint (2) is pushed into adapter
(3), press rubber cap portion (4) against
adapter (3) until it clicks. (Fig. 2)
3) Hold hose adapter (1) or hose (5) and pull
it out. (Fig. 3)
a Since some hydraulic oil flows out,
prepare an oil receiving container.
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
21
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Type 2
1.
Disconnection
1) Hold the tightening portion and push body
(7) straight until sliding prevention ring (6)
contacts contact surface (a) of the hexagonal portion at the male end. (Fig. 6)
2) While holding the condition of Step 1), turn
lever (8) to the right (clockwise). (Fig. 7)
3) While holding the condition of Steps 1)
and 2), pull out whole body (7) to disconnect it. (Fig. 8)
2.
Connection
q
Hold the tightening portion and push body
contacts contact surface (a) of the hexagonal portion at the male end. (Fig. 9)
22
12V140E-3 Series
SEN00296-00
Type 3
1.
Disconnection
1) Hold the tightening portion and push body
contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 10)
2) While holding the condition of Step 1),
push cover (10) straight until it contacts
contact surface (b) of the hexagonal portion at the male end. (Fig. 11)
3) While holding the condition of Steps 1)
and 2), pull out whole body (9) to disconnect it. (Fig. 12)
2.
Connection
q
Hold the tightening portion and push body
(9) straight until the sliding prevention ring
contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 13)
12V140E-3 Series
23
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Standard tightening torque table

1.
Table of tightening torques for bolts and nuts

a Unless there are special instructions, tighten metric nuts and bolts to the torque below. (When using
torque wrench)
a
The following table corresponds to the bolts in Fig. A.
Thread diameter of bolt

mm
6
8
10
12
14
16
18
20
22
24
27
30
33
36
39
a
a Fig. A
Width across flats

mm
10
13
17
19
22
24
27
30
32
36
41
46
50
55
60
Tightening torque
Nm
kgm
11.8 14.7
1.2 1.5
27 34
2.8 3.5
59 74
6 7.5
98 123
10 12.5
153 190
15.5 19.5
235 285
23.5 29.5
320 400
33 41
455 565
46.5 58
610 765
62.5 78
785 980
80 100
1,150 1,440
118 147
1,520 1,910
155 195
1,960 2,450
200 250
2,450 3,040
250 310
2,890 3,630
295 370
The following table corresponds to the bolts in Fig. B.

mm
6
8
10
12
24
Width across flats

mm
10
13
14
27
Tightening torque
Nm
5.9 9.8
13.7 23.5
34.3 46.1
74.5 90.2
kgm
0.6 1.0
1.4 2.4
3.5 4.7
7.6 9.2
a Fig. B
12V140E-3 Series
2.
Table of tightening torques for split flange bolts

a Unless there are special instructions, tighten split flange bolts to the torque below.

mm
10
12
16
3.
Width across flats

mm
14
17
22
Tightening torque
Nm
kgm
59 74
6.0 7.5
98 123
10.0 12.5
235 285
23.5 29.5
Table of tightening torques for O-ring boss piping joints

a Unless there are special instructions, tighten O-ring boss piping joints to the torque below.
Nominal No.
02
03,04
05,06
10,12
14
4.
SEN00296-00
Thread diameter
mm
14
20
24
33
42
Width across flats

mm
Tightening torque Nm {kgm}

Range
Target
35 63 { 3.5 6.5}
44 { 4.5}
84 132 { 8.5 13.5}
103 {10.5}
Varies depending
157 {16.0}
on type of connec- 128 186 {13.0 19.0}
tor.
363 480 {37.0 49.0}
422 {43.0}
746 1,010 {76.0 103}
883 {90.0}
Table of tightening torques for O-ring boss plugs

a Unless there are special instructions, tighten O-ring boss plugs to the torque below.
Nominal
No.
08
10
12
14
16
18
20
24
30
33
36
42
52
Thread diameter
mm
8
10
12
14
16
18
20
24
30
33
36
42
52
12V140E-3 Series
Width across flats

mm
14
17
19
22
24
27
30
32
32
36

Range
Target
5.88 8.82 {0.6 0.9}
7.35 {0.75}
9.81 12.74 {1.0 1.3}
11.27 {1.15}
14.7 19.6 {1.5 2.0}
17.64 {1.8}
19.6 24.5 {2.0 2.5}
22.54 {2.3}
24.5 34.3 {2.5 3.5}
29.4 {3.0}
34.3 44.1 {3.5 4.5}
39.2 {4.0}
44.1 53.9 {4.5 5.5}
49.0 {5.0}
58.8 78.4 {6.0 8.0}
68.6 {7.0}
93.1 122.5 { 9.5 12.5}
107.8 {11.0}
107.8 147.0 {11.0 15.0}
127.4 {13.0}
127.4 176.4 {13.0 18.0}
151.9 {15.5}
181.3 240.1 {18.5 24.5}
210.7 {21.5}
274.4 367.5 {28.0 37.5}
323.4 {33.0}
25
SEN00296-00
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.
Nominal
No. of
hose
Width
across
flats
02
19
22
24
27
32
36
41
46
55
03
04
05
06
(10)
(12)
(14)
6.
Range
44 { 4.5}
74 { 7.5}
78 { 8.0}
103 {10.5}
157 {16.0}
216 {22.0}
216 {22.0}
245 {25.0}
294 {30.0}
Thread size
(mm)
14
18
22
24
30
33
36
42
Face seal
Nominal No. Thread diameNumber of
ter (mm) (Refthreads, type of
erence)
thread
9/16-18UN
14.3
11/16-16UN
17.5
13/16-16UN
20.6
1-14UNS
25.4
1-3/16-12UN
30.2
Table of tightening torques for 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.
mm
6
8
10
12
14
Tightening torque
Bolt
Nm
10 2
24 4
43 6
77 12
BANJO bolt
kgm
1.02 0.20
2.45 0.41
4.38 0.61
7.85 1.22
Nm
8 2
10 2
12 2
24 4
36 5
kgm
0.81 0.20
1.02 0.20
1.22 0.20
2.45 0.41
3.67 0.51
Table of tightening torques for 102, 107 and 114 engine series (Eye joints)
a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine
series to the torque below.
Thread size
mm
6
8
10
12
14
26
Target
34 54 { 3.5 5.5}
34 63 { 3.5 6.5}
54 93 { 5.5 9.5}
59 98 { 6.0 10.0}
84 132 { 8.5 13.5}
128 186 {13.0 19.0}
177 245 {18.0 25.0}
177 245 {18.0 25.0}
197 294 {20.0 30.0}
246 343 {25.0 35.0}
Thread size
7.
Taper seal
Tightening torque
Nm
82
10 2
12 2
24 4
36 5
kgm
0.81 0.20
1.02 0.20
1.22 0.20
2.45 0.41
3.67 0.51
12V140E-3 Series
8.
SEN00296-00
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.
Thread size
inch
1/16
1/8
1/4
3/8
1/2
3/4
1
12V140E-3 Series
Tightening torque
Nm
31
82
12 2
15 2
24 4
36 5
60 9
kgm
0.31 0.10
0.81 0.20
1.22 0.20
1.53 0.20
2.45 0.41
3.67 0.51
6.12 0.92
27
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Conversion table
Method of using the conversion table

The conversion table in this section is provided to enable simple conversion of figures. For details of the
method of using the conversion table, see the example given below.
Example: Method of using the conversion table to convert from millimeters to inches
1.
Convert 55 mm into inches.

1) Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a horizontal line from (A).
2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down
from (B).
3) Take the point where the two lines cross as (C). This point (C) gives the value when converting from
millimeters to inches. Therefore, 55 mm = 2.165 inches.
2.
Convert 550 mm into inches.

1) The number 550 does not appear in the table, so divide it by 10 (move the decimal point one place
to the left) to convert it to 55 mm.
2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal
point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
Millimeters to inches
(A)
28
(B)
0
10
20
30
40
0
0
0.394
0.787
1.181
1.575
1
0.039
0.433
0.827
1.220
1.614
2
0.079
0.472
0.866
1.260
1.654
3
0.118
0.512
0.906
1.299
1.693
4
0.157
0.551
0.945
1.339
1.732
50
60
70
80
90
1.969
2.362
2.756
3.150
3.543
2.008
2.402
2.795
3.189
3.583
2.047
2.441
2.835
3.228
3.622
2.087
2.480
2.874
3.268
3.661
2.126
2.520
2.913
3.307
3.701
5
0.197
0.591
0.984
1.378
1.772
(C)
2.165
2.559
2.953
3.346
3.740
6
0.236
0.630
1.024
1.417
1.811
7
0.276
0.669
1.063
1.457
1.850
2.205
2.598
2.992
3.386
3.780
2.244
2.638
3.032
3.425
3.819
1 mm = 0.03937 in
8
9
0.315
0.354
0.709
0.748
1.102
1.142
1.496
1.536
1.890
1.929
2.283
2.677
3.071
3.465
3.858
2.323
2.717
3.110
3.504
3.898
12V140E-3 Series
SEN00296-00
Millimeters to inches
0
10
20
30
40
0
0
0.394
0.787
1.181
1.575
1
0.039
0.433
0.827
1.220
1.614
2
0.079
0.472
0.866
1.260
1.654
3
0.118
0.512
0.906
1.299
1.693
4
0.157
0.551
0.945
1.339
1.732
5
0.197
0.591
0.984
1.378
1.772
6
0.236
0.630
1.024
1.417
1.811
1 mm = 0.03937 in
7
8
9
0.276
0.315
0.354
0.669
0.709
0.748
1.063
1.102
1.142
1.457
1.496
1.536
1.850
1.890
1.929
50
60
70
80
90
1.969
2.362
2.756
3.150
3.543
2.008
2.402
2.795
3.189
3.583
2.047
2.441
2.835
3.228
3.622
2.087
2.480
2.874
3.268
3.661
2.126
2.520
2.913
3.307
3.701
2.165
2.559
2.953
3.346
3.740
2.205
2.598
2.992
3.386
3.780
2.244
2.638
3.032
3.425
3.819
1 kg = 2.2046 lb
6
7
8
9
13.23
15.43
17.64
19.84
35.27
37.48
39.68
41.89
57.32
59.53
61.73
63.93
79.37
81.57
83.78
85.98
101.41 103.62 105.82 108.03
2.283
2.677
3.071
3.465
3.858
2.323
2.717
3.110
3.504
3.898
Kilogram to pound
0
10
20
30
40
0
0
22.05
44.09
66.14
88.18
1
2.20
24.25
46.30
68.34
90.39
2
4.41
26.46
48.50
70.55
92.59
3
6.61
28.66
50.71
72.75
94.80
4
8.82
30.86
51.91
74.96
97.00
5
11.02
33.07
55.12
77.16
99.21
50
60
70
80
90
110.23
132.28
154.32
176.37
198.42
112.44
134.48
156.53
178.57
200.62
114.64
136.69
158.73
180.78
202.83
116.85
138.89
160.94
182.98
205.03
119.05
141.10
163.14
185.19
207.24
121.25
143.30
165.35
187.39
209.44
123.46
145.51
167.55
189.60
211.64
125.66
147.71
169.76
191.80
213.85
127.87
149.91
171.96
194.01
216.05
130.07
152.12
174.17
196.21
218.26
Liters to U.S. Gallons
0
10
20
30
40
0
1
2
0
0.264
0.528
2.642
2.906
3.170
5.283
5.548
5.812
7.925
8.189
8.454
10.567 10.831 11.095
3
0.793
3.434
6.076
8.718
11.359
4
1.057
3.698
6.340
8.982
11.624
1 l = 0.2642 U.S.Gal
5
6
7
8
9
1.321 1.585
1.849
2.113
2.378
3.963 4.227
4.491
4.755
5.019
6.604 6.869
7.133
7.397
7.661
9.246 9.510
9.774 10.039 10.303
11.888 12.152 12.416 12.680 12.944
50
60
70
80
90
13.209
15.850
18.492
21.134
23.775
14.001
16.643
19.285
21.926
24.568
14.265
16.907
19.549
22.190
24.832
14.529
17.171
19.813
22.455
25.096
12V140E-3 Series
13.473
16.115
18.756
21.398
24.040
13.737
16.379
19.020
21.662
24.304
14.795
17.435
20.077
22.719
25.361
15.058
17.700
20.341
22.983
25.625
15.322
17.964
20.605
23.247
25.889
15.586
18.228
20.870
23.511
26.153
29
SEN00296-00
Liters to U.K. Gallons
0
10
20
30
40
0
0
2.200
4.399
6.599
8.799
1
0.220
2.420
4.619
6.819
9.019
2
0.440
2.640
4.839
7.039
9.239
3
0.660
2.860
5.059
7.259
9.459
4
0.880
3.080
5.279
7.479
9.679
5
1.100
3.300
5.499
7.699
9.899
50
60
70
80
90
10.998
13.198
15.398
17.598
19.797
11.281
13.418
15.618
17.818
20.017
11.438
13.638
15.838
18.037
20.237
11.658
13.858
16.058
18.257
20.457
11.878
14.078
16.278
18.477
20.677
12.098
14.298
16.498
18.697
20.897
1 l = 0.21997 U.K.Gal
6
7
8
9
1.320
1.540
1.760
1.980
3.520
3.740
3.950
4.179
5.719
5.939
6.159
6.379
7.919
8.139
8.359
8.579
10.119 10.339 10.559 10.778
12.318
14.518
16.718
18.917
21.117
12.528
14.738
16.938
19.137
21.337
12.758
14.958
17.158
19.357
21.557
12.978
15.178
17.378
19.577
21.777
kgm to ft.lb
0
10
20
30
40
0
0
72.3
144.7
217.0
289.3
1
7.2
79.6
151.9
224.2
296.6
2
14.5
86.8
159.1
231.5
303.8
3
21.7
94.0
166.4
238.7
311.0
4
28.9
101.3
173.6
245.9
318.3
5
36.2
108.5
180.8
253.2
325.5
6
43.4
115.7
188.1
260.4
332.7
1 kgm = 7.233 ft.lb

7
8
9
50.6
57.9
65.1
123.0
130.2
137.4
195.3
202.5
209.8
267.6
274.9
282.1
340.0
347.2
354.4
50
60
70
80
90
361.7
434.0
506.3
578.6
651.0
368.9
441.2
513.5
585.9
658.2
376.1
448.5
520.8
593.1
665.4
383.4
455.7
528.0
600.3
672.7
390.6
462.9
535.2
607.6
679.9
397.8
470.2
542.5
614.8
687.1
405.1
477.4
549.7
622.0
694.4
412.3
484.6
556.9
629.3
701.6
419.5
491.8
564.2
636.5
708.8
426.8
499.1
571.4
643.7
716.1
100
110
120
130
140
723.3
730.5
737.8 745.0
752.2
759.5 766.7
773.9
781.2
788.4
795.6
802.9
810.1 817.3
824.6
831.8 839.0
846.3
853.5
860.7
868.0
875.2
882.4 889.7
896.9
904.1
911.4
918.6
925.8
933.1
940.3
947.5
954.8 962.0
969.2
976.5 983.7
990.9
998.2 1005.4
1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150
160
170
180
190
1084.9
1157.3
1129.6
1301.9
1374.3
30
1092.2
1164.5
1236.8
1309.2
1381.5
1099.4
1171.7
1244.1
1316.4
1388.7
1106.6
1179.0
1251.3
1323.6
1396.0
1113.9
1186.2
1258.5
1330.9
1403.2
1121.1
1193.4
1265.8
1338.1
1410.4
1128.3
1200.7
1273.0
1345.3
1417.7
1135.6
1207.9
1280.1
1352.6
1424.9
1142.8
1215.1
1287.5
1359.8
1432.1
1150.0
1222.4
1294.7
1367.0
1439.4
12V140E-3 Series
SEN00296-00
kg/cm2 to lb/in2
0
10
20
30
40
0
0
142.2
284.5
426.7
568.9
1
14.2
156.5
298.7
440.9
583.2
2
28.4
170.7
312.9
455.1
597.4
3
42.7
184.9
327.1
469.4
611.6
4
56.9
199.1
341.4
483.6
625.8
5
71.1
213.4
355.6
497.8
640.1
6
85.3
227.6
369.8
512.0
654.3
1 kg/cm2 = 14.2233 lb/in2

7
8
9
99.6
113.8
128.0
241.8
256.0
270.2
384.0
398.3
412.5
526.3
540.5
554.7
668.5
682.7
696.9
50
60
70
80
90
711.2
853.4
995.6
1,138
1,280
725.4
867.6
1,010
1,152
1,294
739.6
881.8
1,024
1,166
1,309
753.8
896.1
1,038
1,181
1,323
768.1
910.3
1,053
1,195
1,337
782.3
924.5
1,067
1,209
1,351
796.5
938.7
1,081
1,223
1,365
810.7
953.0
1,095
1,237
1,380
825.0
967.2
1,109
1,252
1,394
839.2
981.4
1,124
1,266
1,408
100
110
120
130
140
1,422
1,565
1,707
1,849
1,991
1,437
1,579
1,721
1,863
2,005
1,451
1,593
1,735
1,877
2,020
1,465
1,607
1,749
1,892
2,034
1,479
1,621
1,764
1,906
2,048
1,493
1,636
1,778
1,920
2,062
1,508
1,650
1,792
1,934
2,077
1,522
1,664
1,806
1,949
2,091
1,536
1,678
1,821
1,963
2,105
1,550
1,693
1,835
1,977
2,119
150
160
170
180
190
2,134
2,276
2,418
2,560
2,702
2,148
2,290
2,432
2,574
2,717
2,162
2,304
2,446
2,589
2,731
2,176
2,318
2,460
2,603
2,745
2,190
2,333
2,475
2,617
2,759
2,205
2,347
2,489
2,631
2,773
2,219
2,361
2,503
2,646
2,788
2,233
2,375
2,518
2,660
2,802
2,247
2,389
2,532
2,674
2,816
2,262
2,404
2,546
2,688
2,830
200
210
220
230
240
2,845
2,987
3,129
3,271
3,414
2,859
3,001
3,143
3,286
3,428
2,873
3,015
3,158
3,300
3,442
2,887
3,030
3,172
3,314
3,456
2,901
3,044
3,186
3,328
3,470
2,916
3,058
3,200
3,343
3,485
2,930
3,072
3,214
3,357
3,499
2,944
3,086
3,229
3,371
3,513
2,958
3,101
3,243
3,385
3,527
2,973
3,115
3,257
3,399
3,542
12V140E-3 Series
31
SEN00296-00
Temperature
Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vice versa is to enter the accompanying table in the center (boldface column)
of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of
Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of
Centigrade values, and read the corresponding Fahrenheit temperature on the right.
C
40.4
37.2
34.4
31.7
28.9
40
35
30
25
20
F
40.0
31.0
22.0
13.0
4.0
C
11.7
11.1
10.6
10.0
9.4
11
12
13
14
15
F
51.8
53.6
55.4
57.2
59.0
C
7.8
8.3
8.9
9.4
10.0
28.3
27.8
27.2
26.7
26.1
19
18
17
16
15
2.2
0.4
1.4
3.2
5.0
8.9
8.3
7.8
7.2
6.7
16
17
18
19
20
60.8
62.6
64.4
66.2
68.0
25.6
25.0
24.4
23.9
23.3
14
13
12
11
10
6.8
8.6
10.4
12.2
14.0
6.1
5.6
5.0
4.4
3.9
21
22
23
24
25
22.8
22.2
21.7
21.1
20.6
9
8
7
6
5
15.8
17.6
19.4
21.2
23.0
3.3
2.8
2.2
1.7
1.1
20.0
19.4
18.9
18.3
17.8
4
3
2
1
0
24.8
26.6
28.4
30.2
32.0
17.2
16.7
16.1
15.6
15.0
1
2
3
4
5
14.4
13.9
13.3
12.8
12.2
6
7
8
9
10
32
1C = 33.8F
F
81
177.8
82
179.6
83
181.4
84
183.2
85
185.0
46
47
48
49
50
F
114.8
116.6
118.4
120.2
122.0
C
27.2
27.8
28.3
28.9
29.4
10.6
11.1
11.7
12.2
12.8
51
52
53
54
55
123.8
125.6
127.4
129.2
131.0
30.0
30.6
31.1
31.7
32.2
86
87
88
89
90
186.8
188.6
190.4
192.2
194.0
69.8
71.6
73.4
75.2
77.0
13.3
13.9
14.4
15.0
15.6
56
57
58
59
60
132.8
134.6
136.4
138.2
140.0
32.8
33.3
33.9
34.4
35.0
91
92
93
94
95
195.8
197.6
199.4
201.2
203.0
26
27
28
29
30
78.8
80.6
82.4
84.2
86.0
16.1
16.7
17.2
17.8
18.3
61
62
63
64
65
141.8
143.6
145.4
147.2
149.0
35.6
36.1
36.7
37.2
37.8
96
97
98
99
100
204.8
206.6
208.4
210.2
212.0
0.6
0
0.6
1.1
1.7
31
32
33
34
35
87.8
89.6
91.4
93.2
95.0
18.9
19.4
20.0
20.6
21.1
66
67
68
69
70
150.8
152.6
154.4
156.2
158.0
40.6
43.3
46.1
48.9
51.7
105
110
115
120
125
221.0
230.0
239.0
248.0
257.0
33.8
35.6
37.4
39.2
41.0
2.2
2.8
3.3
3.9
4.4
36
37
38
39
40
96.8
98.6
100.4
102.2
104.0
21.7
22.2
22.8
23.3
23.9
71
72
73
74
75
159.8
161.6
163.4
165.2
167.0
54.4
57.2
60.0
62.7
65.6
130
135
140
145
150
266.0
275.0
284.0
293.0
302.0
42.8
44.6
46.4
48.2
50.0
5.0
5.6
6.1
6.7
7.2
41
42
43
44
45
105.8
107.6
109.4
111.2
113.0
24.4
25.0
25.6
26.1
26.7
76
77
78
79
80
168.8
170.6
172.4
174.2
176.0
68.3
71.1
73.9
76.7
79.4
155
160
165
170
175
311.0
320.0
329.0
338.0
347.0
12V140E-3 Series
12V140E-3 Series
SEN00296-00
33
SEN00296-00

2005 KOMATSU
All Rights Reserved
34
12V140E-3 Series
SEN00303-00
ENGINE
1SHOP MANUAL
12V140E-3 Series
01 Specification

Outline .................................................................................................................................................. 2
Specifications........................................................................................................................................ 4
General view......................................................................................................................................... 5
Weight table .......................................................................................................................................... 8
Engine performance curves ................................................................................................................ 10
12V140E-3 Series
SEN00303-00
01 Specification
Outline
1. Applicable machine
Engine
SAA12V140E-3
Engine serial No.
Machine model
D475A-5
Bulldozer
12V140E-3 Series
01 Specification
SEN00303-00
2. Outline of engine
q
The 12V140E-3 engine is a high-performance

and high-efficiency engine which provides low
fuel consumption, low noise, and improved
exhaust gas color, and improved acceleration
performance, and it cleared the strict exhaust
gas regulation (USA: EPA regulations for
2006). Accordingly, this newly developed
engine is suitable as a power source of
c o n s t r u c t i o n m a c h i n e r y, a n d i n d u s t r i a l
machinery used for various purposes.
It is the successor of conventional 12V140-1

engine which introduces various kinds of new
technologies while adhering fundamentally to
the configuration of V12-cylinder, watercooled, direct injection, and 4-stroke diesel
engine.
1)
High-pressure fuel injection system controlled

electronically
The conventional one is a jerk in-line fuel
injection pump-based engine mechanically
controlled by a governor, while in all series of
the new one, an electronic control system- and
high-pressure injection system-based common
rail injection system is adopted. This system
provides high pressure fuel of 118 MPa {1,200
kg/cm2} level from the low-speed range to the
high-speed range. In addition, it can control
the form of injection most properly by the
electronic control system according to the
speed and load. As a result, clean exhaust
g a s , c l e a n e x h a u s t g a s c o l o r, l o w f u e l
consumption, and low noise are attained
simultaneously.
2)
3)
4)
It adopts a re-entrant piston combustion

chamber which has been used since
introduction into the 6D140E-2 engine and also
uses a quality cast iron piston with less thermal
expansion and shaker cooling gallery. As a
result, clean exhaust gas, clean exhaust gas
color, and low fuel consumption are attained
simultaneously, and also high durability and
high reliability are also obtained.
It also provides a higher compression ratio
than the conventional one to improve
combustion efficiency and reduce the white
exhaust smoke when starting the engine in
cold climate areas. In addition, by using the
above-mentioned high-pressure fuel injection
system controlled electronically and setting the
injection characteristics most properly to
improve the startability and reduce the white
exhaust smoke when the temperature is low.
It is equipped with an improved turbocharger
KOMATSU KTR110 of which high reliability
and high performance have been proven in the
12V140-1 engine. The following improvements
12V140E-3 Series
are added: mounting of a recirculation port for

surging control at the compressor side and a
design to improve efficiency of the turbine. As
a result, high performance is attained in a wide
range from the low-speed range to the highspeed range, and high performance and low
fuel consumption are also obtained.
5)
The piston cooling nozzle of 12V140-1 is

reviewed in regard to oil flow. As a result,
durability of the piston is improved and
temperature of the rear surface of the piston is
reduced to prevent deterioration of the piston
due to exposure of lubricating oil on the
surface to high temperature. Since the highpressure fuel injection system controlled
electronically is employed, less-soot
combustion is attained and the draining
interval of the oil is lengthened.
6)
The high-pressure pump to create high

pressure in the common rail injection system is
one-third of the conventional in-line fuel
injection pump, and in addition, it is connected
compact to the timing gear case as a flange
mount rather than a saddle mount. As a result,
sound radiation is reduced to provide low
noise.
7)
Capacity of the lubrication pump is increased

by 10% over the conventional engine to
contribute to the reliability and durability.
8)
The air cleaner is changed from the

conventional end surface seal type to radial
seal type to prevent the entry of dust due to
deformation into the clean side. In addition, the
air cleaner clogging sensor for 5 clogging level
indication is provided to inform users of a
precise cleaning time.
9)
A high performance and high efficiency

combination filter is adopted as an oil filter, and
a filter system to collect small dirts as well as
large dirts is adopted for all specifications.
10) The fuel filter system includes a high efficiency

main filter and prefilter as standard features to
allow use of low-grade fuel in the market
(corresponding to NAS13 level). In addition,
the delivery of the priming pump used to
replace the filters is increased for higher
serviceability.
11) In addition, since the engine controller is
mounted on the engine and equipped with the
automatic high-altitude compensation function,
it can be operated at high altitude without
replacing the controller. As a result, the
serviceability is improved.
SEN00303-00
01 Specification
Specifications
1
Engine name
SAA12V140E-3
Machine model
D475A-5
mm
l {cc}
12 140 x 165
30.5 {30,480}
R1-L1-R5-L5-R3-L3-R6-L6-R2-L2-R4-L4
Overall length
mm
1,772
Overall width
mm
1,532.5
Overall height (excluding exhaust pipe)
mm
2,171.5
Overall height (including exhaust pipe)
mm
Rated output
kW{HP}/rpm
671 {899}/2,000
(Gross)
Max. torque
Nm{kgm}/rpm
3,825 {390}/1,400
(Gross)
No-load max. speed

(High idle speed)
rpm
2,150 50
No-load min. speed

(Low idle speed)
rpm
620 + 80/0
g/kWh
{g/HPh}
210 {156.7}
Dry weight
kg
3,600
Fuel supply pump

Governor
DENSO ECD-U2
Electronic control type
Quantity of lubricating oil (Refill capacity)
134 (128)
Quantity of coolant
210
Alternator
Starting motor
Battery
24V, 90A
24V, 7.5kW x 2
12V, 170Ah x 4
Turbocharger
Air compressor
Others
KOMATSU KTR110L x 2
With air-cooled aftercooler
Performance
Dimensions
Number of cylinders Bore Stroke

Total displacement
Firing order
Fuel consumption ratio at rated output
12V140E-3 Series
01 Specification
General view
SEN00303-00
SAA12V140E-3 (Left side view of engine)

Machine model: D475A-5
The shape is subject to machine models.
1.
2.
Center of crankshaft
Rear face of flywheel housing
12V140E-3 Series
SEN00303-00
01 Specification
SAA12V140E-3 (Front view of engine)

Machine model: D475A-5
1.
2.
Center of crankshaft
Center of cylinder liner
12V140E-3 Series
01 Specification
SEN00303-00
Dimensions table
Unit: mm
Engine
SAA12V140E-3
Machine model
D475A-5
Dimensions of each part

A
287
1,582
1,772
2,171.5
726
507
507
These dimensions are given for reference when the engine is set on a test bench.
12V140E-3 Series
SEN00303-00
01 Specification
Weight table
1
Unit: kg
No.
Item
Main parts
SAA12V140E-3
Turbocharger
KOMATSU KTR110L (Water-cooled)
25 x 2
Cylinder head assembly
Cylinder head, valve,

rocker arm, valve spring
Cylinder block assembly
Cylinder block, bearing cap,

cylinder liner
Gear case
72
Gear case
52
22.5 x 12
810
Oil pan
Integral-type
88.4
Flywheel assembly
Flywheel, ring gear
127.6
Flywheel housing assembly
Crankshaft assembly
Crankshaft, crank gear
10
Camshaft assembly
Camshaft, cam gear

thrust plate
11
Piston and connecting rod assembly
Piston, piston ring,

piston pin, connecting rod
133.5
210
L
20
20
10.5 x 12
12
Oil pump
13
Fuel supply pump
13
14
Water pump
22
15
Alternator
24V,90A
16
Starting motor
24V,7.5kW
17
Aftercooler assembly
12
18 x 2
35 x 2
12V140E-3 Series
01 Specification
12V140E-3 Series
SEN00303-00
SEN00303-00
01 Specification
Engine performance curves

Engine
SAA12V140E-3
10
Engine serial No.
1
Machine model
D475A-5
Page
11
12V140E-3 Series
01 Specification
SEN00303-00
SAA12V140E-3 (Machine model: D475A-5)

Rated output: 671 kW {899 HP}/2,000 rpm (Gross)
Max. torque: 3,825 Nm {390 kgm}/1,400 rpm (Gross)
12V140E-3 Series
11
SEN00303-00
01 Specification

2005 KOMATSU
All Rights Reserved
12
12V140E-3 Series
SEN00307-00
ENGINE
1SHOP MANUAL
12V140E-3 Series
10 Structure, function and

maintenance standard
Structure, function and maintenance

standard, Part 1
Air intake and exhaust system ........................................................................................................................ 3
Air intake and exhaust unit ................................................................................................................... 3
Air cleaner............................................................................................................................................. 4
Turbocharger ........................................................................................................................................ 6
Aftercooler ...........................................................................................................................................11
Muffler ................................................................................................................................................. 12
Engine unit .................................................................................................................................................... 14
Cylinder head...................................................................................................................................... 14
Cylinder block ..................................................................................................................................... 18
Cylinder liner....................................................................................................................................... 22
Main moving parts............................................................................................................................... 24
12V140E-3 Series
SEN00307-00
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
12V140E-3 Series
SEN00307-00
Air intake and exhaust system
Air intake and exhaust unit
(Left side view of engine)
The illustration shows the engine for D575A-5.
A:
B:
C:
D:
Air intake (From air cleaner)

Air intake (To air-cooled aftercooler)
Air intake (From air-cooled aftercooler)
Exhaust gas
12V140E-3 Series
1.
2.
3.
4.
Electrical intake air heater

Air intake manifold
Muffler
Turbocharger
SEN00307-00
Air cleaner
ERB type
[Air cleaner of automatic exhaust gas discharge type (Radial seal type)]
A:
B:
C:
Air inlet
To turbocharger (Intake air)
To muffler (Dust)
1.
2.
3.
4.
Pre-cleaner
Air cleaner casing
Outer element
Inner element
Engine
Machine model
Type
Method of discharging
dust from pre-cleaner
Number of
elements
SAA12V140E-3
D475A-5
Komaclone, multi-cyclone
(ERB type)
Automatic discharge
(Exhaust ejector)
Inner cylinder: 1,
outer cylinder: 1
12V140E-3 Series
12V140E-3 Series
SEN00307-00
SEN00307-00
Turbocharger
Water-cooled type
Type: KTR110L
12V140E-3 Series
A:
B:
C:
D:
E:
F:
G:
SEN00307-00
Intake air inlet

Intake air outlet
Exhaust gas inlet
Exhaust gas outlet
Oil inlet
Oil outlet
Coolant
1.
2.
3.
4.
Blower housing
V-band
Diffuser plate
Center housing
(Water-cooled center housing: Standard for D475A-5, and optional for other machine models)
5. Shroud
6. Turbine housing
7. Blower impeller
8. Seal ring
9. Metal
10. Journal bearing
11. Seal ring
12. Turbine impeller
Specifications
Model:
Overall length:
Overall width:
Overall height:
Weight:
KOMATSU KTR110L (Water-cooled)

308 mm
305 mm
287 mm
25 kg
12V140E-3 Series
SEN00307-00
Model: KTR110L
The illustration shows the water-cooled turbocharger.
12V140E-3 Series
SEN00307-00
Unit: mm
No.
Check item
End play (Play in axial direction)
Radial play (Play in radial direction)
Clearance between blower housing

and impeller
12V140E-3 Series
Criteria
Remedy
Standard
Repair limit
0.08 0.13
0.18
0.43 0.68
0.84
Clearance limit (Min.): 0.14
Replace thrust
parts
Replace
bearing parts
Replace
bearing parts
SEN00307-00
Turbocharger mounting
a
a
The illustration shows the engine for D475A-5.

A:
B:
Intake air inlet

Intake air (Between turbocharger and air-cooled aftercooler)
1.
2.
Exhaust manifold
Turbocharger
10
12V140E-3 Series
Aftercooler
SEN00307-00
Air-cooled type
A:
B:
Air inlet (From turbocharger)

Air outlet (To air intake manifold)
1.
2.
3.
4.
5.
Upper tank
Core
Lower tank
Fin
Tube
12V140E-3 Series
11
SEN00307-00
Muffler
A:
Exhaust gas outlet
1.
2.
Turbocharger
Muffler
12
12V140E-3 Series
12V140E-3 Series
SEN00307-00
13
SEN00307-00
Engine unit
Cylinder head
A:
B:
Air intake
Exhaust gas
C:
D:
To fuel tank
To radiator
1.
2.
3.
4.
5.
Spill pipe
Air bleeding pipe
Cylinder head
Head cover
Head cover bolt
6.
7.
8.
9.
10.
Cylinder head bolt

Injector connector
Injector assembly
Injector holder mounting bolt
Injector holder retainer
14
12V140E-3 Series
SEN00307-00
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
SEN00307-00
Tighten the cylinder head mounting bolt in order of [1] to [7].
Unit: mm
No.
Check item
Strain of cylinder head

mounting face
Projection of nozzle
Tightening torque for cylinder head mounting bolt

(Apply molybdenum disulfied or engine oil to
threaded part)
Tightening torque for

injector holder mounting
bolt
5
6
16
Criteria
Remedy
Tolerance
Repair limit
0 0.06
0.09
Engine
Standard
SAA12V140E-3
2.3 2.9
Bolt No.
Procedure
1st phase
[1] [6]
2nd phase
3rd phase
[7]
Repair by grinding or replace

Replace nozzle
or gasket
Target (Nm{kgm}) Range (Nm{kgm})
Tighten in order
137 157 {14 16} shown above. If
216 {22}
284 294 {29 30} there are 5 punch
marks, replace
Retighten by 90
90(+30/0)
the bolt.
68.6 {7}
58.8 73.5 {6 7.5}
147 {15}
Target (Nm {kgm})
Range (Nm {kgm})
66.7 {6.8}
58.8 73.5 {6 7.5}
Tightening torque for fuel

injection pipe
37.3 {3.8}
34.3 40.2 {3.5 4.1}

head cover mounting bolt
32.4 {3.3}
29.4 34.3 {3.0 3.5}
Retighten
Do not use a cylinder head mounting bolt more than 5 times.

Each time the bolt is used, make a punch mark on its head.
12V140E-3 Series
12V140E-3 Series
SEN00307-00
17
SEN00307-00
Cylinder block
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
18
Cylinder block
Cylinder liner
Clevis seal
O-ring
O-ring
Main bearing metal cap bolt
Main bearing metal cap
Main bearing metal
Piston cooling nozzle
Thrust bearing metal
12V140E-3 Series
Specifications
Cylinder block
Crankshaft: 7 bearings
Camshaft: High cam type, 7 bearings
Main bearing cap bolt: Plastic-region tightening
SEN00307-00
Liner ring
Upper: Clevis seal (Ethylene-propylene rubber)
Middle: O-ring (Ethylene-propylene rubber)
Lower: O-ring (Silicon rubber)
Piston cooling
With piston cooling nozzle
Cylinder liner
Wet type
Machining on inside: Plateau honing
Tufftride
12V140E-3 Series
19
SEN00307-00
20
12V140E-3 Series
SEN00307-00
Unit: mm
No.
Check item
Strain of cylinder head mounting face

Inside diameter of main bearing metal mounting hole
0 0.09
0.135
Standard size
Tolerance
157
+0.025
0.010
Roundness of mounting hole
Repair limit: 0.005

4.5
0.050
0.060
Other
than No.4
4.5
0.065
0.075
Inside diameter of
main bearing metal
No.4 only
(When tightening
bolt with specified
Other
torque)
than No.4
Inside diameter of cam bushing
Tightening torque for main

bearing cap
(Apply engine oil to threaded
portion and washer)
Tightening torque for oil pan
mounting bolt
Level difference between

under surfaces of cylinder
block and front cover
Standard size
Tolerance
Repair limit
148
+0.175
+0.130
148.23
148
+0.145
+0.100
148.20
Standard size
Tolerance
69
+0.025
+0.025
Standard size
Tolerance
Repair limit
65
+0.040
+0.025
65.15
Procedure
Target (Nm {kgm})
Range (Nm {kgm})
1st time
284 {29}
270 299{27.5 30.5}
2nd time
569 {58}
559 579{57.0 59.0}
3rd time
Retighten by 90
90(+30/0)
65.7 {6.7}
58.8 73.6 {6 7.5}
Repair limit: 0.14
Repair by
grinding or
replace
Replace or correct main bearing metal cap
Correct
No.4 only
Repair limit
10S or less
Inside diameter of cam bushing mounting hole
Remedy
Tolerance
Surface roughness of main

bearing metal mounting hole
Thickness of main
bearing metal
Criteria
Replace bearing metal
Correct or
replace block
Replace
cam bushing
Retighten
Reassemble
Do not use a main cap mounting bolt more than 5 times.

12V140E-3 Series
21
SEN00307-00
Cylinder liner
Unit: mm
No.
1
Check item
Criteria
Projection of cylinder liner
Inside diameter of cylinder

liner
2
Repair limit: 0.07 0.15

Rank
Standard size
140
140
Roundness of inside of cylinder liner

Cylindricality of inside of cylinder liner
Outside diameter of cylinder
liner (Counterbore portion)
Repair limit
140.12
140.14
Replace cylinder liner
(Refilling is allowed
only for L)
Repair limit: 0.02

Standard size
170.2
Tolerance
0.10
0.10
Standard clearance: 0 0.163

liner (Lower portion of counterbore)
Standard size
Interference of cylinder liner

and block (Lower portion of
counterbore)
Standard interference
Tolerance
+0.090
+0.050
Interference limit
0.02 0.12
0.02 or above
Standard size
Tolerance
0.024
0.049

liner (at O-ring)
5
Clearance between cylinder
liner and block (O-ring portion)
22
Tolerance
+0.020
+0.020
+0.040
+0.021
Repair limit: 0.02
3
Clearance between cylinder
liner and block
(counterbore portion)
Remedy
or cylinder block
161.2
158
Standard clearance: 0.024 0.094

or block
Replace or correct cylinder liner or block
or block
12V140E-3 Series
12V140E-3 Series
SEN00307-00
23
SEN00307-00
Main moving parts
1.
2.
3.
4.
5.
6.
7.
8.
Piston (FCD piston)

Piston pin
Connecting rod bushing
Top ring
Second ring
Oil ring
Connecting rod cap bolt
Connecting rod
(Front of engine: for L bank, rear: for R bank)
Connecting rod cap
9.
24
10.
11.
12.
13.
Connecting rod bearing metal

Crank gear (Number of teeth: 45)
Crankshaft
Vibration damper
12V140E-3 Series
Specifications
SEN00307-00
Piston rings
Crankshaft
Closed die forging
Journal, filet: Induction hardening
Piston
Special thin ductile cast iron
FCD piston
Re-entrant piston
Connecting rod
Closed die forging
With lubricating oil hole
Cap bolt is screw type, installed by plastic-region
tightening.
12V140E-3 Series
Top ring (1)
: Double-side keystone, inner cut,

ba rr e l f ac e, har d ch ro mi umplated
Second ring (2) : Double-side keystone, inner cut,
taper face, hard chromium-plated
Oil ring (3)
: M-shaped steel, with coil expander,
nitrided surface
25
SEN00307-00
Crankshaft
26
12V140E-3 Series
SEN00307-00
Unit: mm
No.
1
Check item
End play
Outside diameter of main

journal
2
Criteria
Standard value
Repair limit
0.140 0.315
0.50
Rank
Standard size
S.T.D.
148
0.25 U.S.
147.75
0.50 U.S.
147.50
0.75 U.S.
147.25
147.23
1.00 U.S.
147.00
146.98
Roundness of main journal

Clearance of main journal
Surface roughness of main

journal
Surface roughness of
crankpin journal
Bend of crankshaft

adapter mounting bolt

damper mounting bolt
12V140E-3 Series
147.98
147.73
0.020
0.020
147.48
Use undersize journal

or replace
Repair limit: 0.010

Clearance limit
No.4 only
0.130 0.195
0.25
Other than No.4
0.100 0.165
0.22
0.8S (Surface roughness of R portion: 3.2S)

Standard size
S.T.D.
100
0.25 U.S.
99.75
Tolerance

or replace main metal
Correct surface roughness of crankshaft
journal
Repair limit
89.88
89.63
0.020
0.020
0.50 U.S.
89.50
0.75 U.S.
99.25
89.13
1.00 U.S.
99.00
89.38
88.88

or replace
Repair limit: 0.010

Standard clearance
Clearance limit
0.046 0.116
0.17
Replace connecting
rod bearing metal
0.8S (Surface roughness of R portion: 3.2S)

Standard
Repair limit
Coaxiality of all main journals:

0.09 or less
0.09
Coaxiality of adjacent main journals:

0.05 or less
0.05
Procedure
5
Replace thrust bearing

metal or use oversize
metal
Repair limit
Standard clearance
Roundness of pin journal

Clearance of
crank pin journal
Tolerance
Journal
Rank
Outside diameter of crank

pin journal
Remedy
Replace
Target (Nm {kgm}) Range (Nm {kgm})
1st time
74 {7.5}
54 93 {5.5 9.5}
2nd time
245 {25}
226 265 {23 27}
3rd time
745 {76}
725 765 {74 78}
Retighten
108 10 Nm {11 1.0 kgm}
27
SEN00307-00
Camshaft
Unit: mm
No.
1
Check item
Criteria
Standard
Repair limit
0.1 0.25
0.36
Standard size
Tolerance
65
0.016
0.036
Standard clearance
Clearance limit
0.016 0.096
0.15
End play
Outside diameter of camshaft journal
2
Clearance of
camshaft journal
3
Bend of camshaft
Height of cam
28
Remedy
Replace thrust plate
Replace
Replace cam bushing
Repair limit: 0.04 (Overall swing of indicator)

Cam
Standard size
Tolerance
Repair limit
Air intake
55.48
0.1
55.08
Exhaust
55.75
0.1
55.35
Replace
12V140E-3 Series
SEN00307-00
Cam follower, push rod
Unit: mm
No.
Check item
Remedy
Standard size
Tolerance
Repair limit
22
0.021
0.034
21.92
22
+0.021
+0.021
22.07
Outside diameter of cam

roller
31.7
+0.05
+0.02
31.50
Inside diameter of cam

roller
12.7
+0.038
+0.013
12.78

roller pin
12.63
0.006
12.56

follower shaft
Inside diameter of cam
follower shaft hole
Criteria
Diameter of push rod

ball end
Diameter of push rod

socket end
Bend of push rod
12V140E-3 Series
Standard size
Tolerance
12.7
0.20
0.20
13.4
0.20
0.20
Replace
Repair limit: 0.3 (Overall swing of indicator)
29
SEN00307-00
Piston, piston ring, and piston pin
30
12V140E-3 Series
SEN00307-00
Unit: mm
No.
Check item
Outside diameter of piston
Thickness of piston ring
Width of piston ring groove
Criteria
Rank
Standard size
Tolerance
Repair limit
140
0.120
0.135
139.830
140
0.105
0.120
139.845
No.
Measuring point
Standard size
Tolerance
No.1 ring
2.9
0.015
0.035
No.2 ring
2.41
0.010
0.035
Oil ring
0.010
0.030
No.1 ring
No.2 ring
4
No.
2 4 Clearance between piston
ring and piston ring groove
Outside diameter of piston

pin
5
Inside diameter of piston pin

hole
Clearance between piston
pin and piston
12V140E-3 Series
Oil ring
Replace piston
Replace piston
ring
Check with group wear gauge

Replace piston
+0.040
+0.025
Measuring point Standard clearance Clearance limit
No.1 ring
No.2 ring
Oil ring
0.035 0.060
0.14
No.1 ring
0.42 0.57
(Tension:
16.5 23.5 N
{1.68 2.40 kg})
2.0
0.65 0.80
No.2 ring
(Tension:
(Identification
16.2 24.2 N
2RN white mark)
{1.65 2.47 kg})
1.5
0.30 0.50
(Tension:
70.1 94.6 N
{7.15 9.65 kg})
1.0
Closed gap of piston ring
Remedy
Oil ring
Check with group wear gauge
Standard size
Tolerance
52
0.006
0.006
52
+0.045
+0.035
Standard clearance
Clearance limit
0.035 0.051
0.10
Replace piston
or piston ring
Replace piston
ring or cylinder
liner
Replace piston
pin
Replace piston
Replace piston
or piston pin
31
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Connecting rod
32
12V140E-3 Series
SEN00307-00
Unit: mm
No.
Check item
Criteria
Inside diameter of connecting

rod small end bushing
Remedy
Standard size
Tolerance
Repair limit
52
+0.049
+0.030
52.09
Replace bushing
(Refilled part is
semi-finished part)
Clearance between connecting rod small end bushing and

piston pin
Standard clearance
Clearance limit
0.030 0.055
0.11
Standard size
Tolerance

rod small end bushing mounting hole
57.4
+0.030
+0.030

rod large end bearing metal
(Crankpin journal)

+0.026
106
Replace connectrod large end hole

0.004
ing rod (Correction
(Without bearing metal, X, Y,
not allowed)
Tighten
connecting
rod
cap
with
specified
torque
and
measure
and Z directions)
Thickness of connecting rod

bearing metal
Parallelism and twist of connecting rod
Tightening torque for connecting rod cap mounting bolts

(Apply engine oil to seat surface of nut of threaded portion
of bolts)
Inside diameter of
connecting rod large
end
Standard size
Tolerance
Repair limit
100
+0.096
+0.046
100.15
3.0
0.025
0.035
Item
Standard
Repair limit
Parallelism (a)
0 0.10
0.15
Twist (b)
0 0.25
0.30
Dimensions (c)
340
Procedure
Target (Nm {kgm})
Range (Nm {kgm})
1st time
74 {7.5}
69 78
{7 8}
2nd time
Retighten 90
90(+30/0)
Roughness
3.2S
Swell
0.004 (In overall width)
Replace bushing
or piston pin
Replace connecting rod (Correction
not allowed)
Replace bearing
metal
Replace bearing
metal
Replace connecting rod
Tighten in order
shown in figure
Replace
Do not use a connecting rod cap mounting bolt more than 5 times.
12V140E-3 Series
33
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Flywheel and flywheel housing
Unit: mm
No.
Check item
Criteria
Facial runout of
flywheel housing
Repair limit: 0.25
Radial runout of
flywheel housing
Repair limit: 0.25
Facial runout of flywheel
Repair limit: 0.30
Radial runout of flywheel
Repair limit: 0.13

flywheel housing mounting
bolt (Apply engine oil to
threaded portion)
34

flywheel mounting bolt
(Apply engine oil to
threaded portion)
Remedy
Reassemble
Procedure
Target (Nm {kgm})
Range (Nm {kgm})
1st time
343 {35}
294 392 {30 40}
2nd time
412 {42}
392 432 {40 44}
1st time
98 {10}
78 118 {8 12}
2nd time
294 {30}
275 314 {28 32}
3rd time
539 {55}
520 559 {53 57}
Tighten in order
shown in above
figure
12V140E-3 Series
Vibration damper
1.
2.
3.
4.
5.
6.
Vibration damper
Pin (between adapter and vibration damper)
Adapter
Pin (between adapter and crankshaft)
Bolt (between adapter and crankshaft)
Bolt (between adapter and vibration damper)
12V140E-3 Series
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35
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Timing gear
36
12V140E-3 Series
SEN00307-00
Unit: mm
No.
Check item
Criteria
Position
Backlash of each gear
Clearance between main

idler gear bushing and shaft
(Both right and left banks)
Clearance between sub

idler gear bushing and shaft
End play of main idler gear
Measuring point
Remedy
Standard
Crank gear and

right main idler gear (Large)
0.141 0.425
Right main idler gear (small) and

right sub idler gear
0.130 0.390
Right sub idler gear and

right cam gear
0.129 0.391
Right cam gear and

accessory drive gear
0.085 0.492

right fuel injection pump gear
0.051 0.469

water pump driver gear
0.052 0.481

oil pump gear
0.137 0.421
Crank gear and

left main idler gear (Large)
0.141 0.425
Left main idler gear (small) and

left cam gear
0.129 0.391
Left main idler gear (small) and

left fuel injection pump gear
0.051 0.469
Tolerance
Standard
size
Replace
0.6
Standard
clearance
Clearance
limit
+0.034
+0.009
0.025 0.063
0.20
+0.055
+0.055
0.016 0.084
0.20
Shaft
Hole
56
0.016
0.029
56
0.016
0.029
Standard
Repair limit
0.09 0.26
0.4
End play of sub idler gear
0.07 0.18
0.4
End play of fuel injection

pump drive gear
0.07 0.20
0.4
End play of oil pump drive

gear
0.03 0.088
0.4
End play of accessory drive

gear
0.1 0.4
0.4
Repair limit
Replace
bushing
Replace
thrust bearing
12V140E-3 Series
37
SEN00307-00
Valve system
38
12V140E-3 Series
1.
2.
3.
4.
5.
6.
7.
8.
Cam gear
Thrust plate
Camshaft
Cam follower
Cam roller
Rocker arm shaft
Cam follower shaft
Rocker arm adjustment screw
9. Locknut
10. Push rod
11. Rocker arm
12. Crosshead adjustment screw

13. Locknut
14. Crosshead
15. Valve guide
16. Exhaust valve
17. Valve spring (Outer)
18. Valve spring (Inner)
19. Spring seat
20. Valve retainer
21. Air intake valve
22. Cam roller pin
SEN00307-00
Valve timing
Specifications
Camshaft
Drawn steel bar (Machining)
Journal and cam sections: Induction hardening
12V140E-3 Series
39
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Valve and valve guide
40
12V140E-3 Series
SEN00307-00
Unit: mm
No.
1
Check item
Sinking distance of valve
Thickness of valve lip
Valve seat angle
Outside diameter of valve

stem
Inside diameter of valve

guide
Criteria
Remedy
Valve
Standard size
Tolerance
Repair limit
Air intake
0.10
0.70
Exhaust
0.10
0.70
Valve
Standard size
Repair limit
Air intake
2.4
1.9
2.15
1.75
Valve
Standard size
Tolerance
Air intake
30
15'
Exhaust
45
15'
Air intake
10
0.045
0.060
Exhaust
10
0.074
0.089
Before head is
press fitted
10
+0.019
+0.001
Standard size
Tolerance
10
Bend of valve stem

5
Valve
Standard clearance
Clearance limit
0.034 0.071
0.22
Exhaust
0.063 0.100
0.24
Repair limit: 0.02 (Total runout of indicator, per 100)

Standard
Tolerance
22.0
0.2
Spring
Standard size
Repair limit
Outer
81.7
72.0
Free length of valve spring
Inner
Spring
Installed
length
Outer
51.0
6
Installed load of valve spring
Inner
Perpendicularity of valve
spring
12V140E-3 Series
46.0
Replace valve
+0.011
0.009
Air intake
Driving height of valve guide
Correct or replace
valve or valve seat
Press Not press Replace valve guide

fitted
fitted
portion portion
+0.008
0.009
Clearance between valve

guide and stem
Replace valve
Exhaust
After head is
press fitted
Replace valve or
valve seat
Replace valve or
valve guide
Replace valve
Correct
Standard installed Allowable installed

Replace valve
load (N {kg})
load (N {kg})
spring
424.3 21.6
377.3
{43.3 2.2}
{38.5}
215.6 10.8
{22.0 1.1}
192.1
{19.6}
Repair limit: 2 (Both ends)
41
SEN00307-00
Rocker arm and shaft
Unit: mm
No.
Check item
Outside diameter of rocker
arm shaft
42
Valve clearance
(When cold)
Tightening torque
for locknut of rocker arm
adjustment screw
Remedy
Standard size
Tolerance
32.0
0.0065
32.0
+0.087
+0.035
Standard clearance
Clearance limit
0.0285 0.0935
0.13
Inside diameter of rocker

arm bushing
Clearance between rocker
arm shaft and rocker arm
Criteria
Valve
Standard
Tolerance
Air intake
0.35
0.02
Exhaust
0.57
0.02
Target (Nm {kgm})
Range (Nm {kgm})
58.8 {6}
52.9 64.7 {5.4 6.6}
Replace rocker arm

shaft
Replace rocker arm
Replace rocker arm
shaft or rocker arm
Adjust
Tighten
12V140E-3 Series
SEN00307-00
Crosshead and guide
Unit: mm
No.
1
Check item
Depth of crosshead stem
receiver
Inside diameter of crosshead
Outside diameter of crosshead guide
Projection of crosshead
guide
12V140E-3 Series
Criteria
Remedy
Standard size
Tolerance
Repair limit
6.2
+0.3
+0.3
6.61
11.04
0.02
11.17
11
+0.011
+0.011
10.95
49.0
0.25
Replace
Correct
43
SEN00307-00

2005 KOMATSU
All Rights Reserved
44
12V140E-3 Series
SEN00309-00
ENGINE
1SHOP MANUAL
12V140E-3 Series
10 Structure, function and

maintenance standard
Structure, function and maintenance

standard, Part 2
Lubrication system .......................................................................................................................................... 4
Lubrication system diagram .................................................................................................................. 4
Oil pump ............................................................................................................................................... 6
Oil cooler............................................................................................................................................... 7
Oil filter.................................................................................................................................................. 8
Main relief valve.................................................................................................................................... 9
Oil cooler bypass valve and regulator valve ....................................................................................... 10
Fuel system................................................................................................................................................... 12
CRI system diagram ........................................................................................................................... 12
Outline of CRI system ......................................................................................................................... 14
Fuel piping .......................................................................................................................................... 32
12V140E-3 Series
SEN00309-00
Fuel filter ............................................................................................................................................. 37

Priming pump...................................................................................................................................... 39
Cooling system.............................................................................................................................................. 40
Cooling system diagram ..................................................................................................................... 40
Water pump ........................................................................................................................................ 42
Thermostat .......................................................................................................................................... 44
Corrosion resistor................................................................................................................................ 45
Cooling fan drive ................................................................................................................................. 47
Electrical equipment...................................................................................................................................... 48
Alternator ............................................................................................................................................ 48
Starting motor...................................................................................................................................... 50
Starting aid .......................................................................................................................................... 51
Engine controller ................................................................................................................................. 52
12V140E-3 Series
12V140E-3 Series
SEN00309-00
SEN00309-00
Lubrication system
Lubrication system diagram
12V140E-3 Series
SEN00309-00
W: Coolant
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
Oil pan
Strainer
Oil pump (Triple gear pump)
Main relief valve
Oil cooler
Regulator valve
Oil cooler bypass valve
Oil filter
Oil filter safety valve
Main gallery
Crankshaft
Camshaft
Rocker arm
Cam follower
Air intake valve and exhaust valve
Piston
Piston cooling nozzle
Timing gear
Turbocharger
Fuel supply pump
12V140E-3 Series
SEN00309-00
Oil pump
A:
B:
From oil pan

To oil cooler
1.
2.
3.
4.
5.
Pump body
Pump drive gear (Number of teeth: 27)
Drive gear
Driven gear
Pump cover
Specifications
Oil pump
Type: Gear pump
Revolving speed: Engine speed x 1.67
12V140E-3 Series
SEN00309-00
Oil cooler
A: Oil inlet and outlet port (Flow is reversed

depending on front and rear oil cooler)
B: Oil inlet and outlet port (Flow is reversed
depending on front and rear oil cooler)
C: Coolant
1.
2.
Specifications
Oil cooler
Heat dissipation surface area: 0.986 m2
Element: 12 stages
Oil cooler cover

Cooler element
12V140E-3 Series
SEN00309-00
Oil filter
A:
B:
Oil inlet port

Oil outlet port
1.
2.
3.
Safety valve
Filter head
Cartridge
Specifications
Oil filter
Filtration area: 1.62 m2(0.42 m2 x 4)
Rated flow: 330l/min
Safety valve
Cracking pressure: 196 20 kPa {2.0 0.2 kg/cm2}
12V140E-3 Series
SEN00309-00
Main relief valve
1.
2.
3.
Specifications
Main relief valve
Cracking pressure:
1,196 49 kPa {12.2 0.5 kg/cm2}
Valve spring
Main relief valve
Valve body
Unit: mm
No.
Check item
Clearance between main relief

valve and body
Main relief valve spring
Cracking pressure of main relief

valve
12V140E-3 Series
Criteria
Remedy
Tolerance
Standard size Outside diam- Inside diameeter of valve
ter of body
Standard
clearance
33
0.040
0.060
0.040 0.076
Free length
Installed
length
75.8
59.8
0.016
0.016
Replace valve or
body
Installed load Allowable load

(N {kg})
(N {kg})
Replace spring
621 {63.4}
353 {36}
Standard: 1,196 49 kPa {12.2 0.5 kg/cm2}
Correct or
replace spring
SEN00309-00
Oil cooler bypass valve and regulator valve
A:
B:
C:
D:
From main gallery

From oil cooler
To oil pan
To oil filter
1.
2.
3.
4.
5.

Bypass valve spring
Regulator valve
Regulator valve spring
Valve body
10
Specifications
Cracking pressure (differential pressure):
392 20 kPa {4.0 0.2 kg/cm2}
Regulator valve
Cracking pressure: 402 49 kPa {4.1 0.5 kg/cm2}
12V140E-3 Series
SEN00309-00
Unit: mm
No.
Check item
Clearance between regulator

valve and body
Regulator valve spring
Criteria
Tolerance
ter of body
Standard
clearance
22
0.020
0.041
0.020 0.074
Free length
Installed
length
111.5
75
Cracking pressure of regulator

valve
Clearance between oil cooler

bypass valve and body
Oil cooler bypass valve spring

Cracking pressure of oil cooler
bypass valve
12V140E-3 Series
Remedy
+0.033
+0.033
Replace valve or
body
Installed load Allowable load

(N {kg})
(N {kg})
Replace spring
136.0 {13.87}
239 {24.4}
Correct or
replace spring
Standard: 402 49 kPa {4.1 0.5 kg/cm2}

Tolerance
ter of body
Standard
clearance
28
0.020
0.053
+0.033
+0.033
0.020 0.086
Free length
Installed
length
Installed load
(N {kg})
Allowable
load
125.8
89.8
186 {19}
Standard: 392 20 kPa {4.0 0.2 kg/cm2}
Replace valve or
body
Replace spring
Correct or
replace spring
11
SEN00309-00
Fuel system
CRI system diagram
12
CRI is an abbreviation for common rail injection.
12V140E-3 Series
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
SEN00309-00
NE speed sensor
Engine controller
Injector
Fuel tank
Pre-fuel filter
Main fuel filter
Overflow valve
Fuel supply pump assembly
PCV
High-pressure pump
Feed pump
Relief valve
G speed sensor
Common rail
Flow damper
Pressure limiter
High-pressure injection pipe
Priming pump (Main)
12V140E-3 Series
13
SEN00309-00
Outline of CRI system

Outline
q
The CRI system checks the condition of the
engine (engine speed, accelerator angle, coolant temperature, etc.) with sensors.
q
The microcomputer of the CRI system controls
the fuel injection rate, fuel injection timing, fuel
injection pressure, etc. totally to operate the
engine under the best condition.
q
The CRI system has a diagnosis function and
an alarm function, with which the computer of
the system checks the main component parts
and notifies the operator of detected failures.
q
In addition, the CRI system has a failsafe function which stops the engine when a certain
parts fail and a backup function which continues the operation by changing the control
method in such a case.
1
1. Fuel system
Configuration
The CRI system is divided by the function into
the fuel system and control system.
14
The fuel system distributes the high-pressure

fuel generated by the fuel supply pump to the
cylinders through the common rail.
The solenoid valve in the injector opens and
closes the nozzle needle valve to start and finish fuel injection.
12V140E-3 Series
SEN00309-00
2. Control system
To the ECU (engine control unit), the signals

are sent from the sensors installed to the
machine. Based on the signals, the ECU calculates and controls the energizing timing and
energizing period of the injector to inject proper
quantity of fuel in proper timing.
The control system is roughly divided by the
electric parts into the sensors, computer, and
actuators.
12V140E-3 Series
15
SEN00309-00
Structure and operation of CRI system
16
The CRI system consists of fuel supply pump,

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

circuit is changed so that the high-pressure
fuel in the control chamber will flow through the
orifice. As a result, the needle valve is raised
to start fuel injection by the nozzle cracking
pressure of the high-pressure fuel on the nozzle side.
If the TWV is turned OFF (de-energized), the
fuel circuit is changed so that the high-pressure fuel will flow to the control chamber
through the orifice. As a result, the needle
valve lowers to finish fuel injection.
Accordingly, the fuel injection timing and fuel
injection rate are controlled respectively by the
timing to turn on the TWV and the length of the
turn-on time of the TWV.
12V140E-3 Series
SEN00309-00
Structure and operation of component parts
1. Fuel supply pump
1.
2.
3.
4.
5.
3-thread type cam

Overflow valve
Drive gear
No. 1 high-pressure pump
PCV (Discharge rate control valve)
Outline
q
The fuel supply pump consists of priming
pump (7), feed pump (8), and high-pressure
pumps (4) and (6).
q
The function of the fuel supply pump is to generate common rail fuel pressure by controlling
the fuel discharge rate.
Structure
High-pressure pumps (4) and (6) have the
pressure feed systems similar to those of the
conventional in-line fuel injection pump and the
PCVs (pressure control valves) for each cylinder to control the fuel delivery.
q
By employing the 3-head cam, the necessary
number of the cylinders of high-pressure
pumps (4) and (6) is reduced to 1/3 of the
engine cylinders.
q
12V140E-3 Series
6.
7.
8.
9.
No. 2 high-pressure pump

Priming pump
Feed pump
Gear for G speed sensor
Since the number of the times of feeding fuel

to the common rail is the same as the number
of the times of fuel injection, the common rail
fuel pressure is smooth and stable.
The fuel fed by high-pressure pumps (4) and
(6) to the common rail is divided as follows.
No. 1 high-pressure pump (on the drive gear
side) (4) compensates for drop in the common
rail fuel pressure caused by fuel injection into
the No. 1, 3, and 5 cylinders.
No. 2 high-pressure pump (on the feed pump
side) (6) compensates for drop in the common
rail fuel pressure caused by fuel injection into
the No. 2, 4, and 6 cylinders.
q
q
17
SEN00309-00
Operation
(A): The PCV is open when the plunger is in

lowering stroke, through which low-pressure fuel is sucked in the plunger chamber.
(B): While the PCV is not energized and is open
after the plunger starts the rising stroke, the
sucked fuel is returned through the PCV
without being pressurized.
(C): If the PCV is energized and closed in the
timing for the necessary delivery, the return
passage is closed and the pressure in the
plunger chamber rises. Accordingly, the
fuel is fed through the delivery valve (check
valve) to the common rail. That is, the
quantity of the fuel corresponding to the
plunger lift after the PCV is closed is delivery. The delivery is changed and the common rail fuel pressure is controlled by
changing the opening timing of the PCV.
(D): After the cam passes the maximum lift
point, the plunger starts the lowering stroke
and the pressure in it lowers. At this time,
the delivery valve closes to stop feeding the
fuel. Since the PCV is de-energized, it
opens and the low-pressure fuel is sucked
in the plunger chamber, or the state of (A)
starts again.
18
12V140E-3 Series
1) PCV (Pressure control valve)
The PCV adjusts the fuel delivery from the fuel

supply pump to adjust the common rail fuel
pressure. It means that the delivery from the
fuel supply pump to the common rail is decided
by the timing of energizing the PCV.
SEN00309-00
2) Feed pump
q
q
12V140E-3 Series
The feed pump built in the fuel supply pump

assembly draws the fuel from the fuel tank and
sends it through the fuel filter to the high-pressure pump chamber.
The outer and inner rotors of the feed pump
are rotated by the camshaft.
The fuel is sucked in on the suction side and
discharged on the delivery side according to
the increase and decrease of the spaces
between the outer and inner rotors.
19
SEN00309-00
2. Common rail
Structure
q
Common rail (4) distributes the high-pressure
fuel from the high-pressure pump to the injectors of the cylinders.
q
Common rail (4) is equipped with common rail
fuel pressure sensor (2), flow dampers (1), and
pressure limiter (3).
q
The fuel injection pipes are connected to flow
dampers (1) to send the high-pressure fuel to
the injectors.
q
The piping of the pressure limiter (3) is
returned to the fuel tank.
1)
Flow damper
Function
The flow dampers damp the pressure pulses in
the high pressure piping and supply the fuel to
the injectors with stable pressure.
q
If excessive fuel flows out, the flow dampers
block the fuel passage to prevent abnormal
outflow of the fuel.
q
If the fuel flows out abnormally, high pressure
is applied to the piston, which moves to the
right until it reaches the seat to stop the fuel.
q
20
2)
q
Pressure limiter
If abnormally high pressure is generated, the
pressure limiter opens to release that pressure.
If the common rail fuel pressure reaches about
140 MPa {1,430 kg/cm2}, the pressure limiter
operates (Opens).
If the common rail fuel pressure lowers to 30
MPa {310 kg/cm2}, the pressure limiter resets
itself (close) to maintain the pressure.
12V140E-3 Series
3)
q
SEN00309-00
Common rail fuel pressure sensor

The common rail fuel pressure sensor is
installed to the common rail to sense the fuel
pressure.
This sensor is a semiconductor pressure sensor, which utilizes the phenomenon that the
electric resistance of silicon changes according
to pressure applied to it.
12V140E-3 Series
21
SEN00309-00
3. Injector
Outline
q
The function of the injector is to inject the high
pressure fuel from the common rail into each
combustion chamber of the engine in the optimum timing, by the optimum quantity, at the
optimum injection rate, and under the optimum
spray condition.
q
The TWV (2-way solenoid valve) controls the
start and finish of fuel injection by controlling
the pressure in the control chamber.
q
The orifice limits the opening speed of the nozzle and controls the fuel injection rate.
q
The hydraulic piston transmits the force generated by the pressure in the control chamber to
the needle valve of the nozzle.
q
The nozzle sprays the fuel.
22
12V140E-3 Series
SEN00309-00
Structure
1.
2.
3.
4.
5.
6.
Inlet connector
Terminal
Upper body
Solenoid
Valve body
Orifice (out)
The injector consists of the nozzle section, orifice to control the fuel injection rate, hydraulic
piston section, and 2-way solenoid valve section.
12V140E-3 Series
7.
8.
9.
10.
11.
12.
Orifice (in)
Pressure control chamber
Command piston
Spring
Pressure pin
Nozzle assembly
23
SEN00309-00
A:
B:
No fuel injection
Start of fuel injection
C:
D:
Finish of fuel injection

From common rail
1.
2.
3.
4.
Nozzle
Control piston
Orifice (in)
Orifice (out)
5.
6.
7.
8.
Valve body
Solenoid
Spring
Pressure control chamber
3)
Finish of fuel injection (C)

If solenoid (6) is de-energized, valve body (5)
is lowered by spring (7) and the fuel passage is
closed.
Since the high-pressure fuel in the common
rail is applied to pressure control chamber (8)
suddenly at this time, nozzle (1) is closed
quickly and fuel injection is finished sharply.
Operation
1)
q
q
2)
q
q
q
24
No fuel injection (A)

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

If solenoid (6) is energized, valve body (5) is
raised by electromagnetic power to open the
fuel passage.
Since the fuel in pressure control chamber (8)
flows out through orifices (3) and (4), nozzle
(1) rises and the fuel injection pump starts.
The fuel injection rate is increased gradually by
the function of orifices (3) and (4).
Continuing energization to solenoid (6) provides the maximum fuel injection rate.
12V140E-3 Series
SEN00309-00
Electric circuit diagram
Since high voltage (65V) is applied to the

wiring harnesses connected to the ECU,
COMMON1 and COMMON2 of ECU, and
TWV#1 #6 of the injector, take care not to
get an electric shock.
12V140E-3 Series
25
SEN00309-00
4. Various sensors and relays

1)
q
26
Fuel temperature sensor

The fuel temperature sensor senses the fuel
temperature and sends it to the engine controller. The sensor unit is a thermistor the resistance of which changes according to the
temperature.
The engine controller applies voltage to the
thermistor and senses the temperature by the
voltage divided by the resistance in the computer and the resistance of the thermistor.
2)
q
q
NE speed sensor (Crank angle sensor)

If the signal hole made on the flywheel passes
the sensor, the magnetic line of force changes.
If the magnetic line of force changes, the output of the hall element sensor changes linearly
and it is converted into pulse of 0 - 5 V by the
wave form shaping circuit in the sensor, and
then output.
12V140E-3 Series
3)
q
A:
B:
Atmospheric pressure sensor

This sensor is used to correct altitude.
SEN00309-00
4)
Common rail pressure sensor
5)
Oil pressure sensor
Pressure inlet
Mounting screw: M5
Tightening torque:
4.5 0.5 Nm {0.46 0.05 kgm}
The following graph shows the output characteristics of the atmospheric pressure sensor.
12V140E-3 Series
27
SEN00309-00
6)
q
28
Bkup speed sensor (G sensor)

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

This sensor is used to sense the charge pressure (boost pressure).
A:
Mounting screw: M6
Tightening torque:
5.5 0.5 Nm {0.56 0.05 kgm}
1.
2.
Sensor
O-ring
The following graph shows the output characteristics of the charge pressure sensor.
12V140E-3 Series
8)
q
Charge temperature sensor

The charge temperature sensor senses the
intake air temperature (boost temperature) and
sends it to the engine controller.
The sensor unit is a thermistor the resistance
of which changes according to the temperature. The engine controller applies voltage to
the thermistor and senses the temperature by
the voltage divided by the resistance in the
computer and the resistance of the thermistor.
12V140E-3 Series
SEN00309-00
9)
q
Coolant temperature sensor

The coolant temperature sensor senses the
coolant temperature and sends it to the engine
controller.
The sensor unit is a thermistor the resistance
of which changes according to the temperature. The engine controller applies voltage to
the thermistor and senses the temperature by
the voltage divided by the resistance in the
computer and the resistance of the thermistor.
29
SEN00309-00
Various controls
30
12V140E-3 Series
SEN00309-00
The CRI system controls the fuel injection rate

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

q
The fuel injection rate control function is

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

q
The fuel injection timing control function is

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

(Common rail fuel pressure control
function)
q
The fuel injection control function (common rail

fuel pressure control function) controls the fuel
discharge rate of the fuel supply pump by measuring the fuel pressure by the common rail
fuel pressure sensor and feeding it back to
ECU.
This function performs pressure feedback control so that the fuel injection pressure will be
the same as the optimum value (command
value) set according to the engine speed and
fuel injection rate.
12V140E-3 Series
31
SEN00309-00
Fuel piping
Left bank
1.
2.
3.
4.
5.
6.
Main fuel filter

Pre-fuel filter
Priming pump (Main)
Fuel pipe (From pre-fuel filter)
Fuel pipe (To feed pump)
Drain pipe
32
12V140E-3 Series
7.
8.
9.
10.
11.
12.
PCV
Fuel injection pipe (No.1 cylinder)
12V140E-3 Series
SEN00309-00
13.
14.
15.
16.
17.
18.

Common rail
Fuel return pipe
Feed pump
Oil pump (For pump lubricating oil)
High-pressure pump
33
SEN00309-00
Right bank
1.
2.
3.
Fuel pipe (To feed pump)

Fuel pipe (From pre-fuel filter)
Priming pump (Main)
34
12V140E-3 Series
4.
5.
6.
7.
8.
9.

12V140E-3 Series
SEN00309-00
10.
11.
12.
13.
14.
15.
PCV
High-pressure pump
Feed pump
Oil pump (For pump lubricating oil)
Fuel return pipe
Common rail
35
SEN00309-00
Front side
Rear side
36
12V140E-3 Series
Fuel filter
A:
B:
Fuel inlet
Fuel outlet
1.
2.
3.
Air bleeding plug

Filter head
Cartridge
SEN00309-00
Specifications
Filtration area: 1.0 m2
12V140E-3 Series
37
SEN00309-00
Pre-fuel filter
A:
B:
Fuel inlet
Fuel outlet
1.
2.
3.
Air bleeding plug

Filter head
Cartridge
Specifications
Filtration area: 2.12 m2
38
12V140E-3 Series
SEN00309-00
Priming pump
1.
2.
3.
4.
5.
6.
7.
8.
Spring
Cover
Shaft
Bushing
Diaphragm
Diaphragm cover
Body
Check valve
12V140E-3 Series
9.
10.
11.
12.
13.
14.
15.
16.
Valve stopper
Packing
Check valve body
Lever pin
E-ring
Washer
Bolt
Lever
39
SEN00309-00
Cooling system
Cooling system diagram
40
12V140E-3 Series
A:
SEN00309-00
Lubricating oil
1.
2.
Radiator
Cooling fan
2A. Hydraulic fan motor
3. Water pump
4. Oil cooler (For engine)
5. Corrosion resistor
6. Thermostat housing
7. Oil cooler (For power train)
8. Oil cooler bypass circuit (For power train)
9. Air bleeding
10. Turbocharger
12V140E-3 Series
41
SEN00309-00
Water pump
A:
B:
C:
From thermostat (Coolant)

From radiator (Coolant inlet)
To oil cooler (Coolant outlet)
1.
2.
3.
4.
5.
6.
7.
8.
Pump shaft
Water seal
Pump body
Water pump drive gear (Number of teeth: 25)
Ball bearing
Oil seal
Impeller
Pump cover
Specifications
Water pump
Type: Centrifugal, gear-driven
Revolving speed: Engine speed x 1.80
42
12V140E-3 Series
SEN00309-00
Water pump mounting
A.
B:
C:
To radiator inlet (Coolant)

From power train cooler (Coolant)
To power train oil cooler (Coolant)
1.
2.
3.
Oil cooler
Thermostat housing
Water pump
12V140E-3 Series
43
SEN00309-00
Thermostat
A:
B:
C:
To radiator
To water pump (When bypassing)
To thermostat
1.
2.
3.
Thermostat housing
Thermostat
Cylinder block
Specifications
Valve cracking temperature: 76.5 2C
Temperature at full opening: 90C
Lift at full opening: Min. 10 mm
Q'ty: 3
Unit: mm
No.
44
Check item
Criteria
Remedy
Lift of thermostat at full

opening
Min. 10 mm (Before checking, leave it in water tank of 90C for 4

5 minutes)
Opening/Closing of
thermostat
Move valve in fully open condition (in water tank of 90C) to water
tank of 71C and keep it for 4 -5 minutes.
Valve must fully close.
Replace
12V140E-3 Series
SEN00309-00
Corrosion resistor
A:
B:
Coolant inlet
Coolant outlet
1.
2.
3.
4.
Head
Element case (Cartridge)
Inhibitor (Solid anti-corrosion agent)
Valve
12V140E-3 Series
Specifications
Corrosion resistor
Filtration area: 0.373 m2x 2
Quantity of anti-corrosion agent: 1,000 g x 2
45
SEN00309-00
Corrosion resistor mounting
1.
2.
3.
4.
Tube (To radiator)

Tube (From thermostat housing)
Corrosion resistor head
Corrosion resistor cartridge
46
12V140E-3 Series
SEN00309-00
Cooling fan drive
The cooling fan is hydraulic motor-driven. For more information, refer to the shop
manual for the machine body.
12V140E-3 Series
47
SEN00309-00
Electrical equipment
Alternator
Alternator with built-in regulator (Open type, 90A)
1.
2.
3.
4.
5.
Alternator
Alternator pulley
Terminal B
Terminal R
Terminal E
6.
Internal connection diagram

6A. Field coil
6B. Initial excitation resistor
6C. Regulator
Pulley
Engine
SAA12V140E-3
48
Machine model
D475A-5
Type
Open type (brushless) manufactured by NIKKO DENKI
Specifications
24V, 90A
Number
of stages
Outside
diameter
(mm)
Weight
(kg)
95
19
12V140E-3 Series
SEN00309-00
Alternator mounting
a:
Outside diameter of accessory pulley: 167 mm
1.
2.
3.
4.
5.
Adjustment bolt
Alternator pulley
Alternator
Alternator drive belt
Accessory pulley
12V140E-3 Series
49
SEN00309-00
Starting motor
For 7.5 kW
E:
R:
S:
To ground
R terminal of alternator
C terminal of starting motor switch
1.
2.
3.
4.
5.
Pinion gear
Starting motor assembly
Magnetic switch
Terminal B
Terminal C
Engine
Machine model
SAA12V140E-3
D475A-5
50
6.
7.
Safety relay
External connection diagram
(2-pole connector type)
7A. Safety relay section
7B. Starting motor section
Type
Water-resistant, oil-resistant type
manufactured by NIKKO DENKI
Specifications
Number
of pinion
teeth
Weight
(kg)
Type of
connector
24V, 7.5 kW
11
18
DT
12V140E-3 Series
SEN00309-00
Starting aid
Electric heater
1.
2.
3.
4.
Body
Heater coil
Terminal
Connection diagram
12V140E-3 Series
Specifications
Type of heater: Electrical intake air heater
Rated voltage: 22 V (DC)
Load current: 175 A
51
SEN00309-00
Engine controller
Features
Mounting of engine controller on engine
q
Since the engine controller is mounted on the engine, the operator can service it easily in the field.
q
Vibrations are damped by the vibration-proof rubber.
Unified specifications of engine controller
Engine controller CM850 developed by the cooperation between KOMATSU and CUMMINS is
employed.
52
12V140E-3 Series
12V140E-3 Series
SEN00309-00
53
SEN00309-00

2005 KOMATSU
All Rights Reserved
54
12V140E-3 Series
SEN00311-00
ENGINE
1SHOP MANUAL
12V140E-3 Series

Standard service value table ........................................................................................................................... 2
Standard service value table for testing, adjusting, and troubleshooting ............................................. 2
Running-in standard and performance test standard ........................................................................... 3
12V140E-3 Series
SEN00311-00
Air intake and exhaust system
Performance
Category
Standard service value table for testing, adjusting, and troubleshooting1
Necessary
speed for
starting
Body
Lubrication system
Cooling system
Machine model
D475A-5
Standard value
for new machine
Service limit
value
Max. speed at no load
rpm
2,150 25
2,150 25
Min. speed at no load
rpm
600 40
600 40
At 0C (without starting aid)
rpm
Min. 110
At 20C (with starting aid)
rpm
Min. 100
Measurement conditions
Air intake
resistance
Whole speed range
kPa
{mmH2O}
Max. 3.73
{Max. 380}
7.47
{762}
Air boost
pressure
At rated output
kPa
{mmHg}
Min. 132.30
{Min. 1,000}
Exhaust
pressure
At rated output
kPa
{mmHg}
Exhaust
temperature
Whole speed range (20C )
Max. 680
750
At sudden acceleration (Low to High)
Bosch
index
Max. 4.5
5.5
At rated output
Bosch
index
Max. 1.0
2.0
At high idle
Bosch
index
Max. 1.0
2.0
Intake valve
mm
0.35 0.02
0.35 0.02
Exhaust gas
color
Valve clearance
SAA12V140E-3
Unit
Item
Speed
Engine
Exhaust valve
mm
0.57 0.02
0.57 0.02
Min. 4.1
{Min. 42}
2.0
{20}
Compression
pressure
Engine oil temperature: 40 60C

Engine speed: 200 250 rpm
MPa
{kg/cm2}
Blow-by
pressure
At rated output
Engine coolant temperature: Min. 70C
kPa
{mmH2O}
Max. 2.94
{Max. 300}
5.88
{600}
MPa
{kg/cm2}
0.29 0.44
{3.0 4.5}
0.2
{2.0}
MPa
{kg/cm2}
Min. 0.08
{Min. 0.8}
0.07
{0.7}
80 110
120
0.5
1.0
kPa
{kg/cm2}
At rated output
Engine oil temperature: Min. 80C
Oil pressure
At low idle
Engine oil temperature: Min. 80C
SAE0W30E0S
SAE5W40E0S
SAE10W30DH
SAE15W40DH
SAE30DH
Oil temperature Whole speed range (Oil in oil pan)

Oil consumption
Ratio to fuel consumption at continuous rated

output
Function of
radiator pressure valve
Cracking pressure (Differential pressure)
Fan speed
At rated speed
rpm
Hydraulically
driven on
machine side
Hydraulically
driven on
machine side
Alternator belt
tension
Deflection under finger pressure of 59 N {6 kg}
mm
Approx. 20
Approx. 20
12V140E-3 Series
SEN00311-00
Running-in standard and performance test standard
Running-in standard
Engine
SAA12V140E-3
Machine model
D475A-5
Procedure
Item
Running time
min.
15
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
a
This table shows the values when the fan is not installed.
The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Performance test standard

Engine
SAA12V140E-3
Machine model
D475A-5
Test item
Rated output
Max. torque
Max. speed at
no load
Min. speed at
no load
2,150 25 rpm
660 40 rpm
Specification value
(Gross value)
Speed
rpm
2,000 5
1,300 1,500
Dynamometer load
N
{kg}
4,341 4,596
{443 469}
5,174 5,498
{528 561}
Output (Gross value)
kW
{HP}
651 691
{873 926}
Torque (Gross value)
Nm
{kgm}
3,704 3,940
{378 402}
Fuel consumption
sec/300cc
Min. 19.5
Coolant temperature
70 90
70 90
70 90
70 90
Lubricating oil
temperature
90 110
90 110
90 110
90 110
Lubricating oil
pressure
kPa
{kg/cm2}
0.34 0.49
{3.0 4.5}
Min. 0.08
{Min. 0.8}
Exhaust temperature
Max. 620
Max. 680
a
a
a
a
a
a
671 kW/2,000 rpm 3,822 Nm/1,400 rpm

{899 HP/2,000 rpm} {390 kgm/1,400 rpm}
This table shows the standard values obtained by using the JIS correction coefficients.
Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.
This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Use ASTM No.1 or No. 2 diesel fuel as fuel.
Use SAE15W-40 as lubricating oil.
12V140E-3 Series
SEN00311-00

2005 KOMATSU
All Rights Reserved
12V140E-3 Series

Engine Saa12v140e-3 HPCR Sen00291-00d

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00 Index and foreword

00 Index and foreword

Organization list of the shop manual

Shop Manual, contents binder, binder label and tabs

00 Index and foreword

10 Structure, function and maintenance standard

20 Standard value table

00 Index and foreword

00 Index and foreword

00 Index and foreword

20 Standard value table

00 Index and foreword

00 Index and foreword

KOMATSU 12V140E-3 Series engine

00 Index and foreword

Foreword and general information

00 Index and foreword

Foreword and general information

Important safety notice

If welding repairs are needed, always

Preparations for work

00 Index and foreword

When disassembling or assembling, support the machine with blocks, jacks, or

Precautions during work

When removing piping, stop the fuel or oil

Precautions for sling work and making

00 Index and foreword

When installing wire ropes to an angular

11) Do not use twisted or kinked wire ropes.

00 Index and foreword

If the load is unstable or the wire rope

Precautions for using mobile crane

Selecting wire ropes

The allowable load is one-sixth of the

How to read the shop manual

00 Index and foreword

Composition of shop manual

Revision and distribution

00 Index and foreword

Revised edition mark

00 Index and foreword

Explanation of terms for maintenance standard

Standard size and tolerance

The tolerance may be indicated in the text

Usually, the size of a hole and the size of

00 Index and foreword

Standard clearance and standard value

Repair limit and allowable value

Handling electric equipment and hydraulic component

00 Index and foreword

Points to remember when handling electric

Main failures occurring in wiring harness

Defective crimping or soldering of connectors

00 Index and foreword

High-pressure water entering connector

Oil or dirt stuck to connector

Removing, installing, and drying connectors and wiring harnesses

00 Index and foreword

When removing from clips

When removing a connector from a

Action to take after removing connectors

00 Index and foreword