Manual Motor 475,785-7, PC2000 y WA900-3Eo Series 12V140-3 PDF

SEN00291-04
Shop
Manual
12V140E-3 SERIES
ENGINE
This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in
accordance with written authorization from Komatsu America Corp.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to
make changes or improvements at any time without incurring any obligation to install such changes on products
sold previously.
Due to this continuous program of research and development, revisions may be made to this publication. It is
recommended that customers contact their distributor for information on the latest revision.
Copyright 2007 Komatsu

Printed in U.S.A.
Komatsu America Corp.
July 2007
SEN00294-04
ENGINE 1SHOP MANUAL
12V140E-3 Series
00 Index and foreword 1

Index
Composition of shop manual................................................................................................................ 2
Table of contents .................................................................................................................................. 3
12V140E-3 Series 1
SEN00294-04 00 Index and foreword
Composition of shop manual 1

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 accord-
ingly.
Section Title Form Number
Shop Manual, contents binder, binder label and tabs SEN00291-04
00 Index and foreword SEN00292-04

Index SEN00294-04 q
Foreword and general information SEN00296-02 q
01 Specification SEN00301-02
Specification and technical data SEN00303-02 q
10 Structure, function and maintenance standard SEN00304-02

Structure, function and maintenance standard, Part 1 SEN00307-02 q
Structure, function and maintenance standard, Part 2 SEN00309-02 q
20 Standard value table SEN00310-03

Standard service value table SEN00311-03 q
30 Testing and adjusting SEN00312-00

Testing and adjusting SEN00313-00
40 Troubleshooting SEN00314-00
General information on troubleshooting SEN00315-00
Troubleshooting of mechanical system (S-mode) SEN00316-00
Troubleshooting of electrical system (E-mode), Part 1 SEN00317-00
50 Disassembly and assembly SEN00319-00

General information on disassembly and assembly SEN00320-00
Disassembly and assembly, Part 1 SEN00321-00
2 12V140E-3 Series
Table of contents 1
00 Index and foreword
Index SEN00294-04
Composition of shop manual ................................................................................................... 2
Table of contents ..................................................................................................................... 3
Foreword and general information SEN00296-02

Safety notice............................................................................................................................ 2
How to read the shop manual.................................................................................................. 7
Explanation of terms for maintenance standard ...................................................................... 9
Handling of electric equipment and hydraulic component ....................................................... 11
Handling of connectors newly used for engines ...................................................................... 20
How to read electric wire code ................................................................................................ 23
Precautions when carrying out operation ................................................................................ 26
Method of disassembling and connecting push-pull type coupler ........................................... 29
Standard tightening torque table.............................................................................................. 32
Conversion table...................................................................................................................... 36
01 Specification
Specification and technical data SEN00303-02
Outline ..................................................................................................................................... 2
Specifications........................................................................................................................... 4
General view............................................................................................................................ 10
Weight table............................................................................................................................. 19
Engine performance curves..................................................................................................... 20
10 Structure, function and maintenance standard

Structure, function and maintenance standard, Part 1 SEN00307-02
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
Structure, function and maintenance standard, Part 2 SEN00309-02

Lubrication system ...................................................................................................................... 4
Lubrication system diagram..................................................................................................... 4
12V140E-3 Series 3
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
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 .................................................................................................................... 50
Alternator ................................................................................................................................. 50
Starting motor .......................................................................................................................... 52
Starting aid............................................................................................................................... 54
Engine controller...................................................................................................................... 55
20 Standard value table

Standard service value table SEN00311-03
Standard service value table ....................................................................................................... 2
Standard service value table for testing, adjusting, and troubleshooting ................................. 2
Running-in standard and performance test standard .............................................................. 7
30 Testing and adjusting

Testing and adjusting SEN00313-00
Testing and adjusting................................................................................................................... 3
Testing and adjusting tools list ................................................................................................. 3
Testing air boost pressure........................................................................................................ 5
Testing exhaust temperature ................................................................................................... 6
Adjusting valve clearance ........................................................................................................ 7
Testing compression pressure ................................................................................................. 9
Testing blow-by pressure ......................................................................................................... 11
Measuring blow-by pressure.................................................................................................... 12
Testing oil pressure.................................................................................................................. 13
Handling fuel system parts ...................................................................................................... 14
Releasing residual pressure in fuel system ............................................................................. 14
Testing fuel pressure................................................................................................................ 15
Reduced cylinder mode operation ........................................................................................... 16
No-injection cranking ............................................................................................................... 16
Testing leakage-from pressure limiter and return rate from injector ........................................ 17
Bleeding air from fuel circuit (for D475A-5).............................................................................. 20
Bleeding air from fuel circuit (for PC2000)............................................................................... 23
Testing fuel system for leakage ............................................................................................... 25
Adjusting speed sensor ........................................................................................................... 26
Testing and adjusting alternator belt tension ........................................................................... 26
Handling controller high-voltage circuit.................................................................................... 27
40 Troubleshooting
General information on troubleshooting SEN00315-00
General information on troubleshooting ...................................................................................... 2
Points to remember when troubleshooting .............................................................................. 2
4 12V140E-3 Series
Error codes and failure codes list ............................................................................................ 3

Troubleshooting of mechanical system (S-mode) SEN00316-00
Troubleshooting of mechanical system (S-mode) ....................................................................... 3
Method of using troubleshooting charts................................................................................... 3
S-1 Starting performance is poor ............................................................................................. 6
S-2 Engine does not start ........................................................................................................ 7
S-3 Engine does not pick up smoothly .................................................................................... 10
S-4 Engine stops during operations ........................................................................................ 11
S-5 Engine does not rotate smoothly ...................................................................................... 12
S-6 Engine lacks output (or lacks power) ................................................................................ 13
S-7 Exhaust smoke is black (incomplete combustion) ............................................................ 15
S-8 Oil consumption is excessive (or exhaust smoke is blue)................................................. 16
S-9 Oil becomes contaminated quickly ................................................................................... 17
S-10 Fuel consumption is excessive ....................................................................................... 18
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down).............................. 19
S-12 Oil pressure drops........................................................................................................... 20
S-13 Oil level rises (Entry of coolant or fuel) ........................................................................... 21
S-14 Coolant temperature becomes too high (overheating).................................................... 22
S-15 Abnormal noise is made ................................................................................................. 23
S-16 Vibration is excessive ..................................................................................................... 24

Troubleshooting of electrical system (E-mode), Part 1 ............................................................... 4
Information in troubleshooting table ........................................................................................ 4
E-1 Code [111/CA111] ECM Critical Internal Failure (LH bank)............................................... 6
E-2 Code [111/CB111] ECM Critical Internal Failure (RH bank) .............................................. 8
E-3 Code [115/CA115] Eng. Ne and G (Bkup) Speed Sensor Error (LH bank) ....................... 10
E-4 Code [115/CB115] Eng. Ne and G (Bkup) Speed Sensor Error (RH bank)....................... 11
E-5 Code [122/CA122] Charge Air Press. Sensor High Error (LH bank only)......................... 12
E-6 Code [123/CA123] Charge Air Press. Sensor Low Error (LH bank only).......................... 14
E-7 Code [131/CA131] Throttle Sensor High Error (LH bank only) ......................................... 16
E-8 Code [132/CA132] Throttle Sensor Low Error (LH bank only) .......................................... 18
E-9 Code [135/CA135] Oil Press. Sensor High Error (LH bank only)...................................... 20
E-10 Code [141/CA141] Oil Press. Sensor Low Error (LH bank only) .................................... 22
E-11 Code [144/CA144] Coolant Temp. Sensor High Error (LH bank only) ............................ 24
E-12 Code [145/CA145] Coolant Temp. Sensor Low Error (LH bank only) ............................. 26
E-13 Code [153/CA153] Charge Air Temp. Sensor High Error (LH bank only) ....................... 28
E-14 Code [154/CA154] Charge Air Temp. Sensor Low Error (LH bank only) ........................ 30
E-15 Code [187/CA187] Sensor Sup. 2 Volt. Low Error (LH bank) ......................................... 31
E-16 Code [187/CB187] Sensor Sup. 2 Volt. Low Error (RH bank)......................................... 31
E-17 Code [212/CA212] Eng. Oil Temp.Sensor High Error (LH bank only)............................. 32
E-18 Code [213/CA213] Eng. Oil Temp.Sensor Low Error (LH bank only) ............................. 34
E-19 Code [221/CA221] Ambient Air Press. Sensor High Error (LH bank only) ..................... 36
E-20 Code [222/CA222] Ambient Air Press. Sensor Low Error (LH bank only) ...................... 38
E-21 Code [227/CA227] Sensor Sup. 2 Volt. High Error (LH bank) ........................................ 40
E-22 Code [227/CB227] Sensor Sup. 2 Volt. High Error (RH bank)........................................ 42
E-23 Code [234/CA234] Eng. Overspeed (LH bank only) ....................................................... 44
E-24 Code [238/CA238] Ne Speed Sensor Sup. Volt. Error (LH bank) ................................... 46
E-25 Code [238/CB238] Ne Speed Sensor Sup. Volt. Error (RH bank) .................................. 48
E-26 Code [263/CA263] Fuel Temp. Sensor High Error (LH bank) ......................................... 50
E-27 Code [263/CB263] Fuel Temp. Sensor High Error (RH bank) ........................................ 52
E-28 Code [265/CA265] Fuel Temp. Sensor Low Error (LH bank) .......................................... 54
E-29 Code [265/CB265] Fuel Temp. Sensor Low Error (RH bank) ......................................... 54
E-30 Code [271/CA271] PCV1 Short Error (LH bank)............................................................. 56
E-31 Code [271/CB271] PCV1 Short Error (RH bank) ............................................................ 58
E-32 Code [272/CA272] PCV1 Open Error (LH bank) ............................................................ 60
E-33 Code [272/CB272] PCV1 Open Error (RH bank)............................................................ 61
12V140E-3 Series 5
E-34 Code [273/CA273] PCV2 Short Error (LH bank)............................................................. 62

E-35 Code [273/CB273] PCV2 Short Error (RH bank) ............................................................ 64
E-36 Code [274/CA274] PCV2 Open Error (LH bank)............................................................. 66
E-37 Code [274/CB274] PCV2 Open Error (RH bank) ............................................................ 67
E-38 Code [322/CA322] Injector #1 (L/B #1) System Open/Short Error (LH bank)................. 68
E-44 Code [342/CA342] Caribration Code Incompatibility (LH bank) ...................................... 80
E-45 Code [342/CB342] Caribration Code Incompatibility (RH bank) ..................................... 80
E-46 Code [351/CA351] INJ. Drive Circuit Error (LH bank)..................................................... 82
E-47 Code [351/CB351] INJ. Drive Circuit Error (RH bank) .................................................... 84
E-48 Code [352/CA352] Sensor Sup. 1 Volt. Low Error (LH bank) ......................................... 86
E-49 Code [352/CB352] Sensor Sup. 1 Volt. Low Error (RH bank)......................................... 86
E-50 Code [386/CA386] Sensor Sup. 1 Volt. High Error (LH bank)......................................... 88
E-51 Code [386/CB386] Sensor Sup. 1 Volt. High Error (RH bank) ........................................ 90
E-52 Code [441/CA441] Battery Voltage Low Error (LH bank) ................................................ 92
E-53 Code [441/CB441] Battery Voltage Low Error (RH bank) ............................................... 92
E-54 Code [442/CA442] Battery Voltage High Error (LH bank) ............................................... 93
E-55 Code [442/CB442] Battery Voltage High Error (RH bank) .............................................. 93

Troubleshooting of electrical system (E-mode), Part 2................................................................ 3
E-56 Code [449/CA449] Rail Press. Very High Error (LH bank).............................................. 3
E-57 Code [449/CB449] Rail Press. Very High Error (RH bank) ............................................. 3
E-58 Code [451/CA451] Rail Press. Sensor High Error (LH bank).......................................... 4
E-59 Code [451/CB451] Rail Press. Sensor High Error (RH bank) ......................................... 6
E-60 Code [452/CA452] Rail Press. Sensor Low Error (LH bank) .......................................... 8
E-61 Code [452/CB452] Rail Press. Sensor Low Error (RH bank).......................................... 8
E-62 Code [553/CA553] Rail Press. High Error 1 (LH bank) ................................................... 9
E-63 Code [553/CB553] Rail Press. High Error 1 (RH bank) .................................................. 10
E-64 Code [554/CA554] Rail Press. Sensor In Range Error (LH bank) .................................. 11
E-65 Code [554/CB554] Rail Press. Sensor In Range Error (RH bank).................................. 11
E-66 Code [559/CA559] Rail Press. Low Error 1 (LH bank).................................................... 12
E-67 Code [559/CB559] Rail Press. Low Error 1 (RH bank) ................................................... 16
E-68 Code [689/CA689] Eng. Ne Speed Sensor Error (LH bank) ........................................... 20
E-69 Code [689/CB689] Eng. Ne Speed Sensor Error (RH bank)........................................... 22
E-70 Code [691/CA691] Intake Air Temp Sensor High Error (LH bank only) .......................... 24
E-71 Code [692/CA692] Intake Air Temp Sensor Low Error (LH bank only) ........................... 26
E-72 Code [731/CA731] Eng. G (Bkup) Speed Sensor Phase Error (LH bank) ...................... 27
E-73 Code [731/CB731] Eng. G (Bkup) Speed Sensor Phase Error (RH bank)...................... 27
E-74 Code [757/CA757] All Continuous Data Lost Error (LH bank) ........................................ 28
E-75 Code [757/CB757] All Continuous Data Lost Error (RH bank)........................................ 28
E-76 Code [778/CA778] Eng. G (Bkup) Speed Sensor Error (LH bank) ................................. 30
E-77 Code [778/CB778] Eng. G (Bkup) Speed Sensor Error (RH bank)................................. 32
E-78 Code [781/CA781] Inter Multi-controller Communication Error (LH bank) ...................... 34
E-79 Code [781/CB781] Inter Multi-controller Communication Error (RH bank) ..................... 36
E-80 Code [1117/CA1117] Persistent Data Lost Error (LH bank)............................................. 37
E-81 Code [1117/CB1117] Persistent Data Lost Error (RH bank) ............................................ 37
E-82 Code [1257/CA1257] Harness Key error (LH bank)........................................................ 38
E-83 Code [1257/CB1257] Harness Key error (RH bank) ....................................................... 39
E-84 Code [1548/CB1548] Injector #7 (R/B #1) System Open/Short Error (RH bank)............ 40
E-85 Code [1549/CB1549] Injector #8 (R/B #2) System Open/Short Error (RH bank)............ 42
E-86 Code [1551/CB1551] Injector #10 (R/B #4) System Open/Short Error (RH bank).......... 44
E-87 Code [1552/CB1552] Injector #11 (R/B #5) System Open/Short Error (RH bank) .......... 46
E-88 Code [1553/CB1553] Injector #12 (R/B #6) System Open/Short Error (RH bank).......... 48
6 12V140E-3 Series
E-89 Code [1622/CB1622] Injector #9 (R/B #3) System Open/Short Error (RH bank) ........... 50
E-90 Code [1633/CA1633] KOMNET Datalink Timeout Error (LH bank) ................................ 52
E-91 Code [2185/CA2185] Throttle Sens. Sup. Volt. High Error (LH bank only)..................... 54
E-92 Code [2186/CA2186] Throttle Sens. Sup. Volt. Low Error (LH bank only)...................... 56
E-93 Code [2249/CA2249] Rail Press. Very Low Error (LH bank) .......................................... 57
E-94 Code [2249/CB2249] Rail Press. Very Low Error (RH bank) .......................................... 57
E-95 Code [– –*1/–] Eng. Overheat (LH bank only) ................................................................ 58
E-96 Code [– –*2/–] Eng. Oil Press. Low Speed Derate (LH bank only) ................................. 58
E-97 Code [– –*3/–] Press. Low Torque Derate (LH bank only) .............................................. 59
50 Disassembly and assembly

General information on disassembly and assembly SEN00320-00
General information on disassembly and assembly.................................................................... 2
How to read this manual.......................................................................................................... 2
Coating materials list ............................................................................................................... 3
Special tools list ....................................................................................................................... 6

Disassembly and assembly, Part 1 ............................................................................................. 2
General disassembly of engine ............................................................................................... 2

General assembly of engine.................................................................................................... 2

Removal and installation fuel supply pump unit ...................................................................... 2
Replacement of oil seal of engine mounted on machine......................................................... 4
12V140E-3 Series 7
KOMATSU 12V140E-3 Series engine

Form No. SEN00294-04
© 2007 KOMATSU
All Rights Reserved
8 12V140E-3 Series
SEN00296-02
ENGINE 1SHOP MANUAL
12V140E-3 Series
00 Index and foreword 1

Foreword and general information
Safety notice ................................................................................................................................................... 2
How to read the shop manual ......................................................................................................................... 7
Explanation of terms for maintenance standard ............................................................................................. 9
Handling of electric equipment and hydraulic component .............................................................................11
Handling of connectors newly used for engines ........................................................................................... 20
How to read electric wire code...................................................................................................................... 23
Precautions when carrying out operation...................................................................................................... 26
Method of disassembling and connecting push-pull type coupler................................................................. 29
Standard tightening torque table ................................................................................................................... 32
Conversion table ........................................................................................................................................... 36
12V140E-3 Series 1
Safety notice 1 (Rev. 2007/03)

Important safety notice
Proper service and repair are extremely important for safe machine operation. The service and repair
techniques recommended by Komatsu and described in this manual are both effective and safe.
Some of these techniques require the use of tools specially designed by Komatsu for the specific
purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The
cautions accompanying these symbols should always be followed carefully. If any dangerous situa-
tion arises or may possibly arise, first consider safety, and take the necessary actions to deal with
the situation.
1. General precautions 7) If welding repairs are needed, always

k Mistakes in operation are extremely have a trained and experienced welder
dangerous. Read the Operation and carry out the work. When carrying out
Maintenance Manual carefully before weld in g wo rk , al way s wear wel din g
operating the machine. gloves, apron, shielding goggles, cap and
1) Before carrying out any greasing or other clothes suited for welding work.
repairs, read all the safety plates stuck to 8) Before starting work, warm up your body
the machine. For the locations of the thoroughly to start work under good condi-
safety plates and detailed explanation of tion.
precautions, see the Operation and Main-
tenance Manual. Safety points
2) Decide a place in the repair workshop to
keep tools and removed parts. Always 1 Good arrangement
keep the tools and parts in their correct 2 Correct work clothes
places. Always keep the work area clean 3 Following work standard
and make sure that there is no dirt, water,
or oil on the floor. Smoke only in the areas 4 Making and checking signs
provided for smoking. Never smoke while Prohibition of operation and handling by
5
working. unlicensed workers
3) When carrying out any operation, always 6 Safety check before starting work
wear safety shoes and helmet. Do not
wear loose work clothes, or clothes with Wearing protective goggles
7
(for cleaning or grinding work)
buttons missing.
q Always wear safety glasses when hit- Wearing shielding goggles and protectors
8
ting parts with a hammer. (for welding work)
q Always wear safety glasses when 9 Good physical condition and preparation
grinding parts with a grinder, etc.
Precautions against work which you are
4) When carrying out any operation with 2 or 10
not used to or you are used to too much
more workers, always agree on the oper-
ating procedure before starting. Always
inform your fellow workers before starting 2. Preparations for work
any step of the operation. Before starting 1) Before adding oil or making any repairs,
work, hang UNDER REPAIR warning park the machine on hard and level
signs in the operator's compartment. ground, and apply the parking brake and
5) Only qualified workers must carry out work block the wheels or tracks to prevent the
and operation which require license or machine from moving.
qualification. 2) Before starting work, lower the work
6) Keep all tools in good condition, learn the equipment (blade, ripper, bucket, etc.) to
correct way to use them, and use the the ground. If this is not possible, insert
proper ones of them. Before starting work, the lock pin or use blocks to prevent the
thoroughly check the tools, machine, fork- work equipment from falling. In addition,
lift, service car, etc. be sure to lock all the control levers and
hang warning signs on them.
2 12V140E-3 Series
3) When disassembling or assembling, sup- 8) When removing piping, stop the fuel or oil
port the machine with blocks, jacks, or from spilling out. If any fuel or oil drips
stands before starting work. onto the floor, wipe it up immediately. Fuel
4) Remove all mud and oil from the steps or or oil on the floor can cause you to slip
other places used to get on and off the and can even start fires.
machine. Always use the handrails, lad- 9) As a general rule, do not use gasoline to
ders or steps when getting on or off the wash parts. Do not use it to clean electri-
m a c h i n e . N e v e r j u m p o n o r o ff t h e cal parts, in particular.
machine. If it is impossible to use the 10) Be sure to assemble all parts again in their
handrails, ladders or steps, use a stand to original places. Replace any damaged
provide safe footing. parts and parts which must not be reused
with new parts. When installing hoses and
3. Precautions during work wires, be sure that they will not be dam-
1) Before disconnecting or removing compo- aged by contact with other parts when the
nents of the oil, water, or air circuits, first machine is operated.
release the pressure completely from the 11) When installing high pressure hoses,
circuit. When removing the oil filler cap, a make sure that they are not twisted. Dam-
drain plug, or an oil pressure pickup plug, aged tubes are dangerous, so be
loosen it slowly to prevent the oil from extremely careful when installing tubes for
spurting out. high pressure circuits. In addition, check
2) The coolant and oil in the circuits are hot t h a t c o n n e c t i n g pa r ts a r e c o r r e c t l y
when the engine is stopped, so be careful installed.
not to get scalded. Wait for the oil and 12) When assembling or installing parts,
coolant to cool before carrying out any always tighten them to the specified
work on the oil or water circuits. torques. When installing protective parts
3) Before starting work, stop the engine. such as guards, or parts which vibrate vio-
When working on or around a rotating lently or rotate at high speed, be particu-
part, in particular, stop the engine. When l a r ly c a r e fu l t o c he c k t h a t t h e y ar e
checking the machine without stopping installed correctly.
the engine (measuring oil pressure, 13) When aligning 2 holes, never insert your
revolving speed, temperature, etc.), take fingers or hand. Be careful not to get your
extreme care not to get rolled or caught in fingers caught in a hole.
rotating parts or moving parts. 14) When measuring hydraulic pressure,
4) Before starting work, remove the leads check that the measuring tools are cor-
from the battery. Always remove the lead rectly assembled.
from the negative (–) terminal first. 15) Take care when removing or installing the
5) When raising a heavy component (heavier tracks of track-type machines. When
than 25 kg), use a hoist or crane. Before removing the track, the track separates
starting work, check that the slings (wire suddenly, so never let anyone stand at
ropes, chains, and hooks) are free from either end of the track.
damage. Always use slings which have 16) If the engine is operated for a long time in
ample capacity and install them to proper a place which is not ventilated well, you
places. Operate the hoist or crane slowly may suffer from gas poisoning. Accord-
to prevent the component from hitting any ingly, open the windows and doors to ven-
other part. Do not work with any part still tilate well.
raised by the hoist or crane.
6) When removing a cover which is under
internal pressure or under pressure from a
spring, always leave 2 bolts in diagonal
positions. Loosen those bolts gradually
and alternately to release the pressure,
and then remove the cover.
7) When removing components, be careful
not to break or damage the electrical wir-
ing. Damaged wiring may cause electrical
fires.
12V140E-3 Series 3
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.
8) When installing wire ropes to an angular
3) Keep putting on gloves during sling work.
load, apply pads to protect the wire ropes.
(Put on leather gloves, if available.)
If the load is slippery, apply proper mate-
4) Measure the weight of the load by the eye
rial to prevent the wire rope from slipping.
and check its center of gravity.
9) Use the specified eyebolts and fix wire
5) Use proper sling according to the weight
ropes, chains, etc. to them with shackles,
of the load and method of slinging. If too
etc.
thick wire ropes are used to sling a light
10) Apply wire ropes to the middle portion of
load, the load may slip and fall.
the hook.
6) Do not sling a load with 1 wire rope alone.
q Slinging near the tip of the hook may
If it is slung so, it may rotate and may slip
cause the rope to slip off the hook
out of the rope. Install 2 or more wire
during hoisting. The hook has the
ropes symmetrically.
k Slinging with 1 rope may cause
maximum strength at the middle por-
tion.
turning of the load during hoisting,
untwisting of the rope, or slipping
of the rope from its original wind-
ing 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 form-
ing 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 allow-
able 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 11) Do not use twisted or kinked wire ropes.
sling a load vertically, up to 19.6 kN {2,000 12) When lifting up a load, observe the follow-
kg} of total weight can be suspended. ing.
This weight is reduced to 9.8 kN {1,000 q Wind in the crane slowly until wire
kg} when the 2 ropes make a hanging ropes are stretched. When settling
angle of 120°. If the 2 ropes sling a 19.6 the wire ropes with the hand, do not
kN {2,000 kg} load at a lifting angle of grasp them but press them from
150°, each of them is subjected to a force above. If you grasp them, your fingers
as large as 39.2 kN {4,000 kg}. may be caught.
q After the wire ropes are stretched,
stop the crane and check the condi-
tion of the slung load, wire ropes, and
pads.
4 12V140E-3 Series
q If the load is unstable or the wire rope 13) If the hoist stops because of a power fail-
or chains are twisted, lower the load ure, turn the power switch OFF. When
and lift it up again. turning on a switch which was turned OFF
q Do not lift up the load slantingly. by the electric shock prevention earth
13) When lifting down a load, observe the fol- leakage breaker, check that the devices
lowing. related to that switch are not in operation
q When lifting down a load, stop it tem- state.
porarily at 30 cm above the floor, and 14) If you find an obstacle around the hoist,
then lower it slowly. stop the operation.
q Check that the load is stable, and 15) After finishing the work, stop the hoist at
then remove the sling. the specified position and raise the hook
q Remove kinks and dirt from the wire to at least 2 m above the floor. Do not
ropes and chains used for the sling leave the sling installed to the hook.
work, and put them in the specified
place. 7. Selecting wire ropes
1) Select adequate ropes depending on the
5. Precautions for using mobile crane weight of parts to be hoisted, referring to
a Read the Operation and Maintenance the table below.
Manual of the crane carefully in advance
and operate the crane safely. Wire ropes
(Standard “Z” twist ropes without galvanizing)
6. Precautions for using overhead hoist crane (JIS G3525, No. 6, Type 6X37-A)
k When raising a heavy part (heavier Nominal
Allowable load
than 25 kg), use a hoist, etc. In Disas- diameter of rope
sembly and assembly, the weight of a mm kN ton
part heavier than 25 kg is indicated 10 8.8 0.9
after the mark of 4. 12 12.7 1.3
1) Before starting work, inspect the wire 14 17.3 1.7
ropes, brake, clutch, controller, rails, over
16 22.6 2.3
wind stop device, electric shock preven-
18 28.6 2.9
tion earth leakage breaker, crane collision
20 35.3 3.6
prevention device, and power application
warning lamp, and check safety. 25 55.3 5.6
2) Observe the signs for sling work. 30 79.6 8.1
3) Operate the hoist at a safe place. 40 141.6 14.4
4) Check the direction indicator plates (east, 50 221.6 22.6
west, south, and north) and the directions 60 318.3 32.4
of the control buttons without fail.
5) Do not sling a load slantingly. Do not move a The allowable load is one-sixth of the
the crane while the slung load is swinging. breaking strength of the rope used
6) Do not raise or lower a load while the (Safety coefficient: 6).
crane is moving longitudinally or laterally.
7) Do not drag a sling.
8) When lifting up a load, stop it just after it
leaves the ground and check safety, and
then lift it up.
9) Consider the travel route in advance and
lift up a load to a safe height.
10) Place the control switch on a position
where it will not be an obstacle to work
and passage.
11) After operating the hoist, do not swing the
control switch.
12) Remember the position of the main switch
so that you can turn off the power immedi-
ately in an emergency.
12V140E-3 Series 5
8. Precautions for disconnecting and con-

necting hoses and tubes in air conditioner
circuit
1) Disconnection
k Collect the air conditioner refriger-
ant (R134a) from the air condi-
tioner circuit in advance.
a Ask professional traders for collecting
and filling operation of refrigerant
(R134a).
a Never release the refrigerant (R134a)
to the atmosphere.
k If the refrigerant gas (R134a) gets
in your eyes, you may lose your
sight. Accordingly, when collect-
ing or filling it, you must be quali-
fied for handling the refrigerant
and put on protective goggles.
2) Connection
1] When installing the air conditioner cir-
cuit hoses and tubes, take care that
dirt, dust, water, etc. will not enter
them.
2] When connecting the air conditioner
hoses and tubes, check that O-rings
(1) are fitted to their joints.
3] Check that each O-ring is not dam-
aged or deteriorated.
4] When connecting the refrigerant pip-
ing, apply compressor oil for refriger-
ant (R134a) (DENSO: ND-OIL8,
ZEXEL: ZXL100PG (equivalent to
PAG46)) to its O-rings.
a Example of O-ring (Fitted to every joint of

hoses and tubes)
a For tightening torque, see the precautions for

installation in each section of "Disassembly
and assembly".
6 12V140E-3 Series
How to read the shop manual 1
q Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one
of them is required, consult KOMATSU distributors.
q Materials and specifications are subject to change without notice.
q Shop manuals are divided into the “Chassis volume” and “Engine volume”. For the engine unit, see the
engine volume of the engine model mounted on the machine.
1. 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 dis-
assembly 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 7
3. 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 …)
q Revisions
Revised brochures are shown in the shop manual composition table.
4. Symbols
Important safety and quality portions are marked with the following symbols so that the shop manual will
be used practically.
Symbol Item Remarks
k Safety Special safety precautions are necessary when performing work.
Special technical precautions or other precautions for preserving stan-

a Caution
dards are necessary when performing work.
4
Weight of parts of component or parts. Caution necessary when
Weight
selecting hoisting wire, or when working posture is important, etc.
3
Tightening Places that require special attention for tightening torque during
torque assembly.
2 Coat Places to be coated with adhesives, etc. during assembly.
5
Oil, coolant Places where oil, etc. must be added, and capacity.
6
Drain Places where oil, etc. must be drained, and quantity to be drained.
5. Units
In this shop manual, the units are indicated with International System of units (SI). For reference, con-
ventionally used Gravitational System of units is indicated in parentheses { }.
8 12V140E-3 Series
Explanation of terms for maintenance standard 1

The maintenance standard values necessary for judgment of products and parts are described by the follow-
ing terms.
1. Standard size and tolerance

q 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 tem-
porary standard size is set and an allow-
able difference from that size is indicated.
q The above size set temporarily is called
the “standard size” and the range of differ-
ence 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.
Example:
Standard size Tolerance
–0.022
120
–0.126
a 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)
q Usually, the size of a hole and the size of

the shaft to be fitted to that hole are indi-
cated by the same standard size and dif-
ferent tolerances of the hole and shaft.
The tightness of fit is decided by the toler-
ance.
q Indication of size of rotating shaft and hole
and relationship drawing of them
Example:
Tolerance
Standard size
Shaft Hole
–0.030 +0.046
60
–0.076 +0
12V140E-3 Series 9
2. Standard clearance and standard value 5. Clearance limit

q The clearance made when new parts are q Parts can be used until the clearance
assembled is called the “standard clear- between them is increased to a certain
ance“, which is indicated by the range limit. The limit at which those parts cannot
from the minimum clearance to the maxi- be used is called the “clearance limit”.
mum clearance. q If the clearance between the parts
q When some parts are repaired, the clear- exceeds the clearance limit, they must be
ance is generally adjusted to the standard replaced or repaired.
clearance.
q A value of performance and function of 6. Interference limit
new products or equivalent is called the q The allowable maximum interference
“standard value“, which is indicated by a between the hole of a part and the shaft of
range or a target value. another part to be assembled is called the
q When some parts are repaired, the value “interference limit”.
of performance/function is set to the stan- q The interference limit shows the repair
dard value. limit of the part of smaller tolerance.
q If the interference between the parts
3. Standard interference exceeds the interference limit, they must
q When the diameter of a hole of a part be replaced or repaired.
shown in the given standard size and tol-
erance table is smaller than that of the
mating shaft, the difference between those
diameters is called the “interference”.
q The range (A – B) from the difference (A)
between the minimum size of the shaft
and the maximum size of the hole to the
difference (B) between the maximum size
of the shaft and the minimum size of the
hole is the “standard interference”.
q After repairing or replacing some parts,
measure the size of their hole and shaft
and check that the interference is in the
standard range.
4. Repair limit and allowable value

q The size of a part changes because of
wear and deformation while it is used. The
limit of changed size is called the “repair
limit”.
q If a part is worn to the repair limit must be
replaced or repaired.
q The performance and function of a prod-
uct 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 vari-
ous tests or experiences in most cases,
however, it must be judged after consider-
ing the operating condition and customer's
requirement.
10 12V140E-3 Series
Handling of electric equipment and hydraulic component 1

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, con-
nectors used for connecting and disconnecting
one wire from another wire, and protectors or
tubes used for protecting the wiring.
Compared with other electrical components fit-
ted 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 (defec-
tive contact between male and female)
Problems with defective contact are likely
to occur because the male connector is
not properly inserted into the female con-
nector, or because one or both of the con-
nectors is deformed or the position is not
correctly aligned, or because there is cor-
rosion or oxidization of the contact sur-
faces. The corroded or oxidized contact
surfaces may become shiny again (and
contact may become normal) by connect-
ing and disconnecting the connector about
10 times.
2) Defective crimping or soldering of connec-

tors
The pins of the male and female connec-
tors are in contact at the crimped terminal
or soldered portion, but if there is exces-
sive force brought to bear on the wiring,
the plating at the joint will peel and cause
improper connection or breakage.
12V140E-3 Series 11
3) Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with
a crane with the wiring still connected, or a
heavy object hits the wiring, the crimping
of the connector may separate, or the sol-
dering may be damaged, or the wiring
may be broken.
4) High-pressure water entering connector

The connector is designed to make it diffi-
cult for water to enter (drip-proof struc-
ture), but if high-pressure water is sprayed
directly on the connector, water may enter
the connector, depending on the direction
of the water jet. Accordingly, take care not
to splash water over the connector. The
connector is designed to prevent water
from entering, but at the same time, if
water does enter, it is difficult for it to be
drained. Therefore, if water should get into
the connector, the pins will be short-cir-
cuited 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 sur-
face 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 com-
pressed 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 com-
pressed air, the contacts will become
even dirtier, so remove the oil and
water from the compressed air com-
pletely before cleaning with com-
pressed air.
12 12V140E-3 Series
3. Removing, installing, and drying connec-

tors and wiring harnesses
1) Disconnecting connectors
1] Hold the connectors when discon-
necting.
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 connec-
tors apart.
a Never pull with one hand.
2] When removing from clips

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

clip, pull the connector in a parallel
direction to the clip for removing stop-
pers.
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 connec-

tors
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 disassem-
bled for a long time, it is particu-
larly easy for improper contact to
occur, so always cover the con-
nector.
12V140E-3 Series 13
2) Connecting connectors
1] Check the connector visually.
Check that there is no oil, dirt, or
water stuck to the connector pins
(mating portion).
Check that there is no deformation,
defective contact, corrosion, or dam-
age to the connector pins.
Check that there is no damage or
breakage to the outside of the con-
nector.
a If there is any oil, water, or dirt
stuck to the connector, wipe it off
with a dry cloth. If any water has
got inside the connector, warm
the inside of the wiring with a
dryer, but be careful not to make
it too hot as this will cause short
circuits.
a If there is any damage or break-
age, replace the connector.
2] Fix the connector securely.
Align the position of the connector
correctly, and then insert it securely.
For connectors with the lock stopper,
push in the connector until the stop-
per clicks into position.
3] Correct any protrusion of the boot and
any misalignment of the wiring har-
ness.
For connectors fitted with boots, cor-
rect any protrusion of the boot. In
addition, if the wiring harness is mis-
aligned, or the clamp is out of posi-
tion, adjust it to its correct position.
a If the connector cannot be cor-
rected easily, remove the clamp
and adjust the position.
q If the connector clamp has been
removed, be sure to return it to
its original position. Check also
that there are no loose clamps.
14 12V140E-3 Series
3) Heavy duty wire connector (DT 8-pole, 12- q Disconnection q Connection (Example of
pole) incomplete setting of (a))
Disconnection (Left of figure)
While pressing both sides of locks (a)
and (b), pull out female connector (2).
Connection (Right of figure)
1] Push in female connector (2) horizon-
tally until the lock clicks.
Arrow: 1)
2] Since locks (a) and (b) may not be set
completely, push in female connector
(2) while moving it up and down until
the locks are set normally.
Arrow: 1), 2), 3)
a Right of figure: Lock (a) is pulled
down (not set completely) and
lock (b) is set completely.
(1): Male connector
(2): Female connector
(a), (b): Locks
12V140E-3 Series 15
4) Drying wiring harness

If there is any oil or dirt on the wiring har-
ness, 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 fol-
lows.
1] Disconnect the connector and wipe
off the water with a dry cloth.
a If the connector is blown dry with
compressed air, there is the risk
that oil in the air may cause
defective contact, so remove all
oi l a nd wa ter fr om t he c om -
pressed air before blowing with
air.
2] Dry the inside of the connector with a
dryer.
If water gets inside the connector, use
a dryer to dry the connector.
a Hot air from the dryer can be
used, but regulate the time that
the hot air is used in order not to
make the connector or related
parts too hot, as this will cause
deformation or damage to the
connector.
3] Carry out a continuity test on the con-
nector.
After drying, leave the wiring harness
disconnected and carry out a continu-
ity test to check for any short circuits
between pins caused by water.
a After completely drying the con-
n e c t o r, b l o w i t w i t h c o n ta c t
restorer and reassemble.
16 12V140E-3 Series
4. Handling controller
1) The controller contains a microcomputer
and electronic control circuits. These con-
trol all of the electronic circuits on the
machine, so be extremely careful when
handling the controller.
2) Do not place objects on top of the control-
ler.
3) Cover the control connectors with tape or
a vinyl bag. Never touch the connector
contacts with your hand.
4) During rainy weather, do not leave the
controller in a place where it is exposed to
rain.
5) Do not place the controller on oil, water, or
soil, or in any hot place, even for a short
time. (Place it on a suitable dry stand).
6) Precautions when carrying out arc welding
When carrying out arc welding on the
body, disconnect all wiring harness con-
nectors connected to the controller. Fit an
arc welding ground close to the welding
point.
5. Points to remember when troubleshooting

electric circuits
1) Always turn the power OFF before discon-
necting 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 con-
nectors before going on to the next step.
a If the power is turned ON with the
connectors still disconnected, unnec-
essary abnormality displays will be
generated.
4) When carrying out troubleshooting of cir-
cuits (measuring the voltage, resistance,
continuity, or current), move the related
wiring and connectors several times and
check that there is no change in the read-
ing of the tester.
a If there is any change, there is proba-
bly defective contact in that circuit.
12V140E-3 Series 17
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 perfor-
mance 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 clean-
ing device is used, it is possible to filter out the
dirt that has collected during storage, so this is
an even more effective method.
18 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 equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit. Normally, flushing is
carried out twice: primary flushing is carried
out with flushing oil, and secondary flushing is
carried out with the specified hydraulic oil.
7. Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the
machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil cir-
cuit. The oil cleaning equipment is used to
remove the ultra fine (about 3 m) particles that
the filter built in the hydraulic equipment can-
not remove, so it is an extremely effective
device.
12V140E-3 Series 19
Handling of connectors newly used for engines 1

a Mainly, following engines are object for follow- 2. Pull lock type (PACKARD-2)
ing connectors. q 107 – 170, 12V140 engine
q 107E-1 q Various temperature sensors
q 114E-3 Example)
q 125E-5 Intake air temperature sensor in
q 140E-5 intake manifold: TIM
q 170E-5 Fuel temperature sensor: TFUEL
q 12V140E-3 Oil temperature sensor: TOIL
Coolant temperature sensor: TWTR,
1. Slide lock type etc.
(FRAMATOME-3, FRAMATOME-2) Disconnect the connector by pulling lock
q 107 – 170, 12V140 engines (B) (on the wiring harness side) of connec-
q Various pressure sensors and NE tor (2) outward.
speed sensor
Examples)
Intake air pressure in intake manifold:
PIM (125, 170, 12V140 engines)
Oil pressure sensor: POIL
(125, 170, 12V140 engines)
Oil pressure switch
(107, 114 engines)
Ne speed sensor of flywheel housing:
NE (107 – 170, 12V140 engines)
Ambient pressure sensor: PAMB
(125, 170, 12V140 engines)
Disconnect connector (1) according to the fol-

lowing procedure.
1) Slide lock (L1) to the right.
2) While pressing lock (L2), pull out connec-
tor (1) toward you.
a Even if lock (L2) is pressed, connec-
tor (1) cannot be pulled out toward
you, if part A does not float. In this
case, float part A with a small screw-
driver while press lock (L2), and then
pull out connector (1) toward you.
20 12V140E-3 Series
3. Push lock type

q 107, 114 engines
Example)
Fuel pressure sensor in common rail
(BOSCH-03)
Disconnect connector (3) according to the fol-

lowing procedure.
1) While pressing lock (C), pull out connector
(3) in the direction of the arrow.
q 114 engine
q 107, 114 engine

Example)
Intake air pressure/temperature sensor in
intake manifold
(SUMITOMO-04)
3) While pressing lock (D), pull out connector

(4) in the direction of the arrow.
q 107 engine
a If the lock is on the underside, use

flat-head screwdriver [1] since you
cannot insert your fingers.
2) While pressing up lock (C) of the connec-
tor with flat-head screwdriver [1], pull out
connector (3) in the direction of the arrow.
12V140E-3 Series 21
q 125 – 170, 12V140 engine 4. Turn-housing type (Round green connector)

4) While pressing lock (E) of the connector, q 140 engine
pullout connector (5) in the direction of the Example)
arrow. Intake air pressure sensor in intake mani-
fold (CANNON-04): PIM etc.
Example)
Fuel pressure in common rail: PFUEL etc. 1) Disconnect connector (6) according to the
(AMP-3) following procedure.
1] Turn housing (H1) in the direction of
the arrow.
a When connector is unlocked,
housing (H1) becomes heavy to
turn.
2] Pull out housing (H1) in the direction
of the arrow.
a Housing (H1) is left on the wiring har-
ness side.
Example)
Injection pressure control valve of fuel
supply pump: PCV (SUMITOMO-2)
2) Connect the connector according to the

following procedure.
1] Insert the connector to the end, while
setting its groove.
2] Turn housing (H1) in the direction of
the arrow until it “clicks”.
Example)
Speed sensor of fuel supply pump:
G (SUMITOMO-3)
a Pull the connector straight up.
22 12V140E-3 Series
How to read electric wire code 1

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 sym-
bols. The electric wire code is helpful in understanding the electric circuit diagram.
Example: AEX 0.85 L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nomi-
nal No. of 0.85
Indicates color of wire by color code.
Color codes are shown in Table 3.
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 indi-
cated.)
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)
Using
Sym-
Type Material temperature Example of use
bol
range (°C)
Low-voltage Conduc- Annealed copper for elec-
General wiring
wire for AV tor tric appliance
(Nominal No. 5 and above)
automobile Insulator Soft polyvinyl chloride
Thin-cover Conduc- Annealed copper for elec- –30 to +60
low-voltage tor tric appliance General wiring
AVS
wire for (Nominal No. 3 and below)
automobile Insulator Soft polyvinyl chloride
Heat-resis- Conduc- Annealed copper for elec-
General wiring in extremely
tant low-volt- tor tric appliance
AEX –50 to +110 cold district, wiring at high-tem-
age wire for Heat-resistant crosslinked
Insulator perature place
automobile polyethylene
12V140E-3 Series 23
2. Dimensions
(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5
Number of
strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32
eter of strand
Conductor
Sectional
0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
area (mm2)
d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0
AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 –
Cov-
AV Standard – – – – – – – 4.6
er D
AEX Standard 2.0 2.2 2.7 3.0 3.1 – 3.8 4.6
Nominal No. 8 15 20 30 40 50 60 85 100

Number of
strands/Diam- 50/0.45 84/0.45 41/0.80 70/0.80 85/0.80 108/0.80 127/0.80 169/0.80 217/0.80
eter of strand
Conductor
Sectional
7.95 13.36 20.61 35.19 42.73 54.29 63.84 84.96 109.1
area (mm2)
d (approx.) 3.7 4.8 6.0 8.0 8.6 9.8 10.4 12.0 13.6
AVS Standard – – – – – – – – –
Cov-
AV Standard 5.5 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
er D
AEX Standard 5.3 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
“f” of nominal No. denotes flexible”.
24 12V140E-3 Series
3. Color codes table
(Table 3)
Color Code Color of wire Color Code Color of wire
B Black LgW Light green & White
Br Brown LgY Light green & Yellow
BrB Brown & Black LR Blue & Red
BrR Brown & Red LW Blue & White
BrW Brown & White LY Blue & Yellow
BrY Brown & Yellow O Orange
Ch Charcoal P Pink
Dg Dark green R Red
G Green RB Red & Black
GB Green & Black RG Red & Green
GL Green & Blue RL Red & Blue
Gr Gray RW Red & White
GR Green & Red RY Red & Yellow
GW Green & White Sb Sky Blue
GY Green & Yellow Y Yellow
L Blue YB Yellow & Black
LB Blue & Black YG Yellow &Green
Lg Light green YL Yellow & Blue
LgB Light green & Black YR Yellow & Red
LgR Light green & Red YW Yellow & White
Remarks: In a color code consisting of 2 colors, the first color is the color of the background and
the second color is the color of the marking.
Example: “GW” means that the background is Green and marking is White.
4. Types of circuits and color codes
(Table 4)
Type of wire AVS or AV AEX
Charge R WG – – – – R –
Ground B – – – – – B –
Start R – – – – – R –
Light RW RB RY RG RL – D –
Instrument Y YR YB YG YL YW Y Gr
Signal G GW GR GY GB GL G Br
L LW LR LY LB – L –
Type of
Br BrW BrR BrY BrB – – –
circuit
Lg LgR LgY LgB LgW – – –
O – – – – – – –
Others Gr – – – – – – –
P – – – – – – –
Sb – – – – – – –
Dg – – – – – – –
Ch – – – – – – –
12V140E-3 Series 25
Precautions when carrying out operation 1

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

q If the coolant contains antifreeze, dispose of it correctly.
q After disconnecting hoses or tubes, cover them or fit plugs to prevent dirt or dust from entering.
q When draining oil, prepare a container of adequate size to catch the oil.
q Confirm the match marks showing the installation position, and make match marks in the necessary
places before removal to prevent any mistake when assembling.
q To prevent any excessive force from being applied to the wiring, always hold the connectors when dis-
connecting the connectors. Do not pull the wires.
q Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.
q Check the number and thickness of the shims, and keep in a safe place.
q When raising components, be sure to use lifting equipment of ample strength.
q When using forcing screws to remove any components, tighten the forcing screws uniformly in turn.
q Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from
entering after removal.
a Precautions when handling piping during disassembly
Fit the following plugs into the piping after disconnecting it during disassembly operations.
1) Face seal type hoses and tubes
Nominal
Plug (nut end) Sleeve nut (elbow end)
number
02 07376-70210 02789-20210
03 07376-70315 02789-20315
04 07376-70422 02789-20422
05 07376-70522 02789-20522
06 07376-70628 02789-20628
10 07376-71034 07221-21034
12 07376-71234 07221-21234
2) Split flange type hoses and tubes

Nominal
Flange (hose end) Sleeve head (tube end) Split flange
number
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500
3) If the part is not under hydraulic pressure, the following corks can be used.
Nominal Dimensions
Part Number
number D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34
26 12V140E-3 Series
2. Precautions when carrying out installation work

q Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
q Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any.
q Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
q Bend the cotter pins and lock plates securely.
q When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded por-
tion with 2 – 3 drops of adhesive.
q When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is
no dirt or damage, then coat uniformly with gasket sealant.
q Clean all parts, and correct any damage, dents, burrs, or rust.
q Coat rotating parts and sliding parts with engine oil.
q When press fitting parts, coat the surface with anti-friction compound (LM-P).
q After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
q When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
securely.
q When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align
the direction of the hook.
q When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
a When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other
hydraulic equipment removed for repair, always bleed the air as follows:
1) Start the engine and run at low idle.
2) Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times, stopping the
cylinder 100 mm from the end of its stroke.
3) Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke.
4) After doing this, run the engine at normal speed.
a When using the machine for the first time after repair or long storage, follow the same procedure.
3. Precautions when completing the operation

1) Refilling with coolant, oil and grease
q If the coolant has been drained, tighten the drain valve, and add coolant to the specified level.
Run the engine to circulate the coolant through the system. Then check the coolant level
again.
q If the hydraulic equipment has been removed and installed again, add engine oil to the speci-
fied level. Run the engine to circulate the oil through the system. Then check the oil level
again.
q If the piping or hydraulic equipment have been removed, always bleed the air from the system
after reassembling the parts.
a For details, see Testing and adjusting, “Bleeding air”.
q Add the specified amount of grease (molybdenum disulphide grease) to the work equipment
parts.
2) Checking cylinder head and manifolds for looseness
Check the cylinder head and intake and exhaust manifold for looseness.
If any part is loosened, retighten it.
q For the tightening torque, see “Disassembly and assembly”.
3) Checking engine piping for damage and looseness
Intake and exhaust system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for air
suction and exhaust gas leakage.
If any part is loosened or damaged, retighten or repair it.
Cooling system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for
coolant leakage.
Fuel system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel
leakage.
12V140E-3 Series 27
4) Checking muffler and exhaust pipe for damage and looseness

1] Visually check the muffler, exhaust pipe and their mounting parts for a crack and damage.
If any part is damaged, replace it.
2] Check the mounting bolts and nuts of the muffler, exhaust pipe and their mounting parts for
looseness.
If any bolt or nut is loosened, retighten it.
5) Checking muffler function
Check the muffler for abnormal sound and sound different from that of a new muffler.
If any abnormal sound is heard, repair the muffler, referring to “Troubleshooting” and “Disassembly
and assembly”.
28 12V140E-3 Series
Method of disassembling and connecting push-pull type coupler 1

k Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to
release the residual pressure from the hydraulic tank.
k Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly, prepare an oil receiving container.
Type 1
1. Disconnection
1) Hold adapter (1) and push hose joint (2)
into mating adapter (3). (Fig. 1)
a The adapter can be pushed in about
3.5 mm.
a Do not hold rubber cap portion (4).
2) After hose joint (2) is pushed into adapter
(3), press rubber cap portion (4) against
adapter (3) until it clicks. (Fig. 2)
3) Hold hose adapter (1) or hose (5) and pull
it out. (Fig. 3)
a Since some hydraulic oil flows out,
prepare an oil receiving container.
2. Connection
1) Hold hose adapter (1) or hose (5) and
insert it in mating adapter (3), aligning
them with each other. (Fig. 4)
a Do not hold rubber cap portion (4).
2) After inserting the hose in the mating
adapter perfectly, pull it back to check its
connecting condition. (Fig. 5)
a When the hose is pulled back, the
rubber cap portion moves toward the
hose about 3.5 mm. This does not
indicate abnormality, however.
12V140E-3 Series 29
Type 2
1. Disconnection
1) Hold the tightening portion and push body
(7) straight until sliding prevention ring (6)
contacts contact surface (a) of the hexag-
onal portion at the male end. (Fig. 6)
2) While holding the condition of Step 1), turn
lever (8) to the right (clockwise). (Fig. 7)
3) While holding the condition of Steps 1)
and 2), pull out whole body (7) to discon-
nect it. (Fig. 8)
2. Connection
q Hold the tightening portion and push body
contacts contact surface (a) of the hexag-
30 12V140E-3 Series
Type 3
1. Disconnection
1) Hold the tightening portion and push body
contacts contact surface (b) of the hexag-
2) While holding the condition of Step 1),
push cover (10) straight until it contacts
contact surface (b) of the hexagonal por-
tion at the male end. (Fig. 11)
3) While holding the condition of Steps 1)
and 2), pull out whole body (9) to discon-
nect it. (Fig. 12)
2. Connection
q Hold the tightening portion and push body
(9) straight until the sliding prevention ring
contacts contact surface (b) of the hexag-
12V140E-3 Series 31
Standard tightening torque table 1

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 Width across flats Tightening torque

mm mm Nm kgm
6 10 11.8 – 14.7 1.2 – 1.5
8 13 27 – 34 2.8 – 3.5
10 17 59 – 74 6.0 – 7.5
12 19 98 – 123 10.0 – 12.5
14 22 153 – 190 15.5 – 19.5
16 24 235 – 285 23.5 – 29.5
18 27 320 – 400 33.0 – 41.0
20 30 455 – 565 46.5 – 58.0
22 32 610 – 765 62.5 – 78.0
24 36 785 – 980 80.0 – 100.0
27 41 1,150 – 1,440 118 – 147
30 46 1,520 – 1,910 155 – 195
33 50 1,960 – 2,450 200 – 250
36 55 2,450 – 3,040 250 – 310
39 60 2,890 – 3,630 295 – 370
a The following table corresponds to the bolts in Fig. B.

mm mm Nm kgm
6 10 5.9 – 9.8 0.6 – 1.0
8 13 13.7 – 23.5 1.4 – 2.4
10 14 34.3 – 46.1 3.5 – 4.7
12 27 74.5 – 90.2 7.6 – 9.2
a Fig. A a Fig. B
32 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 mm Nm kgm
10 14 59 – 74 6.0 – 7.5
12 17 98 – 123 10.0 – 12.5
16 22 235 – 285 23.5 – 29.5
3. 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.
Thread diameter Width across flats Tightening torque Nm {kgm}

Nominal No.
mm mm Range Target
02 14 35 – 63 { 3.5 – 6.5} 44 { 4.5}
03,04 20 Varies depending 84 – 132 { 8.5 – 13.5} 103 {10.5}
05,06 24 on type of connec- 128 – 186 {13.0 – 19.0} 157 {16.0}
10,12 33 tor. 363 – 480 {37.0 – 49.0} 422 {43.0}
14 42 746 – 1,010 {76.0 – 103} 883 {90.0}
4. 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 Thread diameter Width across flats Tightening torque Nm {kgm}

No. mm mm Range Target
08 8 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}
10 10 17 9.81 – 12.74 {1.0 – 1.3} 11.27 {1.15}
12 12 19 14.7 – 19.6 {1.5 – 2.0} 17.64 {1.8}
14 14 22 19.6 – 24.5 {2.0 – 2.5} 22.54 {2.3}
16 16 24 24.5 – 34.3 {2.5 – 3.5} 29.4 {3.0}
18 18 27 34.3 – 44.1 {3.5 – 4.5} 39.2 {4.0}
20 20 30 44.1 – 53.9 {4.5 – 5.5} 49.0 {5.0}
24 24 32 58.8 – 78.4 {6.0 – 8.0} 68.6 {7.0}
30 30 32 93.1 – 122.5 { 9.5 – 12.5} 107.8 {11.0}
33 33 – 107.8 – 147.0 {11.0 – 15.0} 127.4 {13.0}
36 36 36 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5}
42 42 – 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5}
52 52 – 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0}
12V140E-3 Series 33
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.
Tightening torque Nm {kgm} Taper seal Face seal

Nominal Width Nominal No. -
Thread diame-
No. of across Thread size Number of
Range Target ter (mm) (Ref-
hose flats (mm) threads, type of
erence)
thread
34 – 54 { 3.5 – 5.5} – 9/16-18UN 14.3
02 19 44 { 4.5}
34 – 63 { 3.5 – 6.5} 14 – –
22 54 – 93 { 5.5 – 9.5} 74 { 7.5} – 11/16-16UN 17.5
03
24 59 – 98 { 6.0 – 10.0} 78 { 8.0} 18 – –
04 27 84 – 132 { 8.5 – 13.5} 103 {10.5} 22 13/16-16UN 20.6
05 32 128 – 186 {13.0 – 19.0} 157 {16.0} 24 1-14UNS 25.4
06 36 177 – 245 {18.0 – 25.0} 216 {22.0} 30 1-3/16-12UN 30.2
(10) 41 177 – 245 {18.0 – 25.0} 216 {22.0} 33 – –
(12) 46 197 – 294 {20.0 – 30.0} 245 {25.0} 36 – –
(14) 55 246 – 343 {25.0 – 35.0} 294 {30.0} 42 – –
6. Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts)
a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114
engine series to the torque below.
Tightening torque
Thread size
Bolts and nuts
mm Nm kgm
6 10 ± 2 1.02 ± 0.20
8 24 ± 4 2.45 ± 0.41
10 43 ± 6 4.38 ± 0.61
12 77 ± 12 7.85 ± 1.22
14 — —
7. Table of tightening torques for 102, 107 and 114 engine series (Eye joints)
a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine
series to the torque below.
Thread size Tightening torque

mm Nm kgm
6 8±2 0.81 ± 0.20
8 10 ± 2 1.02 ± 0.20
10 12 ± 2 1.22 ± 0.20
12 24 ± 4 2.45 ± 0.41
14 36 ± 5 3.67 ± 0.51
34 12V140E-3 Series
8. Table of tightening torques for 102, 107 and 114 engine series (Taper screws)
a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114
engine series to the torque below.
Thread size Tightening torque

inch Nm kgm
1/16 3±1 0.31 ± 0.10
1/8 8±2 0.81 ± 0.20
1/4 12 ± 2 1.22 ± 0.20
3/8 15 ± 2 1.53 ± 0.20
1/2 24 ± 4 2.45 ± 0.41
3/4 36 ± 5 3.67 ± 0.51
1 60 ± 9 6.12 ± 0.92
12V140E-3 Series 35
Conversion table 1
Method of using the conversion table
The conversion table in this section is provided to enable simple conversion of figures. For details of the
method of using the conversion table, see the example given below.
Example: Method of using the conversion table to convert from millimeters to inches
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 hori-
zontal line from (A).
2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down
from (B).
3) Take the point where the 2 lines cross as (C). This point (C) gives the value when converting from
millimeters to inches. Therefore, 55 mm = 2.165 inches.
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 (B)

1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
(C)
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
(A)
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
36 12V140E-3 Series
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
Liters to U.S. Gallons

1 l = 0.2642 U.S.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
12V140E-3 Series 37
Liters to U.K. Gallons

1 l = 0.21997 U.K.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.699 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
kgm to ft.lb
1 kgm = 7.233 ft.lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
38 12V140E-3 Series
kg/cm2 to lb/in2
1 kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1,010 1,024 1,038 1,053 1,067 1,081 1,095 1,109 1,124
80 1,138 1,152 1,166 1,181 1,195 1,209 1,223 1,237 1,252 1,266
90 1,280 1,294 1,309 1,323 1,337 1,351 1,365 1,380 1,394 1,408
100 1,422 1,437 1,451 1,465 1,479 1,493 1,508 1,522 1,536 1,550
110 1,565 1,579 1,593 1,607 1,621 1,636 1,650 1,664 1,678 1,693
120 1,707 1,721 1,735 1,749 1,764 1,778 1,792 1,806 1,821 1,835
130 1,849 1,863 1,877 1,892 1,906 1,920 1,934 1,949 1,963 1,977
140 1,991 2,005 2,020 2,034 2,048 2,062 2,077 2,091 2,105 2,119
150 2,134 2,148 2,162 2,176 2,190 2,205 2,219 2,233 2,247 2,262
160 2,276 2,290 2,304 2,318 2,333 2,347 2,361 2,375 2,389 2,404
170 2,418 2,432 2,446 2,460 2,475 2,489 2,503 2,518 2,532 2,546
180 2,560 2,574 2,589 2,603 2,617 2,631 2,646 2,660 2,674 2,688
190 2,702 2,717 2,731 2,745 2,759 2,773 2,788 2,802 2,816 2,830
200 2,845 2,859 2,873 2,887 2,901 2,916 2,930 2,944 2,958 2,973
210 2,987 3,001 3,015 3,030 3,044 3,058 3,072 3,086 3,101 3,115
220 3,129 3,143 3,158 3,172 3,186 3,200 3,214 3,229 3,243 3,257
230 3,271 3,286 3,300 3,314 3,328 3,343 3,357 3,371 3,385 3,399
240 3,414 3,428 3,442 3,456 3,470 3,485 3,499 3,513 3,527 3,542
12V140E-3 Series 39
Temperature
Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centi-
grade temperature reading or vice versa is to enter the accompanying table in the center (boldface column)
of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahren-
heit temperatures and read the corresponding Centigrade temperature in the column at the left.
When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centi-
grade values, and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
–40.4 –40 –40.0 –11.7 11 51.8 7.8 46 114.8 27.2 81 177.8
–37.2 –35 –31.0 –11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
–34.4 –30 –22.0 –10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
–31.7 –25 –13.0 –10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
–28.9 –20 –4.0 –9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
–28.3 –19 –2.2 –8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

–27.8 –18 –0.4 –8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
–27.2 –17 1.4 –7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
–26.7 –16 3.2 –7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
–26.1 –15 5.0 –6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
–25.6 –14 6.8 –6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

–25.0 –13 8.6 –5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
–24.4 –12 10.4 –5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
–23.9 –11 12.2 –4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
–23.3 –10 14.0 –3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
–22.8 –9 15.8 –3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

–22.2 –8 17.6 –2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
–21.7 –7 19.4 –2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
–21.1 –6 21.2 –1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
–20.6 –5 23.0 –1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
–20.0 –4 24.8 –0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

–19.4 –3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
–18.9 –2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
–18.3 –1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
–17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
–17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

–16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
–16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
–15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
–15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
–14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

–13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
–13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
–12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
–12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
40 12V140E-3 Series
12V140E-3 Series 41

© 2007 KOMATSU
All Rights Reserved
42 12V140E-3 Series
SEN00303-02
ENGINE 1SHOP MANUAL
12V140E-3 Series
01 Specification 1
Specification and technical data
Outline.................................................................................................................................................. 2
Specifications ....................................................................................................................................... 4
General view ...................................................................................................................................... 10
Weight table ....................................................................................................................................... 19
Engine performance curves ............................................................................................................... 20
12V140E-3 Series 1
SEN00303-02 01 Specification
Outline 1
1. Applicable machine
Engine Engine serial No. Machine model

D475A-5E0 Bulldozer
HD785-7 Dump truck
SAA12V140E-3
PC2000-8 Hydraulic excavator
WA800-3E0, WA900-3E0 Wheel loader
2 12V140E-3 Series
2. Outline of engine
q The 12V140E-3 engine is a high-performance are added: mounting of a recirculation port for
and high-efficiency engine which provides low surging control at the compressor side and a
fuel consumption, low noise, and improved design to improve efficiency of the turbine. As
exhaust gas color, and improved acceleration a result, high performance is attained in a wide
performance, and it cleared the strict exhaust range from the low-speed range to the high-
gas regulation (USA: EPA regulations for speed range, and high performance and low
2006). Accordingly, this newly developed fuel consumption are also obtained.
engine is suitable as a power source of
c o n s t r u c t i o n m a c h i n e r y, a n d i n d u s t r i a l 5) The piston cooling nozzle of 12V140-1 is
machinery used for various purposes. reviewed in regard to oil flow. As a result,
durability of the piston is improved and
q It is the successor of conventional 12V140-1 temperature of the rear surface of the piston is
engine which introduces various kinds of new reduced to prevent deterioration of the piston
technologies while adhering fundamentally to due to exposure of lubricating oil on the
the configuration of V12-cylinder, water- surface to high temperature. Since the high-
cooled, direct injection, and 4-stroke diesel pressure fuel injection system controlled
engine. electronically is employed, less-soot
combustion is attained and the draining
1) High-pressure fuel injection system controlled interval of the oil is lengthened.
electronically
The conventional one is a jerk in-line fuel 6) The high-pressure pump to create high
injection pump-based engine mechanically pressure in the common rail injection system is
controlled by a governor, while in all series of one-third of the conventional in-line fuel
the new one, an electronic control system- and injection pump, and in addition, it is connected
high-pressure injection system-based common compact to the timing gear case as a flange
rail injection system is adopted. This system mount rather than a saddle mount. As a result,
provides high pressure fuel of 118 MPa {1,200 sound radiation is reduced to provide low
kg/cm2} level from the low-speed range to the noise.
high-speed range. In addition, it can control
the form of injection most properly by the 7) Capacity of the lubrication pump is increased
electronic control system according to the by 10% over the conventional engine to
speed and load. As a result, clean exhaust contribute to the reliability and durability.
g a s , c l e a n e x h a u s t g a s c o l o r, l o w f u e l
consumption, and low noise are attained 8) The air cleaner is changed from the
simultaneously. conventional end surface seal type to radial
seal type to prevent the entry of dust due to
2) It adopts a re-entrant piston combustion deformation into the clean side. In addition, the
chamber which has been used since air cleaner clogging sensor for 5 clogging level
introduction into the 6D140E-2 engine and also indication is provided to inform users of a
uses a quality cast iron piston with less thermal precise cleaning time.
expansion and shaker cooling gallery. As a
result, clean exhaust gas, clean exhaust gas 9) A high performance and high efficiency
color, and low fuel consumption are attained combination filter is adopted as an oil filter, and
simultaneously, and also high durability and a filter system to collect small dirts as well as
high reliability are also obtained. large dirts is adopted for all specifications.
3) It also provides a higher compression ratio 10) The fuel filter system includes a high efficiency
than the conventional one to improve main filter and prefilter as standard features to
combustion efficiency and reduce the white allow use of low-grade fuel in the market
exhaust smoke when starting the engine in (corresponding to NAS13 level). In addition,
cold climate areas. In addition, by using the the delivery of the priming pump used to
above-mentioned high-pressure fuel injection replace the filters is increased for higher
system controlled electronically and setting the serviceability.
injection characteristics most properly to
improve the startability and reduce the white 11) In addition, since the engine controller is
exhaust smoke when the temperature is low. mounted on the engine and equipped with the
automatic high-altitude compensation function,
4) It is equipped with an improved turbocharger it can be operated at high altitude without
KOMATSU KTR110 of which high reliability replacing the controller. As a result, the
and high performance have been proven in the serviceability is improved.
12V140-1 engine. The following improvements
12V140E-3 Series 3
Specifications 1
Engine name SAA12V140E-3
Machine model D475A-5E0
Number of cylinders – Bore × Stroke mm 12 – 140 x 165

Total displacement l {cc} 30.5 {30,480}
Firing order — R1-L1-R5-L5-R3-L3-R6-L6-R2-L2-R4-L4
Overall length mm 1,772
Dimensions
Overall width mm 1,532.5
Overall height (excluding exhaust pipe) mm 2,171.5
Overall height (including exhaust pipe) mm —
671 {899}/2,000
Rated output kW{HP}/rpm
(Gross)
3,825 {390}/1,400
Max. torque Nm{kgm}/rpm
(Gross)
Performance
No-load max. speed

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

rpm 620 + 80/0
(Low idle speed)
g/kW·h
Fuel consumption ratio at rated output 210 {156.7}
{g/HP·h}
Dry weight kg 3,600
Fuel supply pump — DENSO ECD-U2

Governor — Electronic control type
Quantity of lubricating oil (Refill capacity) l 138 (130)

Quantity of coolant l 86 (For only engine)
Alternator — 24V, 90A

Starting motor — 24V, 7.5kW x 2
Battery — 12V, 170Ah x 4
Turbocharger — KOMATSU KTR110L x 2

Air compressor — —
Others — With air-cooled aftercooler
4 12V140E-3 Series
Machine model HD785-7

Overall length mm 2,046.5

Dimensions
895 {1,200}/1,900
(Gross)
5,076 {518}/1,350
(Gross)
Performance
No-load max. speed

rpm 2,250 ± 25
(High idle speed)
No-load min. speed

rpm 650 ± 20
(Low idle speed)
g/kW·h
Fuel consumption ratio at rated output 207 {154}
{g/HP·h}
Dry weight kg 3,600



12V140E-3 Series 5
Machine model PC2000-8

Overall length mm 1,807.7

Dimensions
728 {976}/1,800
(Gross)
4,488 {458}/1,350
(Gross)
Performance
No-load max. speed

rpm 1,980 ± 25
(High idle speed)
No-load min. speed

rpm 825 ± 25
(Low idle speed)
g/kW·h
{g/HP·h}
Dry weight kg 3,600


Starting motor — 24V, 11kW x 2

6 12V140E-3 Series
Machine model WA800-3E0


Dimensions
Overall height (excluding exhaust pipe) mm 1,940
636 {853}/2,000
(Gross)
3,802 {388}/1,400
(Gross)
Performance
No-load max. speed

rpm 2,200 (+10/-20)
(High idle speed)
No-load min. speed

rpm 680 + 50/0
(Low idle speed)
g/kW·h
{g/HP·h}
Dry weight kg 3,600



12V140E-3 Series 7


Dimensions
Overall height (excluding exhaust pipe) mm 1,940
672 {900}/2,050
(Gross)
4,159 {424}/1,300
(Gross)
Performance
No-load max. speed

rpm 2,200 + 10/0
(High idle speed)
No-load min. speed

rpm 680 + 50/0
(Low idle speed)
g/kW·h
{g/HP·h}
Dry weight kg 3,600



8 12V140E-3 Series
12V140E-3 Series 9
General view 1
SAA12V140E-3 (Left side view of engine)
Machine model: D475A-5E0
a The shape is subject to machine models.
1. Center of crankshaft
2. Rear face of flywheel housing
10 12V140E-3 Series
SAA12V140E-3 (Front view of engine)

Machine model: D475A-5E0
2. Center of engine
12V140E-3 Series 11

Machine model: HD785-7
12 12V140E-3 Series

Machine model: HD785-7
2. Center of engine
12V140E-3 Series 13

Machine model: PC2000-8
14 12V140E-3 Series

Machine model: PC2000-8
2. Center of engine
12V140E-3 Series 15

Machine model: WA800-3E0, WA900-3E0
16 12V140E-3 Series

Machine model: WA800-3E0, WA900-3E0
2. Center of engine
12V140E-3 Series 17
Dimensions table
Unit: mm
Dimensions of each part
Engine Machine model
A B C D E F G
D475A-5E0 287 1,582 1,772 2,171.5 726 507 507
HD785-7 230 1,585.8 2,046.5 1,745.3 715 210 210
SAA12V140E-3
PC2000-8 353 1,574.8 1,807.7 1,734.3 726 600 600
WA800-3E0, WA900-3E0 230 1,585.8 2,123 1,940 715.2 210 210
a These dimensions are given for reference when the engine is set on a test bench.
18 12V140E-3 Series
Weight table 1
Unit: kg
No. Item Main parts SAA12V140E-3
1 Turbocharger KOMATSU KTR110L (Water-cooled) 25 x 2
Cylinder head, valve,
2 Cylinder head assembly 22.5 x 12
rocker arm, valve spring
Cylinder block, bearing cap,
3 Cylinder block assembly 810
cylinder liner
4 Gear case 72
5 Gear case 52
D475A-5E0
HD785-7
88.4
6 Oil pan Integral-type WA800-3E0,
WA900-3E0
PC2000-8 89.2
D475A-5E0 127.6
HD785-7 72.5
7 Flywheel assembly Flywheel, ring gear PC2000-8
WA800-3E0, 88.7
WA900-3E0
8 Flywheel housing assembly 133.5
9 Crankshaft assembly Crankshaft, crank gear 210
Camshaft, cam gear L 20
10 Camshaft assembly
thrust plate R 20
Piston, piston ring,
11 Piston and connecting rod assembly 10.5 x 12
piston pin, connecting rod
12 Oil pump 9
13 Fuel supply pump 13
14 Water pump 22
15 Alternator 24V, 90A 12
D475A-5E0
HD785-7
24V, 7.5kW
16 Starting motor WA800-3E0, 18 x 2
WA900-3E0
24V, 11kW PC2000-8
D475A-5E0 35 x 2
HD785-7 33 x 2
17 Aftercooler assembly PC2000-8 43 x 2
WA800-3E0,
40 x 2
WA900-3E0
12V140E-3 Series 19
Engine performance curves 1
Engine Engine serial No. Machine model Page

D475A-5E0 21
HD785-7 22
SAA12V140E-3 PC2000-8 23
WA800-3E0 24
WA900-3E0 25
20 12V140E-3 Series
SAA12V140E-3 (Machine model: D475A-5E0)
Rated output: 671 kW {899 HP}/2,000 rpm (Gross)

Max. torque: 3,825 Nm {390 kgm}/1,400 rpm (Gross)
12V140E-3 Series 21
SAA12V140E-3 (Machine model: HD785-7)
Rated output: 895 kW {1,200 HP}/1,900 rpm (Gross)

22 12V140E-3 Series
SAA12V140E-3 (Machine model: PC2000-8)

12V140E-3 Series 23
SAA12V140E-3 (Machine model: WA800-3E0)

24 12V140E-3 Series
SAA12V140E-3 (Machine model: WA900-3E0)

12V140E-3 Series 25

© 2007 KOMATSU
All Rights Reserved
26 12V140E-3 Series
SEN00307-02
ENGINE 1SHOP MANUAL
12V140E-3 Series
10 Structure, function and

maintenance standard 1
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 1
SEN00307-02 10 Structure, function and maintenance standard
Crankshaft........................................................................................................................................... 26
Camshaft............................................................................................................................................. 28
Cam follower, push rod ....................................................................................................................... 29
Piston, piston ring, and piston pin ....................................................................................................... 30
Connecting rod.................................................................................................................................... 32
Flywheel and flywheel housing ........................................................................................................... 34
Vibration damper................................................................................................................................. 35
Timing gear ......................................................................................................................................... 36
Valve system ....................................................................................................................................... 38
Valve and valve guide ......................................................................................................................... 40
Rocker arm and shaft.......................................................................................................................... 42
Crosshead and guide.......................................................................................................................... 43
2 12V140E-3 Series
Air intake and exhaust system 1

Air intake and exhaust unit 1
(Left side view of engine)
a The illustration shows the engine for D475A-5E0.
A: Air intake (From air cleaner) 1. Electrical intake air heater

B: Air intake (To air-cooled aftercooler) 2. Air intake manifold
C: Air intake (From air-cooled aftercooler) 3. Muffler
D: Exhaust gas
4. Turbocharger
12V140E-3 Series 3
Air cleaner 1
ERB type
[Air cleaner of automatic exhaust gas discharge type (Radial seal type)]
A: Air inlet
B: To turbocharger (Intake air)
C: To muffler (Dust)
1. Pre-cleaner
2. Air cleaner casing
3. Outer element
4. Inner element
Method of discharging Number of

Engine Machine model Type
dust from pre-cleaner elements
D475A-5E0
PC2000-8 Komaclone, multi-cyclone Automatic discharge 1 Inner element,
SAA12V140E-3
WA800-3E0, (ERB type) (Exhaust ejector) 1 Outer element
WA900-3E0
4 12V140E-3 Series
FRG type
[Air cleaner of cyclone pack type with evacuator valve (Radial seal type)]
1. Inlet 6. Evacuator valve

2. Outlet 7. Dust pan
3. Guide vane 8. Guide plate (Sleeve)
4. Primary element 9. Body
5. Safety element 10. Element
Number of
Engine Machine model Type Evacuator valve
elements
1 Inner element,
SAA12V140E-3 HD785-7 FRG (Radial seal type) Automatic discharge
1 Outer element
Structure Operation
q The size of the body is reduced from the con- q Air containing dust is sucked in vertically
ventional type without changing the diameter through inlet (1) and the dust is separated by
of the element. the centrifugal effect of guide vane (3).
q Since the inlet is set in the tangential direction, q More than 99.9% of the dust is removed by pri-
air is given sufficient centrifugal force by the mary element (4) and clean air is sucked in the
simple spiral guide vane, not by the guide engine through safety element (5) and outlet
plate. (2).
q The dust and water separated by guide vane
(3) swirl along the inside wall of body (9) and
enter evacuator valve (6) and then are dis-
charged out automatically.
12V140E-3 Series 5
Turbocharger 1
Water-cooled type
Type: KTR110L
6 12V140E-3 Series
A: Intake air inlet

B: Intake air outlet
C: Exhaust gas inlet
D: Exhaust gas outlet
E: Oil inlet
F: Oil outlet
G: Coolant
1. Blower housing
2. V-band
3. Diffuser plate
4. Center housing
5. Shroud
6. Turbine housing
7. Blower impeller
8. Seal ring
9. Thrust metal
10. Journal bearing
11. Seal ring
12. Turbine impeller
Specifications
Model: KOMATSU KTR110L (Water-cooled)
Overall length: 308 mm
Overall width: 305 mm
Overall height: 287 mm
Weight: 25 kg
12V140E-3 Series 7
Model: KTR110L
a The illustration shows the water-cooled turbocharger.
8 12V140E-3 Series
Unit: mm
No. Check item Criteria Remedy
Standard Repair limit Replace thrust
1 End play (Play in axial direction)
0.08 – 0.13 0.18 parts
Replace
2 Radial play (Play in radial direction) 0.43 – 0.68 0.84
bearing parts
Clearance between blower housing Replace
3 Clearance limit (Min.): 0.14
and impeller bearing parts
12V140E-3 Series 9
Turbocharger mounting

A: Intake air inlet

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

A: Air inlet (From turbocharger)

B: Air outlet (To air intake manifold)
1. Upper tank
2. Core
3. Lower tank
4. Fin
5. Tube
12V140E-3 Series 11
Muffler 1

A: Exhaust gas outlet
1. Turbocharger
2. Muffler
12 12V140E-3 Series
12V140E-3 Series 13
Engine unit 1
Cylinder head 1
A: Air intake C: To fuel tank

B: Exhaust gas D: To radiator
1. Spill pipe 6. Cylinder head bolt

2. Air bleeding pipe 7. Injector connector
3. Cylinder head 8. Injector assembly
4. Head cover 9. Injector holder mounting bolt
5. Head cover bolt 10. Injector holder retainer
14 12V140E-3 Series
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
a Tighten the cylinder head mounting bolt in order of [1] to [7].
Unit: mm
Strain of cylinder head Tolerance Repair limit Repair by grind-
1
mounting face 0 – 0.06 0.09 ing or replace
Engine Standard Replace nozzle
2 Projection of nozzle
SAA12V140E-3 2.3 – 2.9 or gasket
Bolt No. Procedure Target (Nm{kgm}) Range (Nm{kgm})
Tightening torque for cyl- Tighten in order
inder head mounting bolt 1st phase 147 {15} 137 – 157 {14 – 16} shown above. If
3 (Apply molybdenum dis- [1] – [6] 2nd phase 216 {22} 284 – 294 {29 – 30} there are 5 punch
ulfied or engine oil to 3rd phase Retighten by 90° 90(+30/0)° marks, replace
threaded part) the bolt.
[7] — 68.6 {7} 58.8 – 73.5 {6 – 7.5}
Tightening torque for Target (Nm {kgm}) Range (Nm {kgm})
4 injector holder mounting
bolt 66.7 {6.8} 58.8 – 73.5 {6 – 7.5}
Tightening torque for fuel Retighten

5 37.3 {3.8} 34.3 – 40.2 {3.5 – 4.1}
injection pipe
Tightening torque for
6 32.4 {3.3} 29.4 – 34.3 {3.0 – 3.5}
head cover mounting bolt
a Do not use a cylinder head mounting bolt more than 5 times.

Each time the bolt is used, make a punch mark on its head.
16 12V140E-3 Series
12V140E-3 Series 17
Cylinder block 1
1. Cylinder block
2. Cylinder liner
3. Clevis seal
4. O-ring
5. O-ring
6. Main bearing metal cap bolt
7. Main bearing metal cap
8. Main bearing metal
9. Piston cooling nozzle
10. Thrust bearing metal
18 12V140E-3 Series
Specifications Liner ring

Upper: Clevis seal (Ethylene-propylene rubber)
Cylinder block Middle: O-ring (Ethylene-propylene rubber)
Crankshaft: 7 bearings Lower: O-ring (Silicon rubber)
Camshaft: High cam type, 7 bearings
Main bearing cap bolt: Plastic-region tightening
Piston cooling
With piston cooling nozzle
Cylinder liner
Wet type
Machining on inside: Plateau honing and
Tufftride
12V140E-3 Series 19
20 12V140E-3 Series
Unit: mm
Tolerance Repair limit Repair by
Strain of cylinder head mount-
1 grinding or
ing face 0 – 0.09 0.135 replace
Standard size Tolerance Replace or cor-
Inside diameter of main bear-
+0.025 rect main bear-
ing metal mounting hole 157
–0.010 ing metal cap
Surface roughness of main
10S or less
bearing metal mounting hole Correct
2
Roundness of mounting hole Repair limit: 0.005
–0.050
No.4 only 4.5
Thickness of main –0.060
bearing metal Other –0.065
4.5
than No.4 –0.075
Replace bear-
Inside diameter of Standard size Tolerance Repair limit
ing metal
main bearing metal +0.175
No.4 only 148 148.23
3 (When tightening +0.130
bolt with specified Other +0.145
torque) 148 148.20
than No.4 +0.100
Inside diameter of cam bush- Correct or
4 +0.025
ing mounting hole 69 replace block
+0.025
Standard size Tolerance Repair limit
Inside diameter of cam bush- Replace
5 +0.040
ing 65 65.15 cam bushing
+0.025
Procedure Target (Nm {kgm}) Range (Nm {kgm})
Tightening torque for main
bearing cap 1st time 284 {29} 270 – 299{27.5 – 30.5}
6
(Apply engine oil to threaded 2nd time 569 {58} 559 – 579{57.0 – 59.0}
portion and washer) Retighten
3rd time Retighten by 90° 90(+30/0)°
Tightening torque for oil pan
— — 65.7 {6.7} 58.8 – 73.6 {6 – 7.5}
mounting bolt
Level difference between
— under surfaces of cylinder Repair limit: 0.14 Reassemble
block and front cover
a Do not use a main cap mounting bolt more than 5 times.

12V140E-3 Series 21
Cylinder liner 1
Unit: mm
1 Projection of cylinder liner Repair limit: 0.07 – 0.15 Replace cylinder liner
or cylinder block
Rank Standard size Tolerance Repair limit
+0.020
Inside diameter of cylinder S 140 +0.020 140.12
liner
2 L 140 +0.040 140.14
+0.021 Replace cylinder liner
(Refilling is allowed
Roundness of cylinder liner Repair limit: 0.02 only for L)
Cylindricality of cylinder liner Repair limit: 0.02
Outside diameter of cylinder
liner (Counterbore portion) 170.2 –0.10
3 –0.10
Clearance between cylinder
liner and block Standard clearance: 0 – 0.163 Replace cylinder liner
(counterbore portion) or block
Outside diameter of cylinder Standard size Tolerance

liner (Lower portion of coun- +0.090 Replace cylinder liner
terbore) 161.2
4 +0.050
Interference of cylinder liner Standard interference Interference limit
and block (Lower portion of Replace or correct cyl-
counterbore) 0.02 – 0.12 0.02 or above inder liner or block
Outside diameter of cylinder Replace cylinder liner
liner (at O-ring) 158 –0.024
5 –0.049
Clearance between cylinder
liner and block (O-ring por- Standard clearance: 0.024 – 0.094 Replace cylinder liner
tion) or block
22 12V140E-3 Series
12V140E-3 Series 23
Main moving parts 1
1. Piston (FCD piston) 10. Connecting rod bearing metal

2. Piston pin 11. Crank gear (Number of teeth: 45)
3. Connecting rod bushing 12. Crankshaft
4. Top ring 13. Vibration damper
5. Second ring
6. Oil ring
7. Connecting rod cap bolt
8. Connecting rod
(Front of engine: for L bank, rear: for R bank)
9. Connecting rod cap
24 12V140E-3 Series
Specifications Piston rings
Crankshaft
Closed die forging
Journal, filet: Induction hardening
Piston
Special thin ductile cast iron
FCD piston
Re-entrant piston
Connecting rod
Closed die forging
With lubricating oil hole
Cap bolt is screw type, installed by plastic-region Top ring (1) : Double-side keystone, inner cut,
tightening. ba rr e l f ac e, har d ch ro mi um-
plated
Second ring (2) : Double-side keystone, inner cut,
taper face, hard chromium-plated
Oil ring (3) : M-shaped steel, with coil expander,
nitrided surface
12V140E-3 Series 25
Crankshaft 1
26 12V140E-3 Series
Unit: mm
Standard value Repair limit Replace thrust bearing
1 End play metal or use oversize
0.140 – 0.315 0.50 metal
S.T.D. 148 147.98
Outside diameter of main 0.25 U.S. 147.75 147.73
journal –0.020 Use undersize journal
0.50 U.S. 147.50 147.48
–0.020 or replace
0.75 U.S. 147.25 147.23
2
1.00 U.S. 147.00 146.98
Roundness of main journal Repair limit: 0.010
Journal Standard clearance Clearance limit
Use undersize journal
Clearance of main journal No.4 only 0.130 – 0.195 0.25
or replace main metal
Other than No.4 0.100 – 0.165 0.22
Correct surface rough-
Surface roughness of main
0.8S (Surface roughness of R portion: 3.2S) ness of crankshaft
journal
journal
S.T.D. 100 89.88
Outside diameter of crank 0.25 U.S. 99.75 89.63
pin journal –0.020 Use undersize journal
0.50 U.S. 89.50 89.38
–0.020 or replace
0.75 U.S. 99.25 89.13
3 1.00 U.S. 99.00 88.88
Roundness of pin journal Repair limit: 0.010
Clearance of Standard clearance Clearance limit
crank pin journal 0.046 – 0.116 0.17 Replace connecting
Surface roughness of rod bearing metal
0.8S (Surface roughness of R portion: 3.2S)
crankpin journal
Standard Repair limit
Coaxiality of all main journals:
0.09
4 Bend of crankshaft 0.09 or less Replace
Coaxiality of adjacent main journals:
0.05
0.05 or less
Tightening torque for 1st time 74 {7.5} 54 – 93 {5.5 – 9.5}
5
adapter mounting bolt 2nd time 245 {25} 226 – 265 {23 – 27}
Retighten
3rd time 745 {76} 725 – 765 {74 – 78}
6 108 ± 10 Nm {11 ± 1.0 kgm}
damper mounting bolt
12V140E-3 Series 27
Camshaft 1
Unit: mm
1 End play Replace thrust plate
0.1 – 0.25 0.36
Outside diameter of cam-
–0.016 Replace
shaft journal 65
2 –0.036
Clearance of Standard clearance Clearance limit
Replace cam bushing
camshaft journal 0.016 – 0.096 0.15
3 Bend of camshaft Repair limit: 0.04 (Overall swing of indicator)
Cam Standard size Tolerance Repair limit
Replace
4 Height of cam Intake 55.48 ± 0.1 55.08
Exhaust 55.75 ± 0.1 55.35
28 12V140E-3 Series
Cam follower, push rod 1
Unit: mm
Outside diameter of cam
follower shaft –0.021
1 22 –0.034 21.92
Inside diameter of cam +0.021

follower shaft hole 22 +0.021 22.07
Outside diameter of cam +0.05

2 roller 31.7 +0.02 31.50
Inside diameter of cam +0.038

roller 12.7 +0.013 12.78
Replace
3
Outside diameter of cam
roller pin 12.63 ± 0.006 12.56

4 Diameter of push rod
ball end –0.20
12.7 –0.20
Diameter of push rod –0.20
5 socket end 13.4 –0.20
6 Bend of push rod Repair limit: 0.3 (Overall swing of indicator)
12V140E-3 Series 29
Piston, piston ring, and piston pin 1
30 12V140E-3 Series
Unit: mm
–0.120
S 140 139.830
1 Outside diameter of piston –0.135 Replace piston
–0.105
L 140 139.845
–0.120
No. Measuring point Standard size Tolerance
–0.015
2 No.1 ring 2.9
–0.035
Replace piston
Thickness of piston ring –0.010
3 No.2 ring 2.41 ring
–0.035
–0.010
4 Oil ring 4
–0.030
2 No.1 ring
Check with group wear gauge
3 No.2 ring
Width of piston ring groove Replace piston
+0.040
4 Oil ring 4
+0.025
No. Measuring point Standard clearance Clearance limit
2 No.1 ring Replace piston
2 – 4 Clearance between piston Check with group wear gauge
ring and piston ring groove 3 No.2 ring or piston ring
4 Oil ring 0.035 – 0.060 0.14
0.42 – 0.57
(Tension:
2 No.1 ring 2.0
16.5 – 23.5 N
{1.68 – 2.40 kg})
0.65 – 0.80
No.2 ring Replace piston
(Tension:
Closed gap of piston ring 3 (Identification 1.5 ring or cylinder
16.2 – 24.2 N
2RN white mark) liner
{1.65 – 2.47 kg})
0.30 – 0.50
(Tension:
4 Oil ring 1.0
70.1 – 94.6 N
{7.15 – 9.65 kg})
Outside diameter of piston Replace piston
pin –0.006 pin
52
–0.006
5 Inside diameter of piston pin +0.045
52 Replace piston
hole +0.035
Clearance between piston Standard clearance Clearance limit Replace piston
pin and piston 0.035 – 0.051 0.10 or piston pin
12V140E-3 Series 31
Connecting rod 1
32 12V140E-3 Series
Unit: mm
Standard size Tolerance Repair limit Replace bushing
Inside diameter of connecting
+0.049 (Refilled part is
rod small end bushing 52 52.09
+0.030 semi-finished part)
1
Clearance between connect- Standard clearance Clearance limit
Replace bushing
ing rod small end bushing and
0.030 – 0.055 0.11 or piston pin
piston pin
Inside diameter of connecting Standard size Tolerance Replace connect-
2 rod small end bushing mount- +0.030 ing rod (Correction
ing hole 57.4 not allowed)
+0.030
Inside diameter of connecting Standard size Tolerance Repair limit
Replace bearing
3 rod large end bearing metal +0.096
100 100.15 metal
(Crankpin journal) +0.046
Inside diameter of connecting +0.026
106 — Replace connect-
rod large end hole –0.004
4 ing rod (Correction
(Without bearing metal, X, Y,
and Z directions) • Tighten connecting rod cap with specified torque and measure not allowed)
Thickness of connecting rod –0.025 Replace bearing

5 3.0 —
bearing metal –0.035 metal
Item Standard Repair limit
Parallelism and twist of con- Parallelism (a) 0 – 0.10 0.15 Replace connect-
6
necting rod Twist (b) 0 – 0.25 0.30 ing rod
Dimensions (c) 340 —
Tightening torque for connect- Procedure Target (Nm {kgm}) Range (Nm {kgm})
ing rod cap mounting bolts 69 – 78
1st time 74 {7.5} Tighten in order
7 (Apply engine oil to seat sur- {7 – 8} shown in figure
face of nut of threaded portion
of bolts) 2nd time Retighten 90° 90(+30/0)°
Inside diameter of Rough-

3.2S
8 connecting rod large ness Replace
end Swell 0.004 (In overall width)
a Do not use a connecting rod cap mounting bolt more than 5 times.
12V140E-3 Series 33
Flywheel and flywheel housing 1
Unit: mm
Facial runout of
1 Repair limit: 0.25
flywheel housing
Radial runout of
2 Repair limit: 0.25 Reassemble
flywheel housing
3 Facial runout of flywheel Repair limit: 0.30
4 Radial runout of flywheel Repair limit: 0.13

flywheel housing mounting 1st time 343 {35} 294 – 392 {30 – 40}
5
bolt (Apply engine oil to
threaded portion) 2nd time 412 {42} 392 – 432 {40 – 44}
Tighten in order
shown in above
1st time 98 {10} 78 – 118 {8 – 12} figure
flywheel mounting bolt
6 2nd time 294 {30} 275 – 314 {28 – 32}
(Apply engine oil to
threaded portion)
3rd time 539 {55} 520 – 559 {53 – 57}
34 12V140E-3 Series
Vibration damper 1
1. Vibration damper
2. Pin (between adapter and vibration damper)
3. Adapter
4. Pin (between adapter and crankshaft)
5. Bolt (between adapter and crankshaft)
6. Bolt (between adapter and vibration damper)
12V140E-3 Series 35
Timing gear 1
36 12V140E-3 Series
Unit: mm
Posi-
Measuring point Standard Repair limit
tion
Crank gear and
a 0.141 – 0.425
right main idler gear (Large)
Right main idler gear (Small) and
b 0.130 – 0.390
right sub idler gear
Right sub idler gear and
c 0.129 – 0.391
right cam gear
Right cam gear and
d 0.085 – 0.492
accessory drive gear
Right main idler gear (Small) and
— Backlash of each gear e 0.051 – 0.469 Replace
right fuel injection pump gear
0.6
Right main idler gear (Large) and
f 0.052 – 0.481
water pump driver gear
Right main idler gear (Large) and
g 0.137 – 0.421
oil pump gear
Crank gear and
h 0.141 – 0.425
left main idler gear (Large)
Left main idler gear (Small) and
j 0.129 – 0.391
left cam gear
Left main idler gear (Small) and
k 0.051 – 0.469
left fuel injection pump gear
Standard Tolerance Standard Clearance
Clearance between main size clearance limit
Shaft Hole
1 idler gear bushing and shaft
(Both right and left banks) –0.016 +0.034 Replace
56 0.025 – 0.063 0.20 bushing
–0.029 +0.009
Clearance between sub –0.016 +0.055
2 56 0.016 – 0.084 0.20
idler gear bushing and shaft –0.029 +0.055
3 End play of main idler gear
0.09 – 0.26 0.4
4 End play of sub idler gear 0.07 – 0.18 0.4 Replace

thrust bearing
End play of fuel injection
5 0.07 – 0.20 0.4
pump drive gear
End play of oil pump drive
6 0.03 – 0.088 0.4
gear
End play of accessory drive
7 0.1 – 0.4 0.4
gear
12V140E-3 Series 37
Valve system 1
38 12V140E-3 Series
1. Cam gear 12. Crosshead adjust- Valve timing

2. Thrust plate ment screw
3. Camshaft 13. Locknut
4. Cam follower 14. Crosshead
5. Cam roller 15. Valve guide
6. Rocker arm shaft 16. Exhaust valve
7. Cam follower shaft 17. Valve spring (Outer)
8. Rocker arm adjust- 18. Valve spring (Inner)
ment screw 19. Spring seat
9. Locknut 20. Valve retainer
10. Push rod 21. Intake valve
11. Rocker arm 22. Cam roller pin
Specifications
Camshaft
Drawn steel bar (Machining)
Journal and cam sections: Induction hardening
12V140E-3 Series 39
Valve and valve guide 1
40 12V140E-3 Series
Unit: mm
Valve Standard size Tolerance Repair limit
Replace valve or
1 Sinking distance of valve Intake 0 ± 0.10 0.70
valve seat
Exhaust 0 ± 0.10 0.70
Valve Standard size Repair limit
2 Thickness of valve lip Intake 2.4 1.9 Replace valve
Exhaust 2.15 1.75
Valve Standard size Tolerance
Correct or replace
3 Valve seat angle Intake 30° ± 15'
valve or valve seat
Exhaust 45° ± 15'
–0.045
Intake 10
Outside diameter of valve –0.060
Replace valve
stem –0.074
Exhaust 10
–0.089
Before head is +0.019
10
press fitted +0.001
Inside diameter of valve Press Not press Replace valve guide
4 guide After head is fitted fitted
press fitted 10 portion portion
+0.008 +0.011
–0.009 –0.009
Valve Standard clearance Clearance limit
Clearance between valve Replace valve or
Intake 0.034 – 0.071 0.22
guide and stem valve guide
Exhaust 0.063 – 0.100 0.24
Bend of valve stem Repair limit: 0.02 (Total runout of indicator, per 100) Replace valve
Standard Tolerance
5 Driving height of valve guide Correct
22.0 ± 0.2
Spring Standard size Repair limit
Free length of valve spring Outer 81.7 —
Inner 72.0 —
Installed Standard installed Allowable installed
Spring
length load (N {kg}) load (N {kg}) Replace valve
6 424.3 ± 21.6 377.3 spring
Installed load of valve spring Outer 51.0
{43.3 ± 2.2} {38.5}
215.6 ± 10.8 192.1
Inner 46.0
{22.0 ± 1.1} {19.6}
Perpendicularity of valve
Repair limit: 2° (Both ends)
spring
12V140E-3 Series 41
Rocker arm and shaft 1
Unit: mm
Outside diameter of rocker Standard size Tolerance Replace rocker arm
arm shaft 32.0 ± 0.0065 shaft
Inside diameter of rocker +0.087
1 32.0 Replace rocker arm
arm bushing +0.035
Clearance between rocker Standard clearance Clearance limit Replace rocker arm
arm shaft and rocker arm 0.0285 – 0.0935 0.13 shaft or rocker arm
Valve Standard Tolerance
Valve clearance
2 Intake 0.35 ± 0.02 Adjust
(When cold)
Exhaust 0.57 ± 0.02
Tightening torque Target (Nm {kgm}) Range (Nm {kgm})
3 for locknut of rocker arm Tighten
adjustment screw 58.8 {6} 52.9 – 64.7 {5.4 – 6.6}
42 12V140E-3 Series
Crosshead and guide 1
Unit: mm
Depth of crosshead stem
1 +0.3
receiver 6.2 6.61
+0.3
Inside diameter of cross- Replace
11.04 ± 0.02 11.17
head
2
Outside diameter of cross- +0.011
11 10.95
head guide +0.011
Projection of crosshead
3 49.0 ± 0.25 — Correct
guide
12V140E-3 Series 43

© 2007 KOMATSU
All Rights Reserved
44 12V140E-3 Series
SEN00309-02
ENGINE 1SHOP MANUAL
12V140E-3 Series
10 Structure, function and

maintenance standard 1
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 1
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...................................................................................................................................... 50
Alternator ............................................................................................................................................ 50
Starting motor...................................................................................................................................... 52
Starting aid .......................................................................................................................................... 54
Engine controller ................................................................................................................................. 55
2 12V140E-3 Series
12V140E-3 Series 3
Lubrication system 1
Lubrication system diagram 1
4 12V140E-3 Series
W: Coolant
1. Oil pan
2. Strainer
3. Oil pump (Triple gear pump)
4. Main relief valve
5. Oil cooler
6. Regulator valve
7. Oil cooler bypass valve
8. Oil filter
9. Oil filter safety valve
10. Main gallery
11. Crankshaft
12. Camshaft
13. Rocker arm
14. Cam follower
15. Intake valve and exhaust valve
16. Piston
18. Timing gear
19. Turbocharger
20. Fuel supply pump
12V140E-3 Series 5
Oil pump 1
A: From oil pan Specifications

B: To oil cooler Oil pump
Type: Gear pump
1. Pump body Revolving speed: Engine speed x 1.67
2. Pump drive gear (Number of teeth: 27)
3. Drive gear
4. Driven gear
5. Pump cover
6 12V140E-3 Series
Oil cooler 1
A: Oil inlet and outlet port (Flow is reversed Specifications

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

2. Cooler element
12V140E-3 Series 7
Oil filter 1
A: Oil inlet port Specifications

B: Oil outlet port Oil filter
Filtration area: 1.62 m2(0.42 m2 x 4)
1. Safety valve Rated flow: 330l/min
2. Filter head
3. Cartridge Safety valve
Cracking pressure: 196 ± 20 kPa {2.0 ± 0.2 kg/cm2}
8 12V140E-3 Series
Main relief valve 1
1. Valve spring Specifications

2. Main relief valve Main relief valve
3. Valve body Cracking pressure:
1,196 ± 49 kPa {12.2 ± 0.5 kg/cm2}
Unit: mm
Tolerance
Standard
Standard size Outside diam- Inside diame-
Clearance between main relief clearance Replace valve or
4 eter of valve ter of body
valve and body body
–0.040 –0.016
33 0.040 – 0.076
–0.060 –0.016
Installed Installed load Allowable load
Free length
5 Main relief valve spring length (N {kg}) (N {kg}) Replace spring
75.8 59.8 621 {63.4} 353 {36}
Cracking pressure of main relief Correct or

6 Standard: 1,196 ± 49 kPa {12.2 ± 0.5 kg/cm2}
valve replace spring
12V140E-3 Series 9
Oil cooler bypass valve and regulator valve 1
A: From main gallery Specifications

B: From oil cooler
C: To oil pan Oil cooler bypass valve
D: To oil filter Cracking pressure (differential pressure):
392 ± 20 kPa {4.0 ± 0.2 kg/cm2}
1. Oil cooler bypass valve
2. Bypass valve spring Regulator valve
3. Regulator valve Cracking pressure: 402 ± 49 kPa {4.1 ± 0.5 kg/cm2}
4. Regulator valve spring
5. Valve body
10 12V140E-3 Series
Unit: mm
Tolerance
Standard
Clearance between regulator clearance Replace valve or
valve and body body
–0.020 +0.033
22 0.020 – 0.074
–0.041 +0.033
Installed Installed load Allowable load
Free length
2 Regulator valve spring length (N {kg}) (N {kg}) Replace spring
111.5 75 136.0 {13.87} 239 {24.4}
Cracking pressure of regulator Correct or

3 Standard: 402 ± 49 kPa {4.1 ± 0.5 kg/cm2}
valve replace spring
Tolerance
Standard
Clearance between oil cooler clearance Replace valve or
bypass valve and body body
–0.020 +0.033
28 0.020 – 0.086
–0.053 +0.033
Installed Installed load Allowable
Free length
5 Oil cooler bypass valve spring length (N {kg}) load Replace spring
125.8 89.8 186 {19} —
Cracking pressure of oil cooler Correct or
6 Standard: 392 ± 20 kPa {4.0 ± 0.2 kg/cm2}
bypass valve replace spring
12V140E-3 Series 11
Fuel system 1
CRI system diagram 1
a CRI is an abbreviation for common rail injection.
12 12V140E-3 Series
1. NE speed sensor
2. Engine controller
3. Injector
4. Fuel tank
5. Pre-fuel filter
6. Main fuel filter
7. Overflow valve
8. Fuel supply pump assembly
9. PCV
10. High-pressure pump
11. Feed pump
12. Relief valve
13. G speed sensor
14. Common rail
15. Flow damper
16. Pressure limiter
17. High-pressure injection pipe
18. Priming pump (Main)
12V140E-3 Series 13
Outline of CRI system 1

Outline 1. Fuel system
q The CRI system checks the condition of the
engine (engine speed, accelerator angle, cool-
ant 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 func-
tion which stops the engine when a certain part
fails and a backup function which continues
the operation by changing the control method
in such a case.
Configuration
q The CRI system is divided by the function into
the fuel system and control system.
q The fuel system distributes the high-pressure

fuel generated by the fuel supply pump to the
cylinders through the common rail.
q The solenoid valve in the injector opens and
closes the nozzle needle valve to start and fin-
ish fuel injection.
14 12V140E-3 Series
2. Control system
q To the ECU (engine control unit), the signals

are sent from the sensors installed to the
machine. Based on the signals, the ECU cal-
culates and controls the energizing timing and
energizing period of the injector to injecta
proper quantity of fuel in proper timing.
q The control system is roughly divided by the
electric parts into the sensors, computer, and
actuators.
12V140E-3 Series 15
Structure and operation of CRI system
q The CRI system consists of fuel supply pump, q If the TWV is turned ON (energized), the fuel
common rail, injector, ECU which controls circuit is changed so that the high-pressure
these 3 units, and sensors. fuel in the control chamber will flow through the
q The fuel supply pump generates fuel pressure orifice. As a result, the needle valve is raised
in the common rail. The fuel pressure is con- to start fuel injection by the nozzle cracking
trolled by the fuel discharge rate of the supply pressure of the high-pressure fuel on the noz-
pump. zle side.
q The fuel discharge rate is controlled by turning q If the TWV is turned OFF (de-energized), the
on and off the PCV (Fuel injection pressure fuel circuit is changed so that the high-pres-
control valve) of the fuel supply pump accord- sure fuel will flow to the control chamber
ing to the electric signals from the ECU. through the orifice. As a result, the needle
q The common rail receives the pressurized fuel valve lowers to finish fuel injection.
from the fuel supply pump and distributes it to q Accordingly, the fuel injection timing and fuel
the cylinders. injection rate are controlled respectively by the
q The fuel pressure is sensed by the common timing to turn on the TWV and the length of the
rail fuel pressure sensor installed to the com- turn-on time of the TWV.
mon rail.
q A feedback control is applied so that the actual
fuel pressure will match to the command pres-
sure set according to the engine speed and the
load on the engine.
q The fuel pressure in the common rail is applied
to the nozzle side of the injector and to the
control chamber through the fuel injection pipe
of each cylinder.
q The injector controls the fuel injection rate and
fuel injection timing by turning ON and OFF the
TWV (2-way solenoid valve).
16 12V140E-3 Series
Structure and operation of component parts 1

1. Fuel supply pump
1. 3-thread type cam 6. No. 2 high-pressure pump

2. Overflow valve 7. Priming pump
3. Drive gear 8. Feed pump
4. No. 1 high-pressure pump 9. Gear for G speed sensor
5. PCV (Fuel injection pressure control valve)
Outline q Since the number of the times of feeding fuel

q The fuel supply pump consists of priming to the common rail is the same as the number
pump (7), feed pump (8), and high-pressure of the times of fuel injection, the common rail
pumps (4) and (6). fuel pressure is smooth and stable.
q The function of the fuel supply pump is to gen- q The fuel fed by high-pressure pumps (4) and
erate common rail fuel pressure by controlling (6) to the common rail is divided as follows.
the fuel discharge rate. q No. 1 high-pressure pump (on the drive gear
side) (4) compensates for drop in the common
Structure rail fuel pressure caused by fuel injection into
q High-pressure pumps (4) and (6) have the the No. 1, 3, and 5 cylinders.
pressure feed systems similar to those of the q No. 2 high-pressure pump (on the feed pump
conventional in-line fuel injection pump and the side) (6) compensates for drop in the common
PCVs (Fuel injection pressure control valves) rail fuel pressure caused by fuel injection into
for each cylinder to control the fuel delivery. the No. 2, 4, and 6 cylinders.
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.
12V140E-3 Series 17
Operation
q (A): The PCV is open when the plunger is in

lowering stroke, through which low-pres-
sure fuel is sucked in the plunger chamber.
q (B): While the PCV is not energized and is open
after the plunger starts the rising stroke, the
sucked fuel is returned through the PCV
without being pressurized.
q (C): If the PCV is energized and closed in the
timing for the necessary delivery, the return
passage is closed and the pressure in the
plunger chamber rises. Accordingly, the
fuel is fed through the delivery valve (check
valve) to the common rail. That is, the
quantity of the fuel corresponding to the
plunger lift after the PCV is closed is deliv-
ery. The delivery is changed and the com-
mon rail fuel pressure is controlled by
changing the opening timing of the PCV.
(pre-stroke of plunger)
q (D): After the cam passes the maximum lift
point, the plunger starts the lowering stroke
and the pressure in it lowers. At this time,
the delivery valve closes to stop feeding the
fuel. Since the PCV is de-energized, it
opens and the low-pressure fuel is sucked
in the plunger chamber, or the state of (A)
starts again.
18 12V140E-3 Series
1) PCV (Fuel injection pressure control 2) Feed pump

valve)
q The feed pump built in the fuel supply pump

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

q The common rail fuel pressure sensor is
installed to the common rail to sense the fuel
pressure.
q This sensor is a semiconductor pressure sen-
sor, which utilizes the phenomenon that the
electric resistance of silicon changes according
to the pressure applied to it.
12V140E-3 Series 21
3. Injector
Outline
q The function of the injector is to inject the high
pressure fuel from the common rail into each
combustion chamber of the engine in the opti-
mum timing, by the optimum quantity, at the
optimum injection rate, and under the optimum
spray condition.
q The TWV (2-way solenoid valve) controls the
start and finish of fuel injection by controlling
the pressure in the control chamber.
q The orifice limits the opening speed of the noz-
zle and controls the fuel injection rate.
q The hydraulic piston transmits the force gener-
ated by the pressure in the control chamber to
the needle valve of the nozzle.
q The nozzle sprays the fuel.
22 12V140E-3 Series
Structure
1. Inlet connector 7. Orifice (in)

2. Terminal 8. Pressure control chamber
3. Upper body 9. Command piston
4. Solenoid 10. Spring
5. Valve body 11. Pressure pin
6. Orifice (out) 12. Nozzle assembly
q The injector consists of the nozzle section, ori-

fice to control the fuel injection rate, hydraulic
piston section, and 2-way solenoid valve sec-
tion.
12V140E-3 Series 23
A: No fuel injection C: Finish of fuel injection

B: Start of fuel injection D: From common rail
1. Nozzle 5. Valve body

2. Control piston 6. Solenoid
3. Orifice (in) 7. Spring
4. Orifice (out) 8. Pressure control chamber
Operation
1) No fuel injection (A) 3) Finish of fuel injection (C)
q While solenoid (6) is not energized, valve body q If solenoid (6) is de-energized, valve body (5)
(5) is pressed down by spring (7). is lowered by spring (7) and the fuel passage is
q Since the high-pressure fuel is applied from closed.
the common rail to pressure control chamber q Since the high-pressure fuel in the common
(8), nozzle (1) is closed and the fuel is not rail is applied to pressure control chamber (8)
injected. suddenly at this time, nozzle (1) is closed
quickly and fuel injection is finished sharply.
2) Start of fuel injection (B)
q If solenoid (6) is energized, valve body (5) is
raised by electromagnetic power to open the
fuel passage.
q Since the fuel in pressure control chamber (8)
flows out through orifices (3) and (4), nozzle
(1) rises and the fuel injection pump starts.
q The fuel injection rate is increased gradually by
the function of orifices (3) and (4).
q Continuing energization to solenoid (6) pro-
vides the maximum fuel injection rate.
24 12V140E-3 Series
Electric circuit diagram
k Since high voltage (65V) is applied to the

wiring harnesses connected to the ECU,
COMMON1 and COMMON2 of ECU, and
TWV#1 – #6 of the injector, take care not to
get an electric shock.
12V140E-3 Series 25
4. Various sensors and relays
1) Fuel temperature sensor 2) NE speed sensor (Crank angle sensor)

q The fuel temperature sensor senses the fuel q If the signal hole made on the flywheel passes
temperature and sends it to the engine control- the sensor, the magnetic line of force changes.
ler. The sensor unit is a thermistor the resis- q If the magnetic line of force changes, the out-
tance of which changes according to the put of the hall element sensor changes linearly
temperature. and it is converted into pulse of 0 - 5 V by the
q The engine controller applies voltage to the wave form shaping circuit in the sensor, and
thermistor and senses the temperature by the then output.
voltage divided by the resistance in the com-
puter and the resistance of the thermistor.
26 12V140E-3 Series
3) Atmospheric pressure sensor 4) Common rail pressure sensor

q This sensor is used to correct altitude.
5) Oil pressure sensor
A: Pressure inlet
B: Mounting screw: M5
Tightening torque:
4.5 ± 0.5 Nm {0.46 ± 0.05 kgm}
q The following graph shows the output charac-
teristics of the atmospheric pressure sensor.
12V140E-3 Series 27
6) Bkup speed sensor (G sensor) 7) Charge pressure sensor

(Cylinder No. sensor) q This sensor is used to sense the charge pres-
q Similarly to the NE speed sensor, this sensor sure (boost pressure).
utilizes the pulses of 0 – 5 V generated by the
change of the magnetic line of force crossing
the sensor unit.
q 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°.
q In addition to the above teeth, one more tooth
is installed. Accordingly, 7 pulses are gener-
ated every 2 revolutions of the engine.
q The standard pulse of the No. 1 cylinder is rec-
ognized by the combination of the NE speed
sensor pulse and Bkup speed sensor pulse.
A: Mounting screw: M6
Tightening torque:
5.5 ± 0.5 Nm {0.56 ± 0.05 kgm}
1. Sensor
2. O-ring
q The following graph shows the output charac-

teristics of the charge pressure sensor.
28 12V140E-3 Series
8) Charge temperature sensor 9) Coolant temperature sensor

q The charge temperature sensor senses the q The coolant temperature sensor senses the
intake air temperature (boost temperature) and coolant temperature and sends it to the engine
sends it to the engine controller. controller.
q The sensor unit is a thermistor the resistance q The sensor unit is a thermistor the resistance
of which changes according to the tempera- of which changes according to the tempera-
ture. The engine controller applies voltage to ture. The engine controller applies voltage to
the thermistor and senses the temperature by the thermistor and senses the temperature by
the voltage divided by the resistance in the the voltage divided by the resistance in the
computer and the resistance of the thermistor. computer and the resistance of the thermistor.
12V140E-3 Series 29
Various controls
30 12V140E-3 Series
q The CRI system controls the fuel injection rate

and fuel injection timing more properly than the
mechanical governor or timer of the conven-
tional fuel injection pump.
q For the control of the system, calculations nec-
essary to the ECU are performed from the sig-
nals sent from the sensors installed to the
engine and machine.
q 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 con-
ventional 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 con-
ventional timer. It controls the fuel injection tim-
ing 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 mea-
suring the fuel pressure by the common rail
fuel pressure sensor and feeding it back to
ECU.
q This function performs pressure feedback con-
trol 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
Fuel piping 1
Left bank

1. Main fuel filter

2. Pre-fuel filter
4. Fuel pipe (From pre-fuel filter)
5. Fuel pipe (To feed pump)
6. Drain pipe
32 12V140E-3 Series
7. PCV 13. Fuel injection pipe (No.6 cylinder)

8. Fuel injection pipe (No.1 cylinder) 14. Common rail
9. Fuel injection pipe (No.2 cylinder) 15. Fuel return pipe
10. Fuel injection pipe (No.3 cylinder) 16. Feed pump
11. Fuel injection pipe (No.4 cylinder) 17. Oil pump (For pump lubricating oil)
12. Fuel injection pipe (No.5 cylinder) 18. High-pressure pump
12V140E-3 Series 33
Right bank

1. Fuel pipe (To feed pump)

2. Fuel pipe (From pre-fuel filter)
34 12V140E-3 Series
4. Fuel injection pipe (No.6 cylinder) 10. PCV

5. Fuel injection pipe (No.5 cylinder) 11. High-pressure pump
6. Fuel injection pipe (No.4 cylinder) 12. Feed pump
7. Fuel injection pipe (No.3 cylinder) 13. Oil pump (For pump lubricating oil)
8. Fuel injection pipe (No.2 cylinder) 14. Fuel return pipe
9. Fuel injection pipe (No.1 cylinder) 15. Common rail
12V140E-3 Series 35
Front view of engine
Rear view of engine
36 12V140E-3 Series
Fuel filter 1
A: Fuel inlet
B: Fuel outlet
1. Air bleeding plug

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

2. Filter head
3. Cartridge
Specifications
Filtration area: 2.12 m2
38 12V140E-3 Series
Priming pump 1
1. Spring 9. Valve stopper

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

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

B: From power train cooler (Coolant)
C: To power train oil cooler (Coolant)
1. Oil cooler
3. Water pump
12V140E-3 Series 43
Thermostat 1
A: To radiator
B: To water pump (When bypassing)
C: To thermostat
2. Thermostat
3. Cylinder block
Specifications
Valve cracking temperature: 76.5 ± 2°C
Temperature at full opening: 90°C
Lift at full opening: Min. 10 mm
Q'ty: 3
Unit: mm
Lift of thermostat at full Min. 10 mm (Before checking, leave it in water tank of 90°C for 4
opening – 5 minutes)
2 Move valve in fully open condition (in water tank of 90°C) to water Replace
Opening/Closing of
tank of 71°C and keep it for 4 -–5 minutes.
thermostat
Valve must fully close.
44 12V140E-3 Series
Corrosion resistor 1
A: Coolant inlet Specifications

B: Coolant outlet Corrosion resistor
Filtration area: 0.373 m2x 2
1. Head Quantity of anti-corrosion agent: 1,000 g x 2
2. Element case (Cartridge)
3. Inhibitor (Solid anti-corrosion agent)
4. Valve
12V140E-3 Series 45
Corrosion resistor mounting
1. Tube (To radiator)

2. Tube (From thermostat housing)
3. Corrosion resistor head
4. Corrosion resistor cartridge
46 12V140E-3 Series
Cooling fan drive 1

Mounting (Adjustment bolt type)
SAA12V140E-3 (HD785-7)
1. Crankshaft pulley
2. Fan belt
3. Tension pulley
4. Adjustment bolt
5. Tension pulley bracket
6. Fan pulley
7. Fan
Outside diameter of pulley

Unit: mm
Direction of wind
Engine Machine model Crankshaft pulley Tension pulley Fan pulley
from fan
HD785-7 182 154 398 Suck
SAA12V140E-3
WA800-3E0, WA900-3E0 182 154 367 Blow out
12V140E-3 Series 47
Tension pulley
SAA12V140E-3 (HD785-7, WA800-3E0, WA900-3E0)
1. Tension shaft
2. Spring
3. Roller bearing
4. Tension bracket
5. Spacer
6. Tension pulley (outside diameter: 154 mm)
7. Ball bearing
8. Oil seal
9. Grease fitting
10. Grease fitting
48 12V140E-3 Series
(For D475A-5E0, PC2000-8)
The cooling fan is hydraulic motor-driven. For more information, refer to the shop
manual for the machine body.
12V140E-3 Series 49
Electrical equipment 1
Alternator 1
Alternator with built-in regulator (Open type, 90A)
1. Alternator 6. Internal connection diagram

2. Alternator pulley 6A. Field coil
3. Terminal B 6B. Initial excitation resistor
4. Terminal R 6C. Regulator
5. Terminal E
Pulley
Specifica- Outside Weight
Engine Machine model Type Number
tions diameter (kg)
of stages
(mm)
D475A-5E0
HD785-7 Open type (brushless) manu-
SAA12V140E-3 24V, 90A 2 95 19
PC2000-8 factured by NIKKO DENKI
WA800-3E0, WA900-3E0
50 12V140E-3 Series
Alternator mounting
a: Outside diameter of accessory pulley: 167 mm
1. Adjustment bolt
2. Alternator pulley
3. Alternator
4. Alternator drive belt
5. Accessory pulley
12V140E-3 Series 51
Starting motor 1
For 7.5 kW
E: To chassis ground
R: To alternator terminal R
S: To starting switch terminal C
1. Pinion gear 6. Safety relay

2. Starting motor assembly 7. External connection diagram
3. Magnetic switch (2-pole connector type)
4. Terminal B 7A. Safety relay section
5. Terminal C 7B. Starting motor section
Number
Specifica- Weight Type of
Engine Machine model Type of pinion
tions (kg) connector
teeth
D475A-5E0 Water-resistant, oil-resistant
SAA12V140E-3 HD785-7 type manufactured by NIKKO 24V, 7.5 kW 11 18 DT
WA800-3E0, WA900-3E0 DENKI
52 12V140E-3 Series
For 11 kW
E: To chassis ground
R: To alternator terminal R
S: To starting switch terminal C
1. Pinion gear 7. External connection diagram

2. Starting motor assembly (2-pole connector type)
3. Magnetic switch 7A. Safety relay section
4. Terminal B 7B. Starting motor section
5. Terminal C 8. Jump start prohibition label
6. Safety relay 9. Jump start prevention cover
Number
Specifica- Weight Type of
Engine Machine model Type of pinion
tions (kg) connector
teeth
Water-resistant, oil-resistant type
SAA12V140E-3 PC2000-8 24V, 11 kW 11 18 DT
manufactured by NIKKO DENKI
12V140E-3 Series 53
Starting aid 1
Electric heater
1. Body Specifications
2. Heater coil Type of heater: Electrical intake air heater
3. Terminal Rated voltage: 22 V (DC)
4. Connection diagram Load current: 175 A
54 12V140E-3 Series
Engine controller 1
Features
Mounting of engine controller on engine
q Since the engine controller is mounted on the engine, the operator can service it easily in the field.
q Vibrations are damped by the vibration-proof rubber.
Unified specifications of engine controller

q Engine controller CM850 developed by the cooperation between KOMATSU and CUMMINS is
employed.
12V140E-3 Series 55

© 2007 KOMATSU
All Rights Reserved
56 12V140E-3 Series
SEN00311-03
ENGINE 1SHOP MANUAL
12V140E-3 Series
20 Standard value table 1

Standard service value table
Standard service value table ........................................................................................................................... 2
Standard service value table for testing, adjusting, and troubleshooting ............................................. 2
Running-in standard and performance test standard ........................................................................... 7
12V140E-3 Series 1
SEN00311-03 20 Standard value table
Standard service value table 1

Standard service value table for testing, adjusting, and troubleshooting1
Engine SAA12V140E-3
Category
Standard value Service limit

Item Measurement conditions Unit
for new machine value
Max. speed at no load rpm 2,150 (+25/-50) 2,150 (+25/-50)

Performance
Speed
Min. speed at no load rpm 660 ± 40 660 ± 40
Necessary At 0°C (without starting aid) rpm Min. 110 —
speed for
starting At –20°C (with starting aid) rpm Min. 100 —
Air intake kPa Max. 3.73 7.47

Whole speed range
resistance {mmH2O} {Max. 380} {762}
Air boost kPa Min. 126.66
At rated output —
pressure {mmHg} {Min. 950}
Air intake and exhaust system
Exhaust kPa
At rated output — —
pressure {mmHg}
Exhaust
Whole speed range (20°C ) °C Max. 680 750
temperature
Bosch
At sudden acceleration (Low to High) Max. 4.5 5.5
index
Exhaust gas Bosch
At rated output Max. 1.0 2.0
color index
Bosch
At high idle Max. 1.0 2.0
index
Intake valve mm 0.35 ± 0.02 0.35 ± 0.02
Valve clearance
Exhaust valve mm 0.57 ± 0.02 0.57 ± 0.02
Compression Engine oil temperature: 40 – 60°C MPa Min. 4.1 2.8
pressure Engine speed: 200 – 250 rpm {kg/cm2} {Min. 42} {29}
Body
Blow-by At rated output kPa Max. 2.94 5.88

pressure Engine coolant temperature: Min. 70°C {mmH2O} {Max. 300} {600}
At rated output SAE0W30E0S MPa 0.29 – 0.44 0.2
Lubrication system
Engine oil temperature: Min. 80°C SAE5W40E0S {kg/cm2} {3.0 – 4.5} {2.0}
Oil pressure SAE10W30DH
At low idle SAE15W40DH MPa Min. 0.08 0.04
Engine oil temperature: Min. 80°C SAE30DH {kg/cm2} {Min. 0.8} {0.4}
Oil temperature Whole speed range (Oil in oil pan) °C 90 – 110 120
Ratio to fuel consumption at continuous rated
Oil consumption % 0.15 0.3
output
Function of
Cooling system
kPa
radiator pres- Cracking pressure (Differential pressure) — —
{kg/cm2}
sure valve
Hydraulically Hydraulically
Fan speed At rated speed rpm driven on driven on
machine side machine side
Alternator belt
— Deflection under finger pressure of 59 N {6 kg} mm 20 20
tension
2 12V140E-3 Series
Engine SAA12V140E-3
Category

Max. speed at no load rpm 2,250 ± 25 2,250 ± 25

Performance
Speed
speed for

Whole speed range
At rated output —
pressure {mmHg} {Min. 1,250}
Exhaust kPa
pressure {mmHg}
Exhaust
temperature
Bosch
index
Exhaust gas Bosch
color index
Bosch
index
Intake valve mm 0.35 ± 0.02 0.35 ± 0.02
Valve clearance
Exhaust valve mm 0.57 ± 0.02 0.57 ± 0.02
Body

Lubrication system
output
Function of
Cooling system
kPa
{kg/cm2}
sure valve
Fan speed At rated speed rpm 860 860
Alternator belt
tension
12V140E-3 Series 3
Engine SAA12V140E-3
Category

Max. speed at no load rpm 1,980 ± 25 1,980 ± 25

Performance
Speed
speed for

Whole speed range
At rated output —
Exhaust kPa
pressure {mmHg}
Exhaust
temperature
Bosch
index
Exhaust gas Bosch
color index
Bosch
index
Intake valve mm 0.35 ± 0.02 0.35 ± 0.02
Valve clearance
Exhaust valve mm 0.57 ± 0.02 0.57 ± 0.02
Body

Lubrication system
output
Function of
Cooling system
kPa
{kg/cm2}
sure valve
Hydraulically Hydraulically
Fan speed At rated speed rpm driven on driven on
machine side machine side
Alternator belt
tension
4 12V140E-3 Series
Engine SAA12V140E-3
Category


Performance
Speed
Min. speed at no load rpm 680 (+50/0) 680 (+50/0)
speed for

Whole speed range
At rated output —
Exhaust kPa
pressure {mmHg}
Exhaust
temperature
Bosch
index
Exhaust gas Bosch
color index
Bosch
index
Intake valve mm 0.35 ± 0.02 0.35 ± 0.02
Valve clearance
Exhaust valve mm 0.57 ± 0.02 0.57 ± 0.02
Body

Lubrication system
output
Function of
Cooling system
kPa
{kg/cm2}
sure valve
Fan speed At rated speed rpm 980 980
Alternator belt
tension
12V140E-3 Series 5
Engine SAA12V140E-3
Category


Performance
Speed
Min. speed at no load rpm 680 (+50/0) 680 (+50/0)
speed for

Whole speed range
At rated output —
pressure {mmHg} {Min. 1,000}
Exhaust kPa
pressure {mmHg}
Exhaust
temperature
Bosch
index
Exhaust gas Bosch
color index
Bosch
index
Intake valve mm 0.35 ± 0.02 0.35 ± 0.02
Valve clearance
Exhaust valve mm 0.57 ± 0.02 0.57 ± 0.02
Body

Lubrication system
output
Function of
Cooling system
kPa
{kg/cm2}
sure valve
Fan speed At rated speed rpm 1,005 1,005
Alternator belt
tension
6 12V140E-3 Series
Running-in standard and performance test standard 1

Running-in standard
Engine SAA12V140E-3
Procedure
Item
1 2 3 4 5 6
Running time min. 5 15 5 5 20 10
Speed rpm 660 1,000 1,250 1,550 1,800 2,000
Dynamometer load N {kg} 0 {0} 568 {58} 1,127 {115} 2,254 {230} 3,381 {345} 4,508 {460}
Output kW {HP} 0 {0} 43 {57} 106 {142} 263 {352} 457 {612} 677 {907}
a This table shows the values when the fan is not installed.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Performance test standard
Engine SAA12V140E-3
Max. speed at Min. speed at
Test item Rated output Max. torque
no load no load
Specification value 671 kW/2,000 rpm 3,825 Nm/1,400 rpm
— 2,150(+25/-50)rpm 660 ± 40 rpm
(Gross value) {899 HP/2,000 rpm} {390 kgm/1,400 rpm}
Speed rpm 2,000 ± 5 1,300 – 1,500 — —
N 4,341 – 4,596 5,174 – 5,498
Dynamometer load — —
{kg} {443 – 469} {528 – 561}
kW 651 – 691
Output (Gross value) — — —
{HP} {873 – 926}
Nm 3,704 – 3,940
Torque (Gross value) — — —
{kgm} {378 – 402}
Fuel consumption sec/1,000cc Min. 19.5 — — —
Coolant temperature °C 70 – 90 70 – 90 70 – 90 70 – 90
Lubricating oil
°C 90 – 110 90 – 110 90 – 110 90 – 110
temperature
Lubricating oil MPa 0.34 – 0.49 Min. 0.08
— —
pressure {kg/cm2} {3.0 – 4.5} {Min. 0.8}
Exhaust temperature °C Max. 650 Max. 680 — —
a This table shows the standard values obtained by using the JIS correction coefficients.
a Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.
a This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
a Use ASTM No.1 or No. 2 diesel fuel as fuel.
a Use SAE15W-40 as lubricating oil.
a Aftercooler outlet temperature must not exceed 50°C.
12V140E-3 Series 7
Running-in standard
Engine SAA12V140E-3
Procedure
Item
1 2 3 4 5 6
Speed rpm 650 1,000 1,250 1,550 1,800 1,900
Output kW {HP} 0 {0} 59 {79} 147 {197} 365 {489} 635 {852} 894 {1,200}
Engine SAA12V140E-3
no load no load
— 2,250 ± 25 rpm 650 ± 20 rpm
(Gross value) {1,200 HP/1,900 rpm} {518 kgm/1,350 rpm}
Speed rpm 1,900 ± 5 1,300 – 1,400 — —
N 6,086 – 6,468 6,870 – 7,311
{kg} {621 – 660} {701 – 746}
kW 868 – 922
{HP} {1,160 – 1,240}
Nm 4,920 – 5,233
{kgm} {502 – 534}
Lubricating oil
°C 90 – 110 90 – 110 90 – 110 90 – 110
temperature
— —
8 12V140E-3 Series
Running-in standard
Engine SAA12V140E-3
Procedure
Item
1 2 3 4 5 6
Speed rpm 825 1,000 1,250 1,550 1,800 1,800
Output kW {HP} 0 {0} 51 {68} 127 {171} 313 {420} 546 {733} 728 {976}
Engine SAA12V140E-3
no load no load
— 1,980 ± 25 rpm 825 ± 25 rpm
Speed rpm 1,800 ± 5 1,300 – 1,400 — —
N 4,341 – 4,596 6,076 – 6,380
{kg} {534 – 567} {620 – 659}
kW 706 – 750
{HP} {947 – 1,010}
Nm 4,351 – 4,626
{kgm} {444 – 472}
Lubricating oil
°C 90 – 110 90 – 110 90 – 110 90 – 110
temperature
— —
12V140E-3 Series 9
Running-in standard
Engine SAA12V140E-3
Procedure
Item
1 2 3 4 5 6
Speed rpm 680 1,000 1,250 1,550 1,800 2,000
Output kW {HP} 0 {0} 40 {53} 99 {133} 245 {328} 427 {572} 633 {848}
Engine SAA12V140E-3
no load no load
Specification value 636 kW/2,000 rpm 3,802 Nm/1,400 rpm 2,200 (+10/-20)
— 680 (+50/0) rpm
(Gross value) {853 HP/2,000 rpm} {388 kgm/1,400 rpm} rpm
Speed rpm 2,000 ± 5 1,350 – 1,450 — —
N 4,116 – 4,371 5,155 – 5,468
{kg} {420 – 446} {526 – 558}
kW 617 – 655
{HP} {827 – 879}
Nm 3,685 – 3,920
{kgm} {376 – 400}
Lubricating oil
°C 90 – 110 90 – 110 90 – 110 90 – 110
temperature
— —
10 12V140E-3 Series
Running-in standard
Engine SAA12V140E-3
Procedure
Item
1 2 3 4 5 6
Speed rpm 680 1,000 1,250 1,550 1,800 2,050
Output kW {HP} 0 {0} 41 {55} 102 {137} 254 {341} 442 {593} 671 {899}
Engine SAA12V140E-3
no load no load
— 2,200(+10/-20)rpm 680(+50/0)rpm
Speed rpm 2,050 ± 5 1,250 – 1,350 — —
N 4,234 – 4,488 5,625 – 5,978
{kg} {432 – 458} {574 – 610}
kW 652 – 691
{HP} {874 – 927}
Nm 4,028 – 4,283
{kgm} {411 – 437}
Lubricating oil
°C 90 – 110 90 – 110 90 – 110 90 – 110
temperature
— —
12V140E-3 Series 11

© 2007 KOMATSU
All Rights Reserved
12 12V140E-3 Series
SEN00313-00
ENGINE 1SHOP MANUAL

2
3
12V140E-3 Series
30 Testing and adjusting 1

Testing and adjusting
Testing and adjusting ...................................................................................................................................... 3
Testing and adjusting tools list ............................................................................................................. 3
Testing air boost pressure .................................................................................................................... 5
Testing exhaust temperature................................................................................................................ 6
Adjusting valve clearance .................................................................................................................... 7
Testing compression pressure ............................................................................................................. 9
Testing blow-by pressure ....................................................................................................................11
Measuring blow-by pressure .............................................................................................................. 12
Testing oil pressure ............................................................................................................................ 13
Handling fuel system parts ................................................................................................................. 14
Releasing residual pressure in fuel system........................................................................................ 14
Testing fuel pressure .......................................................................................................................... 15
Reduced cylinder mode operation ..................................................................................................... 16
No-injection cranking.......................................................................................................................... 16
Testing leakage-from pressure limiter and return rate from injector................................................... 17
Bleeding air from fuel circuit (for D475A-5) ........................................................................................ 20
12V140E-3 Series 1
SEN00313-00 30 Testing and adjusting
Bleeding air from fuel circuit (for PC2000) ......................................................................................... 23

Testing fuel system for leakage .......................................................................................................... 25
Adjusting speed sensor ...................................................................................................................... 26
Testing and adjusting alternator belt tension ...................................................................................... 26
Handling controller high-voltage circuit .............................................................................................. 27
2 12V140E-3 Series
Testing and adjusting 1

Testing and adjusting tools list 1
Sym-
Q'ty
Testing/Adjusting item Part No. Part name Remarks
bol
Testing air boost 799-201-2202 Boost gauge kit 1 -101 – 200 kPa {-760 – 1,500 mmHg}
A
pressure 799-401-2220 Hose 1
Testing exhaust
B 799-101-1502 Digital thermometer 1 - 99.9 – 1,299°C
temperature
Commercially Intake: 0.35 mm
Adjusting valve clearance C Thickness gauge 1
available Exhaust: 0.57 mm
1 795-502-1590 Compression gauge 1 0 – 6.9 MPa {0 – 70 kg/cm2}
Testing compression
D 795-471-1310 Adapter 1
pressure 2 For 140E-3, 5
6261-71-6150 Gasket 1
1 799-201-1590 Gauge 1 0 – 10 kPa {0 – 1,000 mmH2O}
2 799-201-1450 Adapter 2
Testing blow-by pressure E
3 799-201-1511 Nozzle 2
4 799-201-1571 Tube 1
Pressure gauge: 2.5, 6, 40, 60 MPa
799-101-5002 Hydraulic tester 1
1 {25.5, 61.2, 408, 612 kg/cm2}
Testing oil pressure F
799-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {612 kg/cm2}
2 799-401-2320 Gauge 1 Pressure gauge: 1 MPa {10 kg/cm2}
Pressure gauge: 2.5, 6, 40, 60 MPa
799-101-5002 Hydraulic tester 1
1 {25.5, 61.2, 408, 612 kg/cm2}
799-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {612 kg/cm2}
Testing fuel pressure G 2 (Setting) Adapter 1 8 x 1.25 (male) – PT1/8 (female)
799-101-5220 Nipple (10 x 1.25 mm) 1
3 Size: 10 x 1.25 mm
07002-11023 O-ring 1
4 799-401-2320 Gauge 1 Pressure gauge: 1 MPa {10 kg/cm2}
1 6151-51-8490 Spacer 1 ø 14
2 6141-71-1710 Joint 1 ø 10
Commercially
3 Hose 1 Inside diameter: Approx. 11 mm
available
Testing leakage through Commercially
4 Hose 1 Inside diameter: Approx. 17 mm
pressure limiter and H available
return rate from injector Commercially
5 Measuring cylinder 1
available
Commercially
6 Stopwatch 1
available
7 07376-70315 Plug 1 Size: 03
799-601-4130 T-adapter 1 For Ne sensor
799-601-4330 Socket 1 For G (Bkup) sensor
Controller • sensor 799-601-4240 Socket 1 For atmospheric pressure sensor
J
• Actuator diagnosis 799-601-4250 Socket 1 For boost pressure sensor
799-601-9420 T-adapter 1 For common rail pressure sensor
799-601-4150 T-adapter 1 For oil pressure sensor
12V140E-3 Series 3
Sym-
Q'ty
Testing/Adjusting item Part No. Part name Remarks
bol
For boost temperature sensor
795-799-5540 Socket 1
For intake air sensor
For coolant temperature sensor
795-799-5530 Socket 1 For fuel temperature sensor
Oil temperature sensor
799-601-9430 Socket 1 For supply pump PCV
Controller • sensor 799-601-9020 T-adapter 1 For injector
J
• Actuator diagnosis 799-601-4260 T-adapter 1 For controller (4 - pole)
799-601-4211 T-adapter 1 For controller (50 - pole)
799-601-4220 T-adapter 1 For controller (60 - pole)
799-601-4350 T-box 1 For 60 - pole type
799-601-9320 T-box 1 For 24 - pole type
799-601-9310 Plate 1
4 12V140E-3 Series
Testing air boost pressure 1

a Testing tools for air boost pressure
Symbol Part No. Part name
799-201-2202 Boost gauge kit
A
790-401-2220 Hose
k Be careful not to touch any hot part when

removing or installing the testing tools.
a The test point is subject to machine models.
1. Remove air boost pressure pickup plug ((L1)

on left bank or (R1) on right bank) from the bot-
tom of the air intake connector.
4. After finishing testing, remove the testing tools
and return the removed parts.
2. Install nipple [1] of boost gauge kit A and con-

nect it to gauge [2].
a Example of (L1) on the left bank
3. Run the engine at the rated output and test the

air boost pressure.
a When testing with the engine mounted on
the machine, test on the condition
described in the shop manual for the
machine.
12V140E-3 Series 5
Testing exhaust temperature 1 3. Run the engine and test the exhaust tempera-
ture in the whole speed range.
a Testing tool for exhaust temperature
Symbol Part No. Part name the machine, test on the condition
B 799-101-1502 Digital thermometer described in the shop manual for the
machine.
k Remove and install the testing tools after
the exhaust manifold temperature has low-
ered.
1. Remove an exhaust temperature pickup plug

(1) of the subject section for measuring from
the top of the exhaust manifold.
a Subject section for measuring includes
front left, rear left, front right and rear right
(4 points in total).

2. Install sensor [1] of digital thermometer B and

connect it to thermometer [2].
a Installation example to the rear right-hand
side (RR)
a For engines mounted with the exhaust

temperature sensor, connect temperature
gauge [2] to the sensor on machine.
6 12V140E-3 Series
Adjusting valve clearance 1 5. Hereafter crank the engine similar way in the
firing order. Match the stamped line of the
a Adjusting tool for valve clearance damper to the pointer and adjust the valve
Symbol Part No. Part name clearance of each cylinder.
a Firing order
Commercially
C
available
Clearance gauge R1 – L1 – R5 – L5 – R3 – L3 – R6 – L6 –
R2 – L2 – R4 – L4
Valve clearance adjusting method

1. Remove cylinder head cover.
2. Rotate the crankshaft forward and match

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

screw (5). Insert a clearance gauge C of speci-
fied clearance between the crosshead (4) and
rocker arm (3) and adjust the adjustment
screw to the degree that the clearance gauge
can be moved lightly.
a Valve clearance
Air Intake valve: 0.35 mm, Exhaust valve:
0.57 mm
4. Tighten locknut (6) to secure adjustment

screw.
3 Locknut tightening torque:
52.9 – 64.7 Nm {5.4 – 6.6 kgm}
a After tightening the locknut, check the
valve clearance again.
12V140E-3 Series 7
6. After finishing adjustment, return the removed

parts.
3 Cylinder head cover mounting bolt:
14.7 – 34.3 Nm {1.5 – 3.5 kgm}
8 12V140E-3 Series
Testing compression pressure 1

a Testing tools for compression pressure
Symbol Part No. Part name
1 795-502-1590 Compression gauge
D 795-471-1310 Adapter
2
6261-71-6150 Gasket
k When measuring the compression pres-

sure, take care not to burn yourself on the
exhaust manifold, muffler, etc. or get
caught in a rotating part.
a Measure the compression pressure after the
engine is warmed up.
(Engine oil temperature: 40 – 60°C). 4. Install adapter D2 to the mounting hole on the
injector and compression gauge D1.
1. Remove cylinder head cover (1) of the cylinder a Fit the gasket to the injector end without
to be tested for compression pressure. fail
a Fix the adapter with the injector holder.
3 Holder mounting bolt:
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
a Apply a little amount of engine oil to the
connecting parts of the adapter and gauge
so that air will not leak easily.
5. Install rocker arm assembly (2) and adjust the

valve clearance.
3 Rocker arm assembly mounting bolt:
93 – 103 Nm {9.5 – 10.5 kgm}
a See “Adjusting valve clearance“.
2. Bring the cylinder to be tested to the compres-

sion top dead center and remove rocker arm
assembly (2).
a See “Adjusting valve clearance“.
3. Disconnect fuel high-pressure tube (3) and

injector wiring harness and remove injector (4).
a Disconnect the terminal of the injector wir-
ing harness on the injector side and the
bracket on the rocker housing side and
r e mo v e t he i n j ec to r w i r i ng h a r n es s
(Loosen the 2 terminal nuts alternately)
from the injector. 6. Connect the INSITE (bench test tool) to the
a Pass injector under the fuel path projected engine and set the engine in the no-injection
sideways and pull up the injector through cranking mode.
k If the engine is not set in the no-injec-
wire (Do not pry the injector top up).
tion cranking mode, it will start and will
be dangerous. Accordingly, be sure to
set the engine in this mode.
12V140E-3 Series 9
7. Rotate the engine with the starting motor and

measure the compression pressure.
a Read the pressure gauge pointer when it
is stabilized.

a Install the injector and fuel high-pressure
tube according to the following procedure.
1) Push in injector (11) with the hand to
assemble holder (12) temporarily.
2) Tighten bolt (13) and washer (14) tempo-
rarily.
2 Spherical part of washer: Engine oil
3) Tighten sleeve nut (15) of the fuel high- 4) Tighten the clamp and spacer with the
pressure tube temporarily. bolt.
4) Tighten bolt (13) permanently. 5) Install rocker arm assembly.
3 Bolt: 58.8 – 73.5 Nm {6.0 – 7.5 kgm}
3 Rocker arm assembly mounting bolt:
5) Tighten sleeve nut (15) permanently. 93 – 103 Nm {9.5 – 10.5 kgm}
3 Sleeve nut: 39.2 – 49.0 Nm {4 – 5 kgm}
a Adjust the valve clearance. For details,
see “Adjusting valve clearance“.
6) Install head cover.
3 Cylinder head cover mounting bolt:
29.4 – 34.3 Nm {3.0 – 3.5 kgm}
a Install the injector wiring harness accord-

ing to the following procedure
1) Install the injector wiring harness to the
cylinder head and fix the connector side
with the plate.Install O-ring (16).
2) Install cap (17) with clip on the injector
side of wiring harness.
Press wiring harness (18) between the
injector top and cap to the injector main
body without slack.
3) Tighten nut (19) on the injector side.
3 Nut: 2 ± 0.2 Nm {0.2 ± 0.02 kgm}
10 12V140E-3 Series
Testing blow-by pressure 1 3. Run the engine at the rated output and test the
blow-by pressure.
a Testing tool for blow-by pressure
Symbol Part No. Part name Q'ty the machine, test on the condition
1 799-201-1590 Gauge 1 described in the shop manual for the
machine.
2 799-201-1450 Adapter 2
E
3 799-201-1511 Nozzle 2
4 799-201-1571 Tube 1

a Measure blow-by pressure after the engine is
warmed up.
(Engine coolant temperature: Min. 70°C)
a Breather is provided to each RH and LH
banks. Test the breather on either one of the
banks.
1. Install adaptor [2] and nozzle [3] to the tip of

each breather hose on the RH and LH.
2. Connect tube [4] and gauge [1] to either one of 4. After finishing testing, remove the testing tools
the nozzles.Close the tube connecting mate of and return the removed parts.
other nozzle with a piece of short cut tube, etc.
12V140E-3 Series 11
Measuring blow-by pressure 1

Measuring method of blow-by pressure
k When measuring blow-by pressure, care
should be taken not to burn yourself on the
exhaust manifold or muffler or caught in a
rotating part.
a Measure blow-by pressure after the engine is
warmed up.
(Engine coolant temperature: Min. 70°C)
a Breather is provided to each RH and LH
banks. Test the breather on either one of the
banks.
1. Install adaptor and tool main body of blow-by
checker to the tip of breather tube on one of
the banks.
2. Install adaptor, tool main body of blow-by
checker, hose and gauge to the tip of breather
tube on one of the banks.
3. Run the engine at rated output and read the
pressure indicated on the gauge.
a In the case of actual vehicle, run the
engine to full stroke and read the pressure
indicated on the gauge.
a If rated output or full-stroke operation is not

possible, measure the blow-by in high-idling
operation.
In this case, approx. 80% of blow-by pressure
of the rated output can be obtained.
a Since blow-by pressure varies sharply depend-
ing on engine condition, if measured value is
judged abnormal, investigate phenomena
associated with defective blow-by such as
large oil consumption, abnormal exhaust color,
oil degradation and earlier contamination, etc.
a When measuring on the LH bank, close the
hose on RH bank.
12 12V140E-3 Series
Testing oil pressure 1 3. Run the engine at the rated output and low idle
and test the oil pressure.
a Testing tools for oil pressure a When testing with the engine mounted on
Symbol Part No. Part name the machine, test on the condition
described in the shop manual for the
799-101-5002 Hydraulic tester
1 machine.
F 790-261-1204 Digital hydraulic tester
2 799-401-2320 Hydraulic tester
1. Remove oil temperature sensor (1) on the LH

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

2. Install nipples [1] and [2] of hydraulic tester F1

and connect them to hydraulic tester F2.
a Since the screw size of the sensor mount
is 14 x P1.5, nipple (799-101-5230) may
be used.
12V140E-3 Series 13
Handling fuel system parts 1 Releasing residual pressure in

a Precautions for testing and maintaining fuel fuel system 1
system a Pressure is generated in the low-pressure cir-
The common rail fuel injection system (CRI) cuit and high-pressure circuit of the fuel sys-
consists of more precise parts than the con- tem while the engine is running.
ventional fuel injection pump and nozzle. If for- Low-pressure circuit:
eign matter enters this system, it can cause a Feed pump – Fuel filter – Supply pump
trouble. High-pressure circuit:
When testing and maintaining the fuel system, Supply pump – Common rail – Injector
take care more than the past. If dust, etc. a The pressure in both low-pressure circuit and
sticks to any part, wash that part thoroughly high-pressure circuit lowers to a safety level
with clean fuel. automatically 30 seconds after the engine is
a Precautions for replacement of fuel filter car- stopped.
tridge a Before the fuel circuit is tested and its parts are
The fuel filter cartridge used must be a genuine removed, the residual pressure in the fuel cir-
Komatsu part. cuit must be released completely. Accordingly,
The fuel injection pump and nozzle of the com- observe the following.
mon rail type fuel injection system (CRI) are k Before testing the fuel system or removing
consisted of more precision parts than those its parts, wait at least 30 seconds after stop-
used for the current pumps and nozzles. This ping the engine until the residual pressure
system, therefore, employs a special filter with in the fuel circuit is released. (Do not start
highly efficient filtering performance to prevent the work just after stopping the engine
mixing of foreign substances. Thus, substitut- since there is residual pressure.)
ing it with a non-genuine filter could cause
troubles in the fuel system. It is strictly prohib-
ited to use such part.
14 12V140E-3 Series
Testing fuel pressure 1 3. Run the engine at high idle and measure the
fuel pressure.
a Testing tools for fuel pressure a If the fuel pressure is in the following
Symbol Part No. Part name range, it is normal.
799-101-5002 Hydraulic tester Engine speed Fuel pressure
1
790-261-1204 Digital hydraulic tester 0.15 – 0.3 MPa
High idle
2 (Setting) Adapter {1.5 – 3 kg/cm2}
G
799-101-5220 Nipple
3
07002-11023 O-ring
4 799-401-2320 Gauge
a Test only the fuel pressure in the low-pressure

circuit from the feed pump through the engine
controller cooler and fuel filter to the supply
pump.
k Since the pressure in the high-pressure cir-
cuit from the supply pump through the
common rail to the injector is very high, it
cannot be measured.
a The position of the oil filler varies depending on
the applicable machine.
1. Remove air bleeder plug (1) on the top of fuel 4. Since the fuel circuits on the LH and RH banks
filter. after the priming pump are independent, test
each circuit.

2. Install adapter [G2] and connect to gauge [G4].
12V140E-3 Series 15
Reduced cylinder mode No-injection cranking 1

operation 1 a No-injection cranking means to crank the
a Reduced cylinder mode operation means to engine with the starting motor while all the
run the engine with the fuel injectors of 1 or injections are stopped electrically. The pur-
more cylinders disabled electrically to reduce pose and effect of this operation are as follows.
the number of effective cylinders. The pur- q When a machine or engine has been stored for
poses and effects of this operation are as fol- a long time, implementing the no-injection
lows. cranking before starting the engine lubricates
1. This operation is used to find out a cylinder the engine parts and thus prevents its seizure.
which does not output power normally (or, a Perform the no-injection operation with the
combustion in it is abnormal). engine mounted on the machine or connected
2. When a cylinder is selected for the reduced to INSITE (bench test tool).
cylinder mode operation, if the engine speed Before performing, see Testing method in the
and output do not change from the normal shop manual for the machine or INSITE
operation (all-cylinder operation), that cylinder (bench test tool).
has 1 or more defects. The possible defects
are as follows.
q Leakage through cylinder head gasket
q Defective injection
q Defective piston, piston ring, or cylinder
liner
q Defective valve mechanism
(Moving valve system)
q Defect in electrical system
3. Since the common rail fuel injection system
controls the injector of each cylinder electroni-
cally, the operator can perform the reduced cyl-
inder mode operation easily with switches to
find out a defective cylinder.
a Perform the reduced cylinder mode opera-
tion with the engine mounted on the
machine or connected to INSITE (bench
test tool).
Before performing, see Testing method in
the shop manual for the machine or
INSITE (bench test tool).
16 12V140E-3 Series
Testing leakage-from pressure limiter and return rate from injector 1

Type of engine having intake manifold equipped with return block
a If the engine is of a type that returns the fuel a Prepare an oil pan of about 20 l to receive the
spilling from the injector from the return block fuel flowing out during the test.
installed to the front of intake manifold, check
the engine according to the following (the fig- 1. Preparatory work (case of the LH bank)
ure showing the LH bank for PC2000). 1) Remove tube (4) between common rail (3)
a Testing tools for pressure limiter leakage and and supply pump (5).
injector return rate 2) Insert spacer H1 on supply pump (5) side
Symbol Part No. Part name and tighten the removed joint bolt again.
1 6151-51-8490 Spacer
2 6141-71-1710 Joint
Commercially Inside diameter of the hose:
3
available Approx. 11 mm
Commercially Inside diameter of the hose:
4
H available Approx. 17 mm
Commercially
5 Measuring cylinder
available
Commercially
6 Stopwatch
available
7 07376-70315 Plug
12V140E-3 Series 17
a Connect the return pipe to the fuel 2. Testing leakage from pressure limiter
tank again, too. 1) Lay test hose H3 so that it will not slacken
a Be sure to provide a gasket to both and put its end in the oil pan.
ends of the spacer. 2) Connect INSITE (bench test tool) to the
engine and set it so that it can check the
engine speed.
3) Start the engine and keep its speed to
1,600 rpm with no load.
4) After the engine speed is stabilized, test
the leakage in 1 minute with measuring
cylinder H5.
a You may test for 20 seconds and
judge by multiplying the result by 3.
a If the leakage from the pressure lim-
iter is in the following range, it is nor-
mal.
Engine speed Leakage
(rpm) (cc/min)
3) Insert joint H2 on common rail (3) side and
1,600 Max. 10
tighten the removed joint bolt again.
a Be sure to fit the gaskets to both ends
of the joint.
4) Connect test hose H3 to the end of joint
H2.
a Bind the connecting part of the test
hose with a wire, etc. to prevent it
from coming off.
a The above is the preparation work for
testing the leakage from the pressure
limiter.
5) After finishing testing, stop the engine.
18 12V140E-3 Series
3. Testing return rate from injector

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

After finishing all testing, remove the testing
tools and return the removed parts.
5. Check the RH bank following the identical pro-

cedure.
3) Connect INSITE (bench test tool) to the

engine and set it so that it can check the
engine speed.
4) Run the engine at the rated output.
5) After the engine speed is stabilized, test
the return rate in 1 minute with measuring
cylinder H5.
a You may test for 20 seconds and
judge by multiplying the result by 3.
a If the supply pump is not supplying
fuel, the engine speed may not rise.
In this case, record the engine speed,
too, during the test.
a If the return rate (spill) from the injec-
tor is in the following range, it is nor-
mal.
Rated output speed Limit of return rate (spill)
(rpm) (cc/min)
1,600 960
1,700 1,020
1,800 1,080
1,900 1,140
2,000 1,200
12V140E-3 Series 19
Bleeding air from fuel circuit (for D475A-5) 1
a If fuel is used up or if a fuel circuit part is a Don't fill fuel directly after removing main
removed and installed, bleed air from the fuel filter (1).
circuit according to the following procedure.
a The locations of the fuel circuit parts are sub-
ject to machine models (The figure showing
the LH bank for D475A-5).
1. Remove fuel pre-filter (6) and fill it with fuel.

a Fill the fuel filter with clean fuel and take
care that dirt will not enter it.
a Check that the cap is fitted to part (a)
(central hole) of the fuel pre-filter (6), and
then add fuel through part (b) (holes
around the central hole).
a After filling the fuel pre-filter (6) with fuel,
remove the cap from part (a).
a If clean fuel is not available, do not
2. Install fuel pre-filter (6) to the pre-filter head.
remove the filter but fill it with the fuel by
a Apply engine oil thinly over the packing on
operating priming pump (3).
the fuel pre-filter side.
20 12V140E-3 Series
a After the packing of the fuel pre-filter

touches the sealing face of the filter head,
tighten the fuel filter 1/2 – 3/4 turns.
3. Loosen air bleed plugs (2) and (4) of the fuel

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

flows out of the hole of plug (4). When bubbles
stop coming out, tighten plug (4).
2.0 – 3.9 Nm {0.2 – 0.4 kgm}
5. Loosen air bleeder (5) of the fuel supply pump

and operate priming pump (3) 90 – 100 times.
flows out of the air bleeder and tighten the
air bleeder. Then, operate the priming
pump several times more until it becomes
heavy.
3 Air bleeder:
4.9 – 6.9 Nm {0.5 – 0.7 kgm}
12V140E-3 Series 21
6. Move over to the RH side of the engine.

Loosen the air bleeder (8) of the fuel supply
pump and operate priming pump (7).
flows out of the air bleeder and the fuel is
checked. Further operate the priming
pump until it becomes heavy.
3 Air bleeder:
4.9 – 6.9 Nm {0.5 – 0.7 kgm}
7. Crank the engine with the starting motor to

start engine.
a The air in the high-pressure circuit is bled
automatically if the engine is cranked.
a If the engine does not start, there may be
still air in the low-pressure circuit. In this
case, repeat the above procedure from
step 3.
22 12V140E-3 Series
Bleeding air from fuel circuit (for PC2000) 1
a If fuel is used up or if a fuel circuit part is a Don't fill fuel directly after removing main
removed and installed, bleed air from the fuel filter (1).
circuit according to the following procedure.
a The locations of the fuel circuit parts are sub-
ject to machine models (The figure showing
the LH bank for PC2000).
1. Remove fuel pre-filter and fill it with fuel.

a Fill the fuel filter with clean fuel and take
care that dirt will not enter it.
a Check that the cap is fitted to part (a)
(central hole) of the fuel pre-filter, and then
add fuel through part (b) (holes around the
central hole).
a After filling the fuel pre-filter with fuel,
remove the cap from part (a).
a If clean fuel is not available, do not
2. Install fuel pre-filter to the filter head.
remove the filter but fill it with the fuel by
a Apply engine oil thinly over the packing on
operating priming pump (3).
the fuel pre-filter side.
12V140E-3 Series 23
a After the packing of the fuel pre-filter

touches the sealing face of the filter head,
tighten the fuel filter 1/2 – 3/4 turns.
3. Loosen air bleed plug (2) (plug on the outlet

side) of the fuel main filter and operate priming
pump (3).
flows out of the plug hole and tighten the
plug after checking the fuel.
2.0 – 3.9 Nm {0.2 – 0.4 kgm}
4. Loosen air bleeder (5) of the fuel supply pump

and operate priming pump (3) 90 - 100 times.
flows out of the air bleeder and tighten the
air bleeder. Then, operate the priming
pump several times more until it becomes
heavy.
3 Air bleeder:
4.9 – 6.9 Nm {0.5 – 0.7 kgm}
5. Bleed the air from the RH bank to the above

procedure.
6. Start the engine with the starting motor.

a The air in the high-pressure circuit is bled
automatically if the engine is cranked.
a If the engine does not start, there may be
still air in the low-pressure circuit. In this
case, repeat the above procedure from
step 3.
24 12V140E-3 Series
Testing fuel system for leakage 1 9. Inspect the fuel piping and devices for fuel
k
leakage.
Very high pressure is generated in the high-
a Check mainly around the high-pressure
pressure circuit of the fuel system. If fuel
circuit parts coated with the color checker
leaks while the engine is running, it is dan-
for fuel leakage.
gerous since it can catch fire.
a If any fuel leakage is detected, repair it
After testing the fuel system or removing
and inspect again from step 1.
its parts, test it for fuel leakage according
a If no fuel leakage is detected, check is
to the following procedure.
completed.
a Clean and degrease the engine and the parts
around it in advance so that you can test it eas-
ily for fuel leakage.
1. Spray color checker (developer) over the fuel

supply pump, common rail, fuel injector, and
joints of the high-pressure piping.
2. Run the engine at speed below 1,000 rpm and

stop it after its speed is stabilized.
3. Inspect the fuel piping and devices for fuel

leakage.
for fuel leakage.
4. Run the engine at low idle.

leakage.
for fuel leakage.
6. Run the engine at high idle.

leakage.
for fuel leakage.
8. Run the engine at high idle and load it.

a When checking while the components to
be checked are mounted on the machine,
stall the torque converter or relieve the
hydraulic pump.
12V140E-3 Series 25
Adjusting speed sensor 1 Testing and adjusting alternator

a The G (Bkup) speed sensor and Ne speed belt tension 1
sensor for the common rail fuel injection sys- Testing
tem cannot be adjusted. Press the intermediate point of the belt between
a Adjust speed sensor (1), which detects the sig- alternator pulley and drive pulley with a finger and
nal of the flywheel ring gear to use it for the measure deflection (a) of the belt.
electronic system on the machine side, accord- a Pressing force: Approx. 59 Nm {Approx. 6 kg}
ing to the following procedure. a Deflection (a): approx. 20 mm (1 piece)
1. Remove speed sensor (1) and check that its tip Adjusting
is free from steel chips and flaws, and then a If the deflection is out of the standard range,
install it again temporarily. adjust it according to the following procedure.
2 Threads: Gasket sealant (LG-6)
1. Loosen nut (B) and bolt (2) alternately.

2. Screw in sensor (1) until its tip touches the
tooth tip of flywheel ring gear (2).
2. Adjust belt tension using nut (A).
3. Return sensor (1) by 3/4 – 1 turn.
3. Tighten bolt (2) to have adjust bolt (1) and
a Clearance (a) of 1.1 – 1.5 mm will be
plate (3) made orthogonal to each other.
made between the sensor tip and gear
tooth tip.
4. Tighten nut (B) to fix plate (3).
a After adjusting, test the belt tension again.
4. While fixing sensor (1), tighten nut (3).
3 Nut: 49 – 68.6 Nm {5 – 7 kgm}
26 12V140E-3 Series
Handling controller high-voltage

circuit 1
1. When disconnecting or connecting a connector
between engine controller and engine, be sure
to turn the starting switch OFF.
2. Don't start the engine with T-adapter inserted

or connected to a connector between the
engine controller and the engine for diagnosis.
a You may turn the starting switch to the
OFF or ON position but must not turn it to
the START position.
12V140E-3 Series 27

© 2006 KOMATSU
All Rights Reserved
28 12V140E-3 Series
SEN00315-00
ENGINE 1SHOP MANUAL
12V140E-3 Series
40 Troubleshooting
General information on troubleshooting
General information on troubleshooting.......................................................................................................... 2
Points to remember when troubleshooting ........................................................................................... 2
Error codes and failure codes list ......................................................................................................... 3
12V140E-3 Series 1
SEN00315-00 40 Troubleshooting
General information on troubleshooting

Points to remember when troubleshooting
k When troubleshooting a machine, stop it in a level ground, and check that the lock pin, chocks,
and parking brake are securely fitted.
k When carrying out the operation with two or more workers, keep strictly to the agreed signals,
and do not allow any unauthorized person to come near.
k If the radiator cap is removed when the engine is hot, hot coolant may spurt out and cause
burns, so be sure to wait for the engine to cool down before starting troubleshooting.
k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
k When disconnecting wiring, always disconnect the negative (–) terminal of the battery first.
k When removing the plug or cap from a location which is under pressure from oil, water, or air,
always release the internal pressure first. When installing measuring equipment, be sure to con-
nect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and the
prevent reoccurrence of the failure.When carrying out troubleshooting, and important point is of course to
understand the structure and function. However, a short cut to effective troubleshooting is to ask the operator
various questions to form some idea of possible causes of the failure that would produce the reported symp-
toms.
1. When carrying out troubleshooting, do not 3) Check other inspection items, if neces-
hurry to disassemble the components. sary.
If components are disassembled immediately 4) Some other maintenance items can be
after any failure occurs: checked externally, so check any item that
q Parts that have no connection with the fail- is considered to be necessary.
ure or other unnecessary parts will be dis- 5) Check the controller for display of an error.
assembled.
4. Confirming failure
q It will become impossible to find the cause
Confirm the extent of the failure yourself, and
of the failure.
judge whether to handle it as a real failure or
It will also cause a waste of manhours, parts,
as a problem with the method of operation, etc.
or oil or grease, and at the same time, will also
a When operating the machine or engine to
lose the confidence of the user or operator.
reenact the troubleshooting symptoms, do
For this reason, when carrying out trouble-
not carry out any investigation or mea-
shooting, it is necessary to carry out thorough
surement that may make the problem
prior investigation and to carry out trouble-
worse.
shooting in accordance with the fixed proce-
dure. 5. Troubleshooting
2. Points to ask user or operator Use the results of the investigation and inspec-
1) Have any other problems occurred apart tion in Items 2 – 4 to narrow down the causes
from the problem that has been reported? of failure, then use the troubleshooting matrix
2) Was there anything strange about the to locate the position of the failure exactly.
machine before the failure occurred? a The basic procedure for troubleshooting is
3) Did the failure occur suddenly, or were as follows.
there problems with the machine condition 1) Start from the simple points.
before this? 2) Start from the most likely points.
4) Under what conditions did the failure 3) Investigate other related parts or informa-
occur? tion.
5) Had any repairs been carried out before
6. Measures to remove root cause of failure
the failure? When were these repairs car-
Even if the failure is repaired, if the root cause
ried out?
of the failure is not repaired, the same failure
6) Has the same kind of failure occurred
will occur again. To prevent this, always inves-
before?
tigate why the problem occurred. Then,
3. Check before troubleshooting remove the root cause.
1) Check for symptoms of any abnormality in
the machine and engine.
2) Be sure to check the CHECKS BEFORE
STARTING items.
2 12V140E-3 Series
Error codes and failure codes list
*1 – *3: Machine monitor in KES 6 digit display

INSITE Machine failure
error code code Failure phenomenon
111 CA111 ECM Critical Internal Failure (LH bank)

111 CB111 ECM Critical Internal Failure (RH bank)
115 CA115 Eng. Ne and G (Bkup) Speed Sensor Error (LH bank)
115 CB115 Eng. Ne and G (Bkup) Speed Sensor Error (RH bank)
122 CA122 Charge Air Press. Sensor High Error (LH bank only)
123 CA123 Charge Air Press. Sensor Low Error (LH bank only)
131 CA131 Throttle Sensor High Error (LH bank only)
132 CA132 Throttle Sensor Low Error (LH bank only)
135 CA135 Oil Press. Sensor High Error (LH bank only)
141 CA141 Oil Press. Sensor Low Error (LH bank only)
144 CA144 Coolant Temp. Sensor High Error (LH bank only)
145 CA145 Coolant Temp. Sensor Low Error (LH bank only)
153 CA153 Charge Air Temp. Sensor High Error (LH bank only)
154 CA154 Charge Air Temp. Sensor Low Error (LH bank only)
187 CA187 Sensor Sup. 2 Volt. Low Error (LH bank)
187 CB187 Sensor Sup. 2 Volt. Low Error (RH bank)
212 CA212 Eng. Oil Temp.Sensor High Error (LH bank only)
213 CA213 Eng. Oil Temp.Sensor Low Error (LH bank only)
221 CA221 Ambient Air Press. Sensor High Error (LH bank only)
222 CA222 Ambient Air Press. Sensor Low Error (LH bank only)
227 CA227 Sensor Sup. 2 Volt. High Error (LH bank)
227 CB227 Sensor Sup. 2 Volt. High Error (RH bank)
234 CA234 Eng. Over (LH bank only)
238 CA238 Ne Speed Sensor Sup. Volt. Error (LH bank)
238 CB238 Ne Speed Sensor Sup. Volt. Error (RH bank)
263 CA263 Fuel Temp. Sensor High Error (LH bank)
263 CB263 Fuel Temp. Sensor High Error (RH bank)
265 CA265 Fuel Temp. Sensor Low Error (LH bank only)
265 CB265 Fuel Temp. Sensor Low Error (RH bank)
271 CA271 PCV1 Short Error (LH bank)
271 CB271 PCV1 Short Error (RH bank)
272 CA272 PCV1 Open Error (LH bank)
272 CB272 PCV1 Open Error (RH bank)
273 CA273 PCV2 Short Error (LH bank)
273 CB273 PCV2 Short Error (RH bank)
274 CA274 PCV2 Open Error (LH bank)
274 CB274 PCV2 Open Error (RH bank)
322 CA322 Injector #1 (LA/B #1) System Open/Short Error (LH bank)
12V140E-3 Series 3

342 CA342 Caribration Code Incompatibility (LH bank)
342 CB342 Caribration Code Incompatibility (RH bank)
351 CA351 Inj. Drive Circuit Error (LH bank)
351 CB351 Inj. Drive Circuit Error (RH bank)
352 CA352 Sensor Sup. 1 Volt. Low Error (LH bank)
352 CB352 Sensor Sup. 1 Volt. Low Error (RH bank)
386 CA386 Sensor Sup. 1 Volt. High Error (LH bank)
386 CB386 Sensor Sup. 1 Volt. High Error (RH bank)
441 CA441 Battery Voltage Low Error (LH bank)
441 CB441 Battery Voltage Low Error (RH bank)
442 CA442 Battery Voltage High Error (LH bank)
442 CB442 Battery Voltage High Error (RH bank)
449 CA449 Rail Press. Very High Error (LH bank)
449 CB449 Rail Press. Very High Error (RH bank)
451 CA451 Rail Press. Sensor High Error (LH bank)
451 CB451 Rail Press. Sensor High Error (RH bank)
452 CA452 Rail Press. Sensor Low Error (LH bank)
452 CB452 Rail Press. Sensor Low Error (RH bank)
553 CA553 Rail Press. High Error 1 (LH bank)
553 CB553 Rail Press. High Error 1 (RH bank)
554 CA554 Rail Press. Sensor In Range Error (LH bank)
554 CB554 Rail Press. Sensor In Range Error (RH bank)
559 CA559 Rail Press. Low Error 1 (LH bank)
559 CB559 Rail Press. Low Error 1 (RH bank)
689 CA689 Eng. Ne Speed Sensor Error (LH bank)
689 CB689 Eng. Ne Speed Sensor Error (RH bank)
691 CA691 Intake Air Temp Sensor High Error (LH bank only)
692 CA692 Intake Air Temp Sensor Low Error (LH bank only)
731 CA731 Eng. G (Bkup) Speed Sensor Phase Error (LH bank)
731 CB731 Eng. G (Bkup) Speed Sensor Phase Error (RH bank)
757 CA757 All Continuous Data Lost Error (LH bank)
757 CB757 All Continuous Data Lost Error (RH bank)
778 CA778 Eng. G (Bkup) Speed Sensor Error (LH bank)
778 CB778 Eng. G (Bkup) Speed Sensor Error (RH bank)
781 CA781 Inter Multi-controller Communication Error (LH bank)
781 CB781 Inter Multi-controller Communication Error (RH bank)
1117 CA1117 Persistent Data Lost Error (LH bank)
1117 CB1117 Persistent Data Lost Error (RH bank)
1257 CA1257 Harness Key error (LH bank)
1257 CB1257 Harness Key error (RH bank)
1548 CB1548 Injector #7 (R/B #1) System Open/Short Error (RH bank)
4 12V140E-3 Series

1633 CA1633 KOMNET Data Time Error (LH bank)
2185 CA2185 Throttle Sens. Sup. Volt. High Error (LH bank only)
2186 CA2186 Throttle Sens. Sup. Volt. Low Error (LH bank only)
2249 CA2249 Rail Press. Very Low Error (LH bank)
2249 CB2249 Rail Press. Very Low Error (RH bank)
--*1 — Eng. Overheat (LH bank only)
--*2 — Eng. Oil Press. Low Speed Derate (LH bank only)
--*3 — Eng. Oil Press. Low Torque Derate (LH bank only)
a INSITE error code:
An error code of 3 or 4 digits displayed on the INSITE (bench test tool) when the occurrence condition of
the failure is confirmed with the INSITE.
a Machine failure code:
An error code of 5 or 6 digits displayed on the machine monitor when the occurrence condition of the
failure is confirmed with the machine monitor, etc. on the machine side.
12V140E-3 Series 5

© 2006 KOMATSU
All Rights Reserved
6 12V140E-3 Series
SEN00316-00
ENGINE 1SHOP MANUAL
12V140E-3 Series
40 Troubleshooting 1
Troubleshooting of mechanical system
(S-mode)
Troubleshooting of mechanical system (S-mode)........................................................................................... 3
Method of using troubleshooting charts ................................................................................................ 3
S-1 Starting performance is poor .......................................................................................................... 6
S-2 Engine does not start ..................................................................................................................... 7
S-3 Engine does not pick up smoothly ............................................................................................... 10
S-4 Engine stops during operations.....................................................................................................11
S-5 Engine does not rotate smoothly.................................................................................................. 12
S-6 Engine lacks output (or lacks power) ........................................................................................... 13
S-7 Exhaust smoke is black (incomplete combustion) ....................................................................... 15
S-8 Oil consumption is excessive (or exhaust smoke is blue) ............................................................ 16
S-9 Oil becomes contaminated quickly............................................................................................... 17
S-10 Fuel consumption is excessive .................................................................................................. 18
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) ......................................... 19
S-12 Oil pressure drops ...................................................................................................................... 20
12V140E-3 Series 1
S-13 Oil level rises (Entry of coolant or fuel)....................................................................................... 21

S-14 Coolant temperature becomes too high (overheating) ............................................................... 22
S-15 Abnormal noise is made............................................................................................................. 23
S-16 Vibration is excessive ................................................................................................................. 24
2 12V140E-3 Series
Troubleshooting of mechanical system (S-mode) 1

Method of using troubleshooting charts 1
The troubleshooting chart consists of the “ques-
tions“, “check items“, “causes“, and “troubleshoot-
ing“ blocks.
The questions and check items are used to pinpoint
high probability causes by simple inspection or
from phenomena without using troubleshooting
tools.
Next, troubleshooting tools or direct inspection are
applied to check the narrowed causes in order from
the most probable one to make final confirmation
according to the troubleshooting procedure.
[Questions]:
Items to be drawn from the user or operator.
They correspond to A and B in the chart on the
right.
The items in A are basic ones.
The items in B can be drawn from the user or
operator, depending on their level.
[Check items]:
Simple check items used by the serviceman to
narrow down the causes.
They corresponds to C in the chart on the right.
[Causes]:
Items to be narrowed from the questions and
check items.
The serviceman narrows down the probable
causes from A, B, and C.
[Troubleshooting]:
Items to finally verify whether the narrowed
down causes are undoubtedly the real causes
using the troubleshooting tools and direct
inspections.
Items listed in the [Questions] and [Check items] and related to the [Causes] are marked with E, Q, or w.
E: Causes to be referred to for questions and check items
Q: Causes related to questions and check items
w: Causes highly probable among ones marked with Q
a When narrowing the "auses", apply the items marked with w before those marked with Q.
When narrowing the causes, do not apply the items marked with E. (If no items have other marks and
the causes cannot be narrowed, however, you may apply them.)
12V140E-3 Series 3
<Example of troubleshooting> Exhaust smoke is black

Let us assume that [Clogged air cleaner element] is taken to be the cause of black exhaust gas. Three symp-
toms have causal relationship with this problem: [Color of exhaust gas gradually became black], [Power was
lost gradually], and [Air cleaner clogging caution lamp is flashing].
4 12V140E-3 Series
If we look for the linkage of these three phenomena to possible causes, we find that they have causal rela-
tionship with five causes.
Let us explain here the method of using this causal relationship to pinpoint the most probable cause.
12V140E-3 Series 5
S-1 Starting performance is poor 1

General causes for poor starting performance are Causes
q Defective electrical system
Leaking or clogged fuel piping, entry of air

Clogged air breather hole of fuel tank cap
Defective contact of valve and valve seat
Insufficient supply of fuel
Defective alternator (generator section)

q
Defective alternator (regulator section)

Stuck or seized supply pump plunger
q Insufficient intake of air
Defective intake air heater system

q Improper selection of fuel (particularly during winter)
Defective or deteriorated battery

Clogged feed pump gauze filter
Coolant in exhaust pipe
Worn piston ring and cylinder

q
Clogged air cleaner element

a The common rail fuel injection system (CRI) recognizes
Clogged fuel filter element

the fuel injection timing electrically. Accordingly, even if
the starting operation is carried out, the engine may not
Defective injector
start until the crankshaft revolves 2 turns at maximum.
This phenomenon does not indicate a trouble, however.
Confirm recent repair history

Degree of
machine operation
Operated for long period E E E E
Starting perfor- Became worse gradually Q w w Q Q

mance Engine starts easily when warm w
Questions
Non-specified fuel is being used Q Q Q Q

Replacement of filters not carried out according to Operation and Maintenance
Manual w w w Q Q
Engine oil replenished more frequently w
When engine is preheated or when temperature is low, preheating monitor does not
indicate normally (if monitor is installed) w
During operation, charge level monitor indicates abnormal charge (if monitor is
installed) w w
Dust indicator is red (if indicator is installed) w
Air breather hole of fuel tank cap is clogged w
Fuel is leaking from fuel piping w
When priming pump is operated, it makes no reaction or it is heavy E w Q Q
Starting motor cranks engine slowly w
Fuel does not flow out if air bleeding plug of fuel filter is
While engine is removed w w
cranked with start-
ing motor, If spill hose from injector is disconnected,
Q w
Check items
little fuel spills

When exhaust manifold is touched immediately after starting engine, temperature of
some cylinders is low w
Engine does not pick up smoothly and combustion is irregular Q Q Q Q Q w
There is hunting from engine (rotation is irregular) Q Q Q
Blow-by gas is excessive w
Inspect air cleaner directly q

When compression pressure is measured, it is found to be low q q
When air is bled from fuel system, air comes out q
Inspect fuel filter and strainer directly q
Inspect feed pump gauze filter directly q
Troubleshooting
Carry out troubleshooting according to “No-pressure feed by supply pump (*1)“ in E-

mode q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does
not change on some cylinders q
When starting switch is turned to HEAT, intake air heater mount does not become
warm q
Is voltage 20 – 30 V between alternator terminal B and terminal E with Yes q

engine at low idle? None q
When specific gravity of electrolyte and voltage of battery are measured, they are
low q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Clean
Clean
Clean
Clean
Remedy
*1: Code [559/CA559], [559/CB559] and code [2249/CA2249], [2249/CB2249] in E-mode
6 12V140E-3 Series
S-2 Engine does not start 1

a) Engine does not turn Causes
General causes why engine does not turn
Defective starting motor (safety relay section)

q Engine seized inside
Defective connection of battery terminal
Defective starting motor (motor section)

o See "S-4 Engine stops during operations".
q Water hammer caused by coolant which entered cylinder
Defective electrical system

q
Defective steering circuit wiring

q Problem in drive devices on applicable machine side
o Troubleshoot the applicable machine side
Broken flywheel ring gear
Defective starting switch

Defective battery relay
Questions
Degree of machine opera- Operated for long period

tion E E
Condition of horn when Horn does not sound Q Q
starting switch is turned
ON Horn volume is low w
Battery electrolyte is low w
Battery terminal is loose w
When starting switch is turned ON, there is no operating sound from battery relay Q w
When starting switch is turned to START, starting pinion does not move out Q Q
Check items
Speed of rotation is low w

When starting switch is Makes grating noise w w
turned to START, starting
pinion moves out, but Soon disengages w
Makes rattling noise and does not turn Q Q
Inspect flywheel ring gear directly q
Carry out troubleshooting on

When specific gravity of electrolyte and voltage of battery are measured, they are low q
Troubleshooting
There is not voltage (20 - 30 V) between battery relay terminal B and

terminal E q
installed machine
When terminal B and terminal C of starting switch are connected,
Turn starting switch OFF,
engine starts q
connect cord, turn the
switch ON and carry out When terminal B and terminal C at safety relay outlet are connected,
troubleshooting engine starts q
When terminal B and terminal C at safety relay outlet are connected,
engine does not start q
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Remedy
—
12V140E-3 Series 7
b) Engine turns but no exhaust smoke comes out Causes

General causes why engine turns but no exhaust smoke
Defective operation of overflow valve (Does not close)

comes out
q Fuel is not being supplied
Leaking, clogging and entry of air to fuel piping

q Supply of fuel is extremely small

q Improper selection of fuel (particularly in winter)
Wrong connection of supply pump PCV

Seized, abnormally worn feed pump
Defective operation of flow damper

Broken supply pump shaft spline
Defective supply pump PCV

Clogged fuel filter element
Insufficient fuel in tank
Use of improper fuel
Defective injector
Degree of
Operated for long period E E E
Questions
machine operation
Exhaust smoke suddenly stopped coming out (when starting again) w Q w w w E E
Non-specified fuel is being used w
w w E E Q
Manual
When fuel tank is inspected, it is found to be empty w
Air breather hole of fuel tank cap is clogged Q w
Rust and water are found when fuel tank is drained Q Q Q Q Q
When fuel filter is removed, there is no fuel in it w Q w
w
Check items
Fuel is leaking from fuel piping

When priming pump is operated, it makes no reaction or it is heavy w Q Q
While engine is If air bleeding plug of fuel filter is removed, fuel does not flow
Q Q Q w Q
cranked with out
starting motor, If spill hose from injector is disconnected, little fuel spills Q w w w w Q

Inspect fuel filter directly q
Troubleshooting
Inspect feed pump directly q

Carry out troubleshooting according to “No-pressure feed by supply pump error
q q q
(*1)“ in E-mode
Carry out troubleshooting according to “Abnormality in PCV1 (*2) or Abnormality
q
in PCV2 (*3)“ in E-mode
Inspect overflow valve directly q
Engine can be started in reduced cylinder mode q q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Clean
Remedy
Add

8 12V140E-3 Series
c) Exhaust smoke comes out but engine does not start Causes
(fuel is being injected)
Defective coolant temperature sensor and/or wiring harness

General causes why exhaust smoke comes out but engine
Worn dynamic valve system (Valve, rocker lever, etc.)

does not start
q Lack of rotating force due to defective electrical system
Leaking, clogging of fuel system, and entry of air

q Insufficient supply of fuel
Stuck and/or seized supply pump plunger

Improper selection of fuel
Clogged injector and/or defective spray

q
Worn piston ring and/or cylinder liner
Defective intake air heater system

Clogged fuel filter and/or strainer

Use of improper fuel

Degree of machine
operation
Suddenly failed to start w w Q
Questions

Manual w w w
When engine is preheated or when temperature is low, preheating monitor does not
indicate normally (if monitor is installed) w
Air breather hole of fuel tank cap is clogged Q
Rust and water are found when fuel tank is drained w w
When fuel filter is removed, there is no fuel in it w
Starting motor cranks engine slowly w
When engine is cranked, abnormal sound is generated around cylinder head w
Check items
While engine is Fuel does not flow out if air bleeding plug of fuel filter is
removed Q Q w w
cranked with start-
ing motor, If spill hose from injector is disconnected, little fuel spills Q Q w
some cylinders is low w

Inspect dynamic valve system directly q
When compression pressure is measured, it is found to be low q
q
Troubleshooting
Inspect fuel filter, strainer directly

Carry out troubleshooting according to “No-pressure feed by supply pump error (*1)“
in E-mode q
When injector unit is tested, spray condition is bad q
When specific gravity of electrolyte and voltage of battery are measured, they are low q
Coolant temperature gauge does not indicate normally (if coolant temperature
gauge is installed) q
When starting switch is turned to HEAT, intake air heater mount does not become
warm q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Clean
Clean
Remedy
12V140E-3 Series 9
S-3 Engine does not pick up smoothly 1

General causes why engine does not pick up smoothly Causes
Defective operation of flow damper (Maximum leakage from injector)

q Defective spray condition of fuel
q Improper selection of fuel
q Controller is controlling in derate mode
(limiting injection rate (output) because of an error in electri-
Seized turbocharger or interference of turbocharger

cal system)
Leaking, clogging of or entry of air to fuel piping

Clogged injector and/or defective spray


Improper valve clearance

Degree of
machine operation Operated for long period E E E E E
Questions
Engine pick-up suddenly became worse w Q Q Q

Non-specified fuel is being used w w w w
Replacement of filters not carried out according to Operation and Maintenance Manual w w w
some cylinders is low Q w
Color of exhaust Blue under light load w

Check items
gas is Black w Q w w
When engine is cranked, interference sound is emitted from around turbocharger w
High idle speed under no load is normal, but speed suddenly drops when load is applied Q w w
There is hunting from engine (rotation is irregular) Q Q w Q

Inspect valve clearance directly q
Troubleshooting
When turbocharger is rotated by hand, it is found to be heavy q

Inspect feed pump gauze filter directly
Carry out troubleshooting according to “No-pressure feed by supply pump error (*1)“ in
E-mode q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not
change on some cylinders q q
Adjusting
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Remedy
Clean
Clean
Clean
Clean
10 12V140E-3 Series
S-4 Engine stops during operations 1

General causes why engine stops during operations Causes
q Seized parts inside engine
Broken dynamic valve system (valve, rocker arm, etc.)
Broken auxiliary equipment (pump, compressor, etc.)

Problem in drive devices on installed machine side

q There is overheating
Broken or seized piston and/or connecting rod

q Problem in drive devices on applicable machine side
o Troubleshoot the applicable machine side

Broken or seized crankshaft bearing
Leaking and/or clogged fuel piping

Broken supply pump shaft spline

Broken or seized feed pump
Broken or seized gear train
Degree of machine
operation
Operated for long period EE
Abnormal noise was heard and engine stopped sud-
denly w w w w Q w Q w w
Questions
Condition when engine Engine overheated and stopped w Q Q

stopped
Engine stopped slowly w Q Q
Engine stopped after hunting w Q Q Q Q
Manual w w
Fuel level monitor indicates low level (if monitor is installed) w
Metal particles are found when oil pan is drained w w Q Q
Check items
Does not turn at all w w

When engine is Turns in opposite direction w
cranked by hand Moves by amount of gear backlash w w
Supply pump shaft does not turn w
Engine turns, but stops when load is applied to machine w

Inspect piston and connecting rod directly q
Carry out troubleshooting on
Inspect crankshaft bearing directly q

Troubleshooting
Inspect gear train directly q

installed machine

Inspect feed pump directly q
Carry out troubleshooting according to “No-pressure feed by supply pump
error (*1)“ in E-mode q q
Engine rotates when pump auxiliary equipment (pump, compressor, etc.) is
removed q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Remedy
—
Add
12V140E-3 Series 11
S-5 Engine does not rotate smoothly 1

General causes why engine does not rotate smoothly Causes
q Air in fuel system
Defective operation of flow damper (Maximum leakage from injector)

q Defective speed sensor (Error at degree that it is not indicated)
Clogged injector and/or defective spray (dirt in injector)
Defective G (Bkup) speed sensor or wiring harness

Defective Ne speed sensor and/or wiring harness
Leaking or clogging or entry of air to fuel piping

Low setting of low idle speed
Clogged fuel filter or strainer

Degree of machine
operation Operated for long period E E
Questions
Occurs at a certain speed range Q Q Q

Occurs at low idle w Q Q Q Q Q Q Q
Condition of hunting
Occurs even when speed is raised Q Q Q
Occurs on slopes w Q Q
Replacement of filters not carried out according to Operation and Maintenance Manual w w
Check items
Rust and water are found when fuel tank is drained Q Q


Troubleshooting

Carry out troubleshooting according to “Abnormality in engine Ne speed sensor (*1)“ in E-
mode q
Carry out troubleshooting according to “Abnormality in engine Bkup speed sensor (*2)“ in E-
mode q
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Clean
Remedy
Add
*1: Code [689/CA689] and [689/CB689] in E-mode

*2: Code [778/CA778] and [778/CB778] in E-mode
1
12 12V140E-3 Series
S-6 Engine lacks output (or lacks power) 1

General causes why engine lacks output Causes
Defective installation of boost pressure sensor (air leakage)

Insufficient supply of fuel
Defective fuel temperature sensor and/or wiring harness

q
Defective boost pressure sensor and/or wiring harness

Clogged injector or defective spray (dirt in injector)

Defective drive of injector (signal and/or solenoid)
q Overheat
o See "S-14 Coolant temperature becomes too

high (Overheating)"

Air leakage from air intake piping

(limiting injection rate (output) because of an
Leaking or clogged fuel piping

error in electrical system)

Degree of machine
operation Operated for long period E E E E E
Q Q Q Q
Questions
Suddenly
Power was lost
Gradually Q Q Q Q Q Q Q
Non-specified fuel is being used Q Q
Replacement of filters not carried out according to Operation and Mainte-
nance Manual w Q
Engine oil replenished more frequently Q Q Q
Output becomes insufficient after short stop of operation w
Color of exhaust Black w w
gas Blue under light load w
When exhaust manifold is touched immediately after starting engine,
temperature of some cylinders is low w
w
Check items
When engine is cranked, interference sound is emitted from around turbocharger

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

Inspect air intake piping directly q
When boost pressure is measured, it is found to be low q q q
Troubleshooting

Carry out troubleshooting according to “No-pressure feed by supply
pump error (*1)“ in E-mode q
When a cylinder is cut out for reduced cylinder mode operation, engine
speed does not change on some cylinders q q
Inspect boost pressure sensor mount directly q
Carry out troubleshooting according to “Abnormality in charge pressure
sensor (*2)“ in E-mode q
Carry out troubleshooting according to “Abnormality in fuel temperature
sensor (*3)“ in E-mode q
Adjusting
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
Clean
Clean
Clean
12V140E-3 Series 13

*2: Code [122/CA122] and code[123/CA123] in E-mode.
14 12V140E-3 Series
S-7 Exhaust smoke is black (incomplete combustion) 1

General causes why exhaust smoke is black Causes
Defective coolant temperature sensor or wiring harness

Leakage of air between turbocharger and cylinder head
q Excessive injection of fuel

Clogged fuel spill piping (on cylinder head side)

q Overheat

o See "S-14 Coolant temperature becomes too high

(Overheating)"
Improper fuel injection pressure

(limiting injection rate (output) because of an error in
Crushed or clogged muffler
Clogged or seized injector

electrical system)
Abnormally worn injector
Improper injection timing

Degree of
machine operation Operated for long period E E E E
Suddenly became black w Q Q Q
Questions
Color of exhaust
gas Gradually became black w Q Q
Blue under light load w
Non-specified fuel is being used Q Q
Oil replenished more frequently w
Suddenly w Q Q Q
Power was lost
Gradually Q Q Q Q
Muffler is crushed w
Air leaks between turbocharger and cylinder head, and clamp is loosened w
Engine is operated in low-temperature mode at normal temperature Q Q Q
When exhaust manifold is touched immediately after starting engine, temperature
of some cylinders is low Q w
Check items

Torque converter stall speed or pump relief speed is high
(Fuel is injected excessively) Q Q
Exhaust noise is abnormal Q w Q
Engine does not pick up smoothly and combustion is irregular Q Q Q Q Q w
If spill hose from injector is disconnected, abnormally much fuel spills w

When turbocharger is rotated by hand, it is fount to be heavy q
q
Troubleshooting
Inspect valve clearance directly

When muffler is removed, exhaust sound improves q
Carry out troubleshooting according to “No-pressure feed by supply pump error
(*1)“ in E-mode q q
When a cylinder is cut out for reduced cylinder mode operation, engine speed
does not change on some cylinder q
Inspect fuel spill piping (on cylinder head side) directly q q
Carry out troubleshooting according to “Abnormality in coolant temperature sen-
sor error (*2)“ in E-mode
Adjusting
Adjusting
Adjusting
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Remedy
Clean

*2: Code [144/CA144] and code[145/CA145] in E-mode
12V140E-3 Series 15
S-8 Oil consumption is excessive (or exhaust smoke is blue) 1

General causes why oil consumption is excessive Causes
q Abnormal combustion of oil
Turbocharger 1
q Long-time operation of engine at low idle or high idle
Oil leakage from oil pan, cylinder head, etc.

Worn or damaged valve (stem, guide, seal)
(Do not run engine continuously at idle without load for
more than 20 minutes)

Clogged breather or breather hose
External leakage of oil
Dust sucked in from intake system

q
q Wear of parts in lubrication system
Worn seal at turbocharger end
Worn or damaged rear oil seal
Oil leakage from oil drain plug

Oil leakage from oil cooler
Oil leakage from oil piping

Worn seal at blower end
Oil leakage from oil filter

Broken piston ring
Broken oil cooler

Degree of machine oper-
E E E E
Questions
Operated for long period

ation
Oil consumption suddenly increased w Q
Oil replenished more frequently w Q
Oil becomes contaminated quickly Q Q w
Outside of engine is contaminated with oil w w w w w
There are loose piping clamps in intake system w
Inside of turbocharger intake outlet pipe is contaminated with oil w
Inside of turbocharger exhaust outlet pipe is contaminated with oil Q w
Check items
There is oil in coolant w

Oil level in clutch chamber or damper chamber on the installed machine side is
increasing w
Exhaust smoke is blue under light load w w
Excessive Q Q w w
Amount of blow-by gas
None w
When intake manifold is removed, dust is found inside q

When intake manifold is removed, inside is found contaminated abnormally q
Troubleshooting
Excessive play of turbocharger shaft q q

Check breather and breather hose directly q
Inspect rear oil seal directly q
Pressure-tightness test of oil cooler shows there is leakage q q
There is external leakage of oil from engine q q q q
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
16 12V140E-3 Series
S-9 Oil becomes contaminated quickly 1

General causes why oil becomes contaminated Causes
q Entry of exhaust gas into oil due to internal wear
Clogged turbocharger lubrication drain tube

Defective seal at turbocharger turbine end
q Clogging of lubrication passage
Clogged breather and/or breather hose

q Use of improper fuel

q Use of improper oil
q Operation under excessive load
Worn valve and/or valve guide
Defective oil filter safety valve
Exhaust smoke is bad

Clogged oil cooler
Clogged oil filter
Degree of machine operation Operated for long period E E E
Questions
Non-specified fuel is being used Q

Even when engine oil temperature rises, oil filter clogging monitor indicates clogging (if monitor is
installed) w Q
Metal particles are found when oil filter is drained Q Q w
Inside of exhaust pipe is contaminated with oil w
Engine oil temperature rises quickly w
Blue under light load w
Check items
Color of exhaust gas

Black w
Excessive Q Q w Q
Amount of blow-by gas
None w
Excessive play of turbocharger shaft q

q q
Troubleshooting
When compression pressure is measured, it is found to be low

Inspect breather and breather hose directly q
See S-7
Inspect oil cooler directly q
Inspect oil filter directly q
Spring of oil filter safety valve is hitched or broken q
Inspect turbocharger lubrication drain tube directly q
Replace
Replace
Replace
Replace
Replace
Clean
Clean
Remedy Clean
—
12V140E-3 Series 17
S-10 Fuel consumption is excessive 1

General causes why fuel consumption is excessive Causes
q Leakage of fuel
Defective coolant temperature sensor or wiring harness

q Defective condition of fuel injection (fuel pressure, injection timing)
q Excessive injection of fuel
Fuel leakage from fuel filter, piping, etc.
Defective common rail fuel pressure

Fuel leakage inside head cover
Defective supply pump plunger
Defective operation of injector

Defective feed pump oil seal
Defective spray by injector

Degree of
E E E
Questions
Operated for long period

machine operation
More than other machines of same model Q Q Q Q
Condition of fuel
consumption
Gradually increased Q Q
Suddenly increased Q Q
There is external leakage of fuel from engine w
Combustion is irregular w
Engine oil level rises and oil smells of diesel fuel w w
When exhaust manifold is touched immediately after starting engine, temperature of some cylin-
ders is low w
Check items
Low idle speed is high Q

Torque converter stall speed or hydraulic pump relief speed is high Q
Color of exhaust Black Q Q Q Q
gas White Q
Remove and inspect head cover directly q

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

18 12V140E-3 Series
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)1
General causes why oil is mixed in coolant Causes
q Internal leakage in lubrication system
Broken hydraulic oil cooler or power train oil cooler on installed machine side
q Internal leakage in cooling system
Damaged cylinder liner O-ring and/or hole caused by pitting

Broken cylinder head and/or head gasket
Insufficient protrusion of cylinder liner

Broken oil cooler core and/or O-ring
Cracks inside cylinder block
Degree of machine Operated for long period E E
Questions
operation
Suddenly increased Q Q Q
Oil level
Gradually increased Q Q
Hard water is being used as coolant Q Q
Oil level has risen and oil is milky Q Q w
There are excessive air bubbles in radiator, coolant spurts back w w
Check items
Hydraulic oil or power train oil on installed machine side is milky w

When hydraulic oil or power train oil is drained, water is found w
Pressure-tightness test of cylinder head shows there is leakage q

Carry out troubleshooting
Troubleshooting
on installed machine
Inspect cylinder block and liner directly q q
Inspect cylinder liner directly q
Pressure-tightness test of oil cooler shows there is leakage q

Replace
Replace
Replace
Replace
Replace
Remedy
—
12V140E-3 Series 19
S-12 Oil pressure drops 1

General causes why oil pressure drops Causes
q Leakage, clogging, and/or wear of lubrication system
Defective oil pressure sensor and/or defective wiring harness

q Defective oil pressure control
q Improper selection of fuel (improper viscosity)
q Deterioration of oil due to overheating
Defective oil level sensor and/or wiring harness

Leaking, crushed, clogged hydraulic piping
Clogged and/or broken pipe in oil pan
Defective oil pump relief valve

Coolant and fuel mixing in oil
Clogged strainer in oil pan
Worn journal of bearing
Lack of oil in oil pan
Defective oil pump
Clogged oil filter

Degree of
E E E
Questions
machine operation Operated for long period

Oil pressure monitor indicates low oil pressure (if monitor is installed) Q w
Non-specified oil is being used Q Q
Replacement of filters not carried according to Operation and Maintenance Manual w
Indicates pressure drop at low idling time w Q
Oil pressure Indicates pressure drop at low and high idling times Q w w w Q
monitor
(if installed) Indicates pressure drop on slopes w
Indicates pressure drop occasionally w Q Q
Oil level monitor indicates oil level drop (if monitor is installed) w w
Oil level in oil pan is low w
External hydraulic piping is leaking or crushed w
Check items
Oil is milky or smells of diesel oil w

Metal particles are found when oil pan is drained w
Metal particles are found when oil filter is drained w Q
Metal particles are found in oil filter q

q q
Troubleshooting
Inspect oil pan strainer and pipe directly

See S-13
Oil pump rotation is heavy, there is play in oil pump q

Valve and spring of oil pump relief valve are fatigued and damaged q
Inspect oil filter directly q
Carry out troubleshooting according to “Abnormality in oil pressure sensor (*1)“ in E-mode q
If oil level sensor is replaced, oil level monitor indicates normally q
Adjusting
Replace
Replace
Replace
Correct
Remedy
Clean
Clean
Clean
Clean
—
Add
20 12V140E-3 Series
S-13 Oil level rises (Entry of coolant or fuel) 1

General causes why oil level rises Causes
q Coolant in oil (milky)
Clogged water pump drain hole (breather hole) and/or defective seal
q Fuel in oil (smells diluted diesel fuel)
a If oil is in coolant, carry out troubleshooting for "S-11 Oil is in cool-

ant".
Defective seal of auxiliary equipment (pump, compressor)

Broken oil cooler core and/or O-ring

Fuel leakage inside head cover
Worn or damaged rear oil seal

Cracks inside cylinder block
Defective thermostat seat

Defects in supply pump
Questions
Degree of
machine operation
Fuel consumption increasing w w
Coolant replenished more frequently Q w
There is oil mixed in coolant Q Q Q w
Oil smells of diesel fuel w w
Oil is milky Q w
When engine is started, drops of water come from muffler Q
When radiator cap is removed and engine is run at low idle, an abnormal number of bubbles
appears, or coolant spurts back w Q
Check items
Exhaust smoke is white Q Q

Water pump drain hole (breather hole) is clogged w
When water pump drain hole (breather hole) is cleaned, coolant comes out w
Oil level in clutch or damper chamber of installed machine is low w
Oil level in hydraulic tank of installed machine is low w

Remove and inspect head cover directly q
q q
Troubleshooting
Inspect cylinder block and/or liner directly

Inspect rear oil seal directly q
Pressure-tightness test of oil cooler shows there is leakage q
Remove and inspect water pump directly q
Remove and inspect thermostat cover directly q
Remove and inspect supply pump directly q
Inspect seal of auxiliary equipment directly q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
12V140E-3 Series 21
S-14 Coolant temperature becomes too high (overheating) 1

General causes why coolant temperature becomes too high Causes
q Lack of cooling air (deformation, and/or damages of fan)
Rise in power train oil temperature on applicable machine side

Drop in heat dissipation efficiency

q
q Problem in coolant circulation system
q Rise in oil temperature in power train on applicable
machine side
o Trouble shoot on the applicable machine side
Slipping fan belt and/or worn fan pulley

Defective radiator cap (pressure valve)
Defective coolant temperature gauge

Defective operation of thermostat
Clogged or crushed radiator fins
Clogged or broken oil cooler
Clogged radiator core

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

Inspect cylinder liner directly q
q
Carry out troubleshooting
Inspect oil cooler directly

Troubleshooting
Temperature difference between upper and lower tanks of radiator is large q

on installed machine
When operation of thermostat is tested, it does not open at cracking temperature q

Temperature difference between upper and lower tanks of radiator is slight q
Inspect radiator core directly q
When operation of radiator cap is carried out, its cracking pressure is low q
Inspect fan belt and pulley directly q
When coolant temperature is measured, it is found to be normal q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
—
Add
22 12V140E-3 Series
S-15 Abnormal noise is made 1

General causes why abnormal noise is emitted Causes
q Abnormality due to defective parts
Improper fuel injection timing (abnormality in coolant temperature sensor)

q Abnormal combustion
q Air leakage from air intake system
Deformed cooling fan and/or looseness or interference of fan belt

a Judge if the noise is an internal noise or an external noise
before starting troubleshooting.
a While the engine is not sufficiently warmed up, it is operated
Defective inside of muffler (dividing board out of position)

Broken dynamic valve system (valve and/or rocker lever)
Leakage of air between turbocharger and cylinder head
in the low-temperature mode. Accordingly, the engine sound
rises slightly higher. This is no abnormality, however.
Excessive wear of piston ring and/or cylinder liner

a When the engine is accelerated, the engine sound rises
slightly for approx. 3 seconds maximum. This is no abnor-
mality, however.
Interference or seizure of turbocharger
Removed or seized gear train bushing

Improper gear train backlash
Clogged or seized injector

Dirt caught in injector

Degree of
machine operation
Operated for long period E
Questions
Condition of Gradually increased Q Q

abnormal noise Suddenly increased Q Q Q
Non-specified fuel is being used Q
Oil replenished more frequently w
Metal particles are found when oil filter is drained w w
Air leaks between turbocharger and cylinder head w
When engine is cranked, abnormal sound is generated around EGR gas piping
When engine is cranked, abnormal sound is generated around cylinder head w w
When engine is cranked, beat noise is emitted around muffler w
Check items

some cylinders is low w Q
Color of exhaust Blue under light load w

gas Black Q w Q
Engine does not pick up smoothly and combustion is irregular w
Abnormal noise is loud when engine is accelerated Q Q Q Q
When turbocharger is rotated by hand, it is fount to be heavy q

When muffler is removed, abnormal noise disappears q
Troubleshooting

Inspect gear train directly q q
Inspect fan and fan belt directly q
Abnormal noise is heard only when engine is started q
Confirm with INSITE or with monitoring function on installed machine side q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Remedy
12V140E-3 Series 23
S-16 Vibration is excessive 1

General causes why vibration occurs Causes
q Defective parts (abnormal wear, breakage, etc.)
Broken output shaft and/or parts in damper on installed machine side

Misalignment between engine and devices on installed machine side
q Misalignment between installed machine
q Abnormal combustion
a If abnormal noise vibration occur, carry out troubleshooting for "S-15
Abnormal noise is emitted", too.
Stuck dynamic valve system (valve, rocker lever, etc.)
Loose engine mounting bolts and/or broken cushions

Worn main bearing and/or connecting rod bearing
Worn front support spigot joint portion

Improper gear train backlash

Worn camshaft bushing
Degree of
E E E E
Questions
machine operation Operated for long period

Condition of vibra- Suddenly increased Q Q
tion Gradually increased Q Q Q
Non-specified oil is being used Q Q
Metal particles are found when oil filter is drained w w
Metal particles are found when oil pan is drained w w
Oil pressure is low at low idle Q Q
Check items
Vibration occurs at mid-range speed Q Q

Vibration follows engine speed Q Q Q Q Q
Exhaust smoke is black w Q

Inspect main bearing and connecting rod bearing directly q
q
Troubleshooting
Inspect gear train directly

Inspect camshaft bushing directly q
Confirm with INSITE or with monitoring function on installed machine side q
Inspect engine mounting bolts and cushions directly q
When alignment is checked, radial runout or facial runout is detected q
Inspect front support spigot joint portion directly q
Inspect output shaft or inside of damper directly q
Adjusting
Adjusting
Replace
Replace
Replace
Replace
Replace
Replace
Remedy
24 12V140E-3 Series

© 2006 KOMATSU
All Rights Reserved
26 12V140E-3 Series
SEN00317-00
ENGINE 1SHOP MANUAL
12V140E-3 Series
Troubleshooting of electrical system
(E-mode), Part 1
Troubleshooting of electrical system (E-mode), Part 1 ................................................................................... 4
Information in troubleshooting table ..................................................................................................... 4
E-1 Code [111/CA111] ECM Critical Internal Failure (LH bank) ........................................................... 6
E-2 Code [111/CB111] ECM Critical Internal Failure (RH bank)........................................................... 8
E-3 Code [115/CA115] Eng. Ne and G (Bkup) Speed Sensor Error (LH bank).................................. 10
E-4 Code [115/CB115] Eng. Ne and G (Bkup) Speed Sensor Error (RH bank) ..................................11
E-5 Code [122/CA122] Charge Air Press. Sensor High Error (LH bank only) ................................... 12
E-6 Code [123/CA123] Charge Air Press. Sensor Low Error (LH bank only) .................................... 14
E-7 Code [131/CA131] Throttle Sensor High Error (LH bank only).................................................... 16
E-8 Code [132/CA132] Throttle Sensor Low Error (LH bank only) .................................................... 18
E-9 Code [135/CA135] Oil Press. Sensor High Error (LH bank only) ................................................ 20
E-10 Code [141/CA141] Oil Press. Sensor Low Error (LH bank only) ............................................... 22
E-11 Code [144/CA144] Coolant Temp. Sensor High Error (LH bank only) ....................................... 24
E-12 Code [145/CA145] Coolant Temp. Sensor Low Error (LH bank only) ....................................... 26
12V140E-3 Series 1
E-13 Code [153/CA153] Charge Air Temp. Sensor High Error (LH bank only) .................................. 28
E-14 Code [154/CA154] Charge Air Temp. Sensor Low Error (LH bank only)................................... 30
E-15 Code [187/CA187] Sensor Sup. 2 Volt. Low Error (LH bank) .................................................... 31
E-16 Code [187/CB187] Sensor Sup. 2 Volt. Low Error (RH bank) ................................................... 31
E-17 Code [212/CA212] Eng. Oil Temp.Sensor High Error (LH bank only) ....................................... 32
E-18 Code [213/CA213] Eng. Oil Temp.Sensor Low Error (LH bank only) ........................................ 34
E-19 Code [221/CA221] Ambient Air Press. Sensor High Error (LH bank only) ................................ 36
E-20 Code [222/CA222] Ambient Air Press. Sensor Low Error (LH bank only) ................................. 38
E-21 Code [227/CA227] Sensor Sup. 2 Volt. High Error (LH bank) ................................................... 40
E-22 Code [227/CB227] Sensor Sup. 2 Volt. High Error (RH bank)................................................... 42
E-23 Code [234/CA234] Eng. Overspeed (LH bank only).................................................................. 44
E-24 Code [238/CA238] Ne Speed Sensor Sup. Volt. Error (LH bank).............................................. 46
E-25 Code [238/CB238] Ne Speed Sensor Sup. Volt. Error (RH bank) ............................................. 48
E-26 Code [263/CA263] Fuel Temp. Sensor High Error (LH bank).................................................... 50
E-27 Code [263/CB263] Fuel Temp. Sensor High Error (RH bank) ................................................... 52
E-28 Code [265/CA265] Fuel Temp. Sensor Low Error (LH bank)..................................................... 54
E-29 Code [265/CB265] Fuel Temp. Sensor Low Error (RH bank) .................................................... 54
E-30 Code [271/CA271] PCV1 Short Error (LH bank) ....................................................................... 56
E-31 Code [271/CB271] PCV1 Short Error (RH bank)....................................................................... 58
E-32 Code [272/CA272] PCV1 Open Error (LH bank) ....................................................................... 60
E-33 Code [272/CB272] PCV1 Open Error (RH bank)....................................................................... 61
E-34 Code [273/CA273] PCV2 Short Error (LH bank) ....................................................................... 62
E-35 Code [273/CB273] PCV2 Short Error (RH bank)....................................................................... 64
E-36 Code [274/CA274] PCV2 Open Error (LH bank) ....................................................................... 66
E-37 Code [274/CB274] PCV2 Open Error (RH bank)....................................................................... 67
E-38 Code [322/CA322] Injector #1 (L/B #1) System Open/Short Error (LH bank) ........................... 68
E-44 Code [342/CA342] Caribration Code Incompatibility (LH bank) ................................................ 80
E-45 Code [342/CB342] Caribration Code Incompatibility (RH bank) ................................................ 80
E-46 Code [351/CA351] INJ. Drive Circuit Error (LH bank) ............................................................... 82
E-47 Code [351/CB351] INJ. Drive Circuit Error (RH bank)............................................................... 84
E-48 Code [352/CA352] Sensor Sup. 1 Volt. Low Error (LH bank) .................................................... 86
E-49 Code [352/CB352] Sensor Sup. 1 Volt. Low Error (RH bank) ................................................... 86
E-50 Code [386/CA386] Sensor Sup. 1 Volt. High Error (LH bank) ................................................... 88
E-51 Code [386/CB386] Sensor Sup. 1 Volt. High Error (RH bank)................................................... 90
E-52 Code [441/CA441] Battery Voltage Low Error (LH bank) .......................................................... 92
E-53 Code [441/CB441] Battery Voltage Low Error (RH bank).......................................................... 92
E-54 Code [442/CA442] Battery Voltage High Error (LH bank).......................................................... 93
E-55 Code [442/CB442] Battery Voltage High Error (RH bank) ......................................................... 93
2 12V140E-3 Series
Troubleshooting of electrical system (E-mode), Part 1 1

Information in troubleshooting table 1
a The following information is summarized in the troubleshooting table and the related electrical circuit diagram.
Before carrying out troubleshooting, understand that information fully.
Error code Failure code

Display on Display on Trouble Problem that appears on engine
INSITE applicable machine
Contents of
Contents of trouble detected by engine controller
trouble
Action of Action taken by engine controller to protect system or devices when engine controller detects
controller trouble
Problem that
Phenomenon that appears on engine as trouble as result of action taken by engine controller
appears on
(shown above)
machine
Related
Information related to detected trouble or troubleshooting
information
Causes Standard value in normal state/Remarks on troubleshooting

<Contents of description>
• Standard value in normal state to judge possible causes
• Remarks on judgment
1 <Troubles in wiring harness>

• Disconnection
Connector is connected imperfectly or wiring harness is
broken.
• Ground fault
Wiring harness which is not connected to chassis ground
circuit is in contact with chassis ground circuit.
• Hot short
Wiring harness which is not connected to power source (24
2 V) circuit is in contact with power source (24 V) circuit.
• Short circuit
Independent wiring harnesses are in contact with each
Possible causes other abnormally.
and standard Possible causes of trouble
value in normal (Given numbers are refer-
state ence numbers, which do not <Precautions for troubleshooting>
indicate priority) (1) Method of indicating connector No. and handling of T-
adapter
Insert or connect T-adapter as explained below for trouble-
3 shooting, unless otherwise specified.
• If connector No. has no marks of “male“ and “female“,
disconnect connector and insert T-adapters in both
male side and female side.
• If connector No. has marks of “male“ and “female“, dis-
connect connector and connect T-adapter to only male
side or female side.
(2) Entry order of pin Nos. and handling of tester leads
Connect positive (+) lead and negative (-) lead of tester as
explained below for troubleshooting, unless otherwise
4 specified.
• Connect positive (+) lead to pin No. or wiring harness
entered on front side.
• Connect negative (-) lead to pin No. or wiring harness
entered on rear side.
4 12V140E-3 Series
Related circuit diagram
This drawing is a part of the electric circuit diagram related to troubleshooting.

• Connector No.: Indicates (Model – Number of pins) and (Color).
• “Connector No. and pin No.“ from each branching/merging point: Shows the ends of
branch or source of merging within the parts of the same wiring harness.
• Arrow(io): Roughly shows the location on the machine.
12V140E-3 Series 5
E-1 Code [111/CA111] ECM Critical Internal Failure (LH bank) 1

Trouble Engine Controller Internal Failure (LH bank)
111 CA111
Contents of
• Abnormality occurred in controller.
trouble
Action of
• None in particular.
controller
Problem that
appears • Engine continues operation normally, but it may stop during operation or may not be able to start.
on machine
Related
• Different machine models may have different connector Nos.
information

Check fuse or circuit breaker on machine side directly for defect.
1 Defective fuse (If fuse is burnt or circuit breaker is turned OFF, circuit probably
has ground fault.)
a Prepare with starting switch OFF, then carry out troubleshoot-
Disconnection in wiring har- ing without turning starting switch ON.
ness
Wiring harness between PW L (female) (3), Resis-
2 (Disconnection in wiring or Max. 1 z
(4) – battery (+) tance
Possible causes defective contact in connec-
and standard tor) Wiring harness between PW L (female) (1), Resis-
Max. 1 z
value in normal (2) – chassis ground tance
state Ground fault in wiring har- a Prepare with starting switch OFF, then carry out troubleshoot-
ness ing without turning starting switch ON.
3
(Short circuit with GND cir- Wiring harness between PW L(female) (3), Resis-
cuit) Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
4 Defective engine controller
PW L Voltage
Between (3), (4) – (1), (2) 20 – 30 V
6 12V140E-3 Series
Circuit diagram related to controller power supply
12V140E-3 Series 7
E-2 Code [111/CB111] ECM Critical Internal Failure (RH bank) 1

Trouble Engine Controller Internal Failure (RH bank)
111 CB111
Contents of
• Abnormality occurred in controller.
trouble
Action of
controller
Problem that
appears on • Engine continues operation normally, but it may stop during operation or may not be able to start.
machine
Related infor-
mation

Check fuse or circuit breaker on machine side directly for possible
defect.
1 Defective fuse
(If fuse is burnt or circuit breaker is turned OFF, circuit probably has
ground fault.)
ness
Wiring harness between PW R (female) (3), Resis-
Possible causes (4) – battery (+) tance
defective contact in connec-
and standard Wiring harness between PW R (female) (1), Resis-
tor) Max. 1 z
value in normal (2) – chassis ground tance
state
Ground fault in wiring har- a Prepare with starting switch OFF, then carry out troubleshoot-
3
(Short circuit with GND cir- Wiring harness between PW R (female) (3), Resis-
cuit) Min. 1 Mz
(4) – battery (+) and chassis ground tance
PW R Voltage
Between (3), (4) – (1), (2) 20 – 30 V
8 12V140E-3 Series
12V140E-3 Series 9
E-3 Code [115/CA115] Eng. Ne and G (Bkup) Speed Sensor Error

(LH bank) 1
Trouble Abnormality in engine Ne and G (Bkup) speed sensor (LH bank)
115 CA115
Contents of
• Abnormality occurred in Ne speed sensor circuit and G (Bkup) speed sensor circuit simultaneously.
trouble
Action of
• Engine stop
controller
Phenomenon
• Engine cannot be started (engine has been stopped).
that appears on
• Engine stops (if engine has been running).
machine
Related
information

Defective Ne speed sensor
1 Carry out troubleshooting for code [689/CA689].
system
Defective G (Bkup) speed
sensor system
Possible causes Defective mount of Ne speed Check mount of Ne speed sensor directly for defect (defective
3
and standard sensor installation of sensor, internal defect of flywheel, etc.)
value in normal Defective mount of G (Bkup) Check mount of G (Bkup) speed sensor directly for defect (defec-
state 4
speed sensor tive installation of sensor, internal defect of supply pump, etc.)
Defective connection of sen- Check Ne speed sensor and G (Bkup) speed sensor directly for
5
sor (Wrong connection) defective connection (wrong connection).
If causes 1 – 5 are not detected, engine controller may be defec-
6 Defective engine controller tive. (Since trouble is in system, troubleshooting cannot be carried
out.)
10 12V140E-3 Series
E-4 Code [115/CB115] Eng. Ne and G (Bkup) Speed Sensor Error

(RH bank) 1
Trouble Abnormality in engine Ne and G (Bkup) speed sensor (RH bank)
115 CB115
Contents of
• Abnormality occurred in Ne speed sensor circuit and G (Bkup) speed sensor circuit simultaneously.
trouble
Action of
• Engine stop
controller
Phenomenon
• Engine cannot be started (if engine has been stopped).
that appears on
• Engine stops (if engine has been running).
machine
Related
information

Defective Ne speed sensor
system
Defective G(Bkup) speed
sensor system
Possible causes Defective mount of Ne speed Check mount of Ne speed sensor directly for defect (defective
3
and standard sensor installation of sensor, internal defect of flywheel, etc.)
value in normal Defective mount of G (Bkup) Check mount of G (Bkup) speed sensor directly for defect (defec-
state 4
speed sensor tive installation of sensor, internal defect of supply pump, etc.)
Defective connection Check Ne speed sensor and G (Bkup) speed sensor directly for
5
(Wrong connection) defective connection (wrong connection).
out.)
12V140E-3 Series 11
E-5 Code [122/CA122] Charge Air Press. Sensor High Error (LH bank
only) 1
Error code Failure code Sensor detection of abnormally high charge pressure
Trouble
122 CA122 (LH bank only)
Contents of
• Charge pressure sensor circuit detects abnormally high pressure.
trouble
Action of
• Sets charge pressure to fixed value (400 kPa) and continues operation.
controller
Phenomenon
that appears on • Acceleration performance of engine drops.
machine
Related
information

Defective sensor power sup- If code [187/CA187] or [227/CA227] is indicated, carry out trouble-
1
ply system shooting for it first.
or start engine and carry out troubleshooting.
Defective charge pressure PIM Voltage
2 sensor Between (1) – (2) Power supply 4.75 – 5.25 V
(Internal trouble)
Pressure sensor voltage is measured with wiring harness con-
nected. Accordingly, if voltage is abnormal, check wiring harness
and controller, too, for another cause of trouble, and then judge.
ing without turning starting switch ON.
Disconnection in wiring har- Wiring harness between LH J1 (female) (37) Resis-
ness Max. 1 z
– PIM (female) (1) tance
3 (Disconnection in wiring or
defective contact in connec- Wiring harness between LH J1 (female) (47) Resis-
Max. 1 z
tor) – PIM (female) (3) tance
Possible causes Wiring harness between LH J1 (female) (44) Resis-

Max. 1 z
and standard – PIM (female) (2) tance
value in normal a Prepare with starting switch OFF, then carry out troubleshoot-
state ing without turning starting switch ON.
Ground fault in wiring har- Wiring harness between LH J1 (female) (37) Resis-
Min. 1 Mz
ness – PIM (female) (1) and chassis ground tance
4
(Short circuit with GND cir- Wiring harness between LH J1 (female) (47) Resis-
cuit) Min. 1 Mz
– PIM (female) (3) and chassis ground tance
Wiring harness between LH J1 (female) (44) Resis-
Min. 1 Mz
– PIM (female) (2) and chassis ground tance
Wiring harness between LH J1 (female) (37)
Resis-
– PIM (female) (1) and LH J1 (female) (47) – Min. 1 Mz
Short circuit in wiring har- tance
PIM (female) (3)
ness
5 Wiring harness between LH J1 (female) (37)
(With another wiring har- Resis-
ness) – PIM (female) (1) and LH J1 (female) (44) – Min. 1 Mz
tance
PIM (female) (2)
Resis-
– PIM (female) (3) and LH J1 (female) (44) – Min. 1 Mz
tance
PIM (female) (2)
12 12V140E-3 Series

Possible causes a Prepare with starting switch OFF, then turn starting switch ON
and standard or start engine and carry out troubleshooting.
value in normal 6 Defective engine controller
state LH J1 Voltage
Between (37) – (47) Power supply 4.75 – 5.25 V
Circuit diagram related to charge pressure sensor
12V140E-3 Series 13
E-6 Code [123/CA123] Charge Air Press. Sensor Low Error (LH bank
only) 1
Error code Failure code Sensor detection of abnormally low charge pressure
Trouble
Contents of
• Abnormally low pressure detected in charge pressure sensor circuit.
trouble
Action of
• Sets charge pressure to fixed value (400 kPa) and continues operation.
controller
Phenomenon
that appears on • Acceleration performance of engine drops.
machine
Related
information
Possible causes Causes Standard value in normal state/Remarks on troubleshooting

and standard
value in normal Carry out troubleshooting for E-5 Code [122/CA122].
state
14 12V140E-3 Series
E-7 Code [131/CA131] Throttle Sensor High Error (LH bank only) 1
Throttle sensor of decelerator pedal type (Case of D475-5)
Trouble Throttle sensor detection of abnormally high level (LH bank only)
131 CA131
Contents of
• Throttle sensor circuit detection of abnormally high level.
trouble
Action of • Sets throttle angle with signal other than throttle sensor signal and continues operation.
controller (depending on each model)
Phenomenon
that appears on • Depends on machine model.
machine
Related infor-
mation

Defective sensor power sup- If code [2185/CA2185] or [2186/CA2186] is indicated, carry out
1
ply system troubleshooting for it first.
Defective deceleration sen-
sor DEC (male) Resistance
2
(Internal trouble) Between (A) – (C) 4.0 – 6.0 kz
Between (B) – (A) 0.25 – 5.0 kz
Between (B) – (C) 0.25 – 5.0 kz
Disconnection in wiring har- Wiring harness between OEM L (female) Resis-
ness Max. 1 z
(22) – DEC (female) (A) tance
Possible causes defective contact in connec- Wiring harness between OEM L (female) (9) Resis-
Max. 1 z
and standard tor) – DEC (female) (B) tance
value in normal Wiring harness between OEM L (female) Resis-
state Max. 1 z
(23) – DEC (female) (C) tance
Ground fault in wiring har- Wiring harness between OEM L(female) Resis-
Min. 1 Mz
ness (22) – DEC (female) (A) and chassis ground tance
4
(Short circuit with GND cir- Wiring harness between OEM L(female) (9) Resis-
cuit) Min. 1 Mz
– DEC (female) (B) and chassis ground tance
Wiring harness between OEM L(female) Resis-
Min. 1 Mz
(23) – DEC (female) (C) and chassis ground tance
5 Defective engine controller OEM L Voltage
Between (9) – (23) Signal 0.5 – 4.5 V
16 12V140E-3 Series
Circuit diagram related to deceleration pedal type throttle sensor (Case of D475–5)
12V140E-3 Series 17
E-8 Code [132/CA132] Throttle Sensor Low Error (LH bank only) 1
Trouble Throttle sensor detection of abnormally low level (LH bank only)
132 CA132
Contents of
• Signal voltage in throttle sensor circuit is abnormally low.
trouble
Phenomenon
that appears on • Varies by installed machine
machine
Related
information

and standard
state
18 12V140E-3 Series
E-9 Code [135/CA135] Oil Press. Sensor High Error (LH bank only) 1
Error code Failure code Oil pressure sensor detection of abnormally high pressure
Trouble
Contents of
• Signal voltage in oil pressure sensor circuit is abnormally high.
trouble
Action of
• Set oil pressure to default value (250 kPa) and continue operation.
controller
Phenomenon
that appears on
machine
Related
information

1
POIL Voltage
Defective oil pressure sensor
2 Between (1) – (2) Power supply 4.75 – 5.25 V
(Internal trouble)
Sensor voltage is measured with wiring harness connected.
Accordingly, if voltage is abnormal, check wiring harness and con-
troller, too, for another cause of trouble, and then judge.
ness Max. 1 z
– POIL (female) (1) tance
Max. 1 z
tor) – POIL (female) (2) tance

Max. 1 z
and standard – POIL (female) (3) tance
Min. 1 Mz
ness – POIL (female) (1) and chassis ground tance
4
cuit) Min. 1 Mz
– POIL (female) (2) and chassis ground tance
Min. 1 Mz
– POIL (female) (3) and chassis ground tance
Resis-
– POIL (female) (1) and LH J1 (female) (47) Min. 1 Mz
– POIL (female) (2)
ness
ness) – POIL (female) (1) and LH J1 (female) (13) Min. 1 Mz
tance
Resis-
– POIL (female) (2) and LH J1 (female) (13) Min. 1 Mz
tance
20 12V140E-3 Series

state LH J1 Voltage
Circuit diagram related to oil pressure sensor
12V140E-3 Series 21
E-10 Code [141/CA141] Oil Press. Sensor Low Error (LH bank only) 1
Error code Failure code Oil pressure sensor detection of abnormally low pressure
Trouble
Contents of
• Signal voltage in oil pressure sensor circuit is abnormally low.
trouble
Action of
• Sets oil pressure to default value (250 kPa) and continues operation.
controller
Phenomenon
that appears on
machine
Related
information

and standard
state
22 12V140E-3 Series
E-11 Code [144/CA144] Coolant Temp. Sensor High Error (LH bank
only) 1
Error code Failure code Coolant temperature sensor detection of abnormally high tempera-
Trouble
144 CA144 ture (LH bank only)
Contents of
• Signal voltage in coolant temperature sensor circuit is abnormally high.
trouble
Action of
• Fixes coolant temperature at (90 °C) and continues operation.
controller
Phenomenon
that appears on
machine
Related
information

Defective coolant tempera- ing without turning starting switch ON.
1 ture sensor
TWTR (male) Coolant temperature Resistance
(Internal trouble)
Between (A) – (B) 10 – 100 °C 0.6 – 20 kz
ness
Possible causes 2 (Disconnection in wiring or Max. 1 z
– TWTR (female) (A) tance
and standard defective contact in connec-
value in normal tor) Wiring harness between LH J1 (female) (38) Resis-
Max. 1 z
state – TWTR (female) (B) tance
3
cuit) Min. 1 Mz
– TWTR (female) (A) and chassis ground tance
LH J1 (female) Coolant temperature Resistance
Between (15) – (38) 10 – 100 °C 0.6 – 20 kz
24 12V140E-3 Series
Circuit diagram related to coolant temperature sensor
12V140E-3 Series 25
E-12 Code [145/CA145] Coolant Temp. Sensor Low Error (LH bank only)1
Error code Failure code Coolant temperature sensor detection of abnormally low tempera-
Trouble
Contents of
• Signal voltage in coolant temperature sensor circuit is abnormally low.
trouble
Action of
• Fixes coolant temperature at (90 °C) and continues operation.
controller
Phenomenon
that appears on
machine
Related
information

and standard
state
26 12V140E-3 Series
E-13 Code [153/CA153] Charge Air Temp. Sensor High Error (LH bank
only) 1
Error code Failure code Charge temperature sensor detection of abnormally high tempera-
Trouble
Contents of
• Signal voltage in charge temperature sensor circuit is abnormally high.
trouble
Action of
• Fixes charge temperature (intake air temperature) at (70 °C) and continues operation.
controller
Phenomenon
that appears on
machine
Related
information

Defective charge tempera- Intake air
TIM (male) Resistance
1 ture sensor temperature
(Internal trouble) Between (A) – (B) 10 – 100 °C 0.5 – 20 kz
Between (A) – chas-
All range Min. 1 Mz
sis ground
Possible causes ness
and standard 2 (Disconnection in wiring or Max. 1 z
– TIM (female) (A) tance
value in normal defective contact in connec-
state tor) Wiring harness between LH J1 (female) (47) Resis-
Max. 1 z
– TIM (female) (B) tance
3
cuit) Min. 1 Mz
– TIM (female) (A) and chassis ground tance
4 Defective engine controller Intake air
LH J1 (female) Resistance
temperature
Between (23) – (47) 10 – 100 °C 0.5 – 20 kz
28 12V140E-3 Series
Circuit diagram related to charge temperature sensor
12V140E-3 Series 29
E-14 Code [154/CA154] Charge Air Temp. Sensor Low Error (LH bank
only) 1
Error code Failure code Charge temperature sensor detection of abnormally low charge
Trouble
154 CA154 temperature (LH bank only)
Contents of
• Signal voltage in charge temperature sensor circuit is abnormally low.
trouble
Action of
• Fixes charge temperature (intake air temperature) at (70 °C) and continues operation.
controller
Phenomenon
that appears on
machine
Related
information

and standard
state
30 12V140E-3 Series
E-15 Code [187/CA187] Sensor Sup. 2 Volt. Low Error (LH bank) 1
Error code Failure code Power supply 2 sensor detection of abnormally low voltage
Trouble
187 CA187 (LH bank)
Contents of
• Signal voltage in sensor power supply 2 (5 V) circuit is abnormally low.
trouble
• Sets atmospheric pressure sensor to default value (52.44 kPa) and continues operation.
Action of • Sets oil pressure sensor to default value (250 kPa) and continues operation.
controller • Fixes charge pressure sensor value (400 kPa) and continues operation.
• Operates G (Bkup) sensor with signals of Ne speed sensor.
Phenomenon
that appears on • Output drops.
machine
Related
information

and standard
state
E-16 Code [187/CB187] Sensor Sup. 2 Volt. Low Error (RH bank) 1
Trouble
187 CB187 (RH bank)
Contents of
• Signal voltage in sensor power supply 2(5 V) circuit is abnormally low.
trouble
Action of
• Operate G (Bkup) sensor with signals of Ne speed sensor.
controller
Phenomenon
machine
Related
information

and standard
value in normal Carry out troubleshooting for E-22 Code [227/CB227].
state
12V140E-3 Series 31
E-17 Code [212/CA212] Eng. Oil Temp.Sensor High Error (LH bank
only) 1
Error code Failure code Engine oil temperature sensor detection of abnormally high tem-
Trouble
212 CA212 perature (LH bank only)
Contents of
• Signal voltage in engine oil temperature sensor circuit is abnormally high.
trouble
Action of
• Sets oil pressure to default value (100 °C) and continues operation.
controller
Phenomenon
that appears on
machine
Related
information

Defective oil temperature ing without turning starting switch ON.
1 sensor
TOIL (male) Oil temperature Resistance
(Internal trouble)
Between (A) – (B) 0 – 100 °C 0.5 – 36 kz
ness
Possible causes 2 (Disconnection in wiring or Max. 1 z
– TOIL (female) (A) tance
and standard defective contact in connec-
value in normal tor) Wiring harness between LH J1 (female) (47) Resis-
Max. 1 z
state – TOIL (female) (B) tance
3
cuit) Min. 1 Mz
– TOIL (female) (A) and chassis ground tance
LH J1 Oil temperature Resistance
(17) – (47) 0 – 100 °C 0.5 – 36 kz
32 12V140E-3 Series
Circuit diagram related to engine oil temperature sensor
12V140E-3 Series 33
E-18 Code [213/CA213] Eng. Oil Temp.Sensor Low Error (LH bank
only) 1
Error code Failure code Engine oil temperature sensor detection of abnormally low temper-
Trouble
213 CA213 ature (LH bank only)
Contents of
• Signal voltage in engine oil temperature sensor circuit is abnormally low.
trouble
Action of
• Sets oil temperature to default value (100 °C) and continues operation.
controller
Phenomenon
that appears on
machine
Related
information

and standard
state
34 12V140E-3 Series
E-19 Code [221/CA221] Ambient Air Press. Sensor High Error (LH bank
only) 1
Error code Failure code Atmospheric pressure sensor detection of abnormally high pres-
Trouble
221 CA221 sure (LH bank only)
Contents of
• Signal voltage in atmospheric pressure sensor circuit is abnormally high.
trouble
Action of
• Sets atmospheric pressure to default value (52.44 kPa) and continues operation.
controller
Phenomenon
machine
Related
information

1
PAMB Voltage
Defective atmospheric pres-
2 sure sensor
(Internal trouble) Between (3) – (2) Signal 0.5 – 4.5 V
ness Max. 1 z
– PAMB (female) (1) tance
Max. 1 z
tor) – PAMB (female) (3) tance
and standard Max. 1 z
– PAMB (female) (2) tance
value in normal
state a Prepare with starting switch OFF, then carry out troubleshoot-
Min. 1 Mz
ness – PAMB (female) (1) and chassis ground tance
4
cuit) Min. 1 Mz
– PAMB (female) (3) and chassis ground tance
Min. 1 Mz
– PAMB (female) (2) and chassis ground tance
Resis-
– PAMB (female) (1) and LH J1 (female) Min. 1 Mz
(38) – PAMB (female) (3)
ness
ness) – PAMB (female) (1) and LH J1 (female) (3) Min. 1 Mz
tance
– PAMB (female) (2)
Resis-
– PAMB (female) (3) and LH J1 (female) (3) Min. 1 Mz
tance
– PAMB (female) (2)
36 12V140E-3 Series
value in normal 6 Defective engine controller LH J1 Voltage
state Between (37) – (38) 4.75 – 5.25 V
Between (3) – (38) 0.5 – 4.5 V
Circuit diagram related to atmospheric pressure sensor
12V140E-3 Series 37
E-20 Code [222/CA222] Ambient Air Press. Sensor Low Error (LH bank
only) 1
Error code Failure code Atmospheric pressure sensor detection of abnormally low pressure
Trouble
Contents of
• Signal voltage in atmospheric pressure sensor circuit is abnormally low.
trouble
Action of
• Sets atmospheric pressure to default value (52.44 kPa) and continues operation.
controller
Phenomenon
machine
Related
information

and standard
state
38 12V140E-3 Series
E-21 Code [227/CA227] Sensor Sup. 2 Volt. High Error (LH bank) 1
Error code Failure code Power supply 2 sensor detection of abnormally high voltage
Trouble
227 CA227 (LH bank)
Contents of
• Signal voltage in sensor power supply 2(5 V) circuit is abnormally high.
trouble
Action of • Sets oil pressure sensor to default value (250 kPa) and continues operation.
controller • Fixes charge pressure sensor value (400 kPa) and continues operation.
• Operates G (Bkup) sensor with signals of Ne speed sensor.
Phenomenon
machine
Related
information

1 Defective related system If another failure code is indicated, carry out troubleshooting for it.
Atmospheric
Disconnect devices PAMB connector
Defective sensor pressure sensor
2 at right in order. If
(Internal trouble) error code disap- Oil pressure sensor POIL connector
pears subsequently, Charge pressure
that device has a PIM connector
sensor
defect in it.
G (Bkup) sensor G connector
ness
– respective sensors (female) tance
Possible causes tor) Wiring harness between LH J1 (female) (47) Resis-
Max. 1 z
and standard – respective sensors (female) tance
Ground fault in wiring har- Wiring harness between LH J1 (female) (37)
Resis-
ness – respective sensors (female) and chassis Min. 1 Mz
4 tance
(Short circuit with GND cir- ground
cuit) Wiring harness between LH J1 (female) (47)
Resis-
– respective sensors (female) and chassis Min. 1 Mz
tance
ground
Short circuit in wiring har- ing without turning starting switch ON.
ness
ness) – respective sensors (female) and LH J1 Min. 1 Mz
tance
(female) (47) – respective sensors (female)
LH J1 Voltage
Between (37) – (47) 4.75 – 5.25 V
40 12V140E-3 Series
Circuit diagram related to sensor power supply 2 (5 V)
12V140E-3 Series 41
E-22 Code [227/CB227] Sensor Sup. 2 Volt. High Error (RH bank) 1
Trouble
227 CB227 (RH bank)
Contents of
• Signal voltage in sensor power supply 2 (5 V) circuit is abnormally high.
trouble
Action of
• Operates G(Bkup) sensor with signals of Ne speed sensor.
controller
Phenomenon
machine
Related
information

Disconnect devices
Defective sensor (Internal at right in order. If
2
trouble) error code disap- G (Bkup)speed
G connector
pears subsequently, sensor
that device has a
defect in it.
ness
Wiring harness between RH J1 (female) Resis-
(37) – respective sensors (female) tance
tor) Wiring harness between RH J1 (female) Resis-
Max. 1 z
Possible causes (47) – respective sensors (female) tance
and standard a Prepare with starting switch OFF, then carry out troubleshoot-
value in normal ing without turning starting switch ON.
state Ground fault in wiring har- Wiring harness between RH J1 (female)
Resis-
ness (37) – respective sensors (female) and Min. 1 Mz
4 tance
(Short circuit with GND cir- chassis ground
cuit) Wiring harness between RH J1 (female)
Resis-
(47) – respective sensors (female) and Min. 1 Mz
tance
chassis ground
ness Wiring harness between RH J1 (female)
5
(With another wiring har- (37) – respective sensors (female) and RH Resis-
ness) Min. 1 Mz
J1 (female) (47) – respective sensors tance
(female)
RH J1 Voltage
Between (37) – (47) 4.75 – 5.25 V
42 12V140E-3 Series
12V140E-3 Series 43
E-23 Code [234/CA234] Eng. Overspeed (LH bank only) 1

Trouble Engine overspeed (LH bank only)
234 CA234
Contents of
• Engine speed is above operating range.
trouble
Action of
• Limits fuel injection rate until engine speed lowers to operating range.
controller
Phenomenon
that appears on • Engine speed fluctuates.
machine
Related
information

Possible causes 1 Defective related system If another failure code is indicated, carry out troubleshooting for it.
and standard 2 Improper way of use Way of use may be improper. Teach proper way of use to operator.
value in normal
state
out.)
44 12V140E-3 Series
E-24 Code [238/CA238] Ne Speed Sensor Sup. Volt. Error (LH bank) 1
Trouble Ne Speed Sensor Sup. Volt. Error (LH bank)
238 CA238
Contents of
• Abnormality occurred in Ne speed sensor power supply (5 V) circuit.
trouble
Action of
• Controls Ne speed sensor with signals of G (Bkup) speed sensor.
controller
Phenomenon
• Running engine stops (when G (Bkup) speed sensor is also abnormal).
that appears on
• Stopped engine cannot be started (when G (Bkup) speed sensor is also abnormal).
machine
Related
information

Disconnect devices
Defective Ne speed sensor at right in order. If
1
(Internal trouble) error code disap-
Ne speed sensor NE connector
pears subsequently,
that device has a
defect in it.
ness
– Ne (female) (1) tance
tor) Wiring harness between LH J1 (female) (48) Resis-
Possible causes Max. 1 z
and standard
state Ground fault in wiring har- ing without turning starting switch ON.
ness Wiring harness between LH J1 (female) (16) Resis-
3 Min. 1 Mz
(Short circuit with GND cir- – Ne (female) (1) and chassis ground tance
cuit) Wiring harness between LH J1 (female) (48) Resis-
Min. 1 Mz
– Ne (female) (2) and chassis ground tance
ness
ness) – Ne (female) (1) and LH J1 (female) (48) – Min. 1 Mz
tance
Ne (female) (2)
LH J1 Voltage
Between (16) – (48) 4.75 – 5.25 V
46 12V140E-3 Series
Circuit diagram related to Ne speed sensor power supply
12V140E-3 Series 47
E-25 Code [238/CB238] Ne Speed Sensor Sup. Volt. Error (RH bank) 1
Trouble Ne Speed Sensor Sup. Volt. Error (RH bank)
238 CB238
Contents of
• Abnormality occurred in Ne speed sensor power supply (5 V) circuit.
trouble
Action of
controller
Phenomenon
that appears on
machine
Related
information

Disconnect devices
Defective Ne speed sensor at right in order. If
1
Ne speed sensor NE connector
pears subsequently,
that device has a
defect in it.
ness
(48) – Ne (female) (2) tance
and standard
3 Min. 1 Mz
(Short circuit with GND cir- – Ne (female) (1) and chassis ground tance
cuit) Wiring harness between RH J1 (female) Resis-
Min. 1 Mz
(48) – Ne (female) (2) and chassis ground tance
ness
ness) – Ne (female) (1) and RH J1 (female) (48) – Min. 1 Mz
tance
Ne (female) (2)
Voltage
LH J1 (16) – RH J1 (48)
4.75 – 5.25 V
48 12V140E-3 Series
Circuit diagram related to Ne speed sensor power supply
12V140E-3 Series 49
E-26 Code [263/CA263] Fuel Temp. Sensor High Error (LH bank) 1
Error code Failure code Fuel temperature sensor detection of abnormally high temperature
Trouble
Contents of
• Signal voltage in fuel temperature sensor circuit is abnormally high.
trouble
Action of
• Fixes fuel temperature at (95 °C) and continues operation.
controller
Phenomenon
that appears on
machine
Related
information

Defective fuel temperature ing without turning starting switch ON.
1 sensor
LH TFUEL (male) Fuel temperature Resistance
(Internal trouble)
Between (A) – (B) 10 – 100 °C 0.6 – 20 kz
2 Max. 1 z
Possible causes (Disconnection or defective – LH TFUEL (female) (A) tance
and standard contact in connector) Wiring harness between LH J1 (female) (47) Resis-
value in normal Max. 1 z
– LH TFUEL (female) (B) tance
state
Ground fault in wiring har-
ness Resis-
3 – LH TFUEL (female) (A) and chassis Max. 1 Mz
(Short circuit with GND cir- tance
ground
cuit)
LH J1 (female) Fuel temperature Resistance
Between (30) – (47) 10 – 100 °C 0.6 – 20 kz
50 12V140E-3 Series
Circuit diagram related to fuel temperature sensor
12V140E-3 Series 51
E-27 Code [263/CB263] Fuel Temp. Sensor High Error (RH bank) 1
Error code Failure code Fuel temperature sensor detection of abnormally high temperature
Trouble
263 CB263 (RH bank only)
Contents of
• Signal voltage in fuel temperature sensor circuit is abnormally high.
trouble
Action of
controller
Phenomenon
that appears on
machine
Related
information

Defective fuel temperature ing without turning starting switch ON.
1 sensor
RH TFUEL (male) Fuel temperature Resistance
(Internal trouble)
Between (A) – (B) 10 – 100 °C 0.6 – 20 kz
ness
Possible causes (30) – RH TFUEL (female) (A) tance
and standard tor) Wiring harness between RH J1 (female) Resis-
value in normal Max. 1 z
(47) – RH TFUEL (female) (B) tance
state
Wiring harness between RH J1 (female)
ness Resis-
3 (30) – RH TFUEL (female) (A) and chassis Max. 1 Mz
(Short circuit with GND cir- tance
ground
cuit)
RH J1 (female) Fuel temperature Resistance
Between (30) – (47) 10 – 100 °C 0.6 – 20 kz
52 12V140E-3 Series
Circuit diagram related to fuel temperature sensor
12V140E-3 Series 53
E-28 Code [265/CA265] Fuel Temp. Sensor Low Error (LH bank) 1
Error code Failure code Fuel temperature sensor detection of abnormally low temperature
Trouble
265 CA265 (LH bank)
Contents of
• Signal voltage in fuel temperature sensor circuit is abnormally low.
trouble
• Substitutes with coolant temperature sensor. If coolant temperature sensor is also in abnormal
Action of
state.
controller
• Sets oil temperature to default value (95 °C) and continues operation.
Phenomenon
that appears on
machine
Related
information

and standard
state
E-29 Code [265/CB265] Fuel Temp. Sensor Low Error (RH bank) 1
Error code Failure code Fuel temperature sensor detection of abnormally low temperature
Trouble
265 CB265 (RH bank)
Contents of
• Signal voltage in fuel temperature sensor circuit is abnormally low.
trouble
• Substitutes with coolant temperature sensor. If coolant temperature sensor is also in abnormal
Action of
state.
controller
Phenomenon
that appears on
machine
Related
information

and standard
state
54 12V140E-3 Series
E-30 Code [271/CA271] PCV1 Short Error (LH bank) 1

Trouble PCV1 Short circuit Error (LH bank)
271 CA271
Contents of
• There is short circuit in PCV1 circuit of supply pump.
trouble
Action of
controller
Phenomenon
that appears on
machine
Related
information

Defective supply pump LH PCV1 (male) Resistance
1 PCV1
(Internal trouble) Between (1) – (2) 2.3 – 5.3 z
Between (1), (2) – chassis
Min. 1 Mz
ground
Ground fault in wiring har- ing without turning starting switch ON.
2 Min. 1 Mz
(Short circuit with GND cir- – LH PCV1 (female) (1) and chassis ground tance
Possible causes cuit) Wiring harness between LH J1 (female)(5) – Resis-
and standard Min. 1 Mz
LH PCV1 (female) (2) and chassis ground tance
value in normal
state a Prepare with starting switch OFF, then turn starting switch ON
Hot short in wiring harness Wiring harness between LH J1 (female) (4)
3 Voltage Max. 1 V
(Contact with 24 V) – LH PCV1 (female) (1) and chassis ground
Voltage Max. 1 V
– LH PCV1 (female) (2) and chassis ground
Between (4) – (5) 2.3 – 5.3 z
Min. 1 Mz
ground
56 12V140E-3 Series
Circuit diagram related to supply pump PCV1
12V140E-3 Series 57
E-31 Code [271/CB271] PCV1 Short Error (RH bank) 1

Trouble PCV1 Short circuit Error (RH bank)
271 CB271
Contents of
trouble
Action of
controller
Phenomenon
that appears on
machine
Related
information

Defective supply pump RH PCV1 (male) Resistance
1 PCV1
Min. 1 Mz
ground
ness Wiring harness between RH J1 (female) (4) Resis-
2 Min. 1 Mz
(Short circuit with GND cir- – RH PCV1 (female) (1) and chassis ground tance
Possible causes cuit) Wiring harness between RH J1 (female) (5) Resis-
– RH PCV1 (female) (2) and chassis ground tance
value in normal
Hot short in wiring harness Wiring harness between RH J1 (female) (4)
3 Voltage Max. 1 V
(Contact with 24 V) – RH PCV1 (female) (1) and chassis ground
Wiring harness between RH J1 (female) (5)
Voltage Max. 1 V
– RH PCV1 (female) (2) and chassis ground
RH J1 (female) Resistance
Between (4) – (5) 2.3 – 5.3 z
Min. 1 Mz
ground
58 12V140E-3 Series
12V140E-3 Series 59
E-32 Code [272/CA272] PCV1 Open Error (LH bank) 1

Trouble PCV1 Disconnection Error (LH bank)
272 CA272
Contents of
• There is disconnection in PCV1 circuit of supply pump.
trouble
Action of
controller
Phenomenon
that appears on
machine
Related
information

1 PCV1
(Internal disconnection) Between (1) – (2) 2.3 – 5.3 z
Min. 1 Mz
ground
Possible causes Disconnection in wiring har- ing without turning starting switch ON.
and standard ness
value in normal Wiring harness between LH J1 (female) (4) Resis-
state – LH PCV1 (female) (1) tance
Max. 1 z
– LH PCV1 (female) (2) tance
Between (4) – (5) 2.3 – 5.3 z
Min. 1 Mz
ground
60 12V140E-3 Series
E-33 Code [272/CB272] PCV1 Open Error (RH bank) 1

Trouble PCV1 Disconnection Error (RH bank)
272 CB272
Contents of
trouble
Action of
controller
Phenomenon
that appears on
machine
Related
information

1 PCV1
(Internal disconnection) Between (1) – (2) 2.3 – 5.3 z
Min. 1 Mz
ground
Possible causes Disconnection in wiring har- ing without turning starting switch ON.
and standard ness
value in normal Wiring harness between RH J1 (female) (4) Resis-
state – RH PCV1 (female) (1) tance
tor) Wiring harness between RH J1 (female) (5) Resis-
Max. 1 z
– RH PCV1 (female) (2) tance
RH J1(female) Resistance
Between (4) – (5) 2.3 – 5.3 z
Min. 1 Mz
ground
12V140E-3 Series 61
E-34 Code [273/CA273] PCV2 Short Error (LH bank) 1

Trouble PCV2 Short circuit Error (LH bank)
273 CA273
Contents of
trouble
Action of
controller
Phenomenon
that appears on
machine
Related
information

1 PCV2
Min. 1 Mz
ground
2 Min. 1 Mz
(Short circuit with GND cir- – LH PCV2 (female) (1) and chassis ground tance
Possible causes cuit) Wiring harness between LH J1 (female) (10) Resis-
– LH PCV2 (female) (2) and chassis ground tance
value in normal
Hot short in wiring harness Wiring harness between LH J1 (female) (9)
3 Voltage Max. 1 V
(Contact with 24 V) – LH PCV2 (female) (1) and chassis ground
Voltage Max. 1 V
– LH PCV2 (female) (2) and chassis ground
Between (9) – (10) 2.3 – 5.3 z
Min. 1 Mz
ground
62 12V140E-3 Series
12V140E-3 Series 63
E-35 Code [273/CB273] PCV2 Short Error (RH bank) 1

Trouble PCV2 Short circuit Error (RH bank)
273 CB273
Contents of
trouble
Action of
controller
Phenomenon
that appears on
machine
Related
information

1 PCV2
Min. 1 Mz
ground
ness Wiring harness between RH J1 (female) (9) Resis-
2 Min. 1 Mz
(Short circuit with GND cir- – RH PCV2 (female) (1) and chassis ground tance
Possible causes cuit) Wiring harness between RH J1(female) (10) Resis-
Min. 1 Mz
and standard – RH PCV2 (female) (2) and chassis ground tance
value in normal a Prepare with starting switch OFF, then turn starting switch ON
state and carry out troubleshooting.
Wiring harness between RH J1 (female) (9)
Hot short in wiring harness Voltage Max. 1 V
3 – RH PCV2 (female) (1) and chassis ground
(Contact with 24 V)
(10) – RH PCV2 (female) (2) and chassis Voltage Max. 1 V
ground
Between (9) – (10) 2.3 – 5.3 z
Min. 1 Mz
ground
64 12V140E-3 Series
12V140E-3 Series 65
E-36 Code [274/CA274] PCV2 Open Error (LH bank) 1

Trouble PCV2 Disconnection Error (LH bank)
274 CA274
Contents of
trouble
Action of
controller
Phenomenon
that appears on
machine
Related
information

Defective supply pump ing without turning starting switch ON.
1 PCV2
LH PCV2 (male) Resistance
(Internal disconnection)
Between (1) – (2) 2.3 – 5.3 z
Max. 1 z
Between (9) – (10) 2.3 – 5.3 z
Min. 1 Mz
ground
66 12V140E-3 Series
E-37 Code [274/CB274] PCV2 Open Error (RH bank) 1

Trouble PCV2 Disconnection Error (RH bank)
274 CB274
Contents of
trouble
Action of
controller
Phenomenon
that appears on
machine
Related
information

Defective supply pump ing without turning starting switch ON.
1 PCV2
RH PCV2 (male) Resistance
(Internal disconnection)
Between (1) – (2) 2.3 – 5.3 z
Wiring harness between RH J1 (female) (9) Resis-
– RH PCV2 (female) (1) tance
state tor) Wiring harness between RH J1 (female) Resis-
Max. 1 z
(10) – RH PCV2 (female) (2) tance
Between (9) – (10) 2.3 – 5.3 z
Min. 1 Mz
ground
12V140E-3 Series 67
E-38 Code [322/CA322] Injector #1 (L/B #1) System Open/Short Error

(LH bank) 1
Error code Failure code Disconnection or short circuit in injector #1 (L/B #1) system (LH
Trouble
322 CA322 bank)
Contents of
• There is disconnection or short circuit in injector in injector #1 circuit.
trouble
Action of
controller
Phenomenon
• Output drops.
that appears on
• Idle speed is unstable.
machine
Related
information

Defective injector #1 LH CN1 (male) Resistance
1
Min. 1 Mz
ground
ness
– LH CN1 (female) (1) tance
value in normal
3 Min. 1 Mz
(Short circuit with GND cir- – LH CN1 (female) (1) and chassis ground tance
Min. 1 Mz
– LH CN1 (female) (2) and chassis ground tance
Between (45) – (53) 0.4 – 1.1 z
Min. 1 Mz
ground
68 12V140E-3 Series
Circuit diagram related to injector #1
12V140E-3 Series 69

(LH bank) 1
Error code Failure code Disconnection or short circuit in injector #5 (L/B #5) system
Trouble
323 CA323 (LH bank)
Contents of
• There is disconnection or short circuit in injector #5 circuit.
trouble
Action of
controller
Phenomenon
• Output drops.
that appears on
machine
Related
information

1
Min. 1 Mz
ground
ness
value in normal
3 Min. 1 Mz
Min. 1 Mz
Between (46) – (60) 0.4 – 1.1 z
Min. 1 Mz
ground
70 12V140E-3 Series
12V140E-3 Series 71

(LH bank) 1
Trouble
324 CA324 (LH bank)
Contents of
trouble
Action of
controller
Phenomenon
• Output drops.
that appears on
machine
Related
information

1
Min. 1 Mz
ground
ness
value in normal
3 Min. 1 Mz
Min. 1 Mz
Between (55) – (52) 0.4 – 1.1 z
Min. 1 Mz
ground
72 12V140E-3 Series
12V140E-3 Series 73

(LH bank) 1
Trouble
325 CA325 (LH bank)
Contents of
trouble
Action of
controller
Phenomenon
• Output drops.
that appears on
machine
Related
information

1
Min. 1 Mz
ground
ness
value in normal
3 Min. 1 Mz
Min. 1 Mz
Between (57) – (59) 0.4 – 1.1 z
Min. 1 Mz
ground
74 12V140E-3 Series
12V140E-3 Series 75

(LH bank) 1
Trouble
331 CA331 (LH bank)
Contents of
trouble
Action of
controller
Phenomenon
• Output drops.
that appears on
machine
Related
information

1
Min. 1 Mz
ground
ness
value in normal
3 Min. 1 Mz
Min. 1 Mz
Between (54) – (51) 0.4 – 1.1 z
Min. 1 Mz
ground
76 12V140E-3 Series
12V140E-3 Series 77

(LH bank) 1
Trouble
332 CA332 (LH bank)
Contents of
trouble
Action of
controller
Phenomenon
• Output drops.
that appears on
machine
Related
information

1
Min. 1 Mz
ground
ness
value in normal
3 Min. 1 Mz
Min. 1 Mz
Between (56) – (58) 0.4 – 1.1 z
Min. 1 Mz
ground
78 12V140E-3 Series
12V140E-3 Series 79
E-44 Code [342/CA342] Caribration Code Incompatibility (LH bank) 1

Trouble Engine Controller data matching failure (LH bank)
342 CA342
Contents of
• Matching error occurred in engine controller data.
trouble
Action of
controller
Phenomenon
that appears on • Engine continues operation normally, but it may stop during operation or may not be able to start.
machine
Related
information

and standard
state
E-45 Code [342/CB342] Caribration Code Incompatibility (RH bank) 1

Trouble Engine Controller data matching failure (RH bank)
342 CB342
Contents of
• Matching error occurred in engine controller data.
trouble
Action of
controller
Phenomenon
machine
Related
information

and standard
state
80 12V140E-3 Series
E-46 Code [351/CA351] INJ. Drive Circuit Error (LH bank) 1

Trouble Injector drive circuit error (LH bank)
351 CA351
Contents of
• Abnormality occurred in injector drive circuit.
trouble
Action of
• Limits output and continues operation (Limits common rail pressure).
controller
Phenomenon
machine
Related
information

If another failure code (code of abnormality in injector system) is
1 Defective related system
indicated, carry out troubleshooting for it.
Check fuse or circuit breaker on installed machine side directly for
possible defect.
2 Defective fuse
ground fault.)
Wiring harness between PW L (female) (3), Resis-
tor) Wiring harness between PW L (female) (1), Resis-
state Max. 1 z
(2) – chassis ground tance
4
(Short circuit with GND cir- Wiring harness between PW L (female) (3), Resis-
cuit) Min. 1 Mz
PW L Voltage
Between (3), (4) – (1), (2) 20 – 30 V
82 12V140E-3 Series
12V140E-3 Series 83
E-47 Code [351/CB351] INJ. Drive Circuit Error (RH bank) 1

Trouble Injector drive circuit error (RH bank)
351 CB351
Contents of
• Abnormality occurred in injector drive circuit.
trouble
Action of
controller
Phenomenon
machine
Related
information

If another failure code (code of abnormality in injector system) is
1 Defective related system
indicated, carry out troubleshooting for it.
Check fuse or circuit breaker on installed machine side directly for
possible defect.
2 Defective fuse
ground fault.)
Wiring harness between PW R (female) (3), Resis-
tor) Wiring harness between PW R (female) (1), Resis-
state Max. 1 z
(2) – chassis ground tance
4
(Short circuit with GND cir- Wiring harness between PW R (female) (3), Resis-
cuit) Min. 1 Mz
PW R Voltage
Between (3), (4) – (1), (2) 20 – 30 V
84 12V140E-3 Series
12V140E-3 Series 85
E-48 Code [352/CA352] Sensor Sup. 1 Volt. Low Error (LH bank) 1
Trouble
352 CA352 (LH bank)
Contents of
trouble
Action of
controller
Phenomenon
machine
Related
information

and standard
state
E-49 Code [352/CB352] Sensor Sup. 1 Volt. Low Error (RH bank) 1
Trouble
352 CB352 (RH bank)
Contents of
trouble
Action of
controller
Phenomenon
machine
Related
information

and standard
state
86 12V140E-3 Series
E-50 Code [386/CA386] Sensor Sup. 1 Volt. High Error (LH bank) 1
Trouble
386 CA386 (LH bank)
Contents of
trouble
Action of
controller
Phenomenon
machine
Related
information

Disconnect devices
Defective sensor (Internal at right in order. If
2
trouble) error code disap- LH common rail
LH PFUEL connector
pears subsequently, pressure sensor
that device has a
defect in it.
ness Max. 1 z
– LH PFUEL (female) (1) tance
Max. 1 z
tor) – LH PFUEL (female) (2) tance
Max. 1 z
Possible causes a Prepare with starting switch OFF, then carry out troubleshoot-
and standard ing without turning starting switch ON.
value in normal
state Resis-
– LH PFUEL (female) (1) and chassis Min. 1 Mz
Ground fault in wiring har- tance
ground
ness
(Short circuit with GND cir- Resis-
cuit) – LH PFUEL (female) (2) and chassis Min. 1 Mz
tance
ground
Resis-
tance
ground
Resis-
– LH PFUEL (female) (1) and LH J1 Min. 1 Mz
(female) (25) – LH PFUEL (female) (2)
ness
ness) – LH PFUEL (female) (1) and LH J1 Min. 1 Mz
tance
Resis-
tance
88 12V140E-3 Series

and standard and carry out troubleshooting.
state LH J1 Voltage
Between (33) – (47) 4.75 – 5.25 V
12V140E-3 Series 89
E-51 Code [386/CB386] Sensor Sup. 1 Volt. High Error (RH bank) 1
Trouble
386 CB386 (RH bank)
Contents of
trouble
Action of
controller
Phenomenon
machine
Related
information

Disconnect devices
Defective sensor at right in order. If
2
(Internal trouble) error code disap- RH common rail RH PFUEL
pears subsequently, pressure sensor connector
that device has a
defect in it.
Disconnection in wiring har- Wiring harness between RH J1 (female) Resis-
ness Max. 1 z
(33) – RH PFUEL (female) (1) tance
defective contact in connec- Wiring harness between RH J1 (female) Resis-
Max. 1 z
tor) (25) – RH PFUEL (female) (2) tance
Max. 1 z
Possible causes a Prepare with starting switch OFF, then carry out troubleshoot-
and standard ing without turning starting switch ON.
value in normal Wiring harness between RH J1 (female)
Resis-
state (33) – RH PFUEL (female) (1) and chassis Min. 1 Mz
ground
ness
4 Wiring harness between RH J1 (female)
cuit) (25) – RH PFUEL (female) (2) and chassis Min. 1 Mz
tance
ground
Resis-
(47) – RH PFUEL (female) (2) and chassis Min. 1 Mz
tance
ground
Resis-
(33) – RH PFUEL (female) (1) and RH J1 Min. 1 Mz
tance
Short circuit in wiring har- (female) (25) – RH PFUEL (female) (2)
ness Wiring harness between wiring RH J1
5
(With another wiring har- (female) (33) – RH PFUEL (female) (1) and Resis-
ness) Min. 1 Mz
RH J1 (female) (47) – RH PFUEL (female) tance
(3)
Resis-
tance
(female) (47) – RH PFUEL (female) (3)
90 12V140E-3 Series

and standard and carry out troubleshooting.
state RH J1 Voltage
Between (33) – (47) 4.75 – 5.25 V
12V140E-3 Series 91
E-52 Code [441/CA441] Battery Voltage Low Error (LH bank) 1

Trouble Supply voltage abnormally low (LH bank)
441 CA441
Contents of
• Abnormally low supply voltage in circuit.
trouble
Action of
controller
Phenomenon
machine
Related
information

and standard
state
E-53 Code [441/CB441] Battery Voltage Low Error (RH bank) 1

Trouble Supply voltage abnormally low (RH bank)
441 CB441
Contents of
trouble
Action of
controller
Phenomenon
machine
Related
information

and standard
state
92 12V140E-3 Series
E-54 Code [442/CA442] Battery Voltage High Error (LH bank) 1

Trouble Supply voltage abnormally high (LH bank)
442 CA442
Contents of
trouble
Action of
controller
Phenomenon
machine
Related
information

and standard
state
E-55 Code [442/CB442] Battery Voltage High Error (RH bank) 1

Trouble Supply voltage abnormally high (RH bank)
442 CB442
Contents of
trouble
Action of
controller
Phenomenon
machine
Related
nformation

and standard
state
12V140E-3 Series 93

© 2006 KOMATSU
All Rights Reserved
94 12V140E-3 Series
SEN00318-00
ENGINE 1SHOP MANUAL
12V140E-3 Series
Troubleshooting of electrical system
(E-mode), Part 2
Troubleshooting of electrical system (E-mode), Part 2 ................................................................................... 3
E-56 Code [449/CA449] Rail Press. Very High Error (LH bank) .......................................................... 3
E-57 Code [449/CB449] Rail Press. Very High Error (RH bank).......................................................... 3
E-58 Code [451/CA451] Rail Press. Sensor High Error (LH bank) ...................................................... 4
E-59 Code [451/CB451] Rail Press. Sensor High Error (RH bank) ..................................................... 6
E-60 Code [452/CA452] Rail Press. Sensor Low Error (LH bank)....................................................... 8
E-61 Code [452/CB452] Rail Press. Sensor Low Error (RH bank) ...................................................... 8
E-62 Code [553/CA553] Rail Press. High Error 1 (LH bank) ............................................................... 9
E-63 Code [553/CB553] Rail Press. High Error 1 (RH bank) ............................................................. 10
E-64 Code [554/CA554] Rail Press. Sensor In Range Error (LH bank)..............................................11
E-65 Code [554/CB554] Rail Press. Sensor In Range Error (RH bank) .............................................11
E-66 Code [559/CA559] Rail Press. Low Error 1 (LH bank) .............................................................. 12
E-67 Code [559/CB559] Rail Press. Low Error 1 (RH bank).............................................................. 16
E-68 Code [689/CA689] Eng. Ne Speed Sensor Error (LH bank)...................................................... 20
12V140E-3 Series 1
E-69 Code [689/CB689] Eng. Ne Speed Sensor Error (RH bank) ..................................................... 22
E-70 Code [691/CA691] Intake Air Temp Sensor High Error (LH bank only) ..................................... 24
E-71 Code [692/CA692] Intake Air Temp Sensor Low Error (LH bank only) ...................................... 26
E-72 Code [731/CA731] Eng. G (Bkup) Speed Sensor Phase Error (LH bank)................................. 27
E-73 Code [731/CB731] Eng. G (Bkup) Speed Sensor Phase Error (RH bank) ................................ 27
E-74 Code [757/CA757] All Continuous Data Lost Error (LH bank)................................................... 28
E-75 Code [757/CB757] All Continuous Data Lost Error (RH bank) .................................................. 28
E-76 Code [778/CA778] Eng. G (Bkup) Speed Sensor Error (LH bank) ............................................ 30
E-77 Code [778/CB778] Eng. G (Bkup) Speed Sensor Error (RH bank) ........................................... 32
E-78 Code [781/CA781] Inter Multi-controller Communication Error (LH bank)................................. 34
E-79 Code [781/CB781] Inter Multi-controller Communication Error (RH bank) ................................ 36
E-80 Code [1117/CA1117] Persistent Data Lost Error (LH bank) ....................................................... 37
E-81 Code [1117/CB1117] Persistent Data Lost Error (RH bank)....................................................... 37
E-82 Code [1257/CA1257] Harness Key error (LH bank) .................................................................. 38
E-83 Code [1257/CB1257] Harness Key error (RH bank).................................................................. 39
E-84 Code [1548/CB1548] Injector #7 (R/B #1) System Open/Short Error (RH bank) ...................... 40
E-86 Code [1551/CB1551] Injector #10 (R/B #4) System Open/Short Error (RH bank) .................... 44
E-90 Code [1633/CA1633] KOMNET Datalink Timeout Error (LH bank) ........................................... 52
E-91 Code [2185/CA2185] Throttle Sens. Sup. Volt. High Error (LH bank only)................................ 54
E-92 Code [2186/CA2186] Throttle Sens. Sup. Volt. Low Error (LH bank only) ................................ 56
E-93 Code [2249/CA2249] Rail Press. Very Low Error (LH bank) ..................................................... 57
E-94 Code [2249/CB2249] Rail Press. Very Low Error (RH bank)..................................................... 57
E-95 Code [– –*1/–] Eng. Overheat (LH bank only) ........................................................................... 58
E-96 Code [– –*2/–] Eng. Oil Press. Low Speed Derate (LH bank only)............................................ 58
E-97 Code [– –*3/–] Press. Low Torque Derate (LH bank only)......................................................... 59
2 12V140E-3 Series
Troubleshooting of electrical system (E-mode), Part 2 1

E-56 Code [449/CA449] Rail Press. Very High Error (LH bank) 1
Trouble Common rail pressure abnormally high Error 2 (LH bank)
449 CA449
Contents of
• Common rail pressure sensor circuit detected abnormally high pressure (level 2).
trouble
Action of
controller
Phenomenon
machine
Related
information

and standard
state
E-57 Code [449/CB449] Rail Press. Very High Error (RH bank) 1
Trouble Common rail pressure abnormally high Error 2 (RH bank)
449 CB449
Contents of
trouble
Action of
controller
Phenomenon
machine
Related
information

and standard
state
12V140E-3 Series 3
E-58 Code [451/CA451] Rail Press. Sensor High Error (LH bank) 1
Error code Failure code Common rail pressure sensor detected abnormally high pressure
Trouble
451 CA451 (LH bank)
Contents of
• Signal voltage in common rail pressure sensor circuit is abnormally high.
trouble
Action of
controller
Phenomenon
machine
Related
information

1
LH PFUEL Voltage
Defective common rail pres-
2 sure sensor
Possible causes Disconnection in wiring har- Wiring harness between LH J1 (female) (33) Resis-
and standard ness Max. 1 z
value in normal 3 (Disconnection in wiring or
state defective contact in connec- Wiring harness between LH J1 (female) (25) Resis-
Max. 1 z
tor) – LH PFUEL (female) (2) tance
Max. 1 z
Resis-
ground
ness
cuit) – LH PFUEL (female) (2) and chassis Min. 1 Mz
tance
ground
Resis-
tance
ground
4 12V140E-3 Series

Resis-
ness
Possible causes – LH PFUEL (female) (1) and LH J1 Min. 1 Mz
ness) tance
and standard (female) (47) – LH PFUEL (female) (3)
value in normal
state Resis-
tance
6 Defective engine controller LH J1 Voltage
Between (33) – (47) 4.75 – 5.25 V
Between (25) – (47) 0.25 – 4.6 V
Circuit diagram related to common rail pressure sensor
12V140E-3 Series 5
E-59 Code [451/CB451] Rail Press. Sensor High Error (RH bank) 1
Error code Failure code Common rail pressure sensor detected abnormally high pressure
Trouble
451 CB451 (RH bank)
Contents of
• Signal voltage in common rail pressure sensor circuit is abnormally high.
trouble
Action of
controller
Phenomenon
machine
Related
information

Defective sensor power sup- If code [187/CB187] or [227/CB227] is indicated, carry out trouble-
1
RH PFUEL Voltage
Defective common rail pres-
2 sure sensor
Possible causes Disconnection in wiring har- Wiring harness between RH J1 (female) Resis-
and standard ness Max. 1 z
value in normal 3 (Disconnection in wiring or
state defective contact in connec- Wiring harness between RH J1 (female) Resis-
Max. 1 z
tor) (25) – RH PFUEL (female) (2) tance
Max. 1 z
Resis-
ground
ness
cuit) (25) – RH PFUEL (female) (2) and chassis Min. 1 Mz
tance
ground
Resis-
tance
ground
6 12V140E-3 Series

Resis-
ness
Possible causes (33) – RH PFUEL (female) (1) and RH J1 Min. 1 Mz
ness) tance
and standard (female) (47) – RH PFUEL (female) (3)
value in normal
state Resis-
tance
6 Defective engine controller RH J1 Voltage
Between (33) – (47) 4.75 – 5.25 V
Between (25) – (47) 0.25 – 4.6 V
Circuit diagram related to common rail pressure sensor
12V140E-3 Series 7
E-60 Code [452/CA452] Rail Press. Sensor Low Error (LH bank) 1
Error code Failure code Common rail pressure sensor detected abnormally low pressure
Trouble
452 CA452 (LH bank)
Contents of
• Signal voltage in common rail pressure sensor circuit is abnormally low.
trouble
Action of
controller
Phenomenon
machine
Related
information

and standard
state
E-61 Code [452/CB452] Rail Press. Sensor Low Error (RH bank) 1
Error code Failure code Common rail pressure sensor detected abnormally low pressure
Trouble
452 CA452 (RH bank)
Contents of
• Signal voltage in common rail pressure sensor circuit is abnormally low.
trouble
Action of
controller
Phenomenon
machine
Related
information

and standard
state
8 12V140E-3 Series
E-62 Code [553/CA553] Rail Press. High Error 1 (LH bank) 1

Trouble Common rail pressure abnormally high Error 1 (LH bank)
553 CA553
Contents of
trouble
Action of
controller
Phenomenon
machine
Related
information

Check fuel used directly.
2 Use of improper fuel
(High viscosity)
Defective electrical system of Common rail pressure sensor may have electric trouble.
Possible causes 3
common rail pressure sensor Carry out troubleshooting for code [451/CA451] (E-58).
and standard
value in normal Defective mechanical system
state 4 of common rail pressure sen- Check mechanical system of common rail pressure sensor directly.
sor
Check overflow valve directly for broken spring, worn seat, and
5 Defective overflow valve
stuck ball.
6 Clogging of overflow piping Check overflow piping directly for clogging.
7 Defective pressure limiter Check pressure limiter directly for mechanical defect.
12V140E-3 Series 9
E-63 Code [553/CB553] Rail Press. High Error 1 (RH bank) 1

Trouble Common rail pressure abnormally high Error 1 (RH bank)
553 CB553
Contents of
trouble
Action of
controller
Phenomenon
machine
Related
information

Check fuel used directly.
2 Use of improper fuel
(High viscosity)
Defective electrical system of Common rail pressure sensor may have electric trouble.
Possible causes 3
common rail pressure sensor Carry out troubleshooting for code [451/CB451] (E-59).
and standard
value in normal Defective mechanical system
state 4 of common rail pressure sen- Check mechanical system of common rail pressure sensor directly.
sor
Check overflow valve directly for broken spring, worn seat, and
5 Defective overflow valve
stuck ball.
6 Clogging of overflow piping Check overflow piping directly for clogging.
7 Defective pressure limiter Check pressure limiter directly for mechanical defect.
10 12V140E-3 Series
E-64 Code [554/CA554] Rail Press. Sensor In Range Error (LH bank) 1
Error code Failure code Common rail pressure sensor detection of in range abnormality
Trouble
554 CA554 (LH bank)
Contents of
• In range error occurred in common rail pressure sensor circuit.
trouble
Action of
controller
Phenomenon
machine
Related
information

and standard
state
E-65 Code [554/CB554] Rail Press. Sensor In Range Error (RH bank) 1
Error code Failure code Common rail pressure sensor detected In range abnormality
Trouble
554 CB554 (RH bank)
Contents of
• In range error occurred in common rail pressure sensor circuit.
trouble
Action of
controller
Phenomenon
machine
Related
information

and standard
state
12V140E-3 Series 11
E-66 Code [559/CA559] Rail Press. Low Error 1 (LH bank) 1

Trouble Supply pump no-pressure feed error 1 (LH bank)
559 CA559
Contents of
• Supply pump does not feed fuel (level 1).
trouble
Action of
• Limits common rail pressure.
controller
Phenomenon
machine
Related
information

2 Use of improper fuel Improper fuel may be used. Check fuel used directly .
a For contents of troubleshooting, see Note 1. For checking of
fuel low-pressure circuit, see Testing and adjusting, Testing fuel
Defective low-pressure cir- pressure.
3
cuit device
Pressure in fuel low-pressure Max. 0.15 MPa
circuit {Max. 1.5 kg/cm2}
4 Clogging of filter/strainer a For contents of troubleshooting, see Note 2.
Supply pump PCV may have electric trouble. Carry out trouble-
5 shooting for following codes [271/CA271] (E-30), [272/CA272] (E-
electrical system
32), [273/CA273] (E-34), [274/CA274] (E-36).
Defective common rail pres- Common rail pressure sensor may be defective. Check wiring har-
Possible causes 6
sure sensor ness for damage.
and standard
value in normal a For testing of leakage from pressure limiter, see Testing and
state adjusting, Testing leakage from pressure limiter and return rate
7 Defective pressure limiter from injector.
Leakage from pressure limiter Max. 10 cc/min (at 1,600 rpm)
a For testing of return (spill) limit from injector, see Testing and
adjusting, Testing leakage from pressure limiter and return rate
from injector.
Speed at rated operation Return (Spill) limit from injector
8 Defective injector 1,600 rpm 960 cc/min

1,700 rpm 1,020 cc/min
1,800 rpm 1,080 cc/min
1,900 rpm 1,140 cc/min
2,000 rpm 1,200 cc/min
9 Defective supply pump If causes 1 – 8 are not detected, supply pump may be defective.
<How to use check sheet>

Carry out the above troubleshooting and take a record of the contents of the attached “Check sheet for no-
pressure feed“.
12 12V140E-3 Series
Note 1: When low-pressure circuit is defective, check the following:

1) Fuel level
2) Clogged fuel tank breather
3) Stuck or worn feed pump, clogged filter
4) Leaked or clogged low-pressure fuel pipe
5) Bypass valve malfunction, defective assembly of other parts (See Fig.1.)
6) Clogged fuel filter
7) Fuel in oil pan (fuel leakage in head cover)
Fig. 1: Locations of overflow valve (1), bypass valve (2), and fuel inlet joint (3)
q Overflow valve (1): Spring is seen through both holes.
q Bypass valve (2): Spring is seen through hole on nut side.
q Fuel inlet joint (3): Gauze filter is seen through both holes.
Note 2: Check, clean, and replace the filters and strainers according to the following procedure.
1) Gauze filter: Disassemble and check. If clogged, clean.
2) Upstream strainer of gauze filter: If the gauze filter is clogged, clean the upstream filter, too.
3) Fuel filter: If the trouble is not solved by performing 1) and 2) above, replace the fuel filter.
12V140E-3 Series 13
Check sheet for no-pressure feed
Model Work No.

Machine serial No. # Date of check / /
Engine Service meter h
Engine serial No. # Worker's name
A. Visual check Good NG

1 Fuel leakage to outside
2 Clogging of fuel tank breather
B. Check with machine monitor

Good NG
(Fault history function, monitoring function, and reduced cylinder mode function)
3 Check of error/failure code / / / /
Check of monitoring information
Standard value
Measured
Code Displayed item Checking condition Unit (Reference Good NG
value
value)
Low idle rpm <By models>
*1 Engine speed High idle rpm <By models>
Equivalent to rating <By models> rpm <By models>
Low idle % 0
*2 Throttle opening
High idle % 100
*3 Fuel injection command Equivalent to rating <By models> mm3 — — —
Common rail pressure
4 *4 Equivalent to rating <By models> MPa
command
*5 Common rail fuel pressure Equivalent to rating <By models> MPa
Low idle CA — — —
Fuel injection timing com-
*6 High idle CA — — —
mand
Equivalent to rating <By models> CA — — —
*7 Boost pressure Equivalent to rating <By models> kPa — — —
Engine coolant tempera-
*8 Low idle °C — — —
ture (High)
ture (Low)
*10 Fuel temperature Low idle °C — — —
Check of reduced cylinder mode operation (Engine speed)
Standard value
Func Measured
Reduced cylinder Checking condition Unit (Reference Good NG
tion value
value)
No. 1 cylinder Low idle rpm — — —
5 No. 2 cylinder Low idle rpm — — —
*11
14 12V140E-3 Series
Standard value
Measured
C. Check of fuel circuit pressure Checking condition Unit (Reference Good NG
value
value)
Fuel low-pressure circuit pres- MPa Min. 0.15
6 High idle
sure {kg/cm2} {Min. 1.5}
D. Check of strainers and filters Good NG

7 Visual check of strainers
8 Visual check of gauze filter
9 Visual check of fuel filter
10 Visual check of bypass valve
Standard value
E. Check of leakage and return Measured
Checking condition Unit (Reference Good NG
rate value)
value
11 Leakage through pressure limiter No load, 1,600 rpm cc/min Max. 10

Equivalent to rating
cc/min 960
<By models> 1,600 rpm
cc/min 1,020
<By models> 1,700 rpm Speed:
12 Return rate from injector cc/min 1,080
Return
cc/min 1,140 rate:
cc/min 1,200
*1 – *11:
When inspecting with INSITE (bench test tool), see Operation and Maintenance Manual (Testing
method).
When inspecting with the monitoring function of the machine, use the codes specified for each machine
model.
Equivalent to rating <By models>:
When inspecting the engine unit on the bench, operate it under a load equivalent to the rating. When
the engine is installed to the machine, however, the operation load equivalent to the rating depends on
the machine model.
12V140E-3 Series 15
E-67 Code [559/CB559] Rail Press. Low Error 1 (RH bank) 1

Trouble Supply pump no-pressure feed error 1 (RH bank)
559 CB559
Contents of
trouble
Action of
controller
Phenomenon
machine
Related
information

2 Use of improper fuel Improper fuel may be used. Check fuel used directly .
a For contents of troubleshooting, see Note 1. For checking of
fuel low-pressure circuit, see Testing and adjusting, Testing fuel
Defective low-pressure cir- pressure.
3
cuit device
Pressure in fuel low-pressure Max. 0.15 MPa
circuit {Max. 1.5 kg/cm2}
4 Clogging of filter/strainer a For contents of troubleshooting, see Note 2.
Supply pump PCV may have electric trouble. Carry out trouble-
5 shooting for following codes [271/CB271] (E-31), [272/CB272] (E-
electrical system
33), [273/CB273] (E-35), [274/CB274] (E-37).
Defective common rail pres- Common rail pressure sensor may be defective. Check wiring har-
Possible causes 6
sure sensor ness for damage.
and standard
value in normal a For testing of leakage from pressure limiter, see Testing and
state adjusting, Testing leakage from pressure limiter and return rate
7 Defective pressure limiter from injector.
Leakage from pressure limiter Max. 10 cc/min (at 1,600 rpm)
a For testing of return (spill) limit from injector, see Testing and
adjusting, Testing leakage from pressure limiter and return rate
from injector.
Speed at rated operation Return (Spill) limit from injector
8 Defective injector 1,600 rpm 960 cc/min

1,700 rpm 1,020 cc/min
1,800 rpm 1,080 cc/min
1,900 rpm 1,140 cc/min
2,000 rpm 1,200 cc/min
9 Defective supply pump If causes 1 – 8 are not detected, supply pump may be defective.
<How to use check sheet>

Carry out the above troubleshooting and take a record of the contents of the attached “Check sheet for no-
pressure feed“.
16 12V140E-3 Series
Note 1: When low-pressure circuit is defective, check the following:

1) Fuel level
2) Clogged fuel tank breather
3) Stuck or worn feed pump, clogged filter
4) Leaked or clogged low-pressure fuel pipe
5) Bypass valve malfunction, defective assembly of other parts (See Fig.1.)
6) Clogged fuel filter
7) Fuel in oil pan (fuel leakage in head cover)
Fig. 1: Locations of overflow valve (1), bypass valve (2), and fuel inlet joint (3)
q Overflow valve (1): Spring is seen through both holes.
q Bypass valve (2): Spring is seen through hole on nut side.
q Fuel inlet joint (3): Gauze filter is seen through both holes.
Note 2: Check, clean, and replace the filters and strainers according to the following procedure.
1) Gauze filter: Disassemble and check. If clogged, clean.
2) Upstream strainer of gauze filter: If the gauze filter is clogged, clean the upstream filter, too.
3) Fuel filter: If the trouble is not solved by performing 1) and 2) above, replace the fuel filter.
12V140E-3 Series 17
Check sheet for no-pressure feed
Model Work No.

Machine serial No. # Date of check / /
Engine Service meter h
Engine serial No. # Worker's name
A. Visual check Good NG

1 Fuel leakage to outside
2 Clogging of fuel tank breather
B. Check with machine monitor

Good NG
(Fault history function, monitoring function, and reduced cylinder mode function)
3 Check of error/failure code / / / /
Check of monitoring information
Standard value
Measured
Code Displayed item Checking condition Unit (Reference Good NG
value
value)
Low idle rpm <By models>
*1 Engine speed High idle rpm <By models>
Equivalent to rating <By models> rpm <By models>
Low idle % 0
*2 Throttle opening
High idle % 100
*3 Fuel injection command Equivalent to rating <By models> mm3 — — —
Common rail pressure
4 *4 Equivalent to rating <By models> MPa
command
*5 Common rail fuel pressure Equivalent to rating <By models> MPa
Low idle CA — — —
Fuel injection timing com-
*6 High idle CA — — —
mand
Equivalent to rating <By models> CA — — —
*7 Boost pressure Equivalent to rating <By models> kPa — — —
ture (High)
ture (Low)
*10 Fuel temperature Low idle °C — — —
Check of reduced cylinder mode operation (Engine speed)
Standard value
Func Measured
Reduced cylinder Checking condition Unit (Reference Good NG
tion value
value)
5 No. 2 cylinder Low idle rpm — — —
*11
18 12V140E-3 Series
Standard value
Measured
C. Check of fuel circuit pressure Checking condition Unit (Reference Good NG
value
value)
Fuel low-pressure circuit pres- MPa Min. 0.15
6 High idle
sure {kg/cm2} {Min. 1.5}
D. Check of strainers and filters Good NG

7 Visual check of strainers
8 Visual check of gauze filter
9 Visual check of fuel filter
10 Visual check of bypass valve
Standard value
E. Check of leakage and return Measured
Checking condition Unit (Reference Good NG
rate value)
value
11 Leakage through pressure limiter No load, 1,600 rpm cc/min Max. 10

cc/min 960
cc/min 1,020
<By models> 1,700 rpm Speed:
12 Return rate from injector cc/min 1,080
Return
cc/min 1,140 rate:
cc/min 1,200
*1 – *11:
When inspecting with INSITE (bench test tool), see Operation and Maintenance Manual (Testing
method).
When inspecting with the monitoring function of the machine, use the codes specified for each machine
model.
Equivalent to rating <By models>:
When inspecting the engine unit on the bench, operate it under a load equivalent to the rating. When
the engine is installed to the machine, however, the operation load equivalent to the rating depends on
the machine model.
12V140E-3 Series 19
E-68 Code [689/CA689] Eng. Ne Speed Sensor Error (LH bank) 1

Trouble Engine Ne Speed Sensor detected abnormality (LH bank)
689 CA689
Contents of
• Abnormality occurred in engine Ne speed sensor circuit.
trouble
Action of
controller
Phenomenon
that appears on
machine
Related
information

Defective sensor power sup- If code [238/CA238] is indicated, carry out troubleshooting for it
1
ply system first.
ness Max. 1 z
Max. 1 z
tor) – Ne (female) (2) tance
Max. 1 z
Min. 1 Mz
ness – Ne (female) (1) and chassis ground tance
3
cuit) Min. 1 Mz
– Ne (female) (2) and chassis ground tance
Min. 1 Mz
and standard – Ne (female) (3) and chassis ground tance
Resis-
– Ne (female) (1) and LH J1 (female) (48) – Min. 1 Mz
Ne (female) (2)
ness
ness) – Ne (female) (1) and LH J1 (female) (48) – Min. 1 Mz
tance
Ne (female) (2)
Resis-
– Ne (female) (2) and LH J1 (female) (27) – Min. 1 Mz
tance
Ne (female) (3)
Defective mount of sensor or Check Ne speed sensor directly for defective mount (defective
5 defective rotation sensing clearance) or check rotation sensing part (flywheel) directly for
part defect.
If causes 1 – 5 are not detected, engine Ne speed sensor may be
Defective engine Ne speed
6 defective. (Since trouble is in system, troubleshooting cannot be
sensor
carried out.)
out.)
20 12V140E-3 Series
Circuit diagram related to engine Ne speed sensor
12V140E-3 Series 21
E-69 Code [689/CB689] Eng. Ne Speed Sensor Error (RH bank) 1

Trouble Engine Ne Speed Sensor detected abnormality (RH bank)
689 CB689
Contents of
• Abnormality occurred in engine Ne speed sensor circuit.
trouble
Action of
controller
Phenomenon
that appears on
machine
Related
information

Defective sensor power sup- If code [238/CB238] is indicated, carry out troubleshooting for it
1
ply system first.
ness Max. 1 z
defective contact in connec- Wiring harness between RH J1 (female) Resis-
Max. 1 z
tor) (48) – Ne (female) (2) tance
Max. 1 z
(27) – Ne (female) (3) tance
Min. 1 Mz
ness – Ne (female) (1) and chassis ground tance
3
(Short circuit with GND cir- Wiring harness between RH J1 (female) Resis-
cuit) Min. 1 Mz
(48) – Ne (female) (2) and chassis ground tance
Possible causes Wiring harness between RH J1 (female) Resis-
Min. 1 Mz
and standard (27) – Ne (female) (3) and chassis ground tance
Resis-
– Ne (female) (1) and RH J1 (female) (48) – Min. 1 Mz
Ne (female) (2)
ness
ness) – Ne (female) (1) and RH J1(female) (27) – Min. 1 Mz
tance
Ne (female) (3)
Resis-
(48) – Ne (female) (2) and RH J1 (female) Min. 1 Mz
tance
(27) – Ne (female) (3)
Defective mount of sensor or Check Ne speed sensor directly for defective mount (defective
5 defective rotation sensing clearance) or check rotation sensing part (flywheel) directly for
part defect.
If causes 1 – 5 are not detected, engine Ne speed sensor may be
Defective engine Ne speed
6 defective. (Since trouble is in system, troubleshooting cannot be
sensor
carried out.)
out.)
22 12V140E-3 Series
Circuit diagram related to engine Ne speed sensor
12V140E-3 Series 23
E-70 Code [691/CA691] Intake Air Temp Sensor High Error (LH bank
only) 1
Error code Failure code Intake air temperature sensor detected abnormally high tempera-
Trouble
691 CA691 ture (LH bank)
Contents of
• Intake air temperature sensor circuit detected abnormally high temperature.
trouble
Action of
• Fixes intake air temperature at (25 °C) and continues operation.
controller
Phenomenon
that appears on
machine
Related
information

Defective charge tempera- Intake air
TAM1 Resistance
1 ture sensor temperature
(Internal trouble) Between (A) – (B) 10 – 100 °C 0.5 – 20 kz
Between (A) –
All range Min. 1 Mz
chassis ground
– TAM1 (female) (A) tance
Max. 1 z
– TAM1 (female) (B) tance
3
cuit) Max. 1 Mz
– TAM1 (female) (A) and chassis ground tance
4 Defective engine controller Intake air
TAM1 (male) Resistance
temperature
Between (43) – (47) 10 – 100 °C 0.5 – 20 kz
24 12V140E-3 Series
Circuit diagram related to intake air temperature sensor
12V140E-3 Series 25
E-71 Code [692/CA692] Intake Air Temp Sensor Low Error (LH bank
only) 1
Error code Failure code Intake air temperature sensor detected abnormally low tempera-
Trouble
Contents of
• Intake air temperature sensor circuit detected abnormally low temperature.
trouble
Action of
• Fixes intake air temperature at (25 °C) and continues operation.
controller
Phenomenon
that appears on
machine
Related
information

and standard
state
26 12V140E-3 Series
E-72 Code [731/CA731] Eng. G (Bkup) Speed Sensor Phase Error (LH
bank) 1
Trouble Engine G (Bkup) speed sensor abnormal phase (LH bank)
731 CA731
Contents of
• Engine G (Bkup) sensor circuit detected abnormality in phase.
trouble
Action of
• Controls with signals of engine Ne speed sensor.
controller
Phenomenon
• Running engine stops (when Ne speed sensor is also abnormal).
that appears on
• Stopped engine cannot be started (when Ne speed sensor is also abnormal).
machine
Related
information

Possible causes
Defective engine Ne speed Engine Ne speed sensor may be defective.
and standard 1
sensor system Carry out troubleshooting for [689/CA689] (E-68).
value in normal
state Defective G (Bkup) speed Common rail pressure sensor may have electric trouble.
2
sensor system Carry out troubleshooting for code [778/CA778] (E-76).
E-73 Code [731/CB731] Eng. G (Bkup) Speed Sensor Phase Error (RH
bank) 1
Trouble Engine G (Bkup) speed sensor abnormal phase (RH bank)
731 CB731
Contents of
• Engine G (Bkup) sensor circuit detected abnormality in phase.
trouble
Action of
• Controls with signals of engine Ne speed sensor.
controller
Phenomenon
that appears on
machine
Related
information

Possible causes
Defective engine Ne speed Engine Ne speed sensor may be defective.
and standard 1
sensor system Carry out troubleshooting for [689/CB689] (E-69).
value in normal
state Defective G (Bkup) speed Common rail pressure sensor may have electric trouble.
2
sensor system Carry out troubleshooting for code [778/CB778] (E-77).
12V140E-3 Series 27
E-74 Code [757/CA757] All Continuous Data Lost Error (LH bank) 1
Trouble All Engine Controller Data Lost Error (LH bank)
757 CA757
Contents of
• All data in engine controller are lost.
trouble
Action of
controller
Phenomenon
machine
Related
information

and standard
state
E-75 Code [757/CB757] All Continuous Data Lost Error (RH bank) 1
Trouble All Engine Controller Data Lost Error (RH bank)
757 CB757
Contents of
trouble
Action of c
ontroller
Phenomenon
machine
Related
information

and standard
state
28 12V140E-3 Series
E-76 Code [778/CA778] Eng. G (Bkup) Speed Sensor Error (LH bank) 1
Trouble Engine G (Bkup) speed sensor abnormal (LH bank)
778 CA778
Contents of
• Abnormality occurred in engine G (Bkup) speed sensor circuit.
trouble
Action of
• Controls with signals of Ne speed sensor.
controller
Phenomenon
that appears on
machine
Related
information

1
ness Max. 1 z
– LH G (female) (1) tance
Max. 1 z
tor) – LH G (female) (2) tance
Max. 1 z
– LH G (female) (3) tance
Min. 1 Mz
ness – LH G (female) (1) and chassis ground tance
3
cuit) Min. 1 Mz
– LH G (female) (2) and chassis ground tance
Min. 1 Mz
and standard – LH G (female) (3) and chassis ground tance
Resis-
– LH G (female) (1) and LH J1 Min. 1 Mz
(female) (47) – LH G (female) (2)
ness
ness) – LH G (female) (1) and LH J1 Min. 1 Mz
tance
Resis-
– LH G (female) (2) and LH J1 Min. 1 Mz
tance
Defective mount of sensor or Check G (Bkup) speed sensor directly for defective mount (defec-
5 defective rotation sensing tive clearance) or check rotation sensing part (in supply pump)
part directly for defect.
If causes 1 – 5 are not detected, engine G (Bkup) speed sensor
6 may be defective. (Since trouble is in system, troubleshooting can-
sensor system
not be carried out.)
out.)
30 12V140E-3 Series
Circuit diagram related to engine G (Bkup) speed sensor system
12V140E-3 Series 31
E-77 Code [778/CB778] Eng. G (Bkup) Speed Sensor Error (RH bank) 1
Trouble Engine G (Bkup) speed sensor abnormal (RH bank)
778 CB778
Contents of
• Abnormality occurred in engine G (Bkup) speed sensor circuit.
trouble
Action of
• Controls with signals of Ne speed sensor.
controller
Phenomenon
that appears on
machine
Related
information

Defective sensor power sup- If code [187/CB187] or [227/CB227] is indicated, carry out trouble-
1
Disconnection in wiring har- Wiring harness between RH J1 (female) Resis-
ness Max. 1 z
(37) – RH G (female) (1) tance
defective contact in connec- Max. 1 z
tor)
Max. 1 z
Resis-
(37) – RH G (female) (1) and chassis Min. 1 Mz
ground
ness
cuit) (47) – RH G (female) (2) and chassis Min. 1 Mz
tance
ground
Possible causes Wiring harness between RH J1 (female)
and standard Resis-
(26) – RH G (female) (3) and chassis Min. 1 Mz
value in normal tance
ground
Resis-
(37) – R G (female) (1) and RH J1 Min. 1 Mz
(female) (47) – RH G (female) (2)
ness
ness) (37) – R G (female) (1) and RH J1 Min. 1 Mz
tance
Resis-
(47) – R G (female) (2) and RH J1 Min. 1 Mz
tance
Defective mount of sensor or Check G (Bkup) speed sensor directly for defective mount (defec-
5 defective rotation sensing tive clearance) or check rotation sensing part (in supply pump)
part directly for defect.
If causes 1 – 5 are not detected, engine G (Bkup) speed sensor
6 may be defective. (Since trouble is in system, troubleshooting can-
sensor system
not be carried out.)
out.)
32 12V140E-3 Series
Circuit diagram related to engine G (Bkup) speed sensor system
12V140E-3 Series 33
E-78 Code [781/CA781] Inter Multi-controller Communication Error (LH

bank) 1
Trouble Inter multi-controller communication error (LH bank)
781 CA781
Contents of
• Communication error occurred between engine controllers (LH bank)
trouble
Action of
controller
Phenomenon
• Single-bank operation
that appears on
• Engine cannot be started with the key ON
machine
Related
information

ness
– RH J1 (female) (8) tance
Max. 1 z
– RH J1 (female) (6) tance
Possible causes ing without turning starting switch ON.
and standard
value in normal 2 Min. 1 Mz
(Short circuit with GND cir- – RH J1 (female) (8) and chassis ground tance
state
Min. 1 Mz
– RH J1 (female) (6) and chassis ground tance
Between (8) – (6) 108 – 132 z
Min. 1 Mz
ground
34 12V140E-3 Series
Circuit diagram related to inter multi-controller communication
12V140E-3 Series 35
E-79 Code [781/CB781] Inter Multi-controller Communication Error (RH

bank) 1
Trouble Inter multi-controller communication error (RH bank)
781 CB781
Contents of
• Communication error occurred between engine controllers (LH bank)
trouble
Action of
controller
Phenomenon
• Single-bank operation
that appears on
• Engine cannot be started with the key ON
machine
Related
information

and standard
state
36 12V140E-3 Series
E-80 Code [1117/CA1117] Persistent Data Lost Error (LH bank) 1

Trouble Engine Controller Data Lost Error (LH bank)
1117 CA1117
Contents of
trouble
Action of
controller
Phenomenon
that appears on
machine
Related
information

and standard
state
E-81 Code [1117/CB1117] Persistent Data Lost Error (RH bank) 1

Trouble Engine Controller Data Lost Error (RH bank)
1117 CB1117
Contents of
trouble
Action of
controller
Phenomenon
that appears on
machine
Related
information

and standard
state
12V140E-3 Series 37
E-82 Code [1257/CA1257] Harness Key error (LH bank) 1

Trouble Multi-controller identification harness key error (LH bank)
1257 CA1257
Contents of
• Collation of identification harness between respective bank controllers fail (LH bank)
trouble
Action of
• Stops operation
controller
Phenomenon
that appears on • Engine cannot be started with the key ON
machine
Related
information

Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshoot-
defective contact in connec- Wiring harness between OEM L (female) (7) Resis-
Max. 1 z
tor) – OEM L (female) (34) tance
Possible causes Ground fault in wiring har- a Prepare with starting switch OFF, then carry out troubleshoot-
and standard ness ing without turning starting switch ON.
2
value in normal (Short circuit with GND cir- Between wiring harness OEM L (female) (8) Resis-
cuit) Min. 1 Mz
state and chassis ground tance
Between wiring harness OEM L (female) (7) Resis-
3 Defective engine controller Max. 1 z
and chassis ground tance
Between wiring harness OEM L (female) (8) Resis-
Min. 1 Mz
Circuit diagram related to multi-controller identification harness key
38 12V140E-3 Series
E-83 Code [1257/CB1257] Harness Key error (RH bank) 1

Trouble Multi-controller identification harness key error (RH bank)
1257 CB1257
Contents of
• Collation of identification harness between respective bank controllers fail (RH bank)
trouble
Action of
• Stops operation
controller
Phenomenon
that appears on • Engine cannot be started with the key ON
machine
Related
information

Wrong connection of harness ing without turning starting switch ON.
1
Connector connection error Between OEM R (female) (7) – OEM R Resis-
Min. 1 Mz
(female) (34) terminals tance
Possible causes ing without turning starting switch ON.
ness
and standard 2
(Short circuit with GND cir- Between wiring harness OEM R (female) (8) Resis-
value in normal Min. 1 Mz
cuit) and chassis ground tance
state
Between wiring harness OEM R (female) (7) Resis-
3 Defective engine controller Min. 1 Mz
Between wiring harness OEM R (female) (8) Resis-
Min. 1 Mz
Circuit diagram related to multi-controller identification harness key
12V140E-3 Series 39
E-84 Code [1548/CB1548] Injector #7 (R/B #1) System Open/Short Error

(RH bank) 1
Error code Failure code Disconnection or short circuit in injector #7 (R/B #1) system
Trouble
1548 CB1548 (RH bank)
Contents of
trouble
Action of
controller
Phenomenon
• Output drops.
that appears on
machine
Related
information

Defective injector #7 RH CN1 (male) Resistance
1
Min. 1 Mz
ground
ness
(45) – RH CN1 (female) (1) tance
and standard
Ground fault in wiring har- Wiring harness between RH J1 (female)
Resis-
ness (45) – RH CN1 (female) (1) and chassis Min. 1 Mz
3 tance
Resis-
(53) – RH CN1 (female) (2) and chassis Min. 1 Mz
tance
ground
Between (45) – (53) 0.4 – 1.1 z
Min. 1 Mz
ground
40 12V140E-3 Series
Circuit diagram related to injector #7 (R/B #1) system
12V140E-3 Series 41

(RH bank) 1
Trouble
1549 CB1549 (RH bank)
Contents of
trouble
Action of
controller
Phenomenon
• Output drops.
that appears on
machine
Related
information

1
Min. 1 Mz
ground
ness
and standard
Resis-
3 tance
Resis-
tance
ground
Between (54) – (51) 0.4 – 1.1 z
Min. 1 Mz
ground
42 12V140E-3 Series
12V140E-3 Series 43
E-86 Code [1551/CB1551] Injector #10 (R/B #4) System Open/Short

Error (RH bank) 1
Trouble
1551 CB1551 (RH bank)
Contents of
trouble
Action of
controller
Phenomenon
• Output drops.
that appears on
machine
Related
information

1
Min. 1 Mz
ground
ness
and standard
Resis-
3 tance
Resis-
tance
ground
Between (56) – (58) 0.4 – 1.1 z
Min. 1 Mz
ground
44 12V140E-3 Series
12V140E-3 Series 45

Error (RH bank) 1
Trouble
1552 CB1552 (RH bank)
Contents of
trouble
Action of
controller
Phenomenon
• Output drops.
that appears on
machine
Related
information

1
Min. 1 Mz
ground
ness
and standard
Resis-
3 tance
Resis-
tance
ground
Between (46) – (60) 0.4 – 1.1 z
Min. 1 Mz
ground
46 12V140E-3 Series
12V140E-3 Series 47

Error (RH bank) 1
Trouble
1553 CB1553 (RH bank)
Contents of
trouble
Action of
controller
Phenomenon
• Output drops.
that appears on
machine
Related
information

1
Min. 1 Mz
ground
ness
and standard
Resis-
3 tance
Resis-
tance
ground
Between (57) – (59) 0.4 – 1.1 z
Min. 1 Mz
ground
48 12V140E-3 Series
12V140E-3 Series 49

(RH bank) 1
Trouble
1622 CB1622 (RH bank)
Contents of
trouble
Action of
controller
Phenomenon
• Output drops.
that appears on
machine
Related
information

1
Min. 1 Mz
ground
ness
and standard
Resis-
3 tance
Resis-
tance
ground
Between (55) – (52) 0.4 – 1.1 z
Min. 1 Mz
ground
50 12V140E-3 Series
12V140E-3 Series 51
E-90 Code [1633/CA1633] KOMNET Datalink Timeout Error (LH bank) 1

Trouble KOMNET error (LH bank)
1633 CA1633
Contents of
• Abnormality occurred in circuit of KOMNET communication with machine (LH bank).
trouble
Action of
• Normal control (communication function disabled)
controller
Phenomenon
that appears on • Different problems occur on different machine models.
machine
Related
information

Disconnection in wiring har- Wiring harness between OEM L (female) Resis-
ness Max. 1 z
(46) – OEM R (female) (46) tance
defective contact in connec- Wiring harness between OEM L (female) Resis-
Max. 1 z
tor) (47) – OEM R (female) (47) tance
Wiring harness between OEM L (female) Resis- 108 –
(46) – OEM L (female) (47) tance 132 z
Possible causes
and standard
value in normal Ground fault in wiring har- Wiring harness between OEM L (female)
Resis-
state ness (46) – OEM R (female) (46) and chassis Min. 1 Mz
2 tance
cuit) Wiring harness between OEM L (female)
Resis-
(47) – OEM R (female) (47) and chassis Min. 1 Mz
tance
ground
Wiring harness between OEM L (female) Resis- 108 –
(46) – OEM L (female) (47) tance 132z
Wiring harness between OEM R (female) Resis- 108 –
(46) – OEM R (female) (47) tance 132 z
52 12V140E-3 Series
KOMNET-related circuit diagram
12V140E-3 Series 53
E-91 Code [2185/CA2185] Throttle Sens. Sup. Volt. High Error (LH bank
only) 1
Error code Failure code Throttle sensor detection of abnormally high supply voltage
Trouble
Contents of
• High voltage abnormality occurred to throttle sensor power supply (5 V) circuit.
trouble
Phenomenon
machine
Related
information

Defective deceleration sen- Disconnect devices

1 sor at right in order. If
Decelerator sensor DEC connector
pears subsequently,
that device has a
defect in it.
ness
Wiring harness between OEM L (female) Resis-
(22) – DEC (female) (A) tance
tor) Wiring harness between OEM L (female) Resis-
(23) – DEC (female) (C) tance
and standard
ness Wiring harness between OEM L (female) Resis-
3 Min. 1 Mz
(Short circuit with GND cir- (22) – DEC (female) (A) and chassis ground tance
cuit) Wiring harness between OEM L (female) Resis-
Min. 1 Mz
(23) – DEC (female) (C) and chassis ground tance
ness
4 Wiring harness between OEM L (female)
ness) (22) – DEC (female) (A) and OEM L Min. 1 Mz
tance
(female) (23) – DEC (female) (C)
OEM L Voltage
Between (22) – (23) 4.75 – 5.25 V
54 12V140E-3 Series
Circuit diagram related to deceleration pedal type throttle sensor (Case of D475-5)
12V140E-3 Series 55
E-92 Code [2186/CA2186] Throttle Sens. Sup. Volt. Low Error (LH bank
only) 1
Error code Failure code Throttle sensor detected abnormally low supply voltage
Trouble
Contents of
• Low-voltage abnormality occurred to throttle sensor power supply (5V) circuit.
trouble
Phenomenon
machine
Related
information

and standard
state
56 12V140E-3 Series
E-93 Code [2249/CA2249] Rail Press. Very Low Error (LH bank) 1
Trouble Supply pump no-pressure feed error 2 (LH bank)
2249 CA2249
Contents of
trouble
Action of
controller
Phenomenon
machine
Related
information

and standard
state
E-94 Code [2249/CB2249] Rail Press. Very Low Error (RH bank) 1
Trouble Supply pump no-pressure feed error 2 (RH bank)
2249 CB2249
Contents of
trouble
Action of ontrol-
ler
Phenomenon
machine
Related
information

and standard
state
12V140E-3 Series 57
E-95 Code [– –*1/–] Eng. Overheat (LH bank only) 1

Trouble Engine overheat (LH bank only)
– –*1 –
Contents of
• Engine coolant temperature is above operating range.
trouble
Action of
• Limits output and continues operation.
controller
Phenomenon
machine
Related
information

Possible causes
and standard This defective phenomenon is indicated only on the installed
value in normal Carry out troubleshooting on machine when it was detected.
1
state machine side Accordingly, contents of troubleshooting differ by the machine
model. See Shop manual for machine.
E-96 Code [– –*2/–] Eng. Oil Press. Low Speed Derate (LH bank only) 1
Trouble Engine oil pressure low and speed derate (LH bank only)
– –*2 –
Contents of
• Engine oil pressure is below operating range.
trouble
Action of
• Limits output and continues operation (Limits fuel injection rate and engine speed).
controller
Phenomenon
machine
Related
information

Possible causes
1
58 12V140E-3 Series
E-97 Code [– –*3/–] Press. Low Torque Derate (LH bank only) 1
Trouble Engine oil pressure low and torque derate (LH bank only)
– –*3 –
Contents of
• Engine oil pressure is below operating range.
trouble
Action of
• Limits output and continues operation (Limits fuel injection rate and engine speed).
controller
Phenomenon
machine
Related
information

Possible causes
1
12V140E-3 Series 59

© 2006 KOMATSU
All Rights Reserved
60 12V140E-3 Series
SEN00320-00
ENGINE 1SHOP MANUAL
12V140E-3 Series

General information on disassembly and
assembly
General information on disassembly and assembly ....................................................................................... 2
How to read this manual ....................................................................................................................... 2
Coating materials list ............................................................................................................................ 3
Special tools list .................................................................................................................................... 6
12V140E-3 Series 1
SEN00320-00 50 Disassembly and assembly
General information on disassembly and assembly

How to read this manual 1
Disassembly
q In Disassembly section, the work procedures,
precautions and know-how for carrying out
those procedures, and quantity of the oil and
coolant drained are described.
q The meanings of the symbols used in Disas-
sembly section are as follows.
k Precautions related to safety in execution
of work
a : Know-how or precautions for work
6 : Quantity of oil or coolant drained
4 : Weight of part or component
Assembly
q In Assembly section, the work procedures, pre-
cautions and know-how for carrying out those
procedures, and quantity of the oil and coolant
added are described.
q The meanings of the symbols used in Assem-
bly section are as follows.
k : Precautions related to safety in execution
of work
a : Know-how or precautions for work
2 : Type of coating material
3 : Tightening torque
5 : Quantity of oil or coolant to be added

4 : Weight of part or component
2 12V140E-3 Series
Coating materials list 1

a The recommended coating materials such as adhesives, gasket sealants, and greases used for disas-
sembly and assembly are listed below.
a For coating materials not listed below, use the equivalent of products shown in this list.
Cate- Komatsu
Part No. Q'ty Container Main features and applications
gory code
• Used to prevent falling off of rubber gaskets, rubber
LT-1A 790-129-9030 150 g Tube
cushions, and cork plugs.
• Used for plastic (except polyethylene, polypropylene,
20 g Polyethylene tetrafluoroethylene and vinyl chloride), rubber, metal,
LT-1B 790-129-9050
(2 pcs.) container and non-metal parts which require immediate and
strong adhesion.
Polyethylene • Features: Resistant to heat and chemicals.
LT-2 09940-00030 50 g
container • Used to fix and seal bolts and plugs.
790-129-9060 Adhesive:
Set of 1 kg
LT-3 Can • Used to stick and seal metal, glass, and plastics.
adhesive and Hardener:
hardener 500 g
Adhesive
Polyethylene
LT-4 790-129-9040 250 g • Used to seal plugs for drilled holes.
container
Holtz
790-129-9120 75 g Tube • Heat-resistant sealant used to repair engines.
MH 705
• Quick-setting adhesive.
Three Bond Polyethylene • Setting time: Within 5 sec. to 3 min.
790-129-9140 50 g
1735 container • Used mainly to stick metals, rubbers, plastics, and
woods.
• Quick-setting adhesive.
Aron-alpha Polyethylene • Quick-hardening type. (max. strength is obtained after
790-129-9130 2g
201 container 30 minutes of application)
• Used mainly to stick rubbers, plastics, and metals.
Loctite Polyethylene • Features: Resistant to heat and chemicals.
79A-129-9110 50 cc
648-50 container • Used for fitted portions of high temperatures.
• Used to stick or seal gaskets and packings of power
LG-1 790-129-9010 200 g Tube
train case, etc.
• Used to seal various threaded portions, pipe joints,
Polyethylene and flanges.
LG-5 790-129-9080 1 kg
container • Used to seal tapered plugs, elbows, and nipples of
hydraulic pipes.
• Features: Silicon-based heat and cold-resistant seal-
Gasket sealant
ant.
LG-6 790-129-9020 200 g Tube
• Used to seal flanged surfaces and threaded portions.
• Used to seal oil pan, final drive case, etc.
• Features: Silicon-based quick-hardening sealant.
LG-7 790-129-9070 1 kg Tube • Used to seal flywheel housing, intake manifold, oil
pan, thermostat housing, etc.
Three Bond
790-129-9090 100 g Tube • Gasket sealant used to repair engine.
1211
• Features: Silicon-based, heat-resistant, vibration-
Three Bond
419-15-18131 100 g Tube resistant and impact-resistant sealant.
1207B
• Used to seal transfer case, etc.
12V140E-3 Series 3
Cate- Komatsu
gory code
• Used to lubricate sliding portions.
Molybdenum disulfide
LM-G 09940-00051 60 g Can

(to prevent squeaking)
lubricant
• Used to prevent scuffing and seizure of press-fit-

ted portions, shrink-fitted portions, and threaded
LM-P 09940-00040 200 g Tube
portions.
• Used to lubricate linkages, bearings, etc.
SYG2-400LI
SYG2-350LI
G2-LI SYG2-400LI-A Various Various • General purpose type.
SYG2-160LI
SYGA-160CNLI
SYG2-400CA
SYG2-350CA
• Used for bearings used at normal temperature
G2-CA SYG2-400CA-A Various Various
under light load in contact with water or steam.
SYG2-160CA
SYGA-160CNCA
Molybdenum SYG2-400M 400 gx10 Bellows-type
disulfide grease SYG2-400M-A 400 gx20 container • Used for parts under heavy load.
Grease
LM-G (G2-M) SYGA-16CNM 16 kg Can

SYG2-400T-A
Hyper White
SYG2-16CNT
Grease G2-T, Bellows-type • Seizure resistance and heat resistance higher
SYG0-400T-A 400 g
G0-T (*) container than molybdenum disulfide grease.
(*) 16 kg
*: For cold dis- Can • Not conspicuous on machine since color is white.
SYG0-16CNT
trict
(*)
Biogrease G2- SYG2-400B
B, G2-BT (*) SYGA-16CNB
Bellows-type • Since this grease is decomposed by natural bac-
*: For use at SYG2-400BT 400 g
container teria in short period, it has less effects on micro-
high tempera- (*) 16 kg
Can organisms, animals, and plants.
ture and under SYGA-16CNBT
high load (*)
SUNSTAR • Used as primer for cab side.
Glass
PAINT PRIMER 20 ml (Using limit: 4 months after date of manufac-
container
580 SUPER ture)
SUNSTAR 417-926-3910
• Used as primer for glass side.
GLASS Glass
20 ml (Using limit: 4 months after date of manufac-
PRIMER 580 container
ture)
Adhesive for cab glass
SUPER
• Used as primer for painted surface on cab
SUNSTAR
Glass side.
Primer
PAINT PRIMER 22M-54-27230 20 ml

container (Using limit: 4 months after date of manufac-
435-95
ture)
• Used as primer for black ceramic-coated
SUNSTAR
surface on glass side and for hard polycar-
GLASS
22M-54-27240 150 ml Can bonate-coated surface.
PRIMER
(Using limit: 4 months after date of manufac-
435-41
ture)
SUNSTAR • Used as primer for sash. (Almite)
Glass
SASH PRIMER 22M-54-27250 20 ml (Using limit: 4 months after date of manufac-
container
GP-402 ture)
4 12V140E-3 Series
Cate- Komatsu
gory code
• "S" is used for high-temperature season
SUNSTAR
(April – October) and "W" for low-tempera-
PENGUINE Polyethyl-
ture season (November – April) as adhesive
SEAL 580 417-926-3910 320 ml ene con-
for glass.
SUPER "S" or tainer
(Using limit: 4 months after date of manufac-
"W"
Adhesive
ture)
Polyethyl- • Used as adhesive for glass.
Sika Japan,
20Y-54-39850 310 ml ene con- (Using limit: 6 months after date of manufac-
Adhesive for cab glass

Sikaflex 256HV
tainer ture)
SUNSTAR Ecocart • Used as adhesive for glass.
PENGUINE 22M-54-27210 320 ml (Special (Using limit: 6 months after date of manufac-
SUPER 560 container) ture)
SUNSTAR Polyethyl- • Used to seal joints of glass parts.
PENGUINE 417-926-3920 320 ml ene con- (Using limit: 4 months after date of manufac-
SEAL No. 2505 tainer ture)
Caulking material
SEKISUI SILI- Polyethyl- • Used to seal front window.

CONE SEAL- 20Y-54-55130 333 ml ene con- (Using limit: 6 months after date of manufac-
ANT tainer ture)
• Used to seal joint of glasses.
GE TOSHIBA
Translucent white seal.
SILICONES 22M-54-27220 333 ml Cartridge
(Using limit: 12 months after date of manu-
TOSSEAL 381
facture)
12V140E-3 Series 5
Special tools list 1

a Tools with part number 79QT-QQQ-QQQQ cannot be supplied (they must be locally manufactured).
a Necessity : t . . . . . . Cannot be substituted, should always be installed (used)
: q . . . . . . Extremely useful if available, can be substituted with commercially available part
a New/Remodel
: N . . . . . . Tools newly developed for this model and given new part Nos.
: R . . . . . . Tools remodeled from tools already available for other models and given upgraded
part Nos.
: Blank. . . Tools already available for other models, usable without any modification
a Tools marked with Q in the sketch column are tools introduced in the sketches of the special tools
(See Sketches of special tools)
New/Remodel
Necessity
Sketches
Sym-
Q'ty
Work item Part No. Part name Remarks
bol
790-501-4000 Engine repair stand t 1

790-901-1800 Bracket assembly t 1
790-901-1810 Bracket t 1
790-901-1820 Bracket t 1
790-901-1830 Bracket t 1
Disassembly and 790-901-1840 Bracket t 1
assembly of engine A
assembly 790-901-1510 Plate t 4
02100-01038 Bolt t 36
01252-11050 Bolt t 16
01643-31645 Washer t 12
01643-31032 Washer t 16
01602-21648 Washer t 24
795-102-2102 Spring pusher t 1
795-102-2110 Handle t 1
795-102-2120 Bracket t 1
Disassembly and 795-102-4210 Bracket t 1
assembly of cylinder B
head 01016-50830 Bolt t 1
01580-10806 Nut t 1
01144-31270 Stud t 1
01580-11210 Nut t 1
Removal and
C 795-100-1191 Piston ring tool t 1
installation of piston ring
Measurement of
D 795-502-1121 Holder t 1
cylinder liner projection
Removal of cylinder liner E 795-236-1000 Liner puller t 1
Installation of cylinder
F 795-230-5472 Liner driver t 1
liner
Angle tightening of bolt G 795-331-1110 Wrench t 1
Installation of piston H 795-236-1500 Piston holder t 1
Installation of front oil
J 795-602-2200 Installer t 1
seal
Installation of rear oil
K 795-602-2300 Installer t 1
seal
6 12V140E-3 Series
New/Remodel
Necessity
Sketches
Sym-
Q'ty
Work item Part No. Part name Remarks
bol
Press fitting of valve

L 795-130-1720 Push tool t 1
stem seal
Adjusting valve Commercially
M Thickness gauge q 1 IN: 0.35 mm, EX: 0.57 mm
clearance available
Removal of rear oil seal N 795-931-1100 Seal puller q 1
12V140E-3 Series 7

© 2006 KOMATSU
All Rights Reserved
8 12V140E-3 Series
SEN00321-00
ENGINE 1SHOP MANUAL
12V140E-3 Series

Disassembly and assembly, Part 1
Disassembly and assembly, Part 1 ................................................................................................................. 2
General disassembly of engine ............................................................................................................ 2
12V140E-3 Series 1
Disassembly and assembly, Part 1 1

General disassembly of engine 1
a The shapes, quantity, locations, etc. of the
parts depend on each applicable machine.
Take care.
a When a part is provided on both sides of the
bank, one side alone is shown as an example.
Except where otherwise specified, contents of
the work shall be the same on both sides of the
bank.
1. Preparation work
Before disassembling the engine, check its
parts for cracking, damage, etc. and clean the
entire engine carefully for accurate inspection
of its parts and quick disassembly and assem- 4. Starting motor assembly
bly. Remove engine harness (1) and then remove
a Before cleaning the engine, carefully seal starting motor assemblies (2) and (3).
or remove the openings, electric parts, a Remove the assembly at the top first
and wiring connectors so that water will being followed by that at the bottom.
not enter them.
2. Installation to engine repair stand

1) Install the engine assembly (1) to tool A.
4 Engine assembly:
Approx. 3,800 kg
5. Alternator
1) Remove auxiliary equipment belt (1).
2) Remove alternator (2).
2) Drain the engine coolant and engine oil.

a Quantity of the engine oil depends on
the applicable machines.
6 Engine oil: Approx. 130 l
3. Engine wiring harness

Disconnect the connector and terminal and
then remove engine harness (1) from the
engine assembly.
2 12V140E-3 Series
6. Fuel filter and filter head assembly, and

priming pump
1) Remove fuel tubes (1) and (2).
2) Remove fuel filter and filter head assem-
bly (3).
3) Remove priming pump (4).
9. Air intake connector

1) Remove air intake connector (1).
7. Engine controller and controller cooler

1) Remove engine controller (1).
2) Remove fuel hoses (2) and (3).
3) Remove controller cooler (4).
10. Spill tube

Remove spill tube (1).
8. Air inlet pipe

1) Remove the clamp and then remove air
inlet pipe (1).
2) Remove bracket (2).
a Remove bracket (3) on the right side
bank alone.
11. High-pressure pipe (between supply pump

– common rail)
1) Apply a marking to the installation posi-
tions of clamps (1) – (3) using paint.
3) Remove clamps (1) – (3).
4) Remove high-pressure pipes (5) and (6).
12V140E-3 Series 3
12. High-pressure pipe (between common rail 3) Remove bracket.

– fuel injector) 4) Remove all clamps (2) and (3).
1) Remove bracket (1). 5) Remove 6 high-pressure pipes (4).
2) Apply a marking to every installation posi- 13. Air intake manifold assembly
tions of clamps (2) and (3) using paint. 1) Remove support (1).
2) Lift air intake manifold (2) temporarily and

then remove the mounting bolts.
3) Lift off air intake manifold assembly (2).
4 Air intake manifold assembly:
45 kg
4 12V140E-3 Series
16. Exhaust manifold assembly

1) Remove instation plates (1), muffler
bracket (2), water pipes (3) and bracket
(4).
14. Exhaust connector

Remove exhaust connectors (1) and (2).
2) Lift exhaust manifold assembly (5) tempo-

rarily and then remove the mounting bolts.
3) Lift off exhaust manifold assembly (5).
4 Exhaust manifold assembly: 25 kg
15. Turbocharger assembly

1) Remove 2 water pipes and 2 oil pipes.
a When the air-cooled turbocharger is
used, the oil pipes alone are pro-
vided.
2) Lift turbocharger assembly (1) temporarily
and then remove the mounting bolts. 17. Common rail
3) Lift off turbocharger assembly (1). 1) Remove fuel tube (1).
4 Turbocharger assembly: 35 kg 2) Remove common rail (2).
12V140E-3 Series 5
18. Supply pump assembly 3) Remove water pump assembly (3).

1) Remove oil tube (1)
2) Remove supply pump assembly mount-
ing bolt (2).
3) Remove supply pump assembly (3).
4) Remove housing (5) from water pump (4).
19. Corrosion resister and filter head assembly

Remove corrosion resister and filter head
assembly (1).
21. Oil cooler (rear side)

1) Remove oil manifold (1).
2) Remove oil cooler (2)
a Remove the oil cooler (front side)
after removing the supply pump drive
case.
20. Water pump assembly
1) Remove block (1)
2) Remove water connector (2).
6 12V140E-3 Series
22. Plate and block 25. Head cover

Remove plates (1) and (2) and block (3). Remove head cover (1).
a Repeat the same procedure on every cyl-
inder up to removal of the cylinder head
assembly.
23. Fuel tube

1) Remove fuel tube (1).
26. Rocker arm assembly

1) Loosen locknuts (1) and then loosen
adjustment screws (2) fully.
a Make sure that the valve tension is
not applied to the rocker arm and thus
it is free to move.
2) Remove rocker arm assembly (3).
a Record the parts installation positions
using a tag to avoid confusion in the
later assembly.
24. Oil level gauge and oil filler tube

1) Remove bracket (1) and then remove oil
filler tube (2).
2) Loosen the sleeve nut at the base and
then remove oil level gauge (3).
3) Remove air intake rocker arm (4), spacer

(5) and exhaust rocker arm (6) from rocker
shaft (7).
12V140E-3 Series 7
27. Push rod 2) Insert a small L-bar [1] under the fuel con-
Remove push rod (1). nector and pry out fuel injector (2) slowly.
a Do not grip the solenoid valve at the
top of the injector to pull off the injec-
tor.
28. Injector harness

1) Remove injector terminal mounting nut (1)
and clamp mounting bolt (2).
2) Push connector (3) into the cylinder head 30. Crosshead
and remove injector harness (4). Remove crosshead (1).
29. Fuel injector 31. Cylinder head assembly

1) Remove holder mounting bolt (1). 1) Remove the water tube.
2) Lift off cylinder head assembly (1).
4 Cylinder head assembly: 25 kg
8 12V140E-3 Series
a When removing the cylinder head

assembly without removing the fuel
injector, be sure to prevent its interfer-
ence with the floor surface since the
injector tip protrudes through the bot-
tom of the cylinder head.
32. Oil pan

1) Support the front and rear side of oil pan
(1) with block [1].
2) Remove all oil pan mounting bolts.
3) Separate the gasket sealant.
4) Lift the engine and then remove oil pan
3) Remove the cylinder head gasket.
(1).
4 Oil pan: 90 kg
4) Disassemble the cylinder head assembly
according to the following procedure.
1] Using tool B, compress the valve
spring to remove cotter (2).
2] Remove upper seat (3), outer spring
(4), and inner spring (5).
33. Suction pie and under plate

1) Fix under plate (1) temporarily using sev-
eral oil pan mounting bolts.
2) Remove stay (2) and then remove suction
3] Remove lower seat (6). pipe (3).
4] Raise the cylinder head and remove
valve (7).
12V140E-3 Series 9
3) Support under plate (1) using jack [1]. 36. Breather

4) Remove the bolts used for temporary fix- Remove breather (1), blowby pipe (2) and
ing and then lower the jack carefully to plate (3).
remove under plate (1). a Remove the plate on the left bank alone.
4 Under plate: 25 kg
37. Thermostat case

34. Relief valve 1) Remove water outlets (1).
1) Remove relief valve (1). 2) Remove thermostat case (2).
2) Install the engine again to tool A. 3) Remove thermostat (3) from thermostat
case (2).
35. Alternator bracket
Remove alternator bracket (1).
10 12V140E-3 Series
38. Front engine hanger 2] Remove shaft (5), thrust plate (6) and
Remove front engine hanger (1). gear (7) as a unit.
3] Remove gear (7) from shaft (5).
4] Pull off oil seal (9) and bushing (10)
from housing (8).

1) Remove coolant temperature sensor (1).
2) Remove thermostat housing (2). 41. Flywheel assembly
1) Lift and secure flywheel assembly (1).
2) Remove the mounting bolt.
3) Separate the bolt from the crankshaft
using forcing screw [1].
4) Lift off flywheel assembly (1).
4 Flywheel assembly: 130 kg
40. Accessory drive

1) Remove pulley (1).
2) Remove accessory drive (2).
3) Disassemble the accessory drive accord-

ing to the following procedure.
1] Pull off hub (3) and then remove
thrust plate (4).
12V140E-3 Series 11
42. Flywheel housing 43. Rear oil seal

1) Remove burring tool (1) and Ne speed Remove rear oil seal (1) from the flywheel
sensor (2). housing.
2) Remove engine speed sensor (3). 44. Damper and crank pulley assembly
1) Lift damper and crank pulley assembly (1)
temporarily and then remove the mounting
bolts.
2) Lift off damper and crank pulley assembly
(1).
4 Damper and crank pulley assem-
bly: 75 kg
3) Lift flywheel housing (4) temporarily and

then remove the mounting bolt.
4) Lift off the flywheel housing (4).
4 Flywheel housing: 230 kg
45. Front support

Remove front support (1) using puller [1].
12 12V140E-3 Series
46. Gear case cover

Lift off gear case cover (1).
4 Gear case cover:75 kg
49. Supply pump gear

1) Remove the mounting nut.
2) Remove supply pump gear (1) using puller
47. Front oil seal [1].
Remove front oil seal (1) from the gear case a After removing the supply pump gear,
cover. remove the key from the shaft and
maintain so that it may not be lost.
48. Idler gear (Large)

1) Remove plate (1). 50. Idler gear (Small)
2) Remove idler gears (large) (2) and (3). 1) Remove plate (1).
2) Remove idler gear (small) (2).
3) Remove thrust plate (4) from the shaft.

a A indicates the oil channel.
12V140E-3 Series 13
51. Oil pump assembly

Remove oil pump assembly (1).
2) Remove cam follower assembly (3).
52. Supply pump drive case

1) Remove oil tube (1)
a Remove the oil tube on the left bank
alone.
2) Remove supply pump drive case (2).
3) Disassemble the cam follower assembly

1] Remove snap rings (4)
2] Remove cam followers (5) from shaft
(6).
3] Remove snap rings (7) from shaft (6).
53. Oil cooler (Front side)
Remove oil cooler (front side) (1)
55. Camshaft assembly

1) Turn cam gear (1) to remove mounting
54. Cam follower assembly bolt (2) through lightening hole.
1) Remove plate (1) and cam follower cover
(2).
14 12V140E-3 Series
a Be sure to remove the piston cooling noz-

zle before removing the piston connecting
rod assembly.
a When removing the nozzle, turn it 90° so
that it may not hit the piston.
2) Pull off cam shaft assembly (3) along with

the cam gear.
a Turn the cam shaft carefully when
removing it so that the bushing may
not be damaged.
58. Piston and connecting rod assembly
1) Prior to the removal, measure the side
clearance of the connecting rod using dial
gauge [1] in order to use it as a rough
standard in the assembly.
a Check the stamped No. of the con-
necting rod cap.
q Make sure that the cap No. and
cylinder No. are the same.
q The No. must be stamped on the
cam side.
a If the cylinder No. is not stamped,
write it using an electric pen prior
to the removal (it is not accept-
able to stamp the number).
56. Timing gear case
1) Lift timing gear case (1) temporarily and
then remove the mounting bolt.
2) Lift off timing gear case (1).
4 Gear case cover: 55 kg
2) Rotate the crankshaft in order to drive the

piston to be removed to the bottom dead
center.
3) Loosen connecting rod bolt (1) by 5 to 6
turns.

Remove piston cooling nozzle (1).
12V140E-3 Series 15
4) Hit the connecting rod head lightly using a 9) Disassemble the piston and connecting
plastic hammer to loosen the connecting rod assembly according to the following
rod cap and connecting rod. procedure.
5) Scrub the carbon off the top wall of the 1] Remove snap ring (4)
liner using fine sandpaper. 2] Support connecting rod (5) with hand
6) Turn the crankshaft until the piston comes and then remove piston pin (6) to dis-
to the top dead center and then remove connect piston (7) from the connect-
the connecting rod cap (2). ing rod.
a When the piston pin is firmly
fixed and unremovable, heat it
(roughly 5 minutes at 100°C)
using an industrial dryer.
3] Remove the snap ring on the other
side.
7) Push in and piston and connecting rod

assembly using pushing bar [1] from the
oil pan side and then remove the assem-
bly while supporting piston (3) from the
cylinder head side.
a Take care not to damage the inside of
the cylinder with a corner of the con- 4] Using tool C, remove piston ring (8).
necting rod. 5] Remove oil ring expander (9)
8) Remove other piston and connecting rod a Keep the piston, connecting rod,
assemblies according to the above proce- connecting rod bearing, piston
dure. ring, and piston pin on a cylinder
a Keep the sliding portion and bearing to cylinder basis.
of the piston in a safe place to protect
them from damage.
a Assemble the connecting rod and cap
temporarily and keep them along with
the connecting rod bearing on a cylin-
der to cylinder basis.
16 12V140E-3 Series
59. Crankshaft 4) Lift off crankshaft (4).

1) Before removing crankshaft, measure the a Use care in lifting the crankshaft so
end play of the crankshaft using dial that it may not hit and get damage
gauge [1] in order to use it as a rough from the cylinder block.
standard in the assembly. 4 Crankshaft: 210 kg
2) Remove mounting bolts (2) of main cap 5) Remove upper thrust bearing (5) from
(1). No.7 journal.
3) Insert the bolts in the bolt hole of the main 6) Remove upper bearing (6).
cap (1) and remove the cap, while shaking a Apply marking to the assembly posi-
it. tions of the main cap, main bearing
and thrust bearing using paint or tags
and then keep them on a cap to cap
basis.
a Lower thrust bearing (3) is assembled

to No. 7 main cap. Record its assem-
bly position after removal.
12V140E-3 Series 17
60. Cylinder liner 61. Cylinder block

1) Before removing cylinder liner (1), mea- Lift off the cylinder block from tool A.
sure its projection using tool D and dial 4 Cylinder block: 850 kg
gauge [1].
a Before measuring projection of the
liner, tighten the liner with plate [2] so
that it may not be lifted by the O-ring.
3 Plate mounting bolt:
69 – 98 Nm {7 – 10 kgm}
2) Using tool E, remove cylinder liner (1).
18 12V140E-3 Series

© 2006 KOMATSU
All Rights Reserved
20 12V140E-3 Series
SEN00322-00
ENGINE 1SHOP MANUAL
12V140E-3 Series

General assembly of engine ................................................................................................................. 2
12V140E-3 Series 1

General assembly of engine 5] Check the counterbored part and
remove burrs. If chips or dust is on
a The shapes, quantity, locations, etc. of the face C, the liner does not fit and cool-
parts depend on each applicable machine. ant may leak and the projection of the
Take care. liner may become improper conse-
a When a part is provided on both sides of the quently.
banks, one side alone will be shown as an a If the counterbored part is droop-
example. Except where otherwise noted, the ing, corroded, or pitted, repair it.
same work procedure shall be employed for
the both banks.
a Clean each part carefully, and check it for
bruise, flaw, cavity, etc. Make sure each oil or
coolant path is through.
Tightening bolts by plastic-region turning angle

method
a Bolts tightened by plastic-region turning angle
method
q Cylinder head mounting bolt
q Main cap mounting bolt
q Connecting rod cap mounting bolt
a If the plastic-region turning angle method is
applied, the tightened bolts have permanent 2. Cylinder liner
strain. Accordingly, the allowable number of a Replace the O-ring and clevis seal with
using times of each bolt is limited. Observe the new ones.
following precautions.
1) Check that the cylinder liner O-ring groove
q Check each mounting bolt head for punch
and periphery of the liner are not rough-
marks. If there were punch marks more
ened because of rusting or pitting. If those
than the specified numbers, replace the
parts are roughened, replace the cylinder
bolt.
liner.
2) Install clevis seal (1), O-rings (2) and (3) to
1. Cylinder block
the cylinder liner.
1) Lift the cylinder block and then set it on a Check that there is not a burr, dust,
tool A. etc. in the groove of the liner.
4 Cylinder block: 850 kg
a Fit the clevis seal with the chamfered
2) Before inserting the cylinder liners, pre- side down. When fitting it, press it
pare the cylinder block according to the against the seal groove all round so
following procedure. that it will not be twisted.
1] Remove the rust and scales from a When installing O-rings (2) and (3),
faces A and B with sandpaper, etc. refer to the following.
until the machined surfaces are q O-ring (2): Black
exposed. q O-ring (3): Orange
2] Polish parts B, R and r with sandpa- 2 Clevis seal and O-ring:
p e r o f a b o u t No . 2 0 0 un t i l t h e y Rubber lubricant (RF-1)
become smooth. a RF-1: DAIDO CHEMICAL INDUSTRY
If part R is sharpened or burrs are CO., LTD.
present there, finish it with a scraper If RF-1 is not available, apply clean
or sandpaper. engine oil (EO30).
F i n i s h t h i s s u r f a c e pa r t i c u l a r l y a Since the clevis seal and O-ring are
smoothly so that it will not damage swollen and deteriorated by oil, apply
the O-ring. a small amount of oil to them thinly
3] If face R is so pitted that it cannot be with a brush just before fitting them.
repaired, replace the cylinder block.
4] If faces A and parts R and r are pit-
ted, finish them smoothly.
2 12V140E-3 Series
q Gasket sealant application diam-

eter: ø0.8 – 1.6 mm
3) After fitting the liner O-ring, check it for

twist. If it is twisted, correct it with a
a When applying the gasket seal-
smooth rod (about 10 mm in diameter).
ant, make sure overlapping b
between the coating at start and
the end complies with the follow-
ing dimension.
q Gasket sealant overlapping
dimension b: 6 ± 6 mm
4) Install the cylinder liner according to the

following procedure.
1] Using cloth, wipe dirt and oil com-
pletely off the contact faces between
the counterbored part of the cylinder a After applying the gasket sealant,
block and liner flange. finish the cylinder liner installa-
2] Apply silicon-based gasket sealant to tion within 50 minutes.
the counterbored mating parts a of q When the bottom contact face of
the cylinder block and cylinder liner. the counterbored liner flange is
2 Cylinder block: modified and shim (2) is used.
Gasket sealant (LG-6)
12V140E-3 Series 3
1] Coat the bottom side of shim 8) Using tool F, press-fit cylinder liner (1) to
(2) with a small amount of the cylinder block.
gasket sealant LG-6 and
then assemble the shim.
2] Then apply gasket sealant
LG-6 according to the same
procedure as that employed
when the shim is not used.
9) To prevent the gasket sealant from pro-

jecting through the clearance between the
block and liner after the cylinder head is
tightened, tighten the cylinder head tem-
po r a r i l y wi t h th e u s e d h ea d g a s k e t
inserted.
5) Immediately before press-fitting of the a At this time, observe the following
liner, apply a small amount of engine oil to tightening torque and tightening
the liner O-ring, crevice seal and contact order.
face of the cylinder block. 3 Temporary tightening torque:
2 Clevis seal, O-ring and cylinder 137 – 157 Nm {14 – 16 kgm}
block: Engine oil (EO30) a Installation of No. 7 bolt is not neces-
a Apply the engine oil, using hands, sary.
uniformly on the entire contact face of
the cylinder block.
10) Remove the cylinder head and wipe off

6) Direct stamping "T" on the top face of the the gasket sealant projected from the
liner toward the engine front side and then counterbored part.
insert cylinder liner (1) to the cylinder a Be sure to perform steps 9) and 10)
block while taking care so that the O-ring above since the projected gasket
may not be damaged. sealant can deform the grommet of
7) Push in cylinder liner keeping weight on the head gasket.
both hands. 11) After press-fitting the cylinder liner, mea-
a If the liner does not enter the cylinder sure its projection using tool D.
block smoothly when pushed with a Before measuring projection of the
weight on both hands, stop the work liner, tighten it with plate [1] so that it
since the O-ring is potentially dam- may not be lifted by the O-ring.
aged. In this case, check the cylinder q Measuring position:
block for burrs. 4 positions at a, b, c and d.
4 12V140E-3 Series
3 Plate mounting bolt:

686 – 980 Nm {7 – 10 kgm}
a Standard cylinder projection:
0.07 – 0.15 mm
a If the projection is out of the standard,
correct it according to the mainte-
nance standard.
a If the gasket sealant is projected from
the fitting parts of the cylinder block
and cylinder liner up to the top of the
cylinder block, wipe it off.
2) Drive in the roll pin in such that its projec-

tion from the block end face may become
2.7 – 3.4 mm and then install upper thrust
bearing (5).
a Install the thrust bearing with the
grooved surface on the crankshaft
side.
2 Thrust bearing sliding surface:
Engine oil (EO30)
3) Before assembling crankshaft, confirm the
following items.
3. Crankshaft q Presence/absence of abnormality in
1) Fit upper main bearing (6) to the cylinder the front and rear threaded portions.
block, matching the projection of the (Make sure the bolt can be smoothly
former to the notch of the latter. screwed in with hand.)
q Presence/absence of scratches or
dents on the pin and main journal.
q Presence/absence of dusts in the oil
hole.
a Upper bearing: With oil hole A

a No. 4 bearing is wider than others.
Thus, care must be taken to prevent
an assembly error.
a Bearing with a 4) Lift crankshaft (4) and then install it on the
No. 4 bearing: 52 mm cylinder block.
Bearings other than No. 4: 48 mm a When installing the crankshaft, take
a Before fitting the bearing, make sure care not to hit its sliding surfaces
that its back side is free from foreign against the cylinder block.
matter. 4 Crank shaft: 210 kg
2 Bearing inner surface: 2 Cylinder block journal:
Engine oil (EO30) Engine oil (EO30)
a Don't apply the engine oil to the bear-
ing backside.
12V140E-3 Series 5
5) Install the projection of lower bearing (7) 6) Drive the roll pin of cap No. 7 so that it will
locating it to the notch of main cap (1) and be projected by 2.7 – 3.4 mm from the cap
install. end and then install lower thrust bearings
a Before fitting the bearing, make sure (3) to both sides.
that its back side is free from foreign a Install the thrust bearing with the
matter. grooved surface on the crankshaft
2 Inside of bearing: side.
Engine oil (EO30) 2 Thrust bearing sliding surface:
a Don't apply the engine oil to the bear- Engine oil (EO30)
ing backside. 7) Apply the engine oil to the surface of the
journal of the crankshaft. Then install the
main cap after making sure that the No.
being stamped on respective main caps
(1) is matching the cylinder block No.
2 Crankshaft journal:
Engine oil (EO30)
a When installing the main cap, direct
its cast part number side toward the
front of the engine.
8) Apply engine oil to the threaded portion of
the main cap mounting bolt and washer
and then drive in the bolts alternately until
the main cap is completely fitted.
2 Main cap mounting bolt:
Engine oil (EO30)
a Lower bearing: Without oil hole
a No. 4 bearing is wider than others. Thus, care
must be used to prevent an assembly error.
a Bearing with a
No. 4 bearing: 52 mm
Bearings other than No. 4: 48 mm
9) Tighten main cap mounting bolts (2)

a Tighten the bolts from the center one
to the outer ones in order.
6 12V140E-3 Series
2 Threaded portion of mounting bolt

and washer: Engine oil (EO30)
3 Main cap mounting bolt
1st time: 284 ± 15 Nm {29 ± 1.5 kgm}
2nd time: 569 ± 10 Nm {58 ± 1.0 kgm}
3rd time: Using tool G, retighten the
bolt by 90° (+30°/0°).
4. Piston and connecting rod assembly

1) Assemble the piston and connecting rod
1] Fit in oil ring expander (9) to the oil
ring groove.
2] Using tool C, assemble the oil ring,
second ring and top ring, in this order.
a When tool G is not used, apply
marking b to the main cap and
bolt with paint, and then retighten
the bolt by 90° (+30°/0°).
10) Make punch mark c on the mounting bolt
head.
a When a new bolt is used, do not
make a punch mark on its head.
a Assemble respective piston rings

as shown in the figure.
a When assembling the respective
rings to the piston, direct their
stamped side upward.
a Take the expander out of the oil
ring and fit it to the piston first
and then assemble the oil ring. At
11) Check that the crankshaft turns smoothly. this time, make sure that the
a Standard crankshaft starting torque: expander is fitted to the ring
Max. 147 Nm {15 kgm} groove perfectly.
12) Measure the end play of the crankshaft a Make sure that the coil butt joint
with dial gauge [1]. of the expander is situated in a
a End play standard value: position 180° to the oil ring abut-
0.140 – 0.320 mm ment joint.
a If the end play is out of the standard,
correct it. For details, see "Structure,
function and maintenance standard".
12V140E-3 Series 7
3] Install snap ring (10) to one side of 7] Install the projection of connecting
piston (7). rod upper bearing (11) locating it to
the notch of the connecting rod.
a Before fitting the bearing, make
sure that its back side is free
from foreign matter.
a Don't apply the oil to the bearing
backside.
a Make sure that the connecting
rod small end bushing are large
end bearing hole are aligned with
the connecting rod oil hole.
a Before assembling the connect-
ing rod, check the connecting rod
oil hole for settled dusts.
2 Connecting rod bearing inner
surface: Engine oil (EO30)
4] Set the piston (7) and connecting rod
(5). Mate the cast letters "EX i F" on
the piston against the chamfered hole
side in the big end of the connecting
rod and then assemble them.
5] Apply engine oil to the piston pin boss
and inner surface of the connecting
rod bushing and then insert piston pin
(6) while directing the connecting rod
upward.
2 Piston pin: Engine oil (EO30)
6] Install snap ring (4) on the opposite
side.
a Turn the snap ring to make sure
that the left and right side snap
rings are completely fitted in the 8] Install the projection of connecting
ring groove. rod lower bearing (12) locating it to
a Also make sure that the connect- the notch of the connecting rod cap.
ing rod moves lightly. a Before fitting the bearing, make
sure that its back side is free
from foreign matter. Don't apply
the engine oil to the backside.
8 12V140E-3 Series
2) Apply the engine oil to the cylinder liner. 5) Align the abutment joint of respective pis-
a Apply the engine oil uniformly on the ton rings as well as the piston to the posi-
entire circumference with hands. tion shown in the figure.
2 Cylinder liner: Engine oil (EO30)
3) Turn the crankshaft to drive the pin journal

of the target cylinder of insertion to the top
dead center position.
4) After confirming No. of the piston and con-
necting rod assembly, insert the assembly
to the cylinder block directing it in the
direction shown in the figure.
a Set the direction of the cylinder block
in such that the cylinder may face
sideways. This process is needed to
prevent sudden insertion of the piston
and connecting rod assembly to the
cylinder.
aMake sure that the coil butt joint of the oil ring
a On each bank, install notch A for the
is situated in a position 180° to the abutment
piston cooling nozzle and chamfered
joint
2 Piston ring, piston and crank journal:
side B of the connecting rod. In this
case, their positional relation with
Engine oil (EO30)
front direction F of the engine must be
6) Using tool H, compress the piston ring and
as shown in the figure.
then push in the piston head with a
wooden bar and the like.
12V140E-3 Series 9
7) Using the connecting rod puller [1] shown a When assembling a new connecting
in the figure, pull the connecting rod until it rod, record its cylinder No. on the
is closely contacted against the pin jour- connecting rod cap using a electric
nal. pen (stamping is not acceptable). It is
a Make sure the connecting rod bearing strictly prohibited to change the com-
is not displaced. bination of the connecting rod and
a The connecting rod puller [1] is made cap through this operation.
by welding bar b to unnecessary con-
necting rod bolt a.
a Total length of connecting rod puller l:
Approx. 500 mm.
2 Crank pin journal:
Engine oil (EO30)
11) Apply the engine oil to the threaded por-

tion and washer of the connecting rod.
2 Connecting rod bolt and washer
Engine oil (EO30)
8) Turn the crankshaft 180° while pulling the

connecting rod.
9) Install connecting rod lower bearing (12)
to connecting rod cap (2).
2 Connecting rod lower bearing:
Engine oil (EO30)
10) Install connecting rod cap (2) aligning it to
the dowel pin on the connecting.
a Check the cylinder No.
12) Tighten connecting rod bolts (1) alter-

nately until the connecting rod cap is
closely contacted.
10 12V140E-3 Series
a When tool G is not used, apply marking b to

the connecting rod, connecting rod cap and
bolt with paint and then retighten the bolt by
90° (+30°/0°).
15) After tightening the bolt, make a punch
mark c on its head.
a When a new bolt is used, do not
make a punch mark on its head.
13) Turn the crankshaft 180° and insert the

piston and connecting rod assembly on
one bank according to the steps 1) – 12).
14) Tighten the mounting bolts in the order
indicated in the figure according to the fol-
lowing procedure.
3 Connecting rod bolt:
1st time: 69 – 78 Nm {7 – 8 kgm}
a After assembling the connecting rod,
2nd time:
make sure that the crankshaft rotates
69 – 78 Nm {7 – 8 kgm} (again)
normally.
3rd time: Using tool G, retighten the
16) Measure the side clearance of the con-
bolt by 90° (+30°/0°).
necting rod with dial gauge [1].
q Standard side clearance:
0.3 – 0.454 mm
a When the side clearance is out of the
standard, remove the connecting rod
cap and check the connecting rod for
assembly errors, presence of burrs or
pinching of foreign substances.

1) Install piston cooling nozzle (1).
a After completely inserting the spigot
joint portion to the block side mount-
ing hole, tighten the mounting bolt.
3 Piston cooling nozzle mounting
bolt: 54 ± 20 Nm {5.5 ± 2.0 kgm}
a Prior to the installation, check the
nozzle for damages or internal clog-
ging .
12V140E-3 Series 11
a Make sure prior to the installation that 7. Camshaft assembly

the notch for preventing interference 1) Insert the camshaft assembly (3) to the
of the piston cooling nozzle is pro- cylinder block along with the cam gear.
vided on the piston skirt portion. a Install it carefully turning the cam
shaft so that the cam bushing may
not be damaged.
a Use care when inserting the cam
shaft so that your fingers may not be
pinched.
2 Camshaft: Engine oil (EO30)
2) Turn the crankshaft slowly to make sure

that interference is not observed between
piston cooling nozzle (1) and piston (2) or
connecting rod (3).
2) Turn the cam gear (1) and tighten mount-

ing bolt (2) through the lightening hole
a Replace the current mounting bolt
with a new one.
3 Cam shaft mounting bolt:
88 ± 34 Nm {9.0 ± 3.5 kgm}
6. Timing gear case

Lift and install timing gear case (1).
a Prior to the installation, fix several portions
on the gasket temporarily using the gasket
sealant so that it may not be displaced.
4 Gear case cover: 55 kg
8. Cam follower assembly

1) Assemble the cam follower according to
the following procedure.
1] Install snap ring (7) to shaft (6).
2] Install cam follower (5) to shaft (6).
2 Cam follower bushing inner
surface: Engine oil (EO30)
3] Install snap rings (4).
12 12V140E-3 Series
2) Install cam follower assembly (3). 10. Supply pump drive case
3 Cam follower assembly mounting 1) Install supply pump drive case (2).
bolt: 2) Install oil tube (1).
44.1 – 58.8 Nm {4.5 – 6.0 kgm}
a Install the oil tube on the left bank
alone.
3 Oil tube joint bolt:
7.9 – 12.7 Nm {0.8 – 1.3 kgm}
3) Install cam follower cover (2) and then

tighten it along with plate (1) using the
mounting bolt.
a The plate between No. 3 and No. 4
cylinders is longer than those used in 11. Oil pump assembly
other sections. Install oil pump assembly (1).
3 Cam follower cover mounting bolt: 3 Oil pump mounting bolt:
34.3 – 44.1 Nm {3.5 – 4.5 kgm} 54 ± 20 Nm {5.5 ± 2.0 kgm}
9. Oil cooler (front side)

Install oil cooler (front side) (1)
12V140E-3 Series 13
12. Idler gear (small)

1) Install idler gear (small) (2).
a When installing the idler gear, align
the counter mark "D" to that of the
cam gear (3) for the right bank.
2 Idler gear bushing inner surface:
Engine oil (EO30)
2) Install plate (1) and then tighten the
mounting bolt.
2 Plate sliding surface:
Engine oil (EO30)
3 Idler gear (small) mounting bolt:
98.0 – 122.5 Nm {10.0 – 12.5 kgm}
14. Idler gear (large)

1) Set No. 1 cylinder on the right bank to the
top dead center position.
a It is referenced as the standard posi-
tion when adjusting respective gears.
2) Install thrust plate (4) to the shaft.
a Install the plate in such that oil groove
A may be set on the idler gear side.
2 Thrust plate: Engine oil (EO30)
13. Supply pump gear

1) Install key (2) to the shaft.
3) Install idler gears (large) (2) and (3).

2 Idler gear bushing inner surface:
Engine oil (EO30)
2) Install supply pump gear (1).

a After installing all timing gears, tighten
mounting nut (3) while fixing the
crankshaft.
a Or tighten the nut while retaining the
lightening hole with a general pur-
pose retention tool and fixing the sup-
ply pump gear.
3 Supply pump gear mounting nut:
176 – 196 Nm {18 – 20 kgm}
14 12V140E-3 Series
2) Install water pump assembly (2) tempo-

a Install idler gears (large) (2) and (3) in rarily.
such that their counter marks as well
as that of respective gears may come
to the positions shown in the figure.
3) Measure the backlash and end play of

each gear with the dial gauge.
a Symbols in the figure correspond to
4) Install plate (1) and then tighten the "Position" field in the following table.
mounting bolt.
a Install the plate setting its "OUT"
marking on the outside.
2 Plate sliding surface:
Engine oil (EO30)
3 Idler gear (large) mounting bolt:
98.0 – 122.5 Nm {10.0 – 12.5 kgm}
15. Check of timing gear for backlash and end

play
1) Attach gear (1) to the compressor and
then install them temporarily. (When the
engine is equipped with the compressor)
12V140E-3 Series 15
1] Backlash of each gear a When cover (2) was removed, apply the
(mm) gasket sealant in the position shown in the
Standard figure before installing it again.
Position Measuring points
value 2 Cover: Gasket sealant (LG-7)
Right idler gear (small) and 0.130 – 0.390 q Application diameter: ø2.0 mm
A•A
right sub idler gear (0.125 – 0.363)
Right sub idler gear and right 0.051 – 0.469
B1•B1
supply pump gear (0.125 – 0.363)
Left sub idler gear and left 0.051 – 0.469
B2•B2
supply pump gear (0.125 – 0.363)
Left sub idler gear and left 0.129 – 0.391
C•C
cam gear (0.125 – 0.363)
Right idler gear (small) and 0.129 – 0.391
D•D
right cam gear (0.125 – 0.363)
Right idler gear (large) and
E•E 0.052 – 0.481
water pump drive gear
Right idler gear (large) and
F•F 0.137 – 0.421
oil pump gear
Left supply pump gear and 0.106 – 0.381
G•G
compressor gear (0.138 – 0.354)
Right cam gear and acces- 0.085 – 0.492
H•H
sory drive gear (0.138 – 0.354)
Crank gear and left idler gear
L•L 0.141 – 0.425
(large)
Crank gear and right idler
R•R 0.141 – 0.425
gear (large)
Note): The standard value enclosed in ( ) indicates
the backlash between spur gears
2] End play of each gear

(mm)
Position Gear name Standard value
1 Idler gear (large) end play 0.07 – 0.18
2 Idler gear (small) end play 0.07 – 0.18 17. Front oil seal
3 Supply pump gear end play 0.07 – 0.20 Following remedial actions are needed
4 Oil pump gear end play 0.03 – 0.088 depending on presence and absence wear on
Accessory drive gear end
the contact face of the oil seal on the crank-
5 0.1 – 0.4 shaft.
play
6 Crank gear end play 0.14 – 0.32 1) When a new crankshaft is used or when
7 Cam gear end play 0.10 – 0.25 wear is not recognized on the contact sur-
face of oil seal.
q Either of the dimensions listed in the
16. Gear case cover following table shall apply to oil seal
Lift and install gear case cover (1). press-fitting depth a depending on
4 Gear case cover: 75 kg front cover size b and presence/
absence of bolt hole in the cover end
face.
16 12V140E-3 Series
3) When the actions up to step 2) above

Oil seal
Dimen- Bolt hole
press-fitting
have been conducted on crankshaft (2).
sion b 6-12 x 1.75 q Attach sleeve (3) to crankshaft (2)
depth a
109 mm Absent 13 – 14 mm and then install an oversized oil seal.
114 mm Present 18 – 19 mm
4) Install sleeve (3) according to the following

procedure.
1] Scrub rusts off the press-fitted portion
of the sleeve (60 mm range from the
tip) on crankshaft (2).
2] Apply entire inner surface of the
sleeve with gasket sealant.
2 Inner surface of sleeve:
2) When wear is recognized on the oil seal

contact face of crankshaft (2) and oil seal
installation position is movable.
q Move the oil seal (1) installation posi-
tion backward up to a location where
the lip of the new oil seal (1) won't be
in touch with the wear groove on the
crankshaft (2).
3] Install sleeve (3) in parallel with
crankshaft (2) while hitting sleeve (3)
end face lightly in circumferential
direction using a plastic hammer.
a Since sleeve (3) is symmetric in
its shape, no mounting direction
is specified.
12V140E-3 Series 17
a When rubber is used in the periphery

of the oil seal, use rubber lubricating
liquid (RF-1) or soap water for the
applying.
a Select one of the following 3 oil seal
(1) press-fitting depths depending on
the condition of the crankshaft (2).
1] When a new crankshaft (2) is used or
when wear is not recognized on the
contact surface of oil seal.
q Prior to installation, insert a 1.8 –
2.8 mm spacer [1] between tool J
and oil seal (1).
4] Using tool J, press-fit sleeve (3) to the

specified position.
a Be sure to tighten the bolts
evenly.
a After press-fitting the sleeve,
clean the projected gasket seal-
ant completely (adhesion of such
gasket sealant to the seal lip can
cause leakage of oil).
2] When installing oil seal (1) after modi-

fying its originally intended installation
position.
q Install oil seal (1) as is using tool
J.
5) Using tool J, install front oil seal (1).

a Tighten the mounting bolts evenly.
a Before assembling the oil seal, clean
periphery of the crankshaft and apply
all circumferences with the engine oil.
2 Crankshaft: Engine oil (EO30)
a Apply all circumferences of the oil
seal lip with the engine oil.
2 Oil seal lip: Engine oil (EO30)
2 Metal ring face in oil seal periphery: 3] When sleeve (3) is provided for
Gasket sealant (LG-4) crankshaft (2).
a Use care in above operation so q Install the sleeve using a washer
tha t the s eal li p m ay not be [2] between tool J and crankshaft
applied with the oil. (2).
18 12V140E-3 Series
18. Front support 2) Lift and install damper and crank pulley
Install front support (1). assembly (1).
a Prior to the installation, fill the oil hole with a Install the assembly aligning it to the
grease. dowel pin of the crankshaft.
a Volume of grease filled: 20 cc 4 Damper and crank pulley assem-
2 Front support: Grease (G2-LI) bly: 75 kg
19. Damper and crank pulley assembly

a Tighten the mounting bolts in 3 steps
1) When the damper and crank pulley are
according to the order indicated in the
separated, assemble them again by tight-
figure.
2 Damper and crank pulley pump
ening the mounting bolts in the order indi-
cated in the figure.
assembly mounting bolt and
2 Damper mounting bolt and washer:
washer: Engine oil (EO30)
3 Damper and crank pulley assembly
Engine oil (EO30)
3 Damper mounting bolt:
mounting bolt
98 – 122 Nm {10 – 12.5 kgm}
1st time:
73.5 ± 19.6 Nm {7.5 ± 2 kgm}
2nd time:
245 ± 19.6 Nm {25 ± 2 kgm}
3rd time:
744.8 ± 19.6 Nm {76 ± 2 kgm}
12V140E-3 Series 19
20. Flywheel housing 2) After the installation, cut off the gasket
1) Lift and install flywheel housing (4). projecting from the oil pan mounting sur-
4 Flywheel housing: 230 kg face to make height of the gasket and
mounting surface even.
3) Install burring tool (1) and Ne speed sen-
sor (2).
a Tighten the mounting bolts in 3 steps

according to the order indicated in the
figure.
2 Flywheel housing mounting bolt: 21. Rear oil seal
Engine oil (EO30) Following remedial actions are needed when
3 Flywheel housing mounting bolt: wear is recognized on the contact face of the
1st time: oil seal on the crankshaft.
343 ± 49 Nm {35 ± 5 kgm} 1) When a new crankshaft is used or when
2nd time: Loosen it fully wear is not recognized on the contact sur-
face of oil seal (1).
3rd time:
q Install the rear oil seal in such that the
411.6 ± 19.6 Nm {42 ± 2 kgm}
dimension from the flywheel housing
end face may conform to the standard
dimension indicated in the figure.
20 12V140E-3 Series

(1) installation position is movable.
q Move the oil seal installation position
backward up to the location shown in
the figure where the lip of a new oil
seal won't be in touch with the wear
groove on the crankshaft.

crankshaft (2) while hitting sleeve (3)
end face lightly in circumferential
direction using a plastic hammer.
a Since sleeve (3) is symmetric in
its shape, no mounting direction
is specified.
3) When the actions up to step 2) above

have been conducted on a crankshaft.
q Attach sleeve (3) to crankshaft (2)
and then install an oversized oil seal
(1) in the position indicated in the fig-
ure.
4] Using tool K, press-fit sleeve (3) up to

the position indicated in the figure.
evenly.
4) Install sleeve (3) according to the following gasket sealant to the seal lip can
procedure. cause leakage of oil).
2] Coat entire inner surface of sleeve (3)
with gasket sealant.
12V140E-3 Series 21
5) Using tool K, install rear oil seal (1). 2] When installing the oil seal after mod-
a Tighten the mounting bolts evenly. ifying its originally intended installa-
a Before assembling the oil seal, clean tion position.
periphery of the crankshaft and apply q Don't use a washer [1] between
all circumferences with the engine oil. tool K and crankshaft.
2 Metal ring face in oil seal periphery:
a Use care in above operation so
tha t the s eal li p m ay not be
applied with the oil.
a When rubber is used in the periphery
of the oil seal (1), use rubber lubricat-
ing liquid (RF-1) or soap water for the
applying.
press-fitting depths depending on the
condition of the crankshaft (2). 3] When sleeve (3) is provided for the
1] When a new crankshaft is used or crankshaft.
when wear is not recognized on the q Use 2 washers [1] between tool
contact surface of oil seal. K and crankshaft (2).
q Use 2 washers [1] between tool
K and crankshaft.
22 12V140E-3 Series
22. Flywheel assembly

1) Lift and install flywheel assembly (1).
a Install the assembly aligning it to the
dowel pin of the crankshaft.
4 Flywheel assembly: 130 kg
2) After installing the flywheel, inspect its

facial runout and radial runout using dial
gauge [2].
Standard facial runout: Max. 0.25 mm
Standard radial runout: Max. 0.25 mm
a When tightening the mounting bolt, fix
the space flywheel and flywheel
housing using plate [1] in order to pre-
vent the crankshaft from turning.
3) Install engine speed sensor (3).

a Tighten the locknut until the sensor tip
is contacted against the ring gear
tooth tip of the flywheel. Return the
sensor 3/4 - 1 turn from above posi-
a Tighten the mounting bolts in the fol-
tion and then tighten the locknut.
3 Engine speed sensor locknut:
lowing order.
2 Flywheel assembly mounting bolt:
49 – 68.6 Nm {5 – 7 kgm}
Engine oil (EO30)
3 Flywheel mounting bolt
1st time:
98 ± 19.6 Nm {10 ± 2 kgm}
2nd time:
294 ± 19.6 Nm {30 ± 2 kgm}
3rd time:
539 ± 19.6 Nm {55 ± 2 kgm}
12V140E-3 Series 23
23. Accessory drive assembly 24. Thermostat housing

1) Assemble the accessory drive. 1) Install thermostat housing (2).
1] Pull off bushing (10) and oil seal (9) to 2) Install water temperature sensor (1).
housing (8).
a Press-fit the bushing 2 mm
deeper from the end face.
2 Bushing inner surface:
Engine oil (EO30)
a Press-fit the oil seal 1.5 mm
deeper from the end face.
2 Seal lip: Grease (G2-LI)
a Fill 50 – 80% of the lip open
space with the grease.
2] Press-fit gear to (7) to shaft (5).
3] Assemble thrust plate (6) to the shaft
and gear assembly and then insert
the housing from the rear side.
4] Assemble thrust plate (4) to the shaft
and then press-fit hub (3). 25. Front engine hanger
a Use care in above operation so Install front engine hanger (1).
that the seal lip may not be dam-
aged.
26. Thermostat case

1) Install thermostat (3) to thermostat case
2) Install accessory drive (2).
(2).
3) Install pulley (1).
2) Install thermostat case (2).

3) Install water outlet (1).
24 12V140E-3 Series
29. Relief valve

1) Remove engine assembly (1) from tool A
and then support it using block [1].
a Make sure the engine is supported
stably.
2) Install relief valve (1).
27. Breather
Install breather (1), blow-by pipe (2) and plate
(3).
3 Breather mounting bolt:
24.5 – 29.4 Nm {2.5 – 3.0 kgm}
a Install plate (3) to the left side bank alone.
30. Suction pie and under plate
1) Using jack [1], install under plate (1) and
then fix it temporarily using the oil pan
mounting bolt.
4 Under plate: 25 kg
28. Alternator bracket

Install alternator bracket (1).
2) Install suction pipe (3) and stay (2).
12V140E-3 Series 25
31. Oil pan

1) Install oil pan (1).
4 Oil pan: 75 kg
34. Cylinder head assembly

1) Assemble the cylinder head assembly
2) Install the engine assembly to tool A 1] Install valve (7).
again. 2] Install lower seat (6).
32. Oil level gauge and oil filler tube

1) Install bracket (4).
2) Install oil level gauge (3) and then tighten
the sleeve nut at the base.
3) Install oil filler tube (2).
3] Using tool L, install stem seal (8).

a Drive in tool L until its lower end
a is contacted against lower seat
(6).
33. Common rail

2) Install common rail (2).
a Install the common rail at this point
since positioning of the high-pres-
sure pipe is needed when installing
the fuel injector.
3 Common rail mounting bolt:
59 – 74 Nm {4 – 5 kgm}
4] Install inner spring (5), outer spring

(4) and upper seat (3).
26 12V140E-3 Series
5] Using tool B, compress the valve 3 Cylinder head assembly mounting

spring to install cotter (2). bolt (No. 1 – 6)
a After the installation, hit the valve 1st time:
stem lightly with the plastic ham- 137 – 157 Nm {14 – 16 kgm}
mer to make sure the cotter is 2nd time:
installed stably. 284 – 294 Nm {29 – 30 kgm}
3rd time: 90 (+30/0)°
2) Install the cylinder head gasket.

3) Lift and install cylinder head assembly (1). a When tool G is not used in tight-
4 Cylinder head assembly: 30 kg
ening of the 3rd time, check the
rotating angle after applying
marking b to the cylinder head
and bolt head using paint.
4) Tighten the mounting bolts according to

the following procedure.
1] Tighten mounting bolts (No. 1 – 7)
temporarily. 3] Tighten the mounting bolt (No. 7) with
2] Tighten the mounting bolts (No. 1 – 6) the following torque.
2 Cylinder head assembly mount-
in 3 steps according to the order indi-
cated in the figure. ing bolt:
a When a bolt with 5 punch marks, Molybdenum disulfide lubri-
which indicates the tightening cant (LM-P)
3 Cylinder head assembly mount-
frequency up to today, in its head
is found, replace it with a new ing bolt (No. 7):
one. 66.2 ± 7.4 Nm {6.75 ± 0.75 kgm}
2 Cylinder head assembly mount- 4] After the tightening, stamping punch
ing bolt: Molybdenum disul- mark a to the head of mounting bolts
fide lubricant (LM-P) (No. 1 – 6).
12V140E-3 Series 27
3) Install spherical washer (7) and then

tighten holder mounting bolt (1) tempo-
rarily.
2 Special washer: Engine oil (EO30)
4) Tighten sleeve nut (5) of the high-pressure
pipe temporarily.
a Also tighten the sleeve nut on the
common rail side temporarily to pro-
ceed with the positioning.
a See "High-pressure pipe" for precau-
tions on this operation.
5) Tighten holder mounting bolt (1) with the
specified torque.
3 Holder mounting bolt:
58.8 – 73.5 Nm {6 – 7.5 kgm}
5) Install the water tube. a Leave sleeve nut (5) being tightened
3 Water tube joint bolt: temporarily in above operation as is.
9.8 – 12.7 Nm {1.0 – 1.3 kgm} This nut is to be tightened with the
specified torque in the next step.
35. Fuel injector
a Check that the inside of the injector sleeve
is free from dirt.
1) Install O-rings (4) and (5) and gasket (6) to
the fuel injector.
2 O-ring: Engine oil (EO30)
36. High-pressure pipe (between common rail -

fuel injector)
k Install the high-pressure pipe and
clamp paying attention to the following
points.
q It is strictly prohibited to reuse a high-
pressure pipe by modifying its bend
2) Insert fuel injector (2) to the cylinder head or using the pipe in an unintended
along with holder (3). location.
q The clamp used must be a legitimate
one. And it must be installed in the
specified position with the specified
torque.
q After installing the high-pressure pipe
and clamp, make sure that 10 mm
m i n im u m c le a r a nc e i s p r ov i d e d
between the high-pressure pipe and
adjacent harness. If the clearance is
less than 10 mm, adjust the harness
position to secure the space.
k Before installing the high-pressure
pipe, check it for the following defects.
If there is any of these defects, it can
cause fuel leakage. Accordingly,
replace the high-pressure pipe.
28 12V140E-3 Series
q Check the taper seal of the connect-

ing part (Part a: Part of 2 mm from the
end) for visible lengthwise slit b and
dent c.
q Check part d (end of the taper seal:
Part at 2 mm from the end) for
stepped-type wear (fatigue) which
your nail can feel.
2) Manually tighten and install temporarily

the stay and top and bottom clamps of
high-pressure pipe clamp (7).
3) Tighten the top and bottom clamps perma-
nently.
a Before tightening the stay perma-
nently, deflect the rubber fist.
3 Top and bottom clamp bolt:
1) After installing fuel injector (5) and com-
mon rail (6) temporarily to high-pressure 9.8 ± 1 Nm {1 ± 0.1 kgm}
pipe (4), tighten the sleeve nut with the 4) Tighten the stay permanently.
specified torque. 5) Manually tighten and install temporarily
a Control the torque by using a spanner the stay and top and bottom clamps of the
type torque wrench (commercially high-pressure pipe.
available) for the tightening. 6) Install the high-pressure pipe clamp and
3 High-pressure pipe sleeve nut gate type frame temporarily.
(injector side): a First tighten the high-pressure pipe
39.2 – 49 Nm {4 -– 5 kgm} clamp permanently, and then tighten
3 High-pressure pipe sleeve nut the gate type frame permanently to
(common rail side): the common rail mounting bolt.
39.2 -– 49 Nm {4 – 5 kgm} 3 Gate type frame mounting bolt:
a After the tightening, make sure the O- 9.8 ± 1 Nm {1 ± 0.1 kgm}
ring is not projecting from the sleeve 7) Tighten the high-pressure pipe clamp per-
nut. manently.
3 High pressure pipe clamp bolt:
9.8 ± 1 Nm {1 ± 0.1 kgm}
8) Tighten the clamp stay permanently.
a Tighten the clamp of the air intake
manifold after installing the manifold.
12V140E-3 Series 29
9) Install the rubber cover to the sleeve nut

on the high-pressure pipe.
a Direct the slit downward when install-
ing the rubber cover.
q Injector side (8): Bottom
q Common rail side (9): Cylinder
block side
2) Adjust the crosshead according to the fol-

lowing procedure.
1] Loosen locknut (2) and then loosen
adjustment screw (3) to a position
where it does not valve stem (4).
2] Maintain the contact with valve stem
a When installing the high-pressure pipe without (5) on the push rod side by pressing
removing the fuel injector (for example, when the contact face against the rocker
replacing only the high-pressure pipe with new arm using a finger.
one), follow the procedure below. 3] Tighten adjustment screw (3) to con-
q Tighten sleeve nut (10) by 2 turns with the firm the position where adjustment
hand into the threads of the fuel injector screw (3) is contacted against valve
and then tighten it with the spanner. stem (4).
a If sleeve nut (10) does not catch the 4] Drive in adjustment screw (3) further
threads, it will help to turn the spanner by 20° from the contacting position
while pressing sleeve nut (8) end with a against valve stem (4).
small rod, etc. toward the injector. 5] Tighten locknut (2) while suppressing
move of adjustment screw (3).
3 Locknut:
58.8 ± 5.9 Nm {6.0 ± 0.6 kgm}
37. Crosshead
1) Install crosshead (1).
2 Crosshead sliding portion:
38. Injector harness
Engine oil (EO30)
1) Push connector (3) out of the cylinder
head and then install injector harness (4)
in the cylinder head.
2) Tighten injector terminal mounting nut (1)
and clamp mounting bolt (2).
30 12V140E-3 Series
a Alternately tighten injector terminal

mounting nuts (1).
3 Injector terminal mounting nut:
2 ± 0.2 Nm {0.2 ± 0.02 kgm}
a After tighten the injector terminal
mounting nut, push the harnes s
against the injector body to eliminate
sagging.
2) Install exhaust rocker arm (4), spacer (5)

and air intake rocker arm (6) to rocker arm
shaft (7).
2 Rocker arm shaft:
Engine oil (EO30)
39. Push rod

Install push rod (1).
a Make sure that the push rod end is
securely fitted to the cam follower socket.
2 Both ends of push rod:
Engine oil (EO30)
3) Install rocker arm assembly (3).

a Make sure that the ball of adjustment
screw (2) is securely fitted to the push
rod socket.
a When tightening the mounting bolt,
make sure adjustment screw (2) is
not pushing the push rod.
2 Rocker arm: Engine oil (EO30)
3 Rocker arm assembly mounting
bolt:
40. Rocker arm assembly
93 – 103 Nm {9.5 – 10.5 kgm}
1) Assemble the rocker arm assembly a Tighten locknut (1) after adjustment of
according to the following procedure. the valve clearance is completed.
1] Install adjustment screw (2) on rocker
arms (4) and (6), and then install lock
nut (1).
a Screw in adjustment screw (2)
until its spherical part touches
rocker arms (4) and (6).
12V140E-3 Series 31
3) Tighten locknut (6) to secure adjustment

screw (5).
3 Locknut tightening torque:
52.9 – 64.7 Nm {5.4 – 6.6 kgm}
a After tightening the locknut, check the
valve clearance again.
4) Repeat the same procedure for other
engines, too, in the order of firing. Namely,
crank the engine and then locate the
stamped of the damper to the pointer to
adjust the valve clearance of respective
cylinders.
a Firing order
R1 - L1 - R5 - L5 - R3 - L3 - R6 - L6 -
R2 - L2 - R4 - L4
41. Adjusting valve clearance
1) Rotate the crankshaft forward and drive
right No.1 cylinder to the compression top
dead center, while watching move of the
intake valve on right No. 6 cylinder. Then
locate the stamped line of R1.6 TOP of
vibration damper (1) to pointer (2).
a Crank the engine using the burring
tool (B) being provided in the front
right side of the flywheel housing.
a The intake valve of right No. 6 cylin-
der will start moving as right No. 1 cyl-
i nder i s dri ve n to vi ci nity of the
compression top dead center. (Open)
a Figure shows the cylinder No. and
their firing order (circled numbers
indicate the firing order).
2) Loosen locknut (6) of adjustment screw

(5) of the right No. 1 cylinder and then
in se r t cl ea ra nc e ga ug e M , wh ic h i s
adjusted to the specified thickness,
between crosshead (4) and rocker arm
(3). Then using the adjustment screw,
adjust the clearance to a degree that
allows only slight move of the gauge.
a Standard valve clearance:
q Intake valve: 0.35 ± 0.02 mm
q Exhaust valve: 0.57 ± 0.02 mm
32 12V140E-3 Series
42. Head cover 45. Oil cooler (rear side)

Install head cover (1). 1) Install oil cooler (2).
3 Head cover mounting bolt: 2) Install oil manifold (1).
14.7 – 34.3 Nm {1.5 – 3.5 kgm}
46. Water pump assembly

43. Fuel tube 1) Install housing (5) to water pump (4).
Install fuel tube (1).
3 Fuel tube joint bolt:
9.8 – 12.7 Nm {1.0 – 1.3 kgm}
2) Install water pump assembly (3).
44. Plate and block

Install block (3) and plates (2) and (1).
12V140E-3 Series 33
3) Install water connector (2). a Tighten the mounting bolts in the fol-
4) Install block (1). lowing order.
a Tighten it once and then tighten again
with the same torque.
2 Exhaust manifold assembly mount-
ing bolt:
Molybdenum disulfide lubricant
(LM-P)
3 Exhaust manifold assembly mount-
ing bolt:
44.1 – 53.9 Nm {4.5 – 5.5 kgm}
47. Corrosion resister and filter head assembly

Install corrosion resister and filter head assem-
bly (1).
3) Install bracket (4), water pipe (3), muffler

bracket (2) and insulating plate (1).
48. Exhaust manifold assembly

1) Install the gasket.
a Install the gasket directing its "OUT"
marking to the exhaust manifold side.
2) Lift and install exhaust manifold assembly
(5).
4 Exhaust manifold assembly: 25 kg
34 12V140E-3 Series
49. Turbocharger assembly 50. Exhaust connector

1) Lift and install turbocharger assembly (1). Install exhaust connectors (1) and (2).
a Tighten the turbocharger assembly
mounting bolt after temporarily tight-
ening and positioning of respective
connections.
4 Turbocharger assembly: 35 kg
2 Turbocharger assembly mounting
bolt and nut:
Molybdenum disulfide lubricant
(LM-P)
3 Turbocharger assembly mounting
bolt:
44.1 – 53.9 Nm {4.5 – 5.5 kgm}
51. Air intake manifold assembly

1) Install the gasket.
a Install the gasket setting its "UP"
marking upward and also directing
this side to the intake manifold.
2) Lift and install air intake manifold assem-
bly (2).
4 Intake manifold assembly: 45 kg
2) Install water pipes (2) and (3) and oil pipes

(4) and (5).
a As for the air-cooled turbocharger,
install the oil pipes alone.
3 Water connector (Block side):
78.5 – 103 Nm {8 – 10.5 kgm}
3 Water pipe flare nut (Water connec-
tor side):
24.5 – 59 Nm {2.5 – 6 kgm}
3 Water pipe joint bolt (Turbocharger
side):
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
3 Water connector (Turbocharger
side): 29.4 – 39.2 Nm {3 – 4 kgm} a Tighten the mounting bolts in the fol-
3 Water pipe flare nut (Water connec-
lowing order.
tor side): 3 Intake manifold assembly mounting
29.4 – 39.2 Nm {3 – 4 kgm} bolt: 58.8 – 73.5 Nm {6 – 7.5 kgm}
12V140E-3 Series 35
3) Install support (1). 53. Spill tube

Install spill tube (1).
3 Spill tube joint bolt
Cylinder head side:
9.8 – 12.7 Nm {1.0 – 1.3 kgm}
Intake manifold side:
19.6 – 29.4 Nm {2.0 – 3.0 kgm}
52. High-pressure pipe clamp

Install brackets (1) and (2) to the exhaust man-
ifold and then tighten high-pressure pipe clamp
bolt (3).
3 High pressure pipe clamp bolt:
9.8 ± 1 Nm {1 ± 0.1 kgm}
54. Supply pump assembly and high-pressure
pipe (between supply pump - common rail)
k Install the high-pressure pipe and
clamp paying attention to the following
points.
q It is strictly prohibited to reuse a high-
pressure pipe by modifying its bend
or using the pipe in an unintended
location.
q The clamp used must be a legitimate
one. And it must be installed in the
specified position with the specified
torque.
q After installing the high-pressure pipe
and clamp, make sure that 10 mm
m i n im u m c le a r a nc e i s p r ov i d e d
between the high-pressure pipe and
adjacent harness. If the clearance is
less than 10 mm, adjust the harness
position to secure the space.
1) Install supply pump assembly (1) tempo-
rarily.
a Align and insert the unequal spline
portion of the supply pump side to
unequal spline portion A of the supply
pump drive case side.
a When it is difficult to insert the supply
pump , turn the crankshaft to change
position of unequal spline portion A.
36 12V140E-3 Series
a Tighten mounting bolt (2) with the 6) Install high-pressure pipe clamp (7)
specified torque after tightening the according to the following procedure.
sleeve nut of the high-pressure pipe 1] Manually tighten and install tempo-
(between supply pump and common rarily the stay and top and bottom
rail). clamps of the high-pressure pipe
2 Supply pump assembly mounting
clamp.
bolt: Adhesive (LT-2)
2] Tighten the top and bottom clamps
permanently.
nently, deflect the rubber fist.
a Use care in the tightening so that
ex c e ss i v e fo r ce ma y n ot b e
applied to the supply pump side
install position.
3 Top and bottom clamp bolt:
9.8 ± 1 Nm {1 ± 0.1 kgm}
3] Tighten respective stays permanently.
7) Install the rubber cover to the sleeve nut
on the high-pressure pipe.
a Direct the slit downward when install-
ing the rubber cover.
q Supply pump side (8): Bottom
2) After installing high-pressure pipes (4) and q Common rail side (9): Facing
(5) to supply pump (1) and common rail inward (Opposed)
(3) temporarily, tighten the sleeve nut with
the specified torque.
a Control the torque by using a spanner
type torque wrench (commercially
available part) for the tightening.
3 High-pressure pipe sleeve nut
(supply pump side):
39.2 – 49 Nm {4 – 5 kgm}
(common rail side):
39.2 – 58.8 Nm {4 – 6 kgm}
3) Tighten supply pump assembly mounting
bolt (2).
4) Tighten the mounting bolt across the sup-
ply pump assembly bottom face and
bracket.
3 Supply pump mounting bolt (Bot- 55. Fuel pipe
tom side): 1) Install priming pump (4).
19.6 – 29.4 Nm {2.0 – 3.0 kgm} a If the air bleeding plug is removed,
5) Install oil tube (6). tighten the pump with the following
3 Oil tube joint bolt: torque.
9.8 – 12.7 Nm {1.0 – 1.3 kgm}
12V140E-3 Series 37

24.5 – 34.3 Nm {2.5 – 3.5 kgm}
2) Install fuel pipes (1) – (3).
3 Fuel pipe joint bolt (Common rail
side):
17.7 – 22.6 Nm {1.8 – 2.3 kgm}
3 Fuel pipe joint bolt (Supply pump
side):
14.8 – 19.6 Nm {1.5 – 2.0 kgm}
58. Engine controller and controller cooler

1) Install controller cooler (4).
2) Install fuel hoses (2) and (3).
3) Install engine controller (1).
3 Engine controller mounting bolt:
23.5 Nm {2.4 kgm}
56. Air intake connector

Install air intake connector (1).
59. Fuel filter and filter head assembly

1) Install fuel filter and filter head assembly
(3).
2) Install fuel tubes (1) and (2).
3 Fuel tube joint bolt:
57. Air inlet pipe
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
a Install bracket (3) to the right side
bank alone.
3) Install air inlet pipe (1) and then fix it with
the clamp.
3 Clamping nut:
29.4 – 44.1 Nm {3.0 – 4.5 kgm}
4 Air inlet pipe: 35 kg
38 12V140E-3 Series
60. Alternator
1) Install alternator (2).
2) Install auxiliary equipment belt (1).
3) Adjust tension of the auxiliary equipment
belt.
a Adjust its deflection to 20 mm when
the pushing force of 58.8 Nm {6 kgm}
is applied to the belt center through a
finger.
3 Adjuster lock bolt:
53.9 – 122.6 Nm {5.5 – 12.5 kgm}
63. Checking for fuel leakage

a When removal and installation of fuel sup-
ply pump (1), common rail (2), or high-
pressure pipes (3) and (4) were con-
ducted, check fuel leakage according to
the following procedure after assembling
the engine.
a Here, high-pressure pipes (3) and (4)
denote every fuel pipe (the figure shows
an example).
61. Starting motor assembly

Install staring motor assemblies (3) and (2) and
then connect wiring harness (1) to them.
a Install the top assembly first being fol-
lowed by the bottom one.
3 Starting motor B terminal nut:
19.6 – 25.5 Nm {2 – 2.6 kgm}
a Clean and degrease the engine and the

parts around it in advance so that you can
test it easily for fuel leakage.
1) Spray color checker (developer) over the
fuel supply pump, common rail, fuel injec-
tor, and joints of the high-pressure piping.
2) Run the engine at speed below 1,000 rpm
and stop it after its speed is stabilized.
62. Engine wiring harness 3) Check the fuel piping and devices for fuel
Install engine wiring harness (1) on the engine leakage.
assembly and then connect the connector and a Check mainly around the high-pres-
terminal. sure circuit parts coated with the color
checker for fuel leakage.
a If any fuel leakage is detected, repair
it and check again from step 1).
4) Run the engine at low idle.
12V140E-3 Series 39
5) Check the fuel piping and devices for fuel

leakage.
a Check mainly around the high-pres-
sure circuit parts coated with the color
6) Run the engine at high idle.
leakage.
8) Run the engine at high idle and load it.
a When checking while the components
to be checked are mounted on the
machine, stall the torque converter or
relieve the hydraulic pump.
leakage.
a If no fuel leakage is detected, check
is completed.
40 12V140E-3 Series

© 2006 KOMATSU
All Rights Reserved
42 12V140E-3 Series
SEN00876-00
ENGINE 1SHOP MANUAL
12V140E-3 Series

Removal and installation fuel supply pump unit.................................................................................... 2
Replacement of oil seal of engine mounted on machine ...................................................................... 4
12V140E-3 Series 1
Disassembly and assembly, Part 3 1

Removal and installation fuel
supply pump unit 1
a Figure shows an example of the left side bank.
Except where otherwise noted, the same work
procedure shall be employed for the both
banks.
Removal
1. Remove the connectors (in 3 places).
2. Remove fuel return hose (3) between common
rail (1) and supply pump (2). [*1]
a A fuel return pipe is provided on the right
side bank. Since it does not allow removal
halfway, the whole set of the pipe must be 6. Remove oil tube (9) between supply pump (2)
removed. and the cylinder block. [*4]
7. Disconnect fuel tube (10) between the fuel fil-
ter and supply pump (2) from the supply pump
side. [*5]
3. Remove fuel tube (5) between priming pump

(4) and supply pump (2). [*2]
4. Remove fuel tube and hose assembly (7)
between supply pump (2) and controller cooler 8. Remove supply pump mounting bracket (11).
(6). [*6]
5. Remove 2 high-pressure pipes (8) between

supply pump (2) and common rail (1). [*3]
2 12V140E-3 Series
9. Remove 4 mounting bolts (12) and then a Tighten mounting bolt (12) with the
remove supply pump assembly (2). [*7] specified torque after tightening the
sleeve nut of the high-pressure pipe
(between supply pump and common
rail).
2 Supply pump assembly mounting
bolt: Adhesive (LT-2)
2) After installing high-pressure pipes (8) on
supply pump (2) and common rail (1) tem-
porarily, tighten the sleeve nut with the
specified torque.
a Use a spanner type torque wrench
(commercially available part) should
be used for the tightening to ensure
observance of the specified torque.
(Supply pump side):
Installation 39.2 – 49 Nm {4 – 5 kgm}
q Carry out installation in the reverse order to
removal. (Common rail side):
39.2 – 58.8 Nm {4 – 6 kgm}
[*1] 3) Install the clamp of the high-pressure pipe
3 Fuel return hose (3) joint bolt (Common rail according to the following procedure.
side): 17.7 – 22.6 Nm {1.8 – 2.3 kgm} 1] Manually tighten and install tempo-
rarily the stay and top and bottom
[*2] clamps of the high-pressure pipe.
3 Fuel tube (5) joint bolt: 2] Tighten the top and bottom clamps
24.5 – 34.3 Nm {2.5 – 3.5 kgm} permanently.
[*3] [*7] nently, deflect the rubber fist.
Install the supply pump and high-pressure pipe by a Take care in the tightening so
finalizing their position the following procedure. that excessive force may not be
1) Install supply pump assembly (2) tempo- applied to the supply pump side
rarily. install position.
a Align the unequal spline portion of the 3 Top and bottom clamp bolt:
supply pump side to unequal spline 9.8 ± 1 Nm {1 ± 0.1 kgm}
portion A of the supply pump drive 3] Tighten respective stays permanently.
case side and then insert the supply 4) Install the rubber cover to the sleeve nut
pump.. on the high-pressure pipe.
a When it is difficult to insert the supply a Direct the slit downward when install-
pump , turn the crankshaft to change ing the rubber cover.
position of unequal spline portion A. q Supply pump side: Bottom side
q Common rail side:
Faced inward (Opposed)
[*4]
3 Oil tube (9) joint bolt:
9.8 – 12.7 Nm {1.0 – 1.3 kgm}
[*5]
3 Fuel tube (10) joint bolt:
24.5 – 34.3 Nm {2.5 -– 3.5 kgm}
[*6]
3 Supply pump mounting bolt (Pump bottom
side): 19.6 – 29.4 Nm {2.0 – 3.0 kgm}
12V140E-3 Series 3
Replacement of oil seal of engine

mounted on machine 1
1. Rear oil seal
a For the work up to removal of the flywheel,
see the shop manual for the applicable
machine.
Removal of standard seal

Hitch the end of tool N to the metal ring of seal (1)
and pull out the seal with impacts of slide hammer
[1].
a Before pulling out the seal, drive in it a little to
separate it from the housing for the ease of
removal.
a Do not use a drill, etc. since chips may enter
the engine.
Installation
a Check the Teflon seal (Laydown lip seal) by
checking the wear of the shaft and replace it
with the "Standard seal "or " Sleeved seal".
Removal of sleeved seal a If the shaft is worn to the degree of luster (If
1) Hitch the end of tool N to the metal ring of wear which you feel with your finger is less
seal (1) and pull out the seal with impacts than 10 m) and does not have any flaw,
of slide hammer [1]. install the standard seal.In other cases, install
a Before pulling out the seal, drive in it the sleeved seal.
a little to separate it from housing (2) a The left one in the following figure is the stan-
for the ease of removal. dard seal and the right one is the sleeved seal.
2) Cut and remove sleeve (3) with a chisel
and a hammer.
a When cutting the sleeve, take care
extremely not to damage crankshaft
(4).
a Remove all the chips.
a The left one in the following figure is
the standard seal and the right one is
the sleeved seal.
4 12V140E-3 Series
Installation
Following remedial actions are needed when wear
is recognized on the contact face of the oil seal on
the crankshaft.
1) When a new crankshaft is used or when wear
is not recognized on the contact surface of oil
seal.
q Install the rear oil seal in such that the dimen-
sion from the flywheel housing end face may
conform to the standard dimension indicated in
the figure.
4)Install sleeve (3) according to the following pro-

cedure.
1] Scrub rusts off the press-fitted portion of
the sleeve (60 mm range from the tip) on
crankshaft (2).
2] Apply entire inner surface of sleeve (3)
with gasket sealant.
2) When wear is recognized on the oil seal con-

tact face of crankshaft (2) and oil seal (1)
q Move the oil seal installation position backward
up to the location shown in the figure where
the lip of a new oil seal won't be in touch with
the wear groove on the crankshaft.
3] Install sleeve (3) in parallel with crankshaft

(2) while hitting sleeve (3) end face lightly
in circumferential direction using a plastic
hammer.
a Since sleeve (3) is symmetric in its shape,
no mounting direction is specified.
3) When the actions up to step 2) above have

been conducted on a crankshaft.
q Attach sleeve (3) to crankshaft (2) and then
install an oversized oil seal (1) in the position
indicated in the figure.
12V140E-3 Series 5
4] Using tool K, press-fit sleeve (3) up to the

position indicated in the figure.
a Be sure to tighten the bolts evenly.
a After press-fitting the sleeve, clean the
projected gasket sealant completely
(adhesion of such gasket sealant to the
seal lip can cause leakage of oil).
2] When installing oil seal after modifying its

originally intended installation position.
q Don't use a washer [1] between tool K and
crankshaft.
5)Using tool K, install rear oil seal (1).

a Before assembling the oil seal, clean periphery
of the crankshaft and apply all circumferences
with the engine oil.
a Apply all circumferences of the oil seal lip with
the engine oil.
a Take care in above operation so that the
seal lip may not be applied with the oil. 3] When sleeve (3) is provided for the crank-
a When rubber is used in the periphery of the oil shaft.
seal, use rubber lubricating liquid (RF-1) or q Use 2 washers [1] between tool K and
soap water for the applying. crankshaft (2).
a Select one of the following 3 oil seal press-fit-
ting depths depending on the condition of the
crankshaft.
1] When a new crankshaft is used or when
wear is not recognized on the contact sur-
face of oil seal.
q Use 2 washers [1] between tool K and
crankshaft.
6 12V140E-3 Series
2. Front oil seal
Removal
a For the work up to removal of the damper, see
the shop manual for the applicable machine.
1) Remove front oil seal (1).

q Move the oil seal (1) installation posi-
tion backward up to a location where
the lip of the new oil seal (1) won't be
in touch with the wear groove on the
Installation crankshaft (2).
Install front seal (1) according to the following pro-
cedure.
Following remedial actions are needed depending
on presence and absence wear on the contact face
of the oil seal on the crankshaft.
1) When a new crankshaft is used or when
wear is not recognized on the contact sur-
face of oil seal.
q Either of the dimensions listed in the
following table shall apply to oil seal
press-fitting depth a depending on
front cover size b and presence/
absence of bolt hole in the cover end
face.
Oil seal
Dimen- Bolt hole 3) When the actions up to step 2) above
press-fitting
sion b 6-12 x 1.75
depth a
have been conducted on crankshaft (2).
q Attach sleeve (3) to crankshaft (2)
109 mm Absent 13 – 14 mm
and then install an oversized oil seal.
114 mm Present 18 – 19 mm
12V140E-3 Series 7
4) Install sleeve (3) according to the following

procedure.
2] Apply entire inner surface of the
sleeve with gasket sealant.
5) Using tool J, install front oil seal (1).

a Before assembling the oil seal, clean
periphery of the crankshaft and apply
all circumferences with the engine oil.
crankshaft (2) while hitting sleeve (3) Gasket sealant (LG-4)
end face lightly in circumferential a Take care in above operation so
direction using a plastic hammer. that the se al lip ma y not b e
a Since sleeve (3) is symmetric in applied with the oil.
its shape, no mounting direction a When rubber is used in the periphery
is specified. of the oil seal, use rubber lubricating
liquid (RF-1) or soap water for the
applying.
(1) press-fitting depths depending on
the condition of the crankshaft (2).
1] When a new crankshaft (2) is used or
when wear is not recognized on the
contact surface of oil seal.
q Prior to installation, insert a 1.8 –
2.8 mm spacer [1] between tool J
and oil seal (1).
4] Using tool J, press-fit sleeve (3) to the

specified position.
evenly.
gasket sealant to the seal lip can
cause leakage of oil).
8 12V140E-3 Series
2] When installing oil seal (1) after modi-

fying its originally intended installation
position.
q Install oil seal (1) as is using tool
J.
3] When sleeve (3) is provided for

crankshaft (2).
q Install the sleeve using a washer
[2] between tool J and crankshaft
(2).
12V140E-3 Series 9

© 2006 KOMATSU
All Rights Reserved
10 12V140E-3 Series

Manual Motor 475,785-7, PC2000 y WA900-3Eo Series 12V140-3 PDF

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SEN00291-04

Copyright 2007 Komatsu

ENGINE 1SHOP MANUAL

00 Index and foreword 1

Composition of shop manual 1

Section Title Form Number

Shop Manual, contents binder, binder label and tabs SEN00291-04

00 Index and foreword SEN00292-04

10 Structure, function and maintenance standard SEN00304-02

20 Standard value table SEN00310-03

30 Testing and adjusting SEN00312-00

50 Disassembly and assembly SEN00319-00

Foreword and general information SEN00296-02

10 Structure, function and maintenance standard

Structure, function and maintenance standard, Part 2 SEN00309-02

Oil pump .................................................................................................................................. 6

20 Standard value table

30 Testing and adjusting

Error codes and failure codes list ............................................................................................ 3

Troubleshooting of electrical system (E-mode), Part 1 SEN00317-00

E-34 Code [273/CA273] PCV2 Short Error (LH bank)............................................................. 62

Troubleshooting of electrical system (E-mode), Part 2 SEN00318-00

50 Disassembly and assembly

Disassembly and assembly, Part 1 SEN00321-00

Disassembly and assembly, Part 2 SEN00322-00

Disassembly and assembly, Part 3 SEN00876-00

KOMATSU 12V140E-3 Series engine

ENGINE 1SHOP MANUAL

00 Index and foreword 1

Safety notice 1 (Rev. 2007/03)

1. General precautions 7) If welding repairs are needed, always

4. Precautions for sling work and making

8. Precautions for disconnecting and con-

a Example of O-ring (Fitted to every joint of

a For tightening torque, see the precautions for

How to read the shop manual 1

1. Composition of shop manual

00. Index and foreword

10. Structure, function and maintenance standard

20. Standard value table

30. Testing and adjusting

50. Disassembly and assembly

2. Revision and distribution

q Revised edition mark

Symbol Item Remarks

k Safety Special safety precautions are necessary when performing work.

Special technical precautions or other precautions for preserving stan-

2 Coat Places to be coated with adhesives, etc. during assembly.

Explanation of terms for maintenance standard 1

1. Standard size and tolerance

a The tolerance may be indicated in the text

q Usually, the size of a hole and the size of

2. Standard clearance and standard value 5. Clearance limit

4. Repair limit and allowable value

Handling of electric equipment and hydraulic component 1

Points to remember when handling electric

2. Main failures occurring in wiring harness

2) Defective crimping or soldering of connec-

4) High-pressure water entering connector

5) Oil or dirt stuck to connector

3. Removing, installing, and drying connec-

2] When removing from clips

q When removing a connector from a