Shop Manual Engine 12V 140e PDF

SEN00291-14
ENGINE
12V140E
-3
SERIES
SEN00294-14
ENGINE
1SHOP MANUAL
12V140E-3 Series
00 Index and foreword
Index
Composition of shop manual .......................................................................................................................... 2
Table of contents ............................................................................................................................................. 3
12V140E-3 Series
SEN00294-14
Composition of shop manual
The contents of this shop manual are shown together with Form No. in a list.
Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly.
The marks shown to the right of Form No. denote the following:
Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.)
Note 2: This shop manual can be supplied for each Form No.
Note 3: To file this shop manual in the special binder for management, handle it as follows:
Place a divider on the top of each section in the file after matching the Tub No. with No. indicated
next to each Section Name shown in the table below:
File overview and other materials in sections in the order shown below and utilize them accordingly.
Section Title
Form Number
Shop Manual, contents binder, binder label and tabs
SEN00291-14

Index
Foreword and general information
SEN00292-14
SEN00294-14 q
SEN00296-04
01 Specification
Specification and technical data
SEN00301-03
SEN00303-03
10 Structure, function and maintenance standard

Structure, function and maintenance standard, Part 1
SEN00304-06
SEN00307-05
SEN00309-04
20 Standard value table

Standard service value table
SEN00310-03
SEN00311-03
30 Testing and adjusting

Testing and adjusting
SEN00312-04
SEN00313-04
40 Troubleshooting
General information on troubleshooting
Troubleshooting of mechanical system (S-mode)
Troubleshooting of electrical system (E-mode), Part 1
SEN00314-04
SEN00315-01
SEN00316-01
SEN00317-03
SEN00318-03
50 Disassembly and assembly

General information on disassembly and assembly
Disassembly and assembly, Part 1
SEN00319-04
SEN00320-03
SEN00321-01 q
SEN00322-04 q
SEN00876-03
90 Repair and replacement of parts

Information related to repair and replacement
Parts related to cylinder head
Parts related to cylinder block
SEN05154-01
SEN05155-00
SEN05156-01
SEN05157-00
12V140E-3 Series
SEN00294-14
Table of contents

Index
SEN00294-14
Composition of shop manual.......................................................................................................
2
Table of contents .........................................................................................................................
3
SEN00296-04
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
SEN00303-03
Outline.........................................................................................................................................
2
Specifications ..............................................................................................................................
4
General view ............................................................................................................................... 10
Weight table ................................................................................................................................ 19
Engine performance curves ........................................................................................................ 20
SEN00307-05
Air intake and exhaust unit ..........................................................................................................
3
Air cleaner ...................................................................................................................................
4
Turbocharger...............................................................................................................................
6
Aftercooler ................................................................................................................................... 11
Muffler ......................................................................................................................................... 12
Cylinder head .............................................................................................................................. 14
Cylinder block.............................................................................................................................. 18
Cylinder liner ............................................................................................................................... 22
Main moving parts ....................................................................................................................... 24
Crankshaft ................................................................................................................................... 26
Camshaft ..................................................................................................................................... 28
Cam follower and push rod ......................................................................................................... 29
Piston, piston ring, and piston pin ............................................................................................... 30
Connecting rod............................................................................................................................ 32
Flywheel and flywheel housing ................................................................................................... 34
Vibration damper ......................................................................................................................... 35
Timing gear ................................................................................................................................. 36
Valve system ............................................................................................................................... 38
Valve and valve guide ................................................................................................................. 40
Rocker arm and shaft .................................................................................................................. 42
Crosshead and guide .................................................................................................................. 43
SEN00309-04
Lubrication system ......................................................................................................................
4
12V140E-3 Series
SEN00294-14
Lubrication system diagram.....................................................................................................

Oil pump ..................................................................................................................................
Oil cooler..................................................................................................................................
Oil filter.....................................................................................................................................
Main relief valve.......................................................................................................................
Oil cooler bypass valve and regulator valve ............................................................................
Fuel system .................................................................................................................................
CRI system diagram ................................................................................................................
CRI system diagram (Poor fuel spec.).....................................................................................
Outline of CRI system..............................................................................................................
Fuel piping ...............................................................................................................................
Fuel piping (Poor fuel spec.)....................................................................................................
Fuel filter ..................................................................................................................................
Water separator .......................................................................................................................
Priming pump...........................................................................................................................
Electric priming pump ..............................................................................................................
Cooling system............................................................................................................................
Cooling system diagram ..........................................................................................................
Water pump .............................................................................................................................
Thermostat...............................................................................................................................
Corrosion resistor ....................................................................................................................
Cooling fan drive......................................................................................................................
Electrical equipment ....................................................................................................................
Alternator .................................................................................................................................
Starting motor ..........................................................................................................................
Starting aid...............................................................................................................................
Engine controller......................................................................................................................
Engine controller cooler ...........................................................................................................
4
6
7
8
9
10
12
12
14
16
34
39
44
46
47
48
50
50
52
54
55
57
60
60
62
64
67
68

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
SEN00313-04
Testing and adjusting tools list.....................................................................................................
3
Testing air boost pressure ...........................................................................................................
5
Testing exhaust temperature .......................................................................................................
6
Adjusting valve clearance............................................................................................................
7
Testing compression pressure.....................................................................................................
9
Testing blow-by pressure............................................................................................................. 11
Testing oil pressure ..................................................................................................................... 12
Handling fuel system parts .......................................................................................................... 13
Releasing residual pressure in fuel system................................................................................. 13
Testing fuel pressure ................................................................................................................... 14
Reduced cylinder mode operation............................................................................................... 15
No-injection cranking................................................................................................................... 15
Testing leakage-from pressure limiter and return rate from injector ............................................ 16
Bleeding air from fuel circuit (for D475A-5) ................................................................................. 19
Bleeding air from fuel circuit (for PC2000) .................................................................................. 22
Bleeding air from fuel circuit (Poor fuel spec.)............................................................................. 24
Testing fuel system for leakage ................................................................................................... 26
Adjusting speed sensor ............................................................................................................... 27
Testing and adjusting alternator belt tension ............................................................................... 27
Handling controller high-voltage circuit ....................................................................................... 28
12V140E-3 Series
SEN00294-14
40 Troubleshooting
General information on troubleshooting
SEN00315-01
Points to remember when troubleshooting..................................................................................
2
Error codes and failure codes list................................................................................................
3
Information in troubleshooting table ............................................................................................
7
Connection table for connector pin numbers ..............................................................................
9
T- branch box and T- branch adapter table ................................................................................. 45
Troubleshooting of mechanical system (S-mode)
SEN00316-01
Method of using troubleshooting charts ......................................................................................
3
S-1 Starting performance is poor ................................................................................................
6
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
SEN00317-03
E-1 Code [111/CA111] ECM Critical Internal Failure (LH bank) ..................................................
4
E-2 Code [111/CB111] ECM Critical Internal Failure (RH bank)..................................................
6
E-3 Code [115/CA115] Eng. Ne and G (Bkup) Speed Sensor Error (LH bank)...........................
8
E-4 Code [115/CB115] Eng. Ne and G (Bkup) Speed Sensor Error (RH bank) ..........................
9
E-5 Code [122/CA122] Charge Air Press. Sensor High Error (LH bank only) ............................ 10
E-6 Code [123/CA123] Charge Air Press. Sensor Low Error (LH bank only) ............................. 12
E-7 Code [131/CA131] Throttle Sensor High Error (LH bank only)............................................. 14
E-8 Code [132/CA132] Throttle Sensor Low Error (LH bank only) ............................................. 15
E-9 Code [135/CA135] Oil Press. Sensor High Error (LH bank only) ......................................... 16
E-10 Code [141/CA141] Oil Press. Sensor Low Error (LH bank only) ........................................ 18
E-11 Code [144/CA144] Coolant Temp. Sensor High Error (LH bank only) ................................ 20
E-12 Code [145/CA145] Coolant Temp. Sensor Low Error (LH bank only) ................................ 22
E-13 Code [153/CA153] Charge Air Temp. Sensor High Error (LH bank only) ........................... 24
E-14 Code [154/CA154] Charge Air Temp. Sensor Low Error (LH bank only)............................ 26
E-15 Code [187/CA187] Sensor Sup. 2 Volt. Low Error (LH bank) ............................................. 27
E-16 Code [187/CB187] Sensor Sup. 2 Volt. Low Error (RH bank) ............................................ 27
E-17 Code [212/CA212] Eng. Oil Temp.Sensor High Error (LH bank only) ................................ 28
E-18 Code [213/CA213] Eng. Oil Temp.Sensor Low Error (LH bank only) ................................. 30
E-19 Code [221/CA221] Ambient Air Press. Sensor High Error (LH bank only) ......................... 32
E-20 Code [222/CA222] Ambient Air Press. Sensor Low Error (LH bank only) .......................... 34
E-21 Code [227/CA227] Sensor Sup. 2 Volt. High Error (LH bank) ............................................ 36
E-22 Code [227/CB227] Sensor Sup. 2 Volt. High Error (RH bank) ........................................... 38
E-23 Code [234/CA234] Eng. Overspeed (LH bank only)........................................................... 40
E-24 Code [238/CA238] Ne Speed Sensor Sup. Volt. Error (LH bank)....................................... 42
12V140E-3 Series
SEN00294-14
E-25 Code [238/CB238] Ne Speed Sensor Sup. Volt. Error (RH bank) ......................................
E-26 Code [263/CA263] Fuel Temp. Sensor High Error (LH bank).............................................
E-27 Code [263/CB263] Fuel Temp. Sensor High Error (RH bank) ............................................
E-28 Code [265/CA265] Fuel Temp. Sensor Low Error (LH bank)..............................................
E-29 Code [265/CB265] Fuel Temp. Sensor Low Error (RH bank) .............................................
E-30 Code [271/CA271] PCV1 Short Error (LH bank) ................................................................
E-31 Code [271/CB271] PCV1 Short Error (RH bank)................................................................
E-32 Code [272/CA272] PCV1 Open Error (LH bank) ................................................................
E-33 Code [272/CB272] PCV1 Open Error (RH bank)................................................................
E-34 Code [273/CA273] PCV2 Short Error (LH bank) ................................................................
E-35 Code [273/CB273] PCV2 Short Error (RH bank)................................................................
E-36 Code [274/CA274] PCV2 Open Error (LH bank) ................................................................
E-37 Code [274/CB274] PCV2 Open Error (RH bank)................................................................
E-38 Code [322/CA322] Injector #1 (L/B #1) System Open/Short Error (LH bank) ....................
E-44 Code [342/CA342] Caribration Code Incompatibility (LH bank) .........................................
E-45 Code [342/CB342] Caribration Code Incompatibility (RH bank) .........................................
E-46 Code [351/CA351] INJ. Drive Circuit Error (LH bank) ........................................................
E-47 Code [351/CB351] INJ. Drive Circuit Error (RH bank)........................................................
E-48 Code [352/CA352] Sensor Sup. 1 Volt. Low Error (LH bank) .............................................
E-49 Code [352/CB352] Sensor Sup. 1 Volt. Low Error (RH bank) ............................................
E-50 Code [386/CA386] Sensor Sup. 1 Volt. High Error (LH bank) ............................................
E-51 Code [386/CB386] Sensor Sup. 1 Volt. High Error (RH bank)............................................
E-52 Code [441/CA441] Battery Voltage Low Error (LH bank) ...................................................
E-53 Code [441/CB441] Battery Voltage Low Error (RH bank) ...................................................
E-54 Code [442/CA442] Battery Voltage High Error (LH bank)...................................................
E-55 Code [442/CB442] Battery Voltage High Error (RH bank) ..................................................
44
46
48
50
50
52
54
56
57
58
60
62
63
64
66
68
70
72
74
76
76
78
80
82
82
84
86
88
88
89
89

SEN00318-03
E-56 Code [449/CA449] Rail Press. Very High Error (LH bank) .................................................
3
E-57 Code [449/CB449] Rail Press. Very High Error (RH bank).................................................
3
E-58 Code [451/CA451] Rail Press. Sensor High Error (LH bank) .............................................
4
E-59 Code [451/CB451] Rail Press. Sensor High Error (RH bank).............................................
6
E-60 Code [452/CA452] Rail Press. Sensor Low Error (LH bank) ..............................................
8
E-61 Code [452/CB452] Rail Press. Sensor Low Error (RH bank) .............................................
8
E-62 Code [553/CA553] Rail Press. High Error 1 (LH bank).......................................................
9
E-63 Code [553/CB553] Rail Press. High Error 1 (RH bank) ...................................................... 10
E-64 Code [554/CA554] Rail Press. Sensor In Range Error (LH bank) ...................................... 11
E-65 Code [554/CB554] Rail Press. Sensor In Range Error (RH bank) ..................................... 11
E-66 Code [559/CA559] Rail Press. Low Error 1 (LH bank) ....................................................... 12
E-67 Code [559/CB559] Rail Press. Low Error 1 (RH bank)....................................................... 16
E-68 Code [689/CA689] Eng. Ne Speed Sensor Error (LH bank)............................................... 20
E-69 Code [689/CB689] Eng. Ne Speed Sensor Error (RH bank) .............................................. 22
E-70 Code [691/CA691] Intake Air Temp Sensor High Error (LH bank only) .............................. 24
E-71 Code [692/CA692] Intake Air Temp Sensor Low Error (LH bank only) ............................... 26
E-72 Code [731/CA731] Eng. G (Bkup) Speed Sensor Phase Error (LH bank).......................... 27
E-73 Code [731/CB731] Eng. G (Bkup) Speed Sensor Phase Error (RH bank) ......................... 27
E-74 Code [757/CA757] All Continuous Data Lost Error (LH bank) ............................................ 28
E-75 Code [757/CB757] All Continuous Data Lost Error (RH bank) ........................................... 28
12V140E-3 Series
SEN00294-14
E-76 Code [778/CA778] Eng. G (Bkup) Speed Sensor Error (LH bank).....................................
E-77 Code [778/CB778] Eng. G (Bkup) Speed Sensor Error (RH bank) ....................................
E-78 Code [781/CA781] Inter Multi-controller Communication Error (LH bank) .........................
E-79 Code [781/CB781] Inter Multi-controller Communication Error (RH bank) .........................
E-80 Code [1117/CA1117] Persistent Data Lost Error (LH bank) ................................................
E-81 Code [1117/CB1117] Persistent Data Lost Error (RH bank) ...............................................
E-82 Code [1257/CA1257] Harness Key error (LH bank) ...........................................................
E-83 Code [1257/CB1257] Harness Key error (RH bank) ..........................................................
E-84 Code [1548/CB1548] Injector #7 (R/B #1) System Open/Short Error (RH bank) ...............
E-86 Code [1551/CB1551] Injector #10 (R/B #4) System Open/Short Error (RH bank) .............
E-90 Code [1633/CA1633] KOMNET Datalink Timeout Error (LH bank) ....................................
E-91 Code [2185/CA2185] Throttle Sens. Sup. Volt. High Error (LH bank only) ........................
E-92 Code [2186/CA2186] Throttle Sens. Sup. Volt. Low Error (LH bank only) .........................
E-93 Code [2249/CA2249] Rail Press. Very Low Error (LH bank) ..............................................
E-94 Code [2249/CB2249] Rail Press. Very Low Error (RH bank) .............................................
E-95 Code [ *1/] Eng. Overheat (LH bank only) ....................................................................
E-96 Code [ *2/] Eng. Oil Press. Low Speed Derate (LH bank only).....................................
E-97 Code [ *3/] Press. Low Torque Derate (LH bank only)..................................................
30
32
34
36
37
37
38
39
40
42
44
46
48
50
52
54
56
57
57
58
58
59

General information on disassembly and assembly
SEN00320-03
How to read this manual .............................................................................................................
2
Coating materials list...................................................................................................................
4
Special tools list...........................................................................................................................
7
Sketches of special tools.............................................................................................................
9
SEN00321-01
Disassembly and assembly, Part 1 .............................................................................................
2
General disassembly of engine ...............................................................................................
2
SEN00322-04
General assembly of engine .......................................................................................................
2
SEN00876-03
Removal and installation fuel supply pump unit ..........................................................................
2
Removal and installation oil seal unit ..........................................................................................
5
Information related to repair and replacement
SEN05155-00
Flowchart.....................................................................................................................................
2
Special tool table .........................................................................................................................
4
SEN05156-01
Part names related to cylinder head ...........................................................................................
2
Testing and inspection of cylinder head ......................................................................................
3
Pressure test of cylinder head.....................................................................................................
5
Replacement of valve guide........................................................................................................
5
Replacement of valve seat insert ................................................................................................
6
Replacement of crosshead guide................................................................................................ 13
Repair of cylinder head mounting face by grinding ..................................................................... 14
Repair of valve by grinding.......................................................................................................... 15
12V140E-3 Series
SEN00294-14

SEN05157-00
Part names related to cylinder block ........................................................................................... 3
Testing and inspection of cylinder block ......................................................................................
4
Part names related to crankshaft ................................................................................................
7
Testing and inspection of crankshaft ........................................................................................... 8
Part names related to connecting rod .........................................................................................
9
Testing and inspection of connecting rod .................................................................................... 10
Replacement of flywheel ring gear .............................................................................................. 11
Replacement of crankshaft gear ................................................................................................. 12
Replacement of camshaft gear ................................................................................................... 13
Replacement of main bearing metal cap ..................................................................................... 14
Replacement of connecting rod small end bushing..................................................................... 16
Replacement of cam bushing...................................................................................................... 17
Repair of cylinder block top by grinding ...................................................................................... 19
Repair of counterbore by grinding ............................................................................................... 20
Check and identification after repair by grinding ......................................................................... 22
Gasket sealant application procedure ......................................................................................... 23
Repair standard for cylinder liner O-ring ..................................................................................... 25
Repair of crankshaft by grinding.................................................................................................. 26
Improvement of surface roughness of crankshaft journal ........................................................... 32
12V140E-3 Series
12V140E-3 Series
SEN00294-14
SEN00294-14
KOMATSU 12V140E-3 Series engine

Form No. SEN00294-14
2011 KOMATSU
All Rights Reserved
Printed in Japan 12-11
10
12V140E-3 Series
SEN00296-04
ENGINE
1SHOP MANUAL
12V140E-3 Series

Safety notice ................................................................................................................................................... 2
How to read the shop manual ......................................................................................................................... 7
Explanation of terms for maintenance standard ............................................................................................. 9
Handling of electric equipment and hydraulic component .............................................................................11
Handling of connectors newly used for engines ........................................................................................... 20
How to read electric wire code...................................................................................................................... 23
Precautions when carrying out operation...................................................................................................... 26
Method of disassembling and connecting push-pull type coupler................................................................. 29
Standard tightening torque table ................................................................................................................... 32
Conversion table ........................................................................................................................................... 36
12V140E-3 Series
SEN00296-04
Safety notice
(Rev. 2008/08)
1
Important safety notice

Proper service and repair are extremely important for safe machine operation. The service and repair
techniques recommended by Komatsu and described in this manual are both effective and safe.
Some of these techniques require the use of tools specially designed by Komatsu for the specific
purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The
cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with
the situation.
1.
General precautions
k Mistakes in operation are extremely
dangerous. Read the Operation and
Maintenance Manual carefully before
operating the machine. In addition,
read this manual and understand its
contents before starting the work.
1) Before carrying out any greasing or
repairs, read all the safety labels stuck to
the machine. For the locations of the
safety labels and detailed explanation of
precautions, see the Operation and Maintenance Manual.
2) Decide a place in the repair workshop to
keep tools and removed parts. Always
keep the tools and parts in their correct
places. Always keep the work area clean
and make sure that there is no dirt, water,
or oil on the floor. Smoke only in the areas
provided for smoking. Never smoke while
working.
3) When carrying out any operation, always
wear safety shoes and helmet. Do not
wear loose work clothes, or clothes with
buttons missing.
q
Always wear safety glasses when hitting parts with a hammer.
q
Always wear safety glasses when
grinding parts with a grinder, etc.
4) When carrying out any operation with 2 or
more workers, always agree on the operating procedure before starting. Always
inform your fellow workers before starting
any step of the operation. Before starting
work, hang UNDER REPAIR warning
signs in the operator's compartment.
5) Only qualified workers must carry out work
and operation which require license or
qualification.
6) Keep all tools in good condition, learn the
correct way to use them, and use the
proper ones of them. Before starting work,
thoroughly check the tools, machine, forklift, service car, etc.
7)
8)
9)
If welding repairs are needed, always

have a trained and experienced welder
carry out the work. When carrying out
weld in g wo rk , al way s wear wel din g
gloves, apron, shielding goggles, cap and
other clothes suited for welding work.
Before starting work, warm up your body
thoroughly to start work under good condition.
Avoid continuing work for long hours and
take rests at proper intervals to keep your
body in good condition. Take rests in
specified safe places.
Safety points
1 Good arrangement
2 Correct work clothes
3 Following work standard
4 Making and checking signs
5
Prohibition of operation and handling by

unlicensed workers
6 Safety check before starting work

7
Wearing protective goggles

(for cleaning or grinding work)
Wearing shielding goggles and protectors

(for welding work)
9 Good physical condition and preparation

10
Precautions against work which you are

not used to or you are used to too much
12V140E-3 Series
2.
3.
SEN00296-04
Preparations for work

1) Before adding oil or making any repairs,
park the machine on a hard and level
ground, and apply the parking brake and
block the wheels or tracks to prevent the
machine from moving.
2) Before starting work, lower the work
equipment (blade, ripper, bucket, etc.) to
the ground. If this is not possible, insert
the lock pin or use blocks to prevent the
work equipment from falling. In addition,
be sure to lock all the control levers and
hang warning signs on them.
3) When disassembling or assembling, support the machine with blocks, jacks, or
stands before starting work.
4) Remove all mud and oil from the steps or
other places used to get on and off the
machine. Always use the handrails, ladders or steps when getting on or off the
m a c h i n e . N e v e r j u m p o n o r o ff t h e
machine. If it is impossible to use the
handrails, ladders or steps, use a stand to
provide safe footing.
6)
Precautions during work

1) Before disconnecting or removing components of the oil, water, or air circuits, first
release the pressure completely from the
circuit. When removing the oil filler cap, a
drain plug, or an oil pressure pickup plug,
loosen it slowly to prevent the oil from
spurting out.
2) The coolant and oil in the circuits are hot
when the engine is stopped, so be careful
not to get scalded. Wait for the oil and
coolant to cool before carrying out any
work on the oil or water circuits.
3) Before starting work, stop the engine.
When working on or around a rotating
part, in particular, stop the engine. When
checking the machine without stopping
the engine (measuring oil pressure,
revolving speed, temperature, etc.), take
extreme care not to get rolled or caught in
rotating parts or moving parts.
4) Before starting work, remove the leads
from the battery. Always remove the lead
from the negative () terminal first.
5) When raising a heavy component (heavier
than 25 kg), use a hoist or crane. Before
starting work, check that the slings (wire
ropes, chains, and hooks) are free from
damage. Always use slings which have
ample capacity and install them to proper
places. Operate the hoist or crane slowly
to prevent the component from hitting any
other part. Do not work with any part still
raised by the hoist or crane.
11)
12V140E-3 Series
7)
8)
9)
10)
12)
13)
14)
15)
16)
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.
When removing components, be careful
not to break or damage the electrical wiring. Damaged wiring may cause electrical
fires.
When removing piping, stop the fuel or oil
from spilling out. If any fuel or oil drips
onto the floor, wipe it up immediately. Fuel
or oil on the floor can cause you to slip
and can even start fires.
As a general rule, do not use gasoline to
wash parts. Do not use it to clean electrical parts, in particular.
Be sure to assemble all parts again in their
original places. Replace any damaged
parts and parts which must not be reused
with new parts. When installing hoses and
wires, be sure that they will not be damaged by contact with other parts when the
machine is operated.
When installing high pressure hoses,
make sure that they are not twisted. Damaged tubes are dangerous, so be
extremely careful when installing tubes for
high pressure circuits. In addition, check
t h a t c o n n e c t i n g pa r ts a r e c o r r e c t l y
installed.
When assembling or installing parts,
always tighten them to the specified
torques. When installing protective parts
such as guards, or parts which vibrate violently or rotate at high speed, be particul a r ly c a r e fu l t o c he c k t h a t t h e y ar e
installed correctly.
When aligning 2 holes, never insert your
fingers or hand. Be careful not to get your
fingers caught in a hole.
When measuring hydraulic pressure,
check that the measuring tools are correctly assembled.
Take care when removing or installing the
tracks of track-type machines. When
removing the track, the track separates
suddenly, so never let anyone stand at
either end of the track.
If the engine is operated for a long time in
a place which is not ventilated well, you
may suffer from gas poisoning. Accordingly, open the windows and doors to ventilate well.
SEN00296-04
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 well seen
from the operator's seat and where he can
see the working condition easily. The sign
maker must always stand in front of the
load and guide the operator safely.
q
Do not stand under the load.
q
Do not step on the load.
2) Check the slings before starting sling
work.
3) Keep putting on gloves during sling work.
(Put on leather gloves, if available.)
4) Measure the weight of the load by the eye
and check its center of gravity.
5) Use proper sling according to the weight
of the load and method of slinging. If too
thick wire ropes are used to sling a light
load, the load may slip and fall.
6) Do not sling a load with 1 wire rope alone.
If it is slung so, it may rotate and may slip
out of the rope. Install 2 or more wire
ropes symmetrically.
k Slinging with 1 rope may cause
turning of the load during hoisting,
untwisting of the rope, or slipping
of the rope from its original winding position on the load, which can
result in a dangerous accident.
7) Limit the hanging angle to 60, as a rule.
Do not sling a heavy load with ropes forming a wide hanging angle from the hook.
When hoisting a load with 2 or more
ropes, the force subjected to each rope
will increase with the hanging angle. The
table below shows the variation of allowable load in kN {kg} when hoisting is made
with 2 ropes, each of which is allowed to
sling up to 9.8 kN {1,000 kg} vertically, at
various hanging angles. When the 2 ropes
sling a load vertically, up to 19.6 kN {2,000
kg} of total weight can be suspended.
This weight is reduced to 9.8 kN {1,000
kg} when the 2 ropes make a hanging
angle of 120. If the 2 ropes sling a 19.6
kN {2,000 kg} load at a lifting angle of
150, each of them is subjected to a force
as large as 39.2 kN {4,000 kg}.
8)
When installing wire ropes to an angular

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

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

or chains are twisted, lower the load
and lift it up again.
q
Do not lift up the load slantingly.
13) When lifting down a load, observe the following.
q
When lifting down a load, stop it temporarily at 30 cm above the floor, and
then lower it slowly.
q
Check that the load is stable, and
then remove the sling.
q
Remove kinks and dirt from the wire
ropes and chains used for the sling
work, and put them in the specified
place.
SEN00296-04
13) If the hoist stops because of a power failure, turn the power switch OFF. When
turning on a switch which was turned OFF
by the electric shock prevention earth
leakage breaker, check that the devices
related to that switch are not in operation
state.
14) If you find an obstacle around the hoist,
stop the operation.
15) After finishing the work, stop the hoist at
the specified position and raise the hook
to at least 2 m above the floor. Do not
leave the sling installed to the hook.
5.
6.
Precautions for using mobile crane

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

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

breaking strength of the rope used
(Safety coefficient: 6).
SEN00296-04
8.
Precautions for disconnecting and connecting hoses and tubes in air conditioner
circuit
1) Disconnection
k For the environment, the air conditioner of this machine uses the
refrigerant (air conditioner gas:
R134a) which has fewer factors of
the depletion of the ozone layer.
However, it does not mean that you
may discharge the refrigerant into
the atmosphere as it is. Be sure to
recover the refrigerant when disconnecting the refrigerant gas circuit and then reuse it.
a Ask professional traders for collecting
and filling operation of refrigerant
(R134a).
a Never release the refrigerant (R134a)
to the atmosphere.
k If the refrigerant gas gets in your
eyes or contacts your skin, you
may lose your sight and your skin
may be frozen. Accordingly, put
on safety glasses, safety gloves
and safety clothes when recovering or adding the refrigerant.
Refrigerant gas must be recovered
and added by a qualified person.
2)

a
Example of O-ring (Fitted to every joint of

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

installation in each section of "Disassembly
and assembly".
Connection
1] When installing the air conditioner circuit hoses and tubes, take care that
dirt, dust, water, etc. will not enter
them.
2] When connecting the air conditioner
hoses and tubes, check that O-rings
(1) are fitted to their joints.
3] Check that each O-ring is not damaged or deteriorated.
4] When connecting the refrigerant piping, apply compressor oil for refrigerant (R134a) (DENSO: ND-OIL8,
VA L E O T H E R M A L S Y S T E M S :
ZXL100PG (equivalent to PAG46))
to its O-rings.
12V140E-3 Series
How to read the shop manual

q
q
q
1.
SEN00296-04
Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one
of them is required, consult KOMATSU distributors.
Materials and specifications are subject to change without notice.
Shop manuals are divided into the Chassis volume and Engine volume. For the engine unit, see the
engine volume of the engine model mounted on the machine.
Composition of shop manual
This shop manual contains the necessary technical information for services performed in a workshop.
For ease of understanding, the manual is divided into the following sections.
00. Index and foreword
This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard
This section explains the structure, function, and maintenance standard values of each component.
The structure and function sub-section explains the structure and function of each component. It
serves not only to give an understanding of the structure, but also serves as reference material for
troubleshooting. The maintenance standard sub-section explains the criteria and remedies for disassembly and service.
20. Standard value table
This section explains the standard values for new machine and judgement criteria for testing,
adjusting, and troubleshooting. This standard value table is used to check the standard values in
testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting
This section explains measuring instruments and measuring methods for testing and adjusting, and
method of adjusting each part. The standard values and judgement criteria for testing and adjusting
are explained in Testing and adjusting.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is
divided by failure modes. The S mode of the troubleshooting related to the engine may be also
explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly
This section explains the special tools and procedures for removing, installing, disassembling, and
assembling each component, as well as precautions for them. In addition, tightening torque and
quantity and weight of coating material, oil, grease, and coolant necessary for the work are also
explained.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
q
Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q
Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
2.
Revision and distribution

Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most
up-to-date information before you start any work.
12V140E-3 Series
SEN00296-04
3.
4.
Filing method
File by the brochures in the correct order of the form number printed in the shop manual composition
table.
q
Revised edition mark

When a manual is revised, the ones and tens digits of the form number of each brochure is
increased by 1. (Example: 00, 01, 02 )
Revisions
Revised brochures are shown in the shop manual composition table.
Symbols
Important safety and quality portions are marked with the following symbols so that the shop manual will
be used practically.
Symbol
Item
Safety
Caution
Special technical precautions or other precautions for preserving standards are necessary when performing work.
Weight
Weight of parts of component or parts. Caution necessary when

selecting hoisting wire, or when working posture is important, etc.
Tightening
torque
Coat
Oil, coolant
Drain
Remarks
Special safety precautions are necessary when performing work.
Places that require special attention for tightening torque during

assembly.
Places to be coated with adhesives, etc. during assembly.
Places where oil, etc. must be added, and capacity.
Places where oil, etc. must be drained, and quantity to be drained.
5.
Units
In this shop manual, the units are indicated with International System of units (SI). For reference, conventionally used Gravitational System of units is indicated in parentheses { }.
12V140E-3 Series
SEN00296-04
Explanation of terms for maintenance standard
The maintenance standard chapter explains the criteria for replacing or reusing products and parts in the
machine maintenance work. The following terms are used to explain the criteria.
1.
Standard size and tolerance

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

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

the shaft to be fitted to that hole are indicated by the same standard size and different tolerances of the hole and shaft.
The tightness of fit is decided by the tolerance.
Indication of size of rotating shaft and hole
and relationship drawing of them
Example:
Standard size
60
12V140E-3 Series
Tolerance
Shaft
Hole
0.030
+0.046
0.076
+0
SEN00296-04
2.
Standard clearance and standard value

The clearance made when new parts are
assembled is called the standard clearance, which is indicated by the range
from the minimum clearance to the maximum clearance.
q
When some parts are repaired, the clearance is generally adjusted to the standard
clearance.
q
A value of performance and function of
new products or equivalent is called the
standard value, which is indicated by a
range or a target value.
q
When some parts are repaired, the value
of performance/function is set to the standard value.
5.
3.
Standard interference
q
When the diameter of a hole of a part
shown in the given standard size and tolerance table is smaller than that of the
mating shaft, the difference between those
diameters is called the interference.
q
The range (A B) from the difference (A)
between the minimum size of the shaft
and the maximum size of the hole to the
difference (B) between the maximum size
of the shaft and the minimum size of the
hole is the standard interference.
q
After repairing or replacing some parts,
measure the size of their hole and shaft
and check that the interference is in the
standard range.
4.
Repair limit and allowable value or allowable dimension

q
The size of a part changes because of
wear and deformation while it is used. The
limit of changed size is called the repair
limit.
q
If a part is worn to the repair limit, it must
be replaced or repaired.
q
The performance and function of a product lowers while it is used. A value which
the product can be used without causing a
problem is called the allowable value or
allowable dimension.
q
If a product is worn to the allowable value,
it must be checked or repaired. Since the
permissible value is estimated from various tests or experiences in most cases,
however, it must be judged after considering the operating condition and customer's
requirement.
10
Clearance limit
Parts can be used until the clearance
between them is increased to a certain
limit. The limit at which those parts cannot
be used is called the clearance limit.
q
If the clearance between the parts
exceeds the clearance limit, they must be
replaced or repaired.
q
6.
Interference limit
The allowable maximum interference
between the hole of a part and the shaft of
another part to be assembled is called the
interference limit.
q
The interference limit shows the repair
limit of the part of smaller tolerance.
q
If the interference between the parts
exceeds the interference limit, they must
be replaced or repaired.
q
12V140E-3 Series
Handling of electric equipment and hydraulic component
SEN00296-04
To maintain the performance of the machine over a long period, and to prevent failures or other troubles
before they occur, correct operation, maintenance and inspection, troubleshooting, and repairs must
be carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at
improving the quality of repairs. For this purpose, it gives sections on Handling electric equipment and
Handling hydraulic equipment (particularly gear oil and hydraulic oil).
Points to remember when handling electric
equipment
1. Handling wiring harnesses and connectors
Wiring harnesses consist of wiring connecting
one component to another component, connectors used for connecting and disconnecting
one wire from another wire, and protectors or
tubes used for protecting the wiring.
Compared with other electrical components fitted in boxes or cases, wiring harnesses are
more likely to be affected by the direct effects
of rain, water, heat, or vibration. Furthermore,
during inspection and repair operations, they
are frequently removed and installed again, so
they are likely to suffer deformation or damage.
For this reason, it is necessary to be extremely
careful when handling wiring harnesses.
2.
Main failures occurring in wiring harness

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

The pins of the male and female connectors are in contact at the crimped terminal
or soldered portion, but if there is excessive force brought to bear on the wiring,
the plating at the joint will peel and cause
improper connection or breakage.
12V140E-3 Series
11
SEN00296-04
12
3)
Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with
a crane with the wiring still connected, or a
heavy object hits the wiring, the crimping
of the connector may separate, or the soldering may be damaged, or the wiring
may be broken.
4)
High-pressure water entering connector

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

If oil or grease are stuck to the connector
and an oil film is formed on the mating surface between the male and female pins,
the oil will not let the electricity pass, so
there will be defective contact. If there is
oil or grease stuck to the connector, wipe it
off with a dry cloth or blow it dry with compressed air and spray it with a contact
restorer.
a When wiping the mating portion of the
connector, be careful not to use
excessive force or deform the pins.
a If there is oil or water in the compressed air, the contacts will become
even dirtier, so remove the oil and
water from the compressed air completely before cleaning with compressed air.
12V140E-3 Series
3.
SEN00296-04
Removing, installing, and drying connectors and wiring harnesses

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

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

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

After removing any connector, cover it
with a vinyl bag to prevent any dust,
dirt, oil, or water from getting in the
connector portion.
a If the machine is left disassembled for a long time, it is particularly easy for improper contact to
occur, so always cover the connector.
12V140E-3 Series
13
SEN00296-04
2)
14
Connecting connectors
1] Check the connector visually.
Check that there is no oil, dirt, or
water stuck to the connector pins
(mating portion).
Check that there is no deformation,
defective contact, corrosion, or damage to the connector pins.
Check that there is no damage or
breakage to the outside of the connector.
a If there is any oil, water, or dirt
stuck to the connector, wipe it off
with a dry cloth. If any water has
got inside the connector, warm
the inside of the wiring with a
dryer, but be careful not to make
it too hot as this will cause short
circuits.
a If there is any damage or breakage, replace the connector.
2] Fix the connector securely.
Align the position of the connector
correctly, and then insert it securely.
For connectors with the lock stopper,
push in the connector until the stopper clicks into position.
3] Correct any protrusion of the boot and
any misalignment of the wiring harness.
For connectors fitted with boots, correct any protrusion of the boot. In
addition, if the wiring harness is misaligned, or the clamp is out of position, adjust it to its correct position.
a If the connector cannot be corrected easily, remove the clamp
and adjust the position.
q
If the connector clamp has been
removed, be sure to return it to
its original position. Check also
that there are no loose clamps.
12V140E-3 Series
3)
Heavy duty wire connector (DT 8-pole, 12pole)

Disconnection (Left of figure)
While pressing both sides of locks (a)
and (b), pull out female connector (2).
Connection (Right of figure)
1] Push in female connector (2) horizontally until the lock clicks.
Arrow: 1)
2] Since locks (a) and (b) may not be set
completely, push in female connector
(2) while moving it up and down until
the locks are set normally.
Arrow: 1), 2), 3)
a Right of figure: Lock (a) is pulled
down (not set completely) and
lock (b) is set completely.
(1): Male connector
(2): Female connector
(a), (b): Locks
12V140E-3 Series
SEN00296-04
Disconnection
Connection (Example of
incomplete setting of (a))
15
SEN00296-04
4)
16
Drying wiring harness

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

electric circuits
1) Always turn the power OFF before disconnecting or connecting connectors.
2) Before carrying out troubleshooting, check
that all the related connectors are properly
inserted.
a Disconnect and connect the related
connectors several times to check.
3) Always connect any disconnected connectors before going on to the next step.
a If the power is turned ON with the
connectors still disconnected, unnecessary abnormality displays will be
generated.
4) When carrying out troubleshooting of circuits (measuring the voltage, resistance,
continuity, or current), move the related
wiring and connectors several times and
check that there is no change in the reading of the tester.
a If there is any change, there is probably defective contact in that circuit.
12V140E-3 Series
SEN00296-04
17
SEN00296-04
Points to remember when handling hydraulic equipment

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

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

field
If disassembly or maintenance work is carried
out on hydraulic equipment in the field, there is
danger of dust entering the equipment. It is
also difficult to check the performance after
repairs, so it is desirable to use unit exchange.
Disassembly and maintenance of hydraulic
equipment should be carried out in a specially
prepared dustproof workshop, and the performance should be checked with special test
equipment.
3.
Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from
entering. If the opening is left open or is
blocked with a rag, there is danger of dirt
entering or of the surrounding area being
made dirty by leaking oil so never do this. Do
not simply drain oil out onto the ground, but
collect it and ask the customer to dispose of it,
or take it back with you for disposal.
4.
Do not let any dirt or dust get in during

refilling operations
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers. If an oil cleaning device is used, it is possible to filter out the
dirt that has collected during storage, so this is
an even more effective method.
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 equipment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit. Normally, flushing is
carried out twice: primary flushing is carried
out with flushing oil, and secondary flushing is
carried out with the specified hydraulic oil.
7.
Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the
machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil circuit. The oil cleaning equipment is used to
remove the ultra fine (about 3 m) particles that
the filter built in the hydraulic equipment cannot remove, so it is an extremely effective
device.
12V140E-3 Series
SEN00296-04
19
SEN00296-04
Handling of connectors newly used for engines

a
1.
Mainly, following engines are object for following connectors.

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

95 170, 12V140 engines
q
Various temperature sensors
Example)
Intake air temperature sensor in
intake manifold: TIM
Fuel temperature sensor: TFUEL
Oil temperature sensor: TOIL
Coolant temperature sensor: TWTR,
etc.
Disconnect the connector by pulling lock
(B) (on the wiring harness side) of connector (2) outward.
Disconnect connector (1) according to the following procedure.

1) Slide lock (L1) to the right.
2) While pressing lock (L2), pull out connector (1) toward you.
a Even if lock (L2) is pressed, connector (1) cannot be pulled out toward
you, if part A does not float. In this
case, float part A with a small screwdriver while press lock (L2), and then
pull out connector (1) toward you.
20
12V140E-3 Series
3.
SEN00296-04
Push lock type

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

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

(4) in the direction of the arrow.
107 engine
2)
If the lock is on the underside, use

flat-head screwdriver [1] since you
cannot insert your fingers.
While pressing up lock (C) of the connector with flat-head screwdriver [1], pull out
connector (3) in the direction of the arrow.
12V140E-3 Series
21
SEN00296-04
4)
95, 125 170, 12V140 engines

While pressing lock (E) of the connector,
pull out connector (5) in the direction of
the arrow.
Example)
Fuel pressure sensor in common rail:
PFUEL etc. (AMP-3)
4.
Turn-housing type (Round green connector)

140 engine
Example)
Intake air pressure sensor in intake manifold (CANNON-04): PIM etc.
1)
Disconnect connector (6) according to the

following procedure.
1] Turn housing (H1) in the direction of
the arrow.
a When connector is unlocked,
housing (H1) becomes heavy to
turn.
2] Pull out housing (H1) in the direction
of the arrow.
a Housing (H1) is left on the wiring harness side.
2)
Connect the connector according to the

1] Insert the connector to the end, while
setting its groove.
2] Turn housing (H1) in the direction of
the arrow until it clicks.
Example)
Injection pressure control valve of fuel
supply pump: PCV (SUMITOMO-2)
Example)
Speed sensor of fuel supply pump:
G (SUMITOMO-3)
a Pull the connector straight up.
22
12V140E-3 Series
SEN00296-04
How to read electric wire code

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

AV and AVS are different in only thickness and outside diameter of the cover. AEX is similar to AV in
thickness and outside diameter of AEX and different from AV and AVS in material of the cover.
(Table 1)
Type
Low-voltage
wire for
automobile
Thin-cover
low-voltage
wire for
automobile
Symbol
AV
AVS
Heat-resistant low-voltAEX
age wire for
automobile
12V140E-3 Series
Material
Conductor
Insulator
Conductor
Annealed copper for electric appliance

Soft polyvinyl chloride
Insulator
Soft polyvinyl chloride
Conductor

Heat-resistant crosslinked
polyethylene
Insulator
Using
temperature
range (C)
Example of use
General wiring
(Nominal No. 5 and above)
30 to +60
General wiring
(Nominal No. 3 and below)
General wiring in extremely
50 to +110 cold district, wiring at high-temperature place
23
SEN00296-04
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
CovAV
Standard
4.6
er D
AEX
Standard
2.0
2.2
2.7
3.0
3.1
3.8
4.6
Nominal No.
Number of
strands/Diameter of strand
Conductor
Sectional
area (mm2)
d (approx.)
AVS
Standard
CovAV
Standard
er D
AEX
Standard
15
20
30
40
50
60
85
100
50/0.45
84/0.45
41/0.80
70/0.80
85/0.80
7.95
13.36
20.61
35.19
42.73
54.29
63.84
84.96
109.1
3.7
5.5
5.3
4.8
7.0
7.0
6.0
8.2
8.2
8.0
10.8
10.8
8.6
11.4
11.4
9.8
13.0
13.0
10.4
13.6
13.6
12.0
16.0
16.0
13.6
17.6
17.6
108/0.80 127/0.80 169/0.80 217/0.80
f of nominal No. denotes flexible.
24
12V140E-3 Series
3.
SEN00296-04
Color codes table
(Table 3)
Color Code
B
Br
BrB
BrR
BrW
BrY
Ch
Dg
G
GB
GL
Gr
GR
GW
GY
L
LB
Lg
LgB
LgR
Color of wire
Color Code
LgW
LgY
LR
LW
LY
O
P
R
RB
RG
RL
RW
RY
Sb
Y
YB
YG
YL
YR
YW
Black
Brown
Brown & Black
Brown & Red
Brown & White
Brown & Yellow
Charcoal
Dark green
Green
Green & Black
Green & Blue
Gray
Green & Red
Green & White
Green & Yellow
Blue
Blue & Black
Light green
Light green & Black
Light green & Red
Color of wire
Light green & White
Light green & Yellow
Blue & Red
Blue & White
Blue & Yellow
Orange
Pink
Red
Red & Black
Red & Green
Red & Blue
Red & White
Red & Yellow
Sky Blue
Yellow
Yellow & Black
Yellow &Green
Yellow & Blue
Yellow & Red
Yellow & White
Remarks: In a color code consisting of 2 colors, the first color is the color of the background and
the second color is the color of the marking.
Example: GW means that the background is Green and marking is White.
4.
Types of circuits and color codes
(Table 4)
Type of wire
Charge
Ground
Start
Light
Instrument
Signal
Type of
circuit
Others
12V140E-3 Series
AVS or AV
R
B
R
RW
Y
G
L
Br
Lg
O
Gr
P
Sb
Dg
Ch
AEX
R
B
R
D
Y
G
L
WG
RB
YR
GW
LW
BrW
LgR
RY
YB
GR
LR
BrR
LgY
RG
YG
GY
LY
BrY
LgB
RL
YL
GB
LB
BrB
LgW
YW
GL
Gr
Br
25
SEN00296-04
Precautions when carrying out operation
[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general
precautions given below when carrying out the operation.]
1.
q
q
q
q
q
q
q
q
q
q
Precautions when carrying out removal work

If the coolant contains antifreeze, dispose of it correctly.
After disconnecting hoses or tubes, cover them or fit plugs to prevent dirt or dust from entering.
When draining oil, prepare a container of adequate size to catch the oil.
Confirm the match marks showing the installation position, and make match marks in the necessary
places before removal to prevent any mistake when assembling.
To prevent any excessive force from being applied to the wiring, always hold the connectors when disconnecting the connectors. Do not pull the wires.
Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.
Check the number and thickness of the shims, and keep in a safe place.
When raising components, be sure to use lifting equipment of ample strength.
When using forcing screws to remove any components, tighten the forcing screws uniformly in turn.
Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from
entering after removal.
Precautions when handling piping during disassembly
Fit the following plugs into the piping after disconnecting it during disassembly operations.
1) Face seal type hoses and tubes
Nominal
number
02
03
04
05
06
10
12
2)
26
Sleeve nut (elbow end)
07376-70210
07376-70315
07376-70422
07376-70522
07376-70628
07376-71034
07376-71234
02789-20210
02789-20315
02789-20422
02789-20522
02789-20628
07221-21034
07221-21234
Split flange type hoses and tubes

Nominal
number
04
05
3)
Plug (nut end)
Flange (hose end)
Sleeve head (tube end)
Split flange
07379-00400
07379-00500
07378-10400
07378-10500
07371-30400
07371-30500
If the part is not under hydraulic pressure, the following corks can be used.
Nominal
number
Part Number
06
08
10
12
14
16
18
20
22
24
07049-00608
07049-00811
07049-01012
07049-01215
07049-01418
07049-01620
07049-01822
07049-02025
07049-02228
07049-02430
Dimensions
D
d
L
6
5
8
8
6.5
11
10
8.5
12
12
10
15
14
11.5
18
16
13.5
20
18
15
22
20
17
25
22
18.5
28
24
20
30
27
07049-02734
27
22.5
34
12V140E-3 Series
2.
q
q
q
q
q
q
q
q
q
q
q
q
q
a
3.
SEN00296-04
Precautions when carrying out installation work

Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any.
Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
Bend the cotter pins and lock plates securely.
When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion with 2 3 drops of adhesive.
When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is
no dirt or damage, then coat uniformly with gasket sealant.
Clean all parts, and correct any damage, dents, burrs, or rust.
Coat rotating parts and sliding parts with engine oil.
When press fitting parts, coat the surface with anti-friction compound (LM-P).
After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
securely.
When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align
the direction of the hook.
When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other
hydraulic equipment removed for repair, always bleed the air as follows:
1) Start the engine and run at low idle.
2) Operate the work equipment control lever to operate the hydraulic cylinder 4 5 times, stopping the
cylinder 100 mm from the end of its stroke.
3) Next, operate the hydraulic cylinder 3 4 times to the end of its stroke.
4) After doing this, run the engine at normal speed.
When using the machine for the first time after repair or long storage, follow the same procedure.
Precautions when completing the operation
1) Refilling with coolant, oil and grease
q
If the coolant has been drained, tighten the drain valve, and add coolant to the specified level.
Run the engine to circulate the coolant through the system. Then check the coolant level
again.
q
If the hydraulic equipment has been removed and installed again, add engine oil to the specified level. Run the engine to circulate the oil through the system. Then check the oil level
again.
q
If the piping or hydraulic equipment have been removed, always bleed the air from the system
after reassembling the parts.
a For details, see Testing and adjusting, Bleeding air.
q
Add the specified amount of grease (molybdenum disulphide grease) to the work equipment
parts.
2) Checking cylinder head and manifolds for looseness
Check the cylinder head and intake and exhaust manifold for looseness.
If any part is loosened, retighten it.
q
For the tightening torque, see Disassembly and assembly.
3) Checking engine piping for damage and looseness
Intake and exhaust system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for air
suction and exhaust gas leakage.
If any part is loosened or damaged, retighten or repair it.
Cooling system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for
coolant leakage.
Fuel system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel
leakage.
12V140E-3 Series
27
SEN00296-04
4)
5)
28
Checking muffler and exhaust pipe for damage and looseness

1] Visually check the muffler, exhaust pipe and their mounting parts for a crack and damage.
If any part is damaged, replace it.
2] Check the mounting bolts and nuts of the muffler, exhaust pipe and their mounting parts for
looseness.
If any bolt or nut is loosened, retighten it.
Checking muffler function
Check the muffler for abnormal sound and sound different from that of a new muffler.
If any abnormal sound is heard, repair the muffler, referring to Troubleshooting and Disassembly
and assembly.
12V140E-3 Series
SEN00296-04
Method of disassembling and connecting push-pull type coupler

k
k
Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to
release the residual pressure from the hydraulic tank.
Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly, prepare an oil receiving container.
Type 1
1.
Disconnection
1) Hold adapter (1) and push hose joint (2)
into mating adapter (3). (Fig. 1)
a The adapter can be pushed in about
3.5 mm.
a Do not hold rubber cap portion (4).
2) After hose joint (2) is pushed into adapter
(3), press rubber cap portion (4) against
adapter (3) until it clicks. (Fig. 2)
3) Hold hose adapter (1) or hose (5) and pull
it out. (Fig. 3)
a Since some hydraulic oil flows out,
prepare an oil receiving container.
2.
Connection
1) Hold hose adapter (1) or hose (5) and
insert it in mating adapter (3), aligning
them with each other. (Fig. 4)
a Do not hold rubber cap portion (4).
2) After inserting the hose in the mating
adapter perfectly, pull it back to check its
connecting condition. (Fig. 5)
a When the hose is pulled back, the
rubber cap portion moves toward the
hose about 3.5 mm. This does not
indicate abnormality, however.
12V140E-3 Series
29
SEN00296-04
Type 2
1.
2.
Disconnection
1) Hold the tightening portion and push body
(7) straight until sliding prevention ring (6)
contacts contact surface (a) of the hexagonal portion at the male end. (Fig. 6)
2) While holding the condition of Step 1), turn
lever (8) to the right (clockwise). (Fig. 7)
3) While holding the condition of Steps 1)
and 2), pull out whole body (7) to disconnect it. (Fig. 8)
Connection
Hold the tightening portion and push body
contacts contact surface (a) of the hexagonal portion at the male end. (Fig. 9)
30
12V140E-3 Series
SEN00296-04
Type 3
1.
2.
Disconnection
1) Hold the tightening portion and push body
contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 10)
2) While holding the condition of Step 1),
push cover (10) straight until it contacts
contact surface (b) of the hexagonal portion at the male end. (Fig. 11)
3) While holding the condition of Steps 1)
and 2), pull out whole body (9) to disconnect it. (Fig. 12)
Connection
Hold the tightening portion and push body
(9) straight until the sliding prevention ring
contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 13)
12V140E-3 Series
31
SEN00296-04
Standard tightening torque table

1.
Table of tightening torques for bolts and nuts

a Unless there are special instructions, tighten metric nuts and bolts to the torque below.
a
The following table applies to the bolts in Fig. A.
Thread diameter of bolt

mm
6
8
10
12
14
16
18
20
22
24
27
30
33
36
39
a
Tightening torque
Nm
11.8 14.7
27 34
59 74
98 123
157 196
245 309
343 427
490 608
662 829
824 1,030
1,180 1,470
1,520 1,910
1,960 2,450
2,450 3,040
2,890 3,630
kgm
1.2 1.5
2.8 3.5
6.0 7.5
10.0 12.5
16 20
25 31.5
35 43.5
50 62
67.5 84.5
84 105
120 150
155 195
200 250
250 310
295 370
The following table applies to the bolts in Fig. B.

mm
6
8
10
12
a Fig. A
Width across flats

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

mm
10
12
14
17
Tightening torque
Nm
kgm
5.9 9.8
0.6 1.0
13.7 23.5
1.4 2.4
34.3 46.1
3.5 4.7
74.5 90.2
7.6 9.2
a Fig. B
Remarks: The widths across flats against the thread diameters of flanged bolts (marks with "*") in Fig. A are
the ones indicated in the table for bolts shown in Fig. B.
(Values of tightening torques shown in the table for Fig. A are applied.)
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
10
12
16
3.
Width across flats

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

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

mm
Tightening torque Nm {kgm}

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

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

mm
14
17
19
22
24
27
30
32
32
36

Range
Target
5.88 8.82 {0.6 0.9}
7.35 {0.75}
9.81 12.74 {1.0 1.3}
11.27 {1.15}
14.7 19.6 {1.5 2.0}
17.64 {1.8}
19.6 24.5 {2.0 2.5}
22.54 {2.3}
24.5 34.3 {2.5 3.5}
29.4 {3.0}
34.3 44.1 {3.5 4.5}
39.2 {4.0}
44.1 53.9 {4.5 5.5}
49.0 {5.0}
58.8 78.4 {6.0 8.0}
68.6 {7.0}
93.1 122.5 { 9.5 12.5}
107.8 {11.0}
107.8 147.0 {11.0 15.0}
127.4 {13.0}
127.4 176.4 {13.0 18.0}
151.9 {15.5}
181.3 240.1 {18.5 24.5}
210.7 {21.5}
274.4 367.5 {28.0 37.5}
323.4 {33.0}
33
SEN00296-04
5.
Table of tightening torques for hoses (taper seal type and face seal type)
a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the
torque below.
a Apply the following torque when the threads are coated (wet) with engine oil.
Nominal
No. of
hose
Width
across
flats
02
19
03
04
05
06
(10)
(12)
(14)
6.
22
24
27
32
36
41
46
55
Range
34 54 { 3.5 5.5}
34 63 { 3.5 6.5}
54 93 { 5.5 9.5}
59 98 { 6.0 10.0}
84 132 { 8.5 13.5}
128 186 {13.0 19.0}
177 245 {18.0 25.0}
177 245 {18.0 25.0}
197 294 {20.0 30.0}
246 343 {25.0 35.0}
Target
44 { 4.5}
74 { 7.5}
78 { 8.0}
103 {10.5}
157 {16.0}
216 {22.0}
216 {22.0}
245 {25.0}
294 {30.0}
Taper seal
Thread size
(mm)
14
18
22
24
30
33
36
42
Face seal
Nominal No.
Thread
Number of
diameter (mm)
threads, type of
(Reference)
thread
9/16-18UN
14.3
11/16-16UN
17.5
13/16-16UN
20.6
1-14UNS
25.4
1-3/16-12UN
30.2
Table of tightening torques for face seal joints

a Tighten the face seal joints (sleeve nut type) made of plated steel pipes for low pressure service to
be used for engines etc. to the torque shown in the following table.
a Apply the following torque to the face seal joint while their threaded parts are coated with engine oil
(wetted).
Outer
diameter
of pipe
(mm)
Width
across
flats
(mm)
8
10
12
15 (16)
22 (20)
19
22
24 (27)
30 (32)
36

Range
Target
14 16 {1.4 1.6}
24 27 {2.4 2.7}
43 47 {4.4 4.8}
60 68 {6.1 6.8}
90 95 {9.2 9.7}
15 {1.5}
25.5 {2.6}
45 {4.6}
64 {6.5}
92.5 {9.4}
Face seal
Thread diameter
Nominal No.
(mm)
Number of threads,
(Reference)
type of thread
9/16-18UN
14.3
11/16-16UN
17.5
13/16-16UN
20.6
1-14UN
25.4
1-3/16-12UN
30.2
Reference: The face seal joints of the dimensions in ( ) are also used, depending on the specification.
7.
Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts)
a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114
engine series to the torque below.
Tightening torque
Bolts and nuts
Thread size
mm
6
8
10
12
14
34
Nm
10 2
24 4
43 6
77 12
kgm
1.02 0.20
2.45 0.41
4.38 0.61
7.85 1.22
12V140E-3 Series
8.
Table of tightening torques for 102, 107 and 114 engine series (Eye joints)
a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine
series to the torque below.
Thread size
mm
6
8
10
12
14
9.
SEN00296-04
Tightening torque
Nm
82
10 2
12 2
24 4
36 5
kgm
0.81 0.20
1.02 0.20
1.22 0.20
2.45 0.41
3.67 0.51
Table of tightening torques for 102, 107 and 114 engine series (Taper screws)
a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114
engine series to the torque below.
Material
Thread size (inch)
1/16
1/8
1/4
3/8
1/2
3/4
12V140E-3 Series
Tightening torque
In cast iron or steel
In aluminum
Nm
kgm
Nm
kgm
15 2
1.53 0.20
51
0.51 0.10
20 2
2.04 0.20
15 2
1.53 0.20
25 3
2.55 0.31
20 2
2.04 0.20
35 4
3.57 0.41
25 3
2.55 0.31
55 6
5.61 0.61
35 4
3.57 0.41
75 8
7.65 0.82
45 5
4.59 0.51
35
SEN00296-04
Conversion table
Method of using the conversion table

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

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

1) The number 550 does not appear in the table, so divide it by 10 (move the decimal point one place
to the left) to convert it to 55 mm.
2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal
point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
Millimeters to inches
(A)
36
(B)
0
10
20
30
40
0
0
0.394
0.787
1.181
1.575
1
0.039
0.433
0.827
1.220
1.614
2
0.079
0.472
0.866
1.260
1.654
3
0.118
0.512
0.906
1.299
1.693
4
0.157
0.551
0.945
1.339
1.732
50
60
70
80
90
1.969
2.362
2.756
3.150
3.543
2.008
2.402
2.795
3.189
3.583
2.047
2.441
2.835
3.228
3.622
2.087
2.480
2.874
3.268
3.661
2.126
2.520
2.913
3.307
3.701
5
0.197
0.591
0.984
1.378
1.772
(C)
2.165
2.559
2.953
3.346
3.740
6
0.236
0.630
1.024
1.417
1.811
7
0.276
0.669
1.063
1.457
1.850
2.205
2.598
2.992
3.386
3.780
2.244
2.638
3.032
3.425
3.819
1 mm = 0.03937 in
8
9
0.315
0.354
0.709
0.748
1.102
1.142
1.496
1.536
1.890
1.929
2.283
2.677
3.071
3.465
3.858
2.323
2.717
3.110
3.504
3.898
12V140E-3 Series
SEN00296-04
Millimeters to inches
0
10
20
30
40
0
0
0.394
0.787
1.181
1.575
1
0.039
0.433
0.827
1.220
1.614
2
0.079
0.472
0.866
1.260
1.654
3
0.118
0.512
0.906
1.299
1.693
4
0.157
0.551
0.945
1.339
1.732
5
0.197
0.591
0.984
1.378
1.772
6
0.236
0.630
1.024
1.417
1.811
1 mm = 0.03937 in
7
8
9
0.276
0.315
0.354
0.669
0.709
0.748
1.063
1.102
1.142
1.457
1.496
1.536
1.850
1.890
1.929
50
60
70
80
90
1.969
2.362
2.756
3.150
3.543
2.008
2.402
2.795
3.189
3.583
2.047
2.441
2.835
3.228
3.622
2.087
2.480
2.874
3.268
3.661
2.126
2.520
2.913
3.307
3.701
2.165
2.559
2.953
3.346
3.740
2.205
2.598
2.992
3.386
3.780
2.244
2.638
3.032
3.425
3.819
1 kg = 2.2046 lb
6
7
8
9
13.23
15.43
17.64
19.84
35.27
37.48
39.68
41.89
57.32
59.53
61.73
63.93
79.37
81.57
83.78
85.98
101.41 103.62 105.82 108.03
2.283
2.677
3.071
3.465
3.858
2.323
2.717
3.110
3.504
3.898
Kilogram to pound
0
10
20
30
40
0
0
22.05
44.09
66.14
88.18
1
2.20
24.25
46.30
68.34
90.39
2
4.41
26.46
48.50
70.55
92.59
3
6.61
28.66
50.71
72.75
94.80
4
8.82
30.86
51.91
74.96
97.00
5
11.02
33.07
55.12
77.16
99.21
50
60
70
80
90
110.23
132.28
154.32
176.37
198.42
112.44
134.48
156.53
178.57
200.62
114.64
136.69
158.73
180.78
202.83
116.85
138.89
160.94
182.98
205.03
119.05
141.10
163.14
185.19
207.24
121.25
143.30
165.35
187.39
209.44
123.46
145.51
167.55
189.60
211.64
125.66
147.71
169.76
191.80
213.85
127.87
149.91
171.96
194.01
216.05
130.07
152.12
174.17
196.21
218.26
Liters to U.S. Gallons
0
10
20
30
40
0
1
2
0
0.264
0.528
2.642
2.906
3.170
5.283
5.548
5.812
7.925
8.189
8.454
10.567 10.831 11.095
3
0.793
3.434
6.076
8.718
11.359
4
1.057
3.698
6.340
8.982
11.624
1 l = 0.2642 U.S.Gal
5
6
7
8
9
1.321 1.585
1.849
2.113
2.378
3.963 4.227
4.491
4.755
5.019
6.604 6.869
7.133
7.397
7.661
9.246 9.510
9.774 10.039 10.303
11.888 12.152 12.416 12.680 12.944
50
60
70
80
90
13.209
15.850
18.492
21.134
23.775
14.001
16.643
19.285
21.926
24.568
14.265
16.907
19.549
22.190
24.832
14.529
17.171
19.813
22.455
25.096
12V140E-3 Series
13.473
16.115
18.756
21.398
24.040
13.737
16.379
19.020
21.662
24.304
14.795
17.435
20.077
22.719
25.361
15.058
17.700
20.341
22.983
25.625
15.322
17.964
20.605
23.247
25.889
15.586
18.228
20.870
23.511
26.153
37
SEN00296-04
Liters to U.K. Gallons
0
10
20
30
40
0
0
2.200
4.399
6.599
8.799
1
0.220
2.420
4.619
6.819
9.019
2
0.440
2.640
4.839
7.039
9.239
3
0.660
2.860
5.059
7.259
9.459
4
0.880
3.080
5.279
7.479
9.679
5
1.100
3.300
5.499
7.699
9.899
50
60
70
80
90
10.998
13.198
15.398
17.598
19.797
11.281
13.418
15.618
17.818
20.017
11.438
13.638
15.838
18.037
20.237
11.658
13.858
16.058
18.257
20.457
11.878
14.078
16.278
18.477
20.677
12.098
14.298
16.498
18.697
20.897
1 l = 0.21997 U.K.Gal
6
7
8
9
1.320
1.540
1.760
1.980
3.520
3.740
3.950
4.179
5.719
5.939
6.159
6.379
7.919
8.139
8.359
8.579
10.119 10.339 10.559 10.778
12.318
14.518
16.718
18.917
21.117
12.528
14.738
16.938
19.137
21.337
12.758
14.958
17.158
19.357
21.557
12.978
15.178
17.378
19.577
21.777
kgm to ft.lb
0
10
20
30
40
0
0
72.3
144.7
217.0
289.3
1
7.2
79.6
151.9
224.2
296.6
2
14.5
86.8
159.1
231.5
303.8
3
21.7
94.0
166.4
238.7
311.0
4
28.9
101.3
173.6
245.9
318.3
5
36.2
108.5
180.8
253.2
325.5
6
43.4
115.7
188.1
260.4
332.7
1 kgm = 7.233 ft.lb

7
8
9
50.6
57.9
65.1
123.0
130.2
137.4
195.3
202.5
209.8
267.6
274.9
282.1
340.0
347.2
354.4
50
60
70
80
90
361.7
434.0
506.3
578.6
651.0
368.9
441.2
513.5
585.9
658.2
376.1
448.5
520.8
593.1
665.4
383.4
455.7
528.0
600.3
672.7
390.6
462.9
535.2
607.6
679.9
397.8
470.2
542.5
614.8
687.1
405.1
477.4
549.7
622.0
694.4
412.3
484.6
556.9
629.3
701.6
419.5
491.8
564.2
636.5
708.8
426.8
499.1
571.4
643.7
716.1
100
110
120
130
140
723.3
730.5
737.8 745.0
752.2
759.5 766.7
773.9
781.2
788.4
795.6
802.9
810.1 817.3
824.6
831.8 839.0
846.3
853.5
860.7
868.0
875.2
882.4 889.7
896.9
904.1
911.4
918.6
925.8
933.1
940.3
947.5
954.8 962.0
969.2
976.5 983.7
990.9
998.2 1005.4
1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150
160
170
180
190
1084.9
1157.3
1129.6
1301.9
1374.3
38
1092.2
1164.5
1236.8
1309.2
1381.5
1099.4
1171.7
1244.1
1316.4
1388.7
1106.6
1179.0
1251.3
1323.6
1396.0
1113.9
1186.2
1258.5
1330.9
1403.2
1121.1
1193.4
1265.8
1338.1
1410.4
1128.3
1200.7
1273.0
1345.3
1417.7
1135.6
1207.9
1280.1
1352.6
1424.9
1142.8
1215.1
1287.5
1359.8
1432.1
1150.0
1222.4
1294.7
1367.0
1439.4
12V140E-3 Series
SEN00296-04
kg/cm2 to lb/in2
0
10
20
30
40
0
0
142.2
284.5
426.7
568.9
1
14.2
156.5
298.7
440.9
583.2
2
28.4
170.7
312.9
455.1
597.4
3
42.7
184.9
327.1
469.4
611.6
4
56.9
199.1
341.4
483.6
625.8
5
71.1
213.4
355.6
497.8
640.1
6
85.3
227.6
369.8
512.0
654.3
1 kg/cm2 = 14.2233 lb/in2

7
8
9
99.6
113.8
128.0
241.8
256.0
270.2
384.0
398.3
412.5
526.3
540.5
554.7
668.5
682.7
696.9
50
60
70
80
90
711.2
853.4
995.6
1,138
1,280
725.4
867.6
1,010
1,152
1,294
739.6
881.8
1,024
1,166
1,309
753.8
896.1
1,038
1,181
1,323
768.1
910.3
1,053
1,195
1,337
782.3
924.5
1,067
1,209
1,351
796.5
938.7
1,081
1,223
1,365
810.7
953.0
1,095
1,237
1,380
825.0
967.2
1,109
1,252
1,394
839.2
981.4
1,124
1,266
1,408
100
110
120
130
140
1,422
1,565
1,707
1,849
1,991
1,437
1,579
1,721
1,863
2,005
1,451
1,593
1,735
1,877
2,020
1,465
1,607
1,749
1,892
2,034
1,479
1,621
1,764
1,906
2,048
1,493
1,636
1,778
1,920
2,062
1,508
1,650
1,792
1,934
2,077
1,522
1,664
1,806
1,949
2,091
1,536
1,678
1,821
1,963
2,105
1,550
1,693
1,835
1,977
2,119
150
160
170
180
190
2,134
2,276
2,418
2,560
2,702
2,148
2,290
2,432
2,574
2,717
2,162
2,304
2,446
2,589
2,731
2,176
2,318
2,460
2,603
2,745
2,190
2,333
2,475
2,617
2,759
2,205
2,347
2,489
2,631
2,773
2,219
2,361
2,503
2,646
2,788
2,233
2,375
2,518
2,660
2,802
2,247
2,389
2,532
2,674
2,816
2,262
2,404
2,546
2,688
2,830
200
210
220
230
240
2,845
2,987
3,129
3,271
3,414
2,859
3,001
3,143
3,286
3,428
2,873
3,015
3,158
3,300
3,442
2,887
3,030
3,172
3,314
3,456
2,901
3,044
3,186
3,328
3,470
2,916
3,058
3,200
3,343
3,485
2,930
3,072
3,214
3,357
3,499
2,944
3,086
3,229
3,371
3,513
2,958
3,101
3,243
3,385
3,527
2,973
3,115
3,257
3,399
3,542
12V140E-3 Series
39
SEN00296-04
Temperature
Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vice versa is to enter the accompanying table in the center (boldface column)
of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right.
1C = 33.8F
F
40.4
37.2
34.4
31.7
28.9
40
35
30
25
20
40.0
31.0
22.0
13.0
4.0
11.7
11.1
10.6
10.0
9.4
11
12
13
14
15
51.8
53.6
55.4
57.2
59.0
7.8
8.3
8.9
9.4
10.0
46
47
48
49
50
114.8
116.6
118.4
120.2
122.0
27.2
27.8
28.3
28.9
29.4
81
82
83
84
85
177.8
179.6
181.4
183.2
185.0
28.3
27.8
27.2
26.7
26.1
19
18
17
16
15
2.2
0.4
1.4
3.2
5.0
8.9
8.3
7.8
7.2
6.7
16
17
18
19
20
60.8
62.6
64.4
66.2
68.0
10.6
11.1
11.7
12.2
12.8
51
52
53
54
55
123.8
125.6
127.4
129.2
131.0
30.0
30.6
31.1
31.7
32.2
86
87
88
89
90
186.8
188.6
190.4
192.2
194.0
25.6
25.0
24.4
23.9
23.3
14
13
12
11
10
6.8
8.6
10.4
12.2
14.0
6.1
5.6
5.0
4.4
3.9
21
22
23
24
25
69.8
71.6
73.4
75.2
77.0
13.3
13.9
14.4
15.0
15.6
56
57
58
59
60
132.8
134.6
136.4
138.2
140.0
32.8
33.3
33.9
34.4
35.0
91
92
93
94
95
195.8
197.6
199.4
201.2
203.0
22.8
22.2
21.7
21.1
20.6
9
8
7
6
5
15.8
17.6
19.4
21.2
23.0
3.3
2.8
2.2
1.7
1.1
26
27
28
29
30
78.8
80.6
82.4
84.2
86.0
16.1
16.7
17.2
17.8
18.3
61
62
63
64
65
141.8
143.6
145.4
147.2
149.0
35.6
36.1
36.7
37.2
37.8
96
97
98
99
100
204.8
206.6
208.4
210.2
212.0
20.0
19.4
18.9
18.3
17.8
4
3
2
1
0
24.8
26.6
28.4
30.2
32.0
0.6
0
0.6
1.1
1.7
31
32
33
34
35
87.8
89.6
91.4
93.2
95.0
18.9
19.4
20.0
20.6
21.1
66
67
68
69
70
150.8
152.6
154.4
156.2
158.0
40.6
43.3
46.1
48.9
51.7
105
110
115
120
125
221.0
230.0
239.0
248.0
257.0
17.2
16.7
16.1
15.6
15.0
1
2
3
4
5
33.8
35.6
37.4
39.2
41.0
2.2
2.8
3.3
3.9
4.4
36
37
38
39
40
96.8
98.6
100.4
102.2
104.0
21.7
22.2
22.8
23.3
23.9
71
72
73
74
75
159.8
161.6
163.4
165.2
167.0
54.4
57.2
60.0
62.7
65.6
130
135
140
145
150
266.0
275.0
284.0
293.0
302.0
14.4
13.9
13.3
12.8
12.2
6
7
8
9
10
42.8
44.6
46.4
48.2
50.0
5.0
5.6
6.1
6.7
7.2
41
42
43
44
45
105.8
107.6
109.4
111.2
113.0
24.4
25.0
25.6
26.1
26.7
76
77
78
79
80
168.8
170.6
172.4
174.2
176.0
68.3
71.1
73.9
76.7
79.4
155
160
165
170
175
311.0
320.0
329.0
338.0
347.0
40
12V140E-3 Series
12V140E-3 Series
SEN00296-04
41
SEN00296-04

2009 KOMATSU
All Rights Reserved
Printed in Japan 03-09 (02)
42
12V140E-3 Series
SEN00303-03
ENGINE
1SHOP MANUAL
12V140E-3 Series
01 Specification

Outline.................................................................................................................................................. 2
Specifications ....................................................................................................................................... 4
General view ...................................................................................................................................... 10
Weight table ....................................................................................................................................... 19
Engine performance curves ............................................................................................................... 20
12V140E-3 Series
SEN00303-03
01 Specification
Outline
1. Applicable machine
Engine
SAA12V140E-3
Engine serial No.
Machine model
D475A-5E0
Bulldozer
HD785-7
Dump truck
PC2000-8
Hydraulic excavator
WA800-3E0, WA900-3E0
Wheel loader
12V140E-3 Series
01 Specification
SEN00303-03
2. Outline of engine
q
The 12V140E-3 engine is a high-performance

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

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

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

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

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

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

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

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

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

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

main filter and prefilter as standard features to
allow use of low-grade fuel in the market
(corresponding to NAS13 level). In addition,
the delivery of the priming pump used to
replace the filters is increased for higher
serviceability.
11) In addition, since the engine controller is
mounted on the engine and equipped with the
automatic high-altitude compensation function,
it can be operated at high altitude without
replacing the controller. As a result, the
serviceability is improved.
SEN00303-03
01 Specification
Specifications
1
Engine name
SAA12V140E-3
Machine model
D475A-5E0
mm
l {cc}
12 140 x 165
30.5 {30,480}
R1-L1-R5-L5-R3-L3-R6-L6-R2-L2-R4-L4
Overall length
mm
1,772
Overall width
mm
1,532.5
Overall height (excluding exhaust pipe)
mm
2,171.5
Overall height (including exhaust pipe)
mm
Rated output
kW{HP}/rpm
671 {899}/2,000
(Gross)
Max. torque
Nm{kgm}/rpm
3,825 {390}/1,400
(Gross)
No-load max. speed

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

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

Governor
DENSO ECD-U2
Electronic control type
Quantity of lubricating oil (Refill capacity)
138 (130)
Quantity of coolant
86 (For only engine)
Alternator
Starting motor
Battery
24V, 90A
24V, 7.5kW x 2
12V, 170Ah x 4
Turbocharger
Air compressor
Others
KOMATSU KTR110L x 2
With air-cooled aftercooler
Performance
Dimensions
Number of cylinders Bore Stroke

Total displacement
Firing order
Fuel consumption ratio at rated output
12V140E-3 Series
01 Specification
SEN00303-03
Engine name
SAA12V140E-3
Machine model
HD785-7
mm
l {cc}
12 140 x 165
30.5 {30,480}
R1-L1-R5-L5-R3-L3-R6-L6-R2-L2-R4-L4
Overall length
mm
2,046.5
Overall width
mm
1,479.7
mm
1,745.3
mm
Rated output
kW{HP}/rpm
895 {1,200}/1,900
(Gross)
Max. torque
Nm{kgm}/rpm
5,076 {518}/1,350
(Gross)
No-load max. speed

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

(Low idle speed)
rpm
650 20
g/kWh
{g/HPh}
207 {154}
Dry weight
kg
3,470
Fuel supply pump

Governor
DENSO ECD-U2
138 (130)
Quantity of coolant
Alternator
Starting motor
Battery
24V, 90A
24V, 7.5kW x 2
12V, 170Ah x 4
Turbocharger
Air compressor
Others
KOMATSU KTR110L x 2
Performance
Dimensions

Total displacement
Firing order
12V140E-3 Series
SEN00303-03
01 Specification
Engine name
SAA12V140E-3
Machine model
PC2000-8
mm
l {cc}
12 140 x 165
30.5 {30,480}
R1-L1-R5-L5-R3-L3-R6-L6-R2-L2-R4-L4
Overall length
mm
1,807.7
Overall width
mm
1,588.8
mm
1,734.3
mm
Rated output
kW{HP}/rpm
728 {976}/1,800
(Gross)
Max. torque
Nm{kgm}/rpm
4,488 {458}/1,350
(Gross)
No-load max. speed

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

(Low idle speed)
rpm
825 25
g/kWh
{g/HPh}
207 {154}
Dry weight
kg
3,500
Fuel supply pump

Governor
DENSO ECD-U2
138 (130)
Quantity of coolant
Alternator
Starting motor
Battery
24V, 90A
24V, 11kW x 2
12V, 170Ah x 4
Turbocharger
Air compressor
Others
KOMATSU KTR110L x 2
Performance
Dimensions

Total displacement
Firing order
12V140E-3 Series
01 Specification
SEN00303-03
Engine name
SAA12V140E-3
Machine model
WA800-3E0
mm
l {cc}
12 140 x 165
30.5 {30,480}
R1-L1-R5-L5-R3-L3-R6-L6-R2-L2-R4-L4
Overall length
mm
2,123
Overall width
mm
1,463.5
mm
1,940
mm
Rated output
kW{HP}/rpm
636 {853}/2,000
(Gross)
Max. torque
Nm{kgm}/rpm
3,802 {388}/1,400
(Gross)
No-load max. speed

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

(Low idle speed)
rpm
680 + 50/0
g/kWh
{g/HPh}
215 {160}
Dry weight
kg
3,690
Fuel supply pump

Governor
DENSO ECD-U2
138 (130)
Quantity of coolant
Alternator
Starting motor
Battery
24V, 90A
24V, 7.5kW x 2
12V, 170Ah x 4
Turbocharger
Air compressor
Others
KOMATSU KTR110L x 2
Performance
Dimensions

Total displacement
Firing order
12V140E-3 Series
SEN00303-03
01 Specification
Engine name
SAA12V140E-3
Machine model
WA900-3E0
mm
l {cc}
12 140 x 165
30.5 {30,480}
R1-L1-R5-L5-R3-L3-R6-L6-R2-L2-R4-L4
Overall length
mm
2,123
Overall width
mm
1,463.5
mm
1,940
mm
Rated output
kW{HP}/rpm
672 {900}/2,050
(Gross)
Max. torque
Nm{kgm}/rpm
4,159 {424}/1,300
(Gross)
No-load max. speed

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

(Low idle speed)
rpm
680 + 50/0
g/kWh
{g/HPh}
215 {160}
Dry weight
kg
3,690
Fuel supply pump

Governor
DENSO ECD-U2
138 (130)
Quantity of coolant
Alternator
Starting motor
Battery
24V, 90A
24V, 7.5kW x 2
12V, 170Ah x 4
Turbocharger
Air compressor
Others
KOMATSU KTR110L x 2
Performance
Dimensions

Total displacement
Firing order
12V140E-3 Series
01 Specification
12V140E-3 Series
SEN00303-03
SEN00303-03
General view
01 Specification
SAA12V140E-3 (Left side view of engine)

Machine model: D475A-5E0
The shape is subject to machine models.
1.
2.
Center of crankshaft
Rear face of flywheel housing
10
12V140E-3 Series
01 Specification
SEN00303-03
SAA12V140E-3 (Front view of engine)

Machine model: D475A-5E0
1.
2.
Center of engine
12V140E-3 Series
11
SEN00303-03
01 Specification

Machine model: HD785-7
1.
2.
12
12V140E-3 Series
01 Specification
SEN00303-03

Machine model: HD785-7
1.
2.
Center of engine
12V140E-3 Series
13
SEN00303-03
01 Specification

Machine model: PC2000-8
1.
2.
14
12V140E-3 Series
01 Specification
SEN00303-03

Machine model: PC2000-8
1.
2.
Center of engine
12V140E-3 Series
15
SEN00303-03
01 Specification

Machine model: WA800-3E0, WA900-3E0
1.
2.
16
12V140E-3 Series
01 Specification
SEN00303-03

Machine model: WA800-3E0, WA900-3E0
1.
2.
Center of engine
12V140E-3 Series
17
SEN00303-03
01 Specification
Dimensions table
Unit: mm
Engine
SAA12V140E-3
18
Machine model
Dimensions of each part

A
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
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
These dimensions are given for reference when the engine is set on a test bench.
12V140E-3 Series
01 Specification
SEN00303-03
Weight table
1
Unit: kg
No.
Item
Main parts
SAA12V140E-3
Turbocharger
KOMATSU KTR110L (Water-cooled)
Cylinder head assembly
Cylinder head, valve,

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

cylinder liner
Gear case
72
Gear case
52
Oil pan
Flywheel assembly
25 x 2
22.5 x 12
810
D475A-5E0
HD785-7
WA800-3E0,
WA900-3E0
Integral-type
Flywheel, ring gear
Flywheel housing assembly
Crankshaft assembly
Crankshaft, crank gear
10
Camshaft assembly
Camshaft, cam gear

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

piston pin, connecting rod
88.4
PC2000-8
89.2
D475A-5E0
127.6
HD785-7
72.5
PC2000-8
WA800-3E0,
WA900-3E0
88.7
133.5
210
L
20
20
10.5 x 12
12
Oil pump
13
Fuel supply pump
13
14
Water pump
22
15
Alternator
16
17
Starting motor
Aftercooler assembly
12V140E-3 Series
24V, 90A
12
24V, 7.5kW
D475A-5E0
HD785-7
WA800-3E0,
WA900-3E0
24V, 11kW
PC2000-8
18 x 2
D475A-5E0
35 x 2
HD785-7
33 x 2
PC2000-8
43 x 2
WA800-3E0,
WA900-3E0
40 x 2
19
SEN00303-03
01 Specification
Engine performance curves

Engine
SAA12V140E-3
20
Engine serial No.
1
Machine model
Page
D475A-5E0
21
HD785-7
22
PC2000-8
23
WA800-3E0
24
WA900-3E0
25
12V140E-3 Series
01 Specification
SEN00303-03
SAA12V140E-3 (Machine model: D475A-5E0)

Rated output: 671 kW {899 HP}/2,000 rpm (Gross)
Max. torque: 3,825 Nm {390 kgm}/1,400 rpm (Gross)
12V140E-3 Series
21
SEN00303-03
01 Specification
SAA12V140E-3 (Machine model: HD785-7)

Rated output: 895 kW {1,200 HP}/1,900 rpm (Gross)
22
12V140E-3 Series
01 Specification
SEN00303-03
SAA12V140E-3 (Machine model: PC2000-8)

12V140E-3 Series
23
SEN00303-03
01 Specification
SAA12V140E-3 (Machine model: WA800-3E0)

24
12V140E-3 Series
01 Specification
SEN00303-03
SAA12V140E-3 (Machine model: WA900-3E0)

12V140E-3 Series
25
SEN00303-03
01 Specification

2008 KOMATSU
All Rights Reserved
26
12V140E-3 Series
SEN00307-05
12V140E-3 Series
SEN00307-04
ENGINE
Shop Manual
12V140E-3 Series
Machine model Serial number

12V140E-3 SERIES ENGINE...
10 Structure,function and
maintenance standard
Structure, function and maintenance
standard, Part 1
Air intake and exhaust unit..........................................................................................................................
Air cleaner...................................................................................................................................................
Turbocharger...............................................................................................................................................
Aftercooler................................................................................................................................................... 11
Muffler ......................................................................................................................................................... 12
Cylinder head.............................................................................................................................................. 14
Cylinder block ............................................................................................................................................. 18
Cylinder liner ............................................................................................................................................... 22
12V140E-3 Series
SEN00307-05
10 Structure,function and maintenance standard
Main moving parts ....................................................................................................................................... 24

Crankshaft................................................................................................................................................... 26
Camshaft..................................................................................................................................................... 28
Cam follower and push rod ......................................................................................................................... 29
Piston, piston ring, and piston pin ............................................................................................................... 30
Connecting rod............................................................................................................................................ 32
Flywheel and flywheel housing ................................................................................................................... 34
Vibration damper ......................................................................................................................................... 35
Timing gear ................................................................................................................................................. 36
Valve system ............................................................................................................................................... 38
Valve and valve guide ................................................................................................................................. 40
Rocker arm and shaft.................................................................................................................................. 42
Crosshead and guide .................................................................................................................................. 43
12V140E-3 Series
SEN00307-05
Air intake and exhaust unit

(Left side view of engine)
a The illustration shows the engine for D475A-5E0.

A:
B:
C:
D:
Air intake (From air cleaner)

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

Air intake manifold
Muffler
Turbocharger
SEN00307-05
Air cleaner
ERB type
[Air cleaner of automatic exhaust gas discharge type (Radial seal type)]
a The shape is subject to machine models.

A: Air inlet
B: To turbocharger (Intake air)
C: To muffler (Dust)
1. Pre-cleaner
2. Air cleaner casing
3. Outer element
4. Inner element
Engine
Machine model
D475A-5E0
PC2000-8
SAA12V140E-3
WA800-3E0,
WA900-3E0
Type
Method of discharging
dust from pre-cleaner
Number of
elements
Komaclone, multi-cyclone
(ERB type)
Automatic discharge
(Exhaust ejector)
1 Inner element,
1 Outer element
12V140E-3 Series
SEN00307-05
FRG type
[Air cleaner of cyclone pack type with evacuator valve (Radial seal type)]

1. Inlet
2. Outlet
3. Guide vane
4. Primary element
5. Safety element
6. Evacuator valve
7. Dust pan
8. Guide plate (Sleeve)
9. Body
10. Element
Engine
Machine model
Type
Evacuator valve
SAA12V140E-3
HD785-7
FRG (Radial seal type)
Automatic discharge
Structure
q The size of the body is reduced from the conventional type without changing the diameter of the
element.
q Since the inlet is set in the tangential direction,
air is given sufficient centrifugal force by the simple spiral guide vane, not by the guide plate.
12V140E-3 Series
Number of
elements
1 Inner element,
1 Outer element
Operation
q Air containing dust is sucked in vertically through
inlet (1) and the dust is separated by the centrifugal effect of guide vane (3).
q More than 99.9% of the dust is removed by primary element (4) and clean air is sucked in the
engine through safety element (5) and outlet (2).
q The dust and water separated by guide vane (3)
swirl along the inside wall of body (9) and enter
evacuator valve (6) and then are discharged out
automatically.
SEN00307-05
Turbocharger
Water-cooled type
Type: KTR110L
12V140E-3 Series
SEN00307-05
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
SEN00307-05
Model: KTR110L
a The illustration shows the water-cooled turbocharger.
12V140E-3 Series
SEN00307-05
Unit: mm
No.
Check item
Criteria
Remedy
1 End play (Play in axial direction)
Standard
0.08 0.13
Repair limit
0.18
2 Radial play (Play in radial direction)
0.43 0.68
0.84
Clearance between blower housing and impeller
12V140E-3 Series
Clearance limit (Min.): 0.14
Replace thrust parts

Replace
bearing parts
Replace
bearing parts
SEN00307-05
Turbocharger mounting

A: Intake air inlet
B: Intake air (Between turbocharger and air-cooled aftercooler)
1. Exhaust manifold
2. Turbocharger
10
12V140E-3 Series
SEN00307-05
Aftercooler
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
SEN00307-05
Muffler

A: Exhaust gas outlet
1. Turbocharger
2. Muffler
12
12V140E-3 Series
12V140E-3 Series
SEN00307-05
13
SEN00307-05
Cylinder head

A. Air intake
B. Exhaust gas
C. To fuel tank
D. To radiator
1. Spill pipe
2. Air bleeding pipe
3. Cylinder head
4. Head cover
5. Head cover bolt
6. Cylinder head bolt

7. Injector connector
8. Injector assembly
9. Injector holder mounting bolt
10. Injector holder retainer
14
12V140E-3 Series
SEN00307-05
Specifications
Cylinder head
Direct injection type
4-valve type
Split-type 1 cylinder, 1 cylinder head
Centralized cooling system for valve bridge and injector
Cylinder head bolt: Plastic-region tightening
Valve seat
Valve seat inserts are press fitted to both intake and
exhaust valves
Rocker cover
O-ring seal
Injector
Installation: Dry type (without sleeve)
12V140E-3 Series
15
SEN00307-05
a Tighten the cylinder head mounting bolt in order of [1] to [7].

Unit: mm
No.
1
Check item
Criteria
Tolerance
Repair limit
0 0.06
0.09
Engine
Standard
SAA12V140E-3
2.3 2.9
Strain of cylinder head mounting

face
2 Projection of nozzle
Bolt No.
Tightening torque for cylinder head

mounting bolt (Apply molybdenum
disulfied or engine oil to threaded
part)
[1] [6]
5
6
Tightening torque for injector holder

mounting bolt
Tightening torque for fuel injection
pipe
Tightening torque for head cover
mounting bolt
Repair by grinding
or replace
Replace nozzle or
gasket
Procedure
Target (Nm{kgm})
Range (Nm{kgm})
1st phase
147 {15}
137 157 {14 16}
2nd phase
289 {29.5}
3rd phase
Retighten by 90
68.6 {7}
[7]
Remedy
Tighten in order
shown above. If
284 294 {29 30}
there are 5 punch
marks, replace the
90(+30/0)
bolt.
58.8 73.5 {6 7.5}
Target (Nm {kgm})
Range (Nm {kgm})
66.7 {6.8}
58.8 73.5 {6 7.5}
44.1 {4.5}
39.2 49.0 {4 5}
32.4 {3.3}
29.4 34.3 {3.0 3.5}
Retighten
a Do not use a cylinder head mounting bolt more than 5 times.

Each time the bolt is used, make a punch mark on its head.
16
12V140E-3 Series
12V140E-3 Series
SEN00307-05
17
SEN00307-05
Cylinder block
1. Cylinder block
2. Cylinder liner
3. Clevis seal
4. O-ring
5. O-ring
6. Main bearing metal cap bolt
7. Main bearing metal cap
8. Main bearing metal
9. Piston cooling nozzle
10. Thrust bearing metal
18
12V140E-3 Series
Specifications
Cylinder block
Crankshaft: 7 bearings
Camshaft: High cam type, 7 bearings
Main bearing cap bolt: Plastic-region tightening
SEN00307-05
Liner ring
Upper: Clevis seal (Ethylene-propylene rubber)
Middle: O-ring (Ethylene-propylene rubber)
Lower: O-ring (Silicon rubber)
Piston cooling
With piston cooling nozzle
Cylinder liner
Wet type
Machining on inside: Plateau honing andTufftride
12V140E-3 Series
19
SEN00307-05
20
12V140E-3 Series
SEN00307-05
Unit: mm
No.
1
Check item
Criteria
Strain of cylinder head mounting

face
Inside diameter of main bearing
metal mounting hole
Tolerance
Repair limit
0 0.09
0.135
Repair by grinding
or replace
Standard size
Tolerance
+0.025
0
Replace or correct
main bearing metal
cap
157
Surface roughness of main bearing

metal mounting hole
10S or less
Correct
Roundness of mounting hole
Repair limit: 0.005

4.5
No.4 only
Thickness of main bearing metal

Other than
4.5
No.4
Inside diameter of main

bearing metal
(When tightening bolt
with specified torque)
Standard size
No.4 only
148
Other than
No.4
148
Inside diameter of cam bushing

mounting hole
Tightening torque for main bearing

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

Level difference between under
surfaces of cylinder block and front
cover
Tolerance
+0.175
+0.130
+0.145
+0.100
Standard size
69
Standard size
5 Inside diameter of cam bushing
Remedy
0.050
0.060
0.065
0.075
Repair limit
148.23
148.20
Tolerance
+0.030
0
Repair limit
Procedure
Tolerance
+0.060
0.025
Target (Nm {kgm})
1st time
284 {29}
270 299 {27.5 30.5}
2nd time
569 {58}
559 579 {57.0 59.0}
3rd time
Retighten by 90
90 (+30/0)
65.7 {6.7}
58.8 73.6 {6 7.5}
65
Repair limit: 0.14
Replace bearing
metal
65.15
Correct or replace
block
Replace cam bushing
Range (Nm {kgm})
Retighten
Reassemble
a Do not use a main cap mounting bolt more than 5 times.

12V140E-3 Series
21
SEN00307-05
Cylinder liner
Unit: mm
No.
Check item
Criteria
1 Projection of cylinder liner
Inside diameter of cylinder liner
22
Standard size
140
140
Tolerance
+0.020
0
+0.040
+0.021
Cylindricality of cylinder liner
Repair limit: 0.02
Clearance between cylinder liner

and block
(counterbore portion)
Interference of cylinder liner and

block
(Lower portion of counterbore)
Outside diameter of cylinder liner
(at O-ring)
Rank
Repair limit: 0.02

(Lower portion of counterbore)
Repair limit: 0.07 0.15
Roundness of cylinder liner

(Counterbore portion)
Clearance between cylinder liner

and block
(O-ring portion)
Remedy
Replace cylinder
liner or cylinder
Standard size
170.2
Repair limit
140.12
140.14
Tolerance
0
0.10
Standard clearance: 0 0.163

Standard size
Standard interference
Tolerance
+0.090
+0.050
Interference limit
0.02 0.12
0.02 or above
Standard size
Tolerance
0.053
0.103
161.2
158
Replace cylinder
liner
(Refilling is allowed
only for rank L.)
Standard clearance: 0.093 0.143
Replace cylinder
liner or block
Replace cylinder
liner
Replace or correct
cylinder liner or
block
Replace cylinder
liner
Replace cylinder
liner or block
12V140E-3 Series
12V140E-3 Series
SEN00307-05
23
SEN00307-05
Main moving parts

1. Piston (FCD piston)
2. Piston pin
3. Connecting rod bushing
4. Top ring
5. Second ring
6. Oil ring
7. Connecting rod cap bolt
8. Connecting rod
(Front of engine: for L bank, rear: for R bank)
9. Connecting rod cap
24
10.
11.
12.
13.
Connecting rod bearing metal

Crank gear (Number of teeth: 45)
Crankshaft
Vibration damper
12V140E-3 Series
SEN00307-05
Specifications
Piston rings
Crankshaft
Closed die forging
Journal, filet: Induction hardening
Piston
Special thin ductile cast iron
FCD piston
Re-entrant piston
Connecting rod
Closed die forging
With lubricating oil hole
Cap bolt is screw type, installed by plastic-region
tightening.
12V140E-3 Series
Top ring (1)
: Double-side keystone, inner cut,

barrel face, hard chromium-plated
Second ring (2): Double-side keystone, inner cut, taper face, hard chromium-plated
Oil ring (3)
: M-shaped steel, with coil expander, nitrided surface
25
SEN00307-05
Crankshaft
26
12V140E-3 Series
SEN00307-05
Unit: mm
No.
Check item
Criteria
Standard value
1 End play
Outside diameter of main journal
0.140 0.32
0.50
Rank
Standard size
S.T.D.
148
0.25 US
147.75
Surface roughness of main journal
4 Bend of crankshaft
Tightening torque for adapter

mounting bolt
Tightening torque for damper

mounting bolt
Repair limit
147.97
147.72
0
0.030
147.50
0.75 US
147.25
147.22
1.00 US
147.00
146.97
147.47
Use undersize journal or replace
Repair limit: 0.010

Journal
Standard clearance
Clearance limit
No.4 only
0.130 0.205
0.25
Other than No.4
0.100 0.175
0.22
Tolerance
Use undersize journal or replace main

metal
Correct surface
roughness of crankshaft journal
0.8S (Surface roughness of R portion: 3.2S)

Rank
Standard size
S.T.D.
100
99.87
0.25 US
99.75
99.62
0.50 US
89.50
0.75 US
99.25
99.12
1.00 US
99.00
98.87
Roundness of main journal

Clearance of main journal
Tolerance
0.50 US
Surface roughness of main journal
Outside diameter of main journal
Replace thrust
bearing metal or
use oversize metal
Repair limit
Roundness of main journal
Clearance of main journal
Remedy
Repair limit
0
0.030
99.37
Use undersize journal or replace
Repair limit: 0.010

Standard clearance
Clearance limit
0.046 0.126
0.17
0.8S (Surface roughness of R portion: 3.2S)

Standard
Coaxiality of all main journals:
Replace connecting rod bearing

metal
Repair limit
0.15 or less
Coaxiality of adjacent main journals:
0.07 or less
Procedure
Target (Nm {kgm})
0.15
Replace
0.07
Range (Nm {kgm})
1st time
74 {7.5}
54 93 {5.5 9.5}
2nd time
245 {25}
226 265 {23 27}
3rd time
745 {76}
725 765 {74 78}
Retighten
108 10 Nm {11 1.0 kgm}
a US: Undersize
12V140E-3 Series
27
SEN00307-05
Camshaft
Unit: mm
No.
Check item
Criteria
Standard
Repair limit
0.1 0.25
0.36
Standard size
Standard clearance
Tolerance
0.016
0.036
Clearance limit
0.016 0.096
0.15
1 End play
Outside diameter of camshaft journal
2
Clearance of camshaft journal
65
3 Bend of camshaft
4 Height of cam
28
Remedy
Replace thrust plate
Replace
Replace cam bushing
Repair limit: 0.04 (Overall swing of indicator)

Cam
Standard size
Tolerance
Repair limit
Intake
55.48
0.1
55.08
Exhaust
55.75
0.1
55.35
Replace
12V140E-3 Series
SEN00307-05
Cam follower and push rod
Unit: mm
No.
Check item
Outside diameter of cam follower
shaft
Inside diameter of cam follower
shaft hole
2 Outside diameter of cam roller
Criteria
Standard size
22
22
31.7
Inside diameter of cam roller
12.7
Outside diameter of cam roller pin
12.63
3
Standard size
4 Diameter of push rod ball end

5 Diameter of push rod socket end
6 Bend of push rod
12V140E-3 Series
12.7
13.4
Remedy
Tolerance
0.021
0.034
+0.021
0
+0.05
+0.02
+0.038
+0.013
Repair limit
0.006
12.56
21.92
22.07
31.50
12.78
Replace
Tolerance
0
0.20
0
0.20
Repair limit: 0.3 (Overall swing of indicator)
29
SEN00307-05
Piston, piston ring, and piston pin
30
12V140E-3 Series
SEN00307-05
Unit: mm
No.
Check item
Outside diameter of piston
Thickness of piston ring
Width of piston ring groove
Clearance between piston ring and

2 4 piston ring groove
Closed gap of piston ring
Outside diameter of piston pin
Inside diameter of piston pin hole
Clearance between piston pin and

piston
Criteria
Rank
Standard size
Tolerance
0.120
0.135
0.105
0.120
Standard size
140
140
No.
Measuring point
No.1 ring
No.2 ring
Oil ring
2
3
No.1 ring
No.2 ring
Oil ring
No.
Measuring point
Standard clearance
No.1 ring
No.2 ring
Oil ring
Remedy
Repair limit
139.830
139.845
Tolerance
0.015
2.9
0.035
0.010
2.41
0.035
0.010
4
0.030
Judge using groove wear gauge (*1)
Judge using groove wear gauge (*2)
+0.030
+0.010
Clearance limit
Check with groove wear gauge
0.020 0.060
Replace piston(Refilling is
allowed only for
rank S.)
Replace piston ring
Replace piston
Replace piston or
piston ring
0.14
0.42 0.57
(Tension:
2
No.1 ring
2.0
16.5 23.5 N
{1.68 2.40 kg})
1.15 1.30
No.2 ring
(Tension:
3
(Identification 2RN
1.5
16.2 24.2 N
white mark)
{1.65 2.47 kg})
0.30 0.50
(Tension:
4
Oil ring
1.0
84.4 112 N
{8.61 11.39 kg})
Standard size
Tolerance
0
52
0.006
+0.045
Lateral:
+0.035
52
+0.055
Vertical:
+0.035
Standard clearance
Clearance limit
Lateral:0.035 0.051
0.10
Vertical:0.035 0.061
Replace piston ring

or cylinder liner
Replace piston pin
Replace piston
Replace piston or
piston pin
a *1: Part No. (Groove wear gauge) 795-901-1150

a *2: Part No. (Groove wear gauge) 795-901-1130
12V140E-3 Series
31
SEN00307-05
Connecting rod
32
12V140E-3 Series
SEN00307-05
Unit: mm
No.
Check item
Criteria
Inside diameter of connecting rod

small end bushing
1
Clearance between connecting rod
small end bushing and piston pin

small end bushing mounting hole
3 large end bearing metal
4
5
(Crankpin journal)
large end hole
(Without bearing metal, X, Y, and Z
q
directions)
Thickness of connecting rod bearing metal
Parallelism and twist of connecting

rod
Tightening torque for connecting

rod cap mounting bolts
(Apply engine oil to seat surface of
nut of threaded portion of bolts)
Inside diameter of connecting rod large end
Standard size
Remedy
Tolerance
+0.049
+0.030
52
Repair limit
52.09
Standard clearance
Clearance limit
0.030 0.055
0.11
Standard size
Tolerance
57.4
+0.030
0
Standard size
100
106
Tolerance
+0.096
+0.046
+0.026
0.004
Repair limit
100.15
Tighten connecting rod cap with specified torque and measure
Item
0.025
0.035
Standard
Repair limit
Parallelism (a)
0 0.10
0.15
Twist (b)
0 0.25
0.30
Dimensions (c)
340
Procedure
Target (Nm {kgm})
1st time
74 {7.5}
Range (Nm {kgm})

69 78
{7 8}
2nd time
Retighten 90
3.0
Roughness
3.2S
Swell
0.004 (In overall width)
Replace bushing
(Refilled part is
semi-finished part)
Replace bushing or
piston pin
Replace connecting rod
(Correction not
allowed)
Replace bearing
metal
(Correction not
allowed)
Replace bearing
metal
Tighten in order
shown in figure
90(+30/0)
Replace
a Do not use a connecting rod cap mounting bolt more than 5 times.
12V140E-3 Series
33
SEN00307-05
Flywheel and flywheel housing
Unit: mm
No.
Check item
Criteria
1 Facial runout of flywheel housing
Repair limit: 0.25
2 Radial runout of flywheel housing
Repair limit: 0.25
3 Facial runout of flywheel
Repair limit: 0.30
4 Radial runout of flywheel
Repair limit: 0.13
Remedy
Reassemble
34
Tightening torque for flywheel

housing mounting
(Apply engine oil to threaded portion)
Tightening torque for flywheel
mounting bolt
(Apply engine oil to threaded portion)
Procedure
Target (Nm {kgm})
Range (Nm {kgm})
1st time
343 {35}
294 392 {30 40}
2nd time
412 {42}
392 432 {40 44}
1st time
98 {10}
78 118 {8 12}
2nd time
294 {30}
275 314 {28 32}
3rd time
539 {55}
520 559 {53 57}
Tighten in order
shown in above figure
12V140E-3 Series
SEN00307-05
Vibration damper

1.
2.
3.
4.
5.
6.
Vibration damper
Pin (between adapter and vibration damper)
Adapter
Pin (between adapter and crankshaft)
Bolt (between adapter and crankshaft)
Bolt (between adapter and vibration damper)
12V140E-3 Series
35
SEN00307-05
Timing gear
36
12V140E-3 Series
SEN00307-05
Unit: mm
No.
Check item
Criteria
Position
Measuring point
Crank gear and right main idler

a
gear (Large)
Right main idler gear (Small) and
b
right sub idler gear
Right sub idler gear and right
c
cam gear
Right cam gear and accessory
d
drive gear
Right main idler gear (Small) and
e
Backlash of each gear
right fuel injection pump gear
Right main idler gear (Large) and
f
water pump driver gear
Right main idler gear (Large) and
g
oil pump gear
Crank gear and left main idler
h
gear (Large)
Left main idler gear (Small) and
j
left cam gear
Left main idler gear (Small) and
k
left fuel injection pump gear
Tolerance
Clearance between main idler gear Standard size
Shaft
Hole
1 bushing and shaft
0.016
+0.034
(Both right and left banks)
56
0.029
+0.009
Clearance between sub idler gear
0.016
+0.055
56
2
bushing and shaft
0.029
0
Standard
3 End play of main idler gear
0.09 0.26
4 End play of sub idler gear
Remedy
Standard
0.141 0.425
0.130 0.390
0.129 0.391
0.085 0.492
0.051 0.469
0.052 0.481
0.137 0.421
0.141 0.425
0.129 0.391
0.051 0.469
Standard
clearance
Clearance
limit
0.025 0.063
0.20
0.016 0.084
0.20
Replace bushing
Repair limit
0.4
0.4
End play of fuel injection pump

drive gear
0.07 0.20
0.4
6 End play of oil pump drive gear
0.03 0.094
0.4
0.1 0.4
0.4
7 End play of accessory drive gear
Replace
0.6
0.07 0.18
Repair limit
Replace thrust
bearing
12V140E-3 Series
37
SEN00307-05
Valve system
38
12V140E-3 Series
SEN00307-05
1. Cam gear
2. Thrust plate
3. Camshaft
4. Cam follower
5. Cam roller
6. Rocker arm shaft
7. Cam follower shaft
8. Rocker arm adjustment screw
9. Locknut
10. Push rod
11. Rocker arm
12. Crosshead adjustment screw
13. Locknut
14. Crosshead
15. Valve guide
16. Exhaust valve
17. Valve spring (Outer)
18. Valve spring (Inner)
19. Spring seat
20. Valve retainer
21. Intake valve
22. Cam roller pin
Valve timing
Specifications
Camshaft
Drawn steel bar (Machining)
Journal and cam sections: Induction hardening
12V140E-3 Series
39
SEN00307-05
Valve and valve guide
40
12V140E-3 Series
SEN00307-05
Unit: mm
No.
Check item
1 Sinking distance of valve
Criteria
Remedy
Valve
Standard size
Tolerance
Repair limit
Intake
0.10
0.70
Exhaust
0.10
0.70
Valve
Standard size
Repair limit
Intake
2.4
1.9
Exhaust
2.15
1.75
Valve
Standard size
Tolerance
Intake
30
15'
Exhaust
45
15'
Intake
10
Exhaust
10
Before head is press

fitted
10
2 Thickness of valve lip
3 Valve seat angle
Outside diameter of valve stem
Standard size
Inside diameter of valve guide
10
Valve
Standard clearance
Intake
0.034 0.071
0.22
Exhaust
0.063 0.100
0.24
Bend of valve stem
Repair limit: 0.02 (Total runout of indicator, per 100)

Standard
Tolerance
22.0
0.2
5 Driving height of valve guide
Standard size
Repair limit
Outer
81.7
Inner
72.0
Standard installed
load (N {kg})
424.3 21.6
{43.3 2.2}
215.6 10.8
{22.0 1.1}
Allowable installed
load (N {kg})
377.3
{38.5}
192.1
{19.6}
Installed load of valve spring
Perpendicularity of valve spring
12V140E-3 Series
Spring
Installed
length
Outer
51.0
Inner
46.0
Correct or replace
valve or valve seat
Replace valve or
valve guide
Replace valve
Correct
Spring
Free length of valve spring
Replace valve
0.045
0.060
Replace valve
0.074
0.089
+0.019
+0.001
Tolerance
Not press Replace valve
Press fitfitted por- guide
ted portion
tion
+0.008
+0.011
0.009
0.009
Clearance limit
After head is press fitted
Clearance between valve guide

and stem
Replace valve or
valve seat
Replace valve
spring
Repair limit: 2 (Both ends)
41
SEN00307-05
Rocker arm and shaft
Unit: mm
No.
Check item
Outside diameter of rocker arm
shaft
Criteria
Standard size
Tolerance
32.0
0.0065
1 Inside diameter of rocker arm bush-
32.0
ing
Clearance between rocker arm
shaft and rocker arm
2 Valve clearance (When cold)
42
Tightening torque for locknut of

rocker arm adjustment screw
Remedy
Standard clearance
0.0215 0.0945
Valve
Standard
+0.088
+0.028
Clearance limit
0.13
Tolerance
Intake
0.35
0.02
Exhaust
0.57
0.02
Target (Nm {kgm})
Range (Nm {kgm})
58.8 {6}
52.9 64.7 {5.4 6.6}
Replace rocker arm

shaft
Replace rocker arm
Replace rocker arm
shaft or rocker arm
Adjust
Tighten
12V140E-3 Series
SEN00307-05
Crosshead and guide
Unit: mm
No.
Check item
Criteria
Standard size
1 Depth of crosshead stem receiver

Inside diameter of crosshead
Outside diameter of crosshead

guide
3 Projection of crosshead guide
12V140E-3 Series
Remedy
Tolerance
+0.3
0
Repair limit
11.04
0.02
11.17
11
+0.011
0
10.95
49.0
0.25
6.2
6.61
Replace
Correct
43
SEN00307-05

Form Number : SEN00307-05
2009 KOMATSU
All Rights Reserved
44
SEN00309-04
ENGINE
1SHOP MANUAL
12V140E-3 Series
10 Structure, function and

maintenance standard
Structure, function and maintenance

standard, Part 2
Lubrication system .......................................................................................................................................... 4
Lubrication system diagram.................................................................................................................. 4
Oil pump ............................................................................................................................................... 6
Oil cooler............................................................................................................................................... 7
Oil filter.................................................................................................................................................. 8
Main relief valve.................................................................................................................................... 9
Oil cooler bypass valve and regulator valve ....................................................................................... 10
Fuel system................................................................................................................................................... 12
CRI system diagram ........................................................................................................................... 12
CRI system diagram (Poor fuel spec.)................................................................................................ 14
Outline of CRI system......................................................................................................................... 16
12V140E-3 Series
SEN00309-04
Fuel piping .......................................................................................................................................... 34

Fuel piping (Poor fuel spec.) ............................................................................................................... 39
Fuel filter ............................................................................................................................................. 44
Water separator .................................................................................................................................. 46
Priming pump...................................................................................................................................... 47
Electric priming pump ......................................................................................................................... 48
Cooling system.............................................................................................................................................. 50
Cooling system diagram ..................................................................................................................... 50
Water pump ........................................................................................................................................ 52
Thermostat.......................................................................................................................................... 54
Corrosion resistor................................................................................................................................ 55
Cooling fan drive ................................................................................................................................. 57
Electrical equipment...................................................................................................................................... 60
Alternator ............................................................................................................................................ 60
Starting motor...................................................................................................................................... 62
Starting aid .......................................................................................................................................... 64
Engine controller ................................................................................................................................. 67
Engine controller cooler ...................................................................................................................... 68
12V140E-3 Series
12V140E-3 Series
SEN00309-04
SEN00309-04
Lubrication system
Lubrication system diagram
12V140E-3 Series
SEN00309-04
W: Coolant
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
Oil pan
Strainer
Oil pump (Triple gear pump)
Main relief valve
Oil cooler
Regulator valve
Oil cooler bypass valve
Oil filter
Oil filter safety valve
Main gallery
Crankshaft
Camshaft
Rocker arm
Cam follower
Intake valve and exhaust valve
Piston
Piston cooling nozzle
Timing gear
Turbocharger
Fuel supply pump
*1 When install optional parts. Since pre-lubrication

pump is to be installed in the machine, so for the
detail see the Shop Manual for the Machine.
12V140E-3 Series
SEN00309-04
Oil pump
A:
B:
From oil pan

To oil cooler
1.
2.
3.
4.
5.
Pump body
Pump drive gear (Number of teeth: 27)
Drive gear
Driven gear
Pump cover
Specifications
Oil pump
Type: Gear pump
Revolving speed: Engine speed x 1.67
12V140E-3 Series
SEN00309-04
Oil cooler
A: Oil inlet and outlet port (Flow is reversed

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

Cooler element
12V140E-3 Series
SEN00309-04
Oil filter
A:
B:
Oil inlet port

Oil outlet port
1.
2.
3.
Safety valve
Filter head
Cartridge
Specifications
Oil filter
Filtration area: 1.62 m2(0.42 m2 x 4)
Rated flow: 480l/min
Safety valve
Cracking pressure: 196 20 kPa {2.0 0.2 kg/
cm2}
12V140E-3 Series
SEN00309-04
Main relief valve
1.
2.
3.
Specifications
Main relief valve
Cracking pressure:
1,245 69 kPa {12.7 0.7 kg/cm2}
Valve spring
Main relief valve
Valve body
Unit: mm
No.
Check item
Clearance between main relief

valve and body
Criteria
Tolerance
Standard size Outside diam- Inside diameeter of valve
ter of body
Standard
clearance
33
0.040
0.060
0.040 0.076
Free length
Installed
length
75.8
59.8
Main relief valve spring
Cracking pressure of main relief

valve
12V140E-3 Series
Remedy
+0.016
+0.016
Installed load Allowable load

(N {kg})
(N {kg})
621 {63.4}
Replace valve or
body
Replace spring
353 {36}
Standard: 1,245 69 kPa {12.7 0.7 kg/cm2}
Correct or
replace spring
SEN00309-04
Oil cooler bypass valve and regulator valve
A:
B:
C:
D:
From main gallery

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

Bypass valve spring
Regulator valve
Regulator valve spring
Valve body
10
Specifications
Cracking pressure (differential pressure):
392 20 kPa {4.0 0.2 kg/cm2}
Regulator valve
Cracking pressure: 402 49 kPa {4.1 0.5 kg/
cm2}
12V140E-3 Series
SEN00309-04
Unit: mm
No.
Check item
Clearance between regulator

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

valve
Clearance between oil cooler

bypass valve and body
Oil cooler bypass valve spring

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

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

Tolerance
ter of body
Standard
clearance
28
0.020
0.053
+0.033
+0.033
0.020 0.086
Free length
Installed
length
Installed load
(N {kg})
Allowable
load
125.8
89.8
186 {19}
Standard: 392 20 kPa {4.0 0.2 kg/cm2}
Replace valve or
body
Replace spring
Correct or
replace spring
11
SEN00309-04
Fuel system
CRI system diagram
12
CRI is an abbreviation for common rail injection.
12V140E-3 Series
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
SEN00309-04
NE speed sensor
Engine controller
Injector
Fuel tank
Pre-fuel filter
Main fuel filter
Overflow valve
Fuel supply pump assembly
PCV
High-pressure pump
Feed pump
Relief valve
G speed sensor
Common rail
Flow damper
Pressure limiter
High-pressure injection pipe
Priming pump (Main)
12V140E-3 Series
13
SEN00309-04
CRI system diagram (Poor fuel spec.)
14
CRI is an abbreviation for common rail injection.
12V140E-3 Series
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
SEN00309-04
NE speed sensor
Engine controller
Injector
Fuel tank
Pre-fuel filter
Main fuel filter
Overflow valve
Fuel supply pump assembly
PCV
High-pressure pump
Feed pump
Relief valve
G speed sensor
Common rail
Flow damper
Pressure limiter
High-pressure injection pipe
Electrical priming pump (Main)
Water separator
12V140E-3 Series
15
SEN00309-04
Outline of CRI system

Outline
q
The CRI system checks the condition of the
engine (engine speed, accelerator angle, coolant temperature, etc.) with sensors.
q
The microcomputer of the CRI system controls
the fuel injection rate, fuel injection timing, fuel
injection pressure, etc. totally to operate the
engine under the best condition.
q
The CRI system has a diagnosis function and
an alarm function, with which the computer of
the system checks the main component parts
and notifies the operator of detected failures.
q
In addition, the CRI system has a failsafe function which stops the engine when a certain part
fails and a backup function which continues
the operation by changing the control method
in such a case.
1
1. Fuel system
Configuration
The CRI system is divided by the function into
the fuel system and control system.
16
The fuel system distributes the high-pressure

fuel generated by the fuel supply pump to the
cylinders through the common rail.
The solenoid valve in the injector opens and
closes the nozzle needle valve to start and finish fuel injection.
12V140E-3 Series
SEN00309-04
2. Control system
To the ECU (engine control unit), the signals

are sent from the sensors installed to the
machine. Based on the signals, the ECU calculates and controls the energizing timing and
energizing period of the injector to injecta
proper quantity of fuel in proper timing.
The control system is roughly divided by the
electric parts into the sensors, computer, and
actuators.
12V140E-3 Series
17
SEN00309-04
Structure and operation of CRI system
18
The CRI system consists of fuel supply pump,

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

circuit is changed so that the high-pressure
fuel in the control chamber will flow through the
orifice. As a result, the needle valve is raised
to start fuel injection by the nozzle cracking
pressure of the high-pressure fuel on the nozzle side.
If the TWV is turned OFF (de-energized), the
fuel circuit is changed so that the high-pressure fuel will flow to the control chamber
through the orifice. As a result, the needle
valve lowers to finish fuel injection.
Accordingly, the fuel injection timing and fuel
injection rate are controlled respectively by the
timing to turn on the TWV and the length of the
turn-on time of the TWV.
12V140E-3 Series
SEN00309-04
Structure and operation of component parts
1. Fuel supply pump
1.
2.
3.
4.
5.
3-thread type cam

Overflow valve
Drive gear
No. 1 high-pressure pump
PCV (Fuel injection pressure control valve)
6.
7.
8.
9.
No. 2 high-pressure pump

Priming pump
Feed pump
Gear for G speed sensor
Outline
q
The fuel supply pump consists of priming
pump (7), feed pump (8), and high-pressure
pumps (4) and (6).
q
The function of the fuel supply pump is to generate common rail fuel pressure by controlling
the fuel discharge rate.
Since the number of the times of feeding fuel

to the common rail is the same as the number
of the times of fuel injection, the common rail
fuel pressure is smooth and stable.
The fuel fed by high-pressure pumps (4) and
(6) to the common rail is divided as follows.
No. 1 high-pressure pump (on the drive gear
side) (4) compensates for drop in the common
rail fuel pressure caused by fuel injection into
the No. 1, 3, and 5 cylinders.
No. 2 high-pressure pump (on the feed pump
side) (6) compensates for drop in the common
rail fuel pressure caused by fuel injection into
the No. 2, 4, and 6 cylinders.
Structure
High-pressure pumps (4) and (6) have the
pressure feed systems similar to those of the
conventional in-line fuel injection pump and the
PCVs (Fuel injection pressure control valves)
for each cylinder to control the fuel delivery.
q
By employing the 3-head cam, the necessary
number of the cylinders of high-pressure
pumps (4) and (6) is reduced to 1/3 of the
engine cylinders.
q
12V140E-3 Series
q
q
19
SEN00309-04
Operation
(A): The PCV is open when the plunger is in

lowering stroke, through which low-pressure fuel is sucked in the plunger chamber.
(B): While the PCV is not energized and is open
after the plunger starts the rising stroke, the
sucked fuel is returned through the PCV
without being pressurized.
(C): If the PCV is energized and closed in the
timing for the necessary delivery, the return
passage is closed and the pressure in the
plunger chamber rises. Accordingly, the
fuel is fed through the delivery valve (check
valve) to the common rail. That is, the
quantity of the fuel corresponding to the
plunger lift after the PCV is closed is delivery. The delivery is changed and the common rail fuel pressure is controlled by
changing the opening timing of the PCV.
(pre-stroke of plunger)
(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.
20
12V140E-3 Series
1) PCV (Fuel injection pressure control

valve)
SEN00309-04
2) Feed pump
q
q
The PCV adjusts the fuel delivery from the fuel

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

assembly draws the fuel from the fuel tank and
sends it through the fuel filter to the high-pressure pump chamber.
The outer and inner rotors of the feed pump
are rotated by the camshaft.
The fuel is sucked in on the suction side and
discharged on the delivery side according to
the increase and decrease of the spaces
between the outer and inner rotors.
21
SEN00309-04
2. Common rail
Structure
q
Common rail (4) distributes the high-pressure
fuel from the high-pressure pump to the injectors of the cylinders.
q
Common rail (4) is equipped with common rail
fuel pressure sensor (2), flow dampers (1), and
pressure limiter (3).
q
The fuel injection pipes are connected to flow
dampers (1) to send the high-pressure fuel to
the injectors.
q
The piping of the pressure limiter (3) is
returned to the fuel tank.
1)
Flow damper
Function
The flow dampers damp the pressure pulses in
the high pressure piping and supply the fuel to
the injectors with stable pressure.
q
If excessive fuel flows out, the flow dampers
block the fuel passage to prevent abnormal
outflow of the fuel.
q
If the fuel flows out abnormally, high pressure
is applied to the piston, which moves to the
right until it reaches the seat to stop the fuel.
q
22
2)
q
Pressure limiter
If abnormally high pressure is generated, the
pressure limiter opens to release that pressure.
If the common rail fuel pressure reaches about
140 MPa {1,430 kg/cm2}, the pressure limiter
operates (Opens).
If the common rail fuel pressure lowers to 30
MPa {310 kg/cm2}, the pressure limiter resets
itself (close) to maintain the pressure.
12V140E-3 Series
3)
q
SEN00309-04
Common rail fuel pressure sensor

The common rail fuel pressure sensor is
installed to the common rail to sense the fuel
pressure.
This sensor is a semiconductor pressure sensor, which utilizes the phenomenon that the
electric resistance of silicon changes according
to the pressure applied to it.
12V140E-3 Series
23
SEN00309-04
3. Injector
Outline
q
The function of the injector is to inject the high
pressure fuel from the common rail into each
combustion chamber of the engine in the optimum timing, by the optimum quantity, at the
optimum injection rate, and under the optimum
spray condition.
q
The TWV (2-way solenoid valve) controls the
start and finish of fuel injection by controlling
the pressure in the control chamber.
q
The orifice limits the opening speed of the nozzle and controls the fuel injection rate.
q
The hydraulic piston transmits the force generated by the pressure in the control chamber to
the needle valve of the nozzle.
q
The nozzle sprays the fuel.
24
12V140E-3 Series
SEN00309-04
Structure
1.
2.
3.
4.
5.
6.
Inlet connector
Terminal
Upper body
Solenoid
Valve body
Orifice (out)
The injector consists of the nozzle section, orifice to control the fuel injection rate, hydraulic
piston section, and 2-way solenoid valve section.
12V140E-3 Series
7.
8.
9.
10.
11.
12.
Orifice (in)
Pressure control chamber
Command piston
Spring
Pressure pin
Nozzle assembly
25
SEN00309-04
A:
B:
No fuel injection
Start of fuel injection
C:
D:
Finish of fuel injection

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

If solenoid (6) is de-energized, valve body (5)
is lowered by spring (7) and the fuel passage is
closed.
Since the high-pressure fuel in the common
rail is applied to pressure control chamber (8)
suddenly at this time, nozzle (1) is closed
quickly and fuel injection is finished sharply.
Operation
1)
q
q
2)
q
q
q
26
No fuel injection (A)

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

If solenoid (6) is energized, valve body (5) is
raised by electromagnetic power to open the
fuel passage.
Since the fuel in pressure control chamber (8)
flows out through orifices (3) and (4), nozzle
(1) rises and the fuel injection pump starts.
The fuel injection rate is increased gradually by
the function of orifices (3) and (4).
Continuing energization to solenoid (6) provides the maximum fuel injection rate.
12V140E-3 Series
SEN00309-04
Electric circuit diagram
Since high voltage (65V) is applied to the

wiring harnesses connected to the ECU,
COMMON1 and COMMON2 of ECU, and
TWV#1 #6 of the injector, take care not to
get an electric shock.
12V140E-3 Series
27
SEN00309-04
4. Various sensors and relays

1)
q
28
Fuel temperature sensor

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

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

This sensor is used to correct altitude.
SEN00309-04
4)
Common rail pressure sensor
5)
Oil pressure sensor
Pressure inlet
Mounting screw: M5
Tightening torque:
4.5 0.5 Nm {0.46 0.05 kgm}
The following graph shows the output characteristics of the atmospheric pressure sensor.
12V140E-3 Series
29
SEN00309-04
6)
q
30
Bkup speed sensor (G sensor)

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

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

The charge temperature sensor senses the
intake air temperature (boost temperature) and
sends it to the engine controller.
The sensor unit is a thermistor the resistance
of which changes according to the temperature. The engine controller applies voltage to
the thermistor and senses the temperature by
the voltage divided by the resistance in the
computer and the resistance of the thermistor.
12V140E-3 Series
SEN00309-04
9)
q
Coolant temperature sensor

The coolant temperature sensor senses the
coolant temperature and sends it to the engine
controller.
The sensor unit is a thermistor the resistance
of which changes according to the temperature. The engine controller applies voltage to
the thermistor and senses the temperature by
the voltage divided by the resistance in the
computer and the resistance of the thermistor.
31
SEN00309-04
Various controls
32
12V140E-3 Series
SEN00309-04
The CRI system controls the fuel injection rate

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

q
The fuel injection rate control function is

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

q
The fuel injection timing control function is

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

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

fuel pressure control function) controls the fuel
discharge rate of the fuel supply pump by measuring the fuel pressure by the common rail
fuel pressure sensor and feeding it back to
ECU.
This function performs pressure feedback control so that the fuel injection pressure will be
the same as the optimum value (command
value) set according to the engine speed and
fuel injection rate.
12V140E-3 Series
33
SEN00309-04
Fuel piping
Left bank
a
a

The illustration shows the engine for D475A-5E0.
1.
2.
3.
4.
5.
6.
Main fuel filter

Pre-fuel filter
Priming pump (Main)
Fuel pipe (From pre-fuel filter)
Fuel pipe (To feed pump)
Drain pipe
34
12V140E-3 Series
7.
8.
9.
10.
11.
12.
PCV
Fuel injection pipe (No.1 cylinder)
12V140E-3 Series
SEN00309-04
13.
14.
15.
16.
17.
18.

Common rail
Fuel return pipe
Feed pump
Oil pump (For pump lubricating oil)
High-pressure pump
35
SEN00309-04
Right bank
a
a

The illustration shows the engine for D475A-5E0.
1.
2.
3.

Priming pump (Main)
36
12V140E-3 Series
4.
5.
6.
7.
8.
9.

12V140E-3 Series
SEN00309-04
10.
11.
12.
13.
14.
15.
PCV
High-pressure pump
Feed pump
Fuel return pipe
Common rail
37
SEN00309-04
Front view of engine
Rear view of engine
38
12V140E-3 Series
Fuel piping (Poor fuel spec.)
SEN00309-04
Left bank
1.
2.
3.
4.
5.
6.
Main fuel filter

Electrical pre-fuel filter
Priming pump
Drain pipe
12V140E-3 Series
39
SEN00309-04
7.
8.
9.
10.
11.
12.
PCV
40
13.
14.
15.
16.
17.
18.

Common rail
Fuel return pipe
Feed pump
High-pressure pump
12V140E-3 Series
SEN00309-04
Right bank
1.
2.
3.

Priming pump (Main)
12V140E-3 Series
41
SEN00309-04
4.
5.
6.
7.
8.
9.
42

10.
11.
12.
13.
14.
15.
PCV
High-pressure pump
Feed pump
Fuel return pipe
Common rail
12V140E-3 Series
SEN00309-04
Front view of engine
Rear view of engine
12V140E-3 Series
43
SEN00309-04
Fuel filter
A:
B:
Fuel inlet
Fuel outlet
1.
2.
3.
Air bleeding plug

Filter head
Cartridge
Specifications
Filtration area: 1.0 m2
44
12V140E-3 Series
SEN00309-04
Pre-fuel filter
A:
B:
Fuel inlet
Fuel outlet
1.
2.
3.
Air bleeding plug

Filter head
Cartridge
Specifications
Filtration area: 2.12 m2
12V140E-3 Series
45
SEN00309-04
Water separator
A:
B:
Fuel inlet
Fuel outlet
1.
2.
3.
4.
5.
6.
Head
Screen
Gasket
Ring
Case
Drain cup
46
12V140E-3 Series
SEN00309-04
Priming pump
1.
2.
3.
4.
5.
6.
7.
8.
Spring
Cover
Shaft
Bushing
Diaphragm
Diaphragm cover
Body
Check valve
12V140E-3 Series
9.
10.
11.
12.
13.
14.
15.
16.
Valve stopper
Packing
Check valve body
Lever pin
E-ring
Washer
Bolt
Lever
47
SEN00309-04
Electric priming pump
A:
B:
Fuel IN
Fuel OUT
1.
2.
Connector
Vibration prevention rubber
48
12V140E-3 Series
12V140E-3 Series
SEN00309-04
49
SEN00309-04
Cooling system
Cooling system diagram
50
12V140E-3 Series
A:
SEN00309-04
Lubricating oil
1.
2.
Radiator
Cooling fan
2A. Hydraulic fan motor
3. Water pump
4. Oil cooler (For engine)
5. Corrosion resistor
6. Thermostat housing
7. Oil cooler (For power train)
8. Oil cooler bypass circuit (For power train)
9. Air bleeding
10. Turbocharger
12V140E-3 Series
51
SEN00309-04
Water pump
A:
B:
C:
From thermostat (Coolant)

From radiator (Coolant inlet)
To oil cooler (Coolant outlet)
1.
2.
3.
4.
5.
6.
7.
8.
Pump shaft
Water seal
Pump body
Water pump drive gear (Number of teeth: 25)
Ball bearing
Oil seal
Impeller
Pump cover
Specifications
Water pump
Type: Centrifugal, gear-driven
Revolving speed: Engine speed x 1.80
52
12V140E-3 Series
SEN00309-04
Water pump mounting
A.
B:
C:
To radiator inlet (Coolant)

From power train cooler (Coolant)
To power train oil cooler (Coolant)
1.
2.
3.
Oil cooler
Thermostat housing
Water pump
12V140E-3 Series
53
SEN00309-04
Thermostat
A:
B:
C:
To radiator
To water pump (When bypassing)
To thermostat
1.
2.
3.
Thermostat housing
Thermostat
Cylinder block
Specifications
Valve cracking temperature: 76.5 2?
Temperature at full opening: 90?
Lift at full opening: Min. 10 mm
Q'ty: 3
Unit: mm
No.
54
Check item
Criteria
Remedy
Lift of thermostat at full

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

5 minutes)
Opening/Closing of
thermostat
Move valve in fully open condition (in water tank of 90?) to water
tank of 71? and keep it for 4 -5 minutes.
Valve must fully close.
Replace
12V140E-3 Series
SEN00309-04
Corrosion resistor
A:
B:
Coolant inlet
Coolant outlet
1.
2.
3.
4.
Head
Element case (Cartridge)
Inhibitor (Solid anti-corrosion agent)
Valve
12V140E-3 Series
Specifications
Corrosion resistor
Filtration area: 0.373 m2x 2
Quantity of anti-corrosion agent: 1,000 g x 2
55
SEN00309-04
Corrosion resistor mounting
1.
2.
3.
4.
Tube (To radiator)

Tube (From thermostat housing)
Corrosion resistor head
Corrosion resistor cartridge
56
12V140E-3 Series
SEN00309-04
Cooling fan drive
Mounting (Adjustment bolt type)

SAA12V140E-3 (HD785-7)
a
a

For HD785-7cold area arrangement models, type of grease for fan pulley and fan belt material are different. See the Shop Manual or Operation and Maintenance Manual for HD785-7 -40C specification
models for the detail.
1.
2.
3.
4.
5.
6.
7.
Crankshaft pulley
Fan belt
Tension pulley
Adjustment bolt
Tension pulley bracket
Fan pulley
Fan
Outside diameter of pulley

Unit: mm
Machine model
Crankshaft pulley
Tension pulley
Fan pulley
Direction of wind
from fan
HD785-7
182
154
398
Suck
WA800-3E0, WA900-3E0
182
154
367
Blow out
Engine
SAA12V140E-3
12V140E-3 Series
57
SEN00309-04
Tension pulley
SAA12V140E-3 (HD785-7, WA800-3E0, WA900-3E0)
a
a

For HD785-7 cold area arrangement models, type of grease is different.
See the Shop Manual or Operation and Maintenance Manual for HD785-7 -40C specification models
for the detail.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Tension shaft
Spring
Roller bearing
Tension bracket
Spacer
Tension pulley (outside diameter: 154 mm)
Ball bearing
Oil seal
Grease fitting
Grease fitting
58
12V140E-3 Series
SEN00309-04
(For D475A-5E0, PC2000-8)

The cooling fan is hydraulic motor-driven. For more information, refer to the shop
manual for the machine body.
12V140E-3 Series
59
SEN00309-04
Electrical equipment
Alternator
Alternator with built-in regulator (Open type, 90A)
1.
2.
3.
4.
5.
Alternator
Alternator pulley
Terminal B
Terminal R
Terminal E
Engine
6.
Machine model
Internal connection diagram

6A. Field coil
6B. Initial excitation resistor
6C. Regulator
Type
D475A-5E0
HD785-7
Open type (brushless) manuSAA12V140E-3
PC2000-8
factured by NIKKO DENKI
WA800-3E0, WA900-3E0
60
Pulley
SpecificaOutside
Number
tions
diameter
of stages
(mm)
24V, 90A
95
Weight
(kg)
19
12V140E-3 Series
SEN00309-04
Alternator mounting
a
a

For HD785-7 cold area arrangement models, material of alternator drive belt is different.
See the Shop Manual or Operation and Maintenance Manual for HD785-7 -40C specification models for
the detail.
a:
Outside diameter of accessory pulley: 167 mm
1.
2.
3.
4.
5.
Adjustment bolt
Alternator pulley
Alternator
Alternator drive belt
Accessory pulley
12V140E-3 Series
61
SEN00309-04
Starting motor
For 7.5 kW
E:
R:
S:
To chassis ground
To alternator terminal R
To starting switch terminal C
1.
2.
3.
4.
5.
Pinion gear
Starting motor assembly
Magnetic switch
Terminal B
Terminal C
Engine
Machine model
6.
7.
Type
Safety relay
External connection diagram
(2-pole connector type)
7A. Safety relay section
7B. Starting motor section
Specifications
D475A-5E0
Water-resistant, oil-resistant
SAA12V140E-3 HD785-7
type manufactured by NIKKO 24V, 7.5 kW
WA800-3E0, WA900-3E0 DENKI
62
Number
of pinion
teeth
11
Weight
Type of
(kg)
connector
18
DT
12V140E-3 Series
SEN00309-04
For 11 kW
E:
R:
S:
To chassis ground
To alternator terminal R
To starting switch terminal C
1.
2.
3.
4.
5.
6.
Pinion gear
Magnetic switch
Terminal B
Terminal C
Safety relay
Engine
Machine model
SAA12V140E-3
PC2000-8
12V140E-3 Series
7.
8.
9.
External connection diagram

(2-pole connector type)
7A. Safety relay section
7B. Starting motor section
Jump start prohibition label
Jump start prevention cover
Type
Water-resistant, oil-resistant type
manufactured by NIKKO DENKI
Specifications
Number
of pinion
teeth
Weight
(kg)
Type of
connector
24V, 11 kW
11
18
DT
63
SEN00309-04
Starting aid
Electric heater
1.
2.
3.
4.
Body
Heater coil
Terminal
Connection diagram
64
Specifications
Type of heater: Electrical intake air heater
Rated voltage: 22 V (DC)
Load current: 175 A
12V140E-3 Series
SEN00309-04
oil pan heater, coolant heater (Option)
1.
2.
oil pan heater

coolant heater
12V140E-3 Series
65
SEN00309-04
oil pan heater
Specifications
Rated voltage: 230 V (AC)
Capacity
: 600 W
Coolant heater
Specifications
Rated voltage: 230 V (AC)
Capacity
: 1.5 kW
66
12V140E-3 Series
SEN00309-04
Engine controller
Features
Mounting of engine controller on engine
q
Since the engine controller is mounted on the engine, the operator can service it easily in the field.
q
Vibrations are damped by the vibration-proof rubber.
Unified specifications of engine controller
Engine controller CM850 developed by the cooperation between KOMATSU and CUMMINS is
employed.
12V140E-3 Series
67
SEN00309-04
Engine controller cooler
HD785-7, PC2000-8
A:
B:
Fuel IN (From feed pump of fuel supply pump)

Fuel OUT (Main fuel filter)
1.
2.
Engine controller
Engine controller cooler
Outline
q
The fuel is circulated as refrigerant through
engine controller cooler (2) to prevent engine
controller (1) from overheating.
q
The fuel is not circuited in some applicable
machines.
68
12V140E-3 Series
12V140E-3 Series
SEN00309-04
69
SEN00309-04

2010 KOMATSU
All Rights Reserved
70
12V140E-3 Series
SEN00311-03
ENGINE
1SHOP MANUAL
12V140E-3 Series

Standard service value table ........................................................................................................................... 2
Standard service value table for testing, adjusting, and troubleshooting ............................................. 2
Running-in standard and performance test standard ........................................................................... 7
12V140E-3 Series
SEN00311-03
Air intake and exhaust system
Performance
Category
Standard service value table for testing, adjusting, and troubleshooting1
Necessary
speed for
starting
Body
Lubrication system
Cooling system
Machine model
D475A-5E0
Standard value
for new machine
Max. speed at no load
rpm
2,150 (+25/-50) 2,150 (+25/-50)
Min. speed at no load
rpm
660 40
660 40
At 0C (without starting aid)
rpm
Min. 110
At 20C (with starting aid)
rpm
Min. 100
Measurement conditions
Service limit
value
Air intake
resistance
Whole speed range
kPa
{mmH2O}
Max. 3.73
{Max. 380}
7.47
{762}
Air boost
pressure
At rated output
kPa
{mmHg}
Min. 126.66
{Min. 950}
Exhaust
pressure
At rated output
kPa
{mmHg}
Exhaust
temperature
Whole speed range (20C )
Max. 680
750
At sudden acceleration (Low to High)
Bosch
index
Max. 4.5
5.5
At rated output
Bosch
index
Max. 1.0
2.0
At high idle
Bosch
index
Max. 1.0
2.0
Intake valve
mm
0.35 0.02
0.35 0.02
Exhaust gas
color
Valve clearance
SAA12V140E-3
Unit
Item
Speed
Engine
Exhaust valve
mm
0.57 0.02
0.57 0.02
Min. 4.1
{Min. 42}
2.8
{29}
Compression
pressure
Engine oil temperature: 40 60C

Engine speed: 200 250 rpm
MPa
{kg/cm2}
Blow-by
pressure
At rated output
Engine coolant temperature: Min. 70C
kPa
{mmH2O}
Max. 2.94
{Max. 300}
5.88
{600}
MPa
{kg/cm2}
0.29 0.44
{3.0 4.5}
0.2
{2.0}
MPa
{kg/cm2}
Min. 0.08
{Min. 0.8}
0.04
{0.4}
90 110
120
0.15
0.3
kPa
{kg/cm2}
At rated output
Engine oil temperature: Min. 80C
Oil pressure
At low idle
SAE0W30E0S
SAE5W40E0S
SAE10W30DH
SAE15W40DH
SAE30DH
Oil temperature Whole speed range (Oil in oil pan)

Oil consumption
Ratio to fuel consumption at continuous rated

output
Function of
radiator pressure valve
Cracking pressure (Differential pressure)
Fan speed
At rated speed
rpm
Hydraulically
driven on
machine side
Hydraulically
driven on
machine side
Alternator belt
tension
Deflection under finger pressure of 59 N {6 kg}
mm
20
20
12V140E-3 Series
Performance
Category
Necessary
speed for
starting
Body
Lubrication system
Cooling system
SAA12V140E-3
Machine model
HD785-7
Standard value
for new machine
Service limit
value
rpm
2,250 25
2,250 25
rpm
650 20
650 20
rpm
Min. 110
rpm
Min. 100
Air intake
resistance
Whole speed range
kPa
{mmH2O}
Max. 3.73
{Max. 380}
7.47
{762}
Air boost
pressure
At rated output
kPa
{mmHg}
Min. 165.40
{Min. 1,250}
Exhaust
pressure
At rated output
kPa
{mmHg}
Exhaust
temperature
Max. 700
750
Bosch
index
Max. 4.5
5.5
At rated output
Bosch
index
Max. 1.0
2.0
At high idle
Bosch
index
Max. 1.0
2.0
Intake valve
mm
0.35 0.02
0.35 0.02
Exhaust gas
color
Valve clearance
Engine
Unit
Item
Speed
SEN00311-03
Exhaust valve
mm
0.57 0.02
0.57 0.02
Min. 4.1
{Min. 42}
2.8
{29}
Compression
pressure

MPa
{kg/cm2}
Blow-by
pressure
At rated output
kPa
{mmH2O}
Max. 2.94
{Max. 300}
5.88
{600}
MPa
{kg/cm2}
0.29 0.44
{3.0 4.5}
0.2
{2.0}
MPa
{kg/cm2}
Min. 0.08
{Min. 0.8}
0.04
{0.4}
90 110
120
0.15
0.3
kPa
{kg/cm2}
At rated output
Oil pressure
At low idle
SAE0W30E0S
SAE5W40E0S
SAE10W30DH
SAE15W40DH
SAE30DH

Oil consumption

output
Function of
Fan speed
At rated speed
rpm
860
860
Alternator belt
tension
mm
20
20
12V140E-3 Series
Performance
Category
SEN00311-03
Speed
Necessary
speed for
starting
Body
Lubrication system
Cooling system
Engine
SAA12V140E-3
Machine model
PC2000-8
Unit
Standard value
for new machine
Service limit
value
rpm
1,980 25
1,980 25
rpm
825 25
825 25
rpm
Min. 110
rpm
Min. 100
Item
Air intake
resistance
Whole speed range
kPa
{mmH2O}
Max. 3.73
{Max. 380}
7.47
{762}
Air boost
pressure
At rated output
kPa
{mmHg}
Min. 125.70
{Min. 950}
Exhaust
pressure
At rated output
kPa
{mmHg}
Exhaust
temperature
Max. 700
750
Bosch
index
Max. 4.5
5.5
At rated output
Bosch
index
Max. 1.0
2.0
At high idle
Bosch
index
Max. 1.0
2.0
Intake valve
mm
0.35 0.02
0.35 0.02
Exhaust gas
color
Valve clearance
Exhaust valve
mm
0.57 0.02
0.57 0.02
Min. 4.1
{Min. 42}
2.8
{29}
Compression
pressure

MPa
{kg/cm2}
Blow-by
pressure
At rated output
kPa
{mmH2O}
Max. 2.94
{Max. 300}
5.88
{600}
MPa
{kg/cm2}
0.29 0.44
{3.0 4.5}
0.2
{2.0}
MPa
{kg/cm2}
Min. 0.08
{Min. 0.8}
0.06
{0.6}
90 110
120
0.15
0.3
kPa
{kg/cm2}
At rated output
Oil pressure
At low idle
SAE0W30E0S
SAE5W40E0S
SAE10W30DH
SAE15W40DH
SAE30DH

Oil consumption

output
Function of
Fan speed
At rated speed
rpm
Hydraulically
driven on
machine side
Hydraulically
driven on
machine side
Alternator belt
tension
mm
20
20
12V140E-3 Series
Performance
Category
Necessary
speed for
starting
Body
Lubrication system
Cooling system
SAA12V140E-3
Machine model
WA800-3E0
Standard value
for new machine
rpm
2,200 (+10/-20) 2,200 (+10/-20)
rpm
680 (+50/0)
680 (+50/0)
rpm
Min. 110
rpm
Min. 100
Service limit
value
Air intake
resistance
Whole speed range
kPa
{mmH2O}
Max. 3.73
{Max. 380}
7.47
{762}
Air boost
pressure
At rated output
kPa
{mmHg}
Min. 125.70
{Min. 950}
Exhaust
pressure
At rated output
kPa
{mmHg}
Exhaust
temperature
Max. 680
750
Bosch
index
Max. 4.5
5.5
At rated output
Bosch
index
Max. 1.0
2.0
At high idle
Bosch
index
Max. 1.0
2.0
Intake valve
mm
0.35 0.02
0.35 0.02
Exhaust gas
color
Valve clearance
Engine
Unit
Item
Speed
SEN00311-03
Exhaust valve
mm
0.57 0.02
0.57 0.02
Min. 4.1
{Min. 42}
2.8
{29}
Compression
pressure

MPa
{kg/cm2}
Blow-by
pressure
At rated output
kPa
{mmH2O}
Max. 2.94
{Max. 300}
5.88
{600}
MPa
{kg/cm2}
0.29 0.44
{3.0 4.5}
0.2
{2.0}
MPa
{kg/cm2}
Min. 0.08
{Min. 0.8}
0.04
{0.4}
90 110
120
0.15
0.3
kPa
{kg/cm2}
At rated output
Oil pressure
At low idle
SAE0W30E0S
SAE5W40E0S
SAE10W30DH
SAE15W40DH
SAE30DH

Oil consumption

output
Function of
Fan speed
At rated speed
rpm
980
980
Alternator belt
tension
mm
20
20
12V140E-3 Series
Performance
Category
SEN00311-03
Speed
Necessary
speed for
starting
Body
Lubrication system
Cooling system
Engine
SAA12V140E-3
Machine model
WA900-3E0
Unit
Standard value
for new machine
rpm
2,200 (+10/-20) 2,200 (+10/-20)
rpm
680 (+50/0)
680 (+50/0)
rpm
Min. 110
rpm
Min. 100
Item
Service limit
value
Air intake
resistance
Whole speed range
kPa
{mmH2O}
Max. 3.73
{Max. 380}
7.47
{762}
Air boost
pressure
At rated output
kPa
{mmHg}
Min. 132.30
{Min. 1,000}
Exhaust
pressure
At rated output
kPa
{mmHg}
Exhaust
temperature
Max. 700
750
Bosch
index
Max. 4.5
5.5
At rated output
Bosch
index
Max. 1.0
2.0
At high idle
Bosch
index
Max. 1.0
2.0
Intake valve
mm
0.35 0.02
0.35 0.02
Exhaust gas
color
Valve clearance
Exhaust valve
mm
0.57 0.02
0.57 0.02
Min. 4.1
{Min. 42}
2.8
{29}
Compression
pressure

MPa
{kg/cm2}
Blow-by
pressure
At rated output
kPa
{mmH2O}
Max. 2.94
{Max. 300}
5.88
{600}
MPa
{kg/cm2}
0.29 0.44
{3.0 4.5}
0.2
{2.0}
MPa
{kg/cm2}
Min. 0.08
{Min. 0.8}
0.04
{0.4}
90 110
120
0.15
0.3
kPa
{kg/cm2}
At rated output
Oil pressure
At low idle
SAE0W30E0S
SAE5W40E0S
SAE10W30DH
SAE15W40DH
SAE30DH

Oil consumption

output
Function of
Fan speed
At rated speed
rpm
1,005
1,005
Alternator belt
tension
mm
20
20
12V140E-3 Series
SEN00311-03
Running-in standard and performance test standard
Running-in standard
Engine
SAA12V140E-3
Machine model
D475A-5E0
Procedure
Item
Running time
min.
15
20
10
Speed
rpm
660
1,000
1,250
1,550
1,800
2,000
Dynamometer load
N {kg}
0 {0}
568 {58}
1,127 {115}
2,254 {230}
3,381 {345}
4,508 {460}
Output
kW {HP}
0 {0}
43 {57}
106 {142}
263 {352}
457 {612}
677 {907}
a
a
This table shows the values when the fan is not installed.
The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Performance test standard

Engine
SAA12V140E-3
Machine model
D475A-5E0
Test item
Rated output
Max. torque
Max. speed at
no load
Min. speed at
no load
Specification value
(Gross value)
Speed
rpm
2,000 5
1,300 1,500
Dynamometer load
N
{kg}
4,341 4,596
{443 469}
5,174 5,498
{528 561}
Output (Gross value)
kW
{HP}
651 691
{873 926}
Torque (Gross value)
Nm
{kgm}
3,704 3,940
{378 402}
Fuel consumption
sec/1,000cc
Min. 19.5
Coolant temperature
70 90
70 90
70 90
70 90
Lubricating oil
temperature
90 110
90 110
90 110
90 110
Lubricating oil
pressure
MPa
{kg/cm2}
0.34 0.49
{3.0 4.5}
Min. 0.08
{Min. 0.8}
Exhaust temperature
Max. 650
Max. 680
a
a
a
a
a
a
a
671 kW/2,000 rpm 3,825 Nm/1,400 rpm

2,150(+25/-50)rpm
{899 HP/2,000 rpm} {390 kgm/1,400 rpm}
660 40 rpm
This table shows the standard values obtained by using the JIS correction coefficients.
Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.
This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
Use ASTM No.1 or No. 2 diesel fuel as fuel.
Use SAE15W-40 as lubricating oil.
Aftercooler outlet temperature must not exceed 50C.
12V140E-3 Series
SEN00311-03
Running-in standard
Engine
SAA12V140E-3
Machine model
HD785-7
Procedure
Item
Running time
min.
15
20
10
Speed
rpm
650
1,000
1,250
1,550
1,800
1,900
Dynamometer load
N {kg}
0 {0}
784 {80}
1,568 {160}
3,136 {320}
4,704 {480}
6,272 {640}
Output
kW {HP}
0 {0}
59 {79}
147 {197}
365 {489}
635 {852}
894 {1,200}
a
a

Engine
SAA12V140E-3
Machine model
HD785-7
Test item
Rated output
Max. torque
Max. speed at
no load
Min. speed at
no load
2,250 25 rpm
650 20 rpm
Specification value
(Gross value)
Speed
rpm
1,900 5
1,300 1,400
Dynamometer load
N
{kg}
6,086 6,468
{621 660}
6,870 7,311
{701 746}
kW
{HP}
868 922
{1,160 1,240}
Nm
{kgm}
4,920 5,233
{502 534}
Fuel consumption
sec/1,000cc
Min. 15.2
Coolant temperature
70 90
70 90
70 90
70 90
Lubricating oil
temperature
90 110
90 110
90 110
90 110
Lubricating oil
pressure
MPa
{kg/cm2}
0.34 0.49
{3.0 4.5}
Min. 0.08
{Min. 0.8}
Exhaust temperature
Max. 650
Max. 700
a
a
895 kW/1,900 rpm 5,076 Nm/1,350 rpm

{1,200 HP/1,900 rpm} {518 kgm/1,350 rpm}
a
a
a
a
12V140E-3 Series
SEN00311-03
Running-in standard
Engine
SAA12V140E-3
Machine model
PC2000-8
Procedure
Item
Running time
min.
15
20
10
Speed
rpm
825
1,000
1,250
1,550
1,800
1,800
Dynamometer load
N {kg}
0 {0}
676 {69}
1,352 {138}
2,695 {275}
4,074 {413}
5,390 {550}
Output
kW {HP}
0 {0}
51 {68}
127 {171}
313 {420}
546 {733}
728 {976}
a
a

Engine
SAA12V140E-3
Machine model
PC2000-8
Test item
Rated output
Max. torque
Max. speed at
no load
Min. speed at
no load
1,980 25 rpm
825 25 rpm
Specification value
(Gross value)
Speed
rpm
1,800 5
1,300 1,400
Dynamometer load
N
{kg}
4,341 4,596
{534 567}
6,076 6,380
{620 659}
kW
{HP}
706 750
{947 1,010}
Nm
{kgm}
4,351 4,626
{444 472}
Fuel consumption
sec/1,000cc
Min. 18.6
Coolant temperature
70 90
70 90
70 90
70 90
Lubricating oil
temperature
90 110
90 110
90 110
90 110
Lubricating oil
pressure
MPa
{kg/cm2}
0.34 0.49
{3.0 4.5}
Min. 0.08
{Min. 0.8}
Exhaust temperature
Max. 650
Max. 700
a
a
a
a
a
a
a
728 kW/1,800 rpm 4,488 Nm/1,350 rpm

{976 HP/1,800 rpm} {458 kgm/1,350 rpm}
12V140E-3 Series
SEN00311-03
Running-in standard
Engine
SAA12V140E-3
Machine model
WA800-3E0
Procedure
Item
Running time
min.
15
20
10
Speed
rpm
680
1,000
1,250
1,550
1,800
2,000
Dynamometer load
N {kg}
0 {0}
529 {54}
1,058 {108}
2,107 {215}
3,156 {322}
4,214 {430}
Output
kW {HP}
0 {0}
40 {53}
99 {133}
245 {328}
427 {572}
633 {848}
a
a

Engine
SAA12V140E-3
Machine model
WA800-3E0
Test item
Rated output
Max. torque
Max. speed at
no load
Min. speed at
no load
2,200 (+10/-20)
rpm
680 (+50/0) rpm
Specification value
(Gross value)
Speed
rpm
2,000 5
1,350 1,450
Dynamometer load
N
{kg}
4,116 4,371
{420 446}
5,155 5,468
{526 558}
kW
{HP}
617 655
{827 879}
Nm
{kgm}
3,685 3,920
{376 400}
Fuel consumption
sec/1,000cc
Min. 20.5
Coolant temperature
70 90
70 90
70 90
70 90
Lubricating oil
temperature
90 110
90 110
90 110
90 110
Lubricating oil
pressure
MPa
{kg/cm2}
0.34 0.49
{3.0 4.5}
Min. 0.08
{Min. 0.8}
Exhaust temperature
Max. 650
Max. 680
a
a
a
a
a
a
a
10
636 kW/2,000 rpm 3,802 Nm/1,400 rpm

{853 HP/2,000 rpm} {388 kgm/1,400 rpm}
12V140E-3 Series
SEN00311-03
Running-in standard
Engine
SAA12V140E-3
Machine model
WA900-3E0
Procedure
Item
Running time
min.
15
20
10
Speed
rpm
680
1,000
1,250
1,550
1,800
2,050
Dynamometer load
N {kg}
0 {0}
549 {56}
1,088 {111}
2,185 {223}
3,273 {334}
4,361 {445}
Output
kW {HP}
0 {0}
41 {55}
102 {137}
254 {341}
442 {593}
671 {899}
a
a

Engine
SAA12V140E-3
Machine model
WA900-3E0
Test item
Rated output
Max. torque
Max. speed at
no load
Min. speed at
no load
Specification value
(Gross value)
Speed
rpm
2,050 5
1,250 1,350
Dynamometer load
N
{kg}
4,234 4,488
{432 458}
5,625 5,978
{574 610}
kW
{HP}
652 691
{874 927}
Nm
{kgm}
4,028 4,283
{411 437}
Fuel consumption
sec/1,000cc
Min. 19.5
Coolant temperature
70 90
70 90
70 90
70 90
Lubricating oil
temperature
90 110
90 110
90 110
90 110
Lubricating oil
pressure
MPa
{kg/cm2}
0.34 0.49
{3.0 4.5}
Min. 0.08
{Min. 0.8}
Exhaust temperature
Max. 650
Max. 700
a
a
a
a
a
a
a
672 kW/2,050 rpm 4,159 Nm/1,300 rpm

2,200(+10/-20)rpm
{900 HP/2,050 rpm} {424 kgm/1,300 rpm}
680(+50/0)rpm
12V140E-3 Series
11
SEN00311-03

2007 KOMATSU
All Rights Reserved
12
12V140E-3 Series
SEN00313-04
ENGINE
1SHOP MANUAL
2
3
12V140E-3 Series

Testing and adjusting tools list ........................................................................................................................ 3
Testing air boost pressure............................................................................................................................... 5
Testing exhaust temperature........................................................................................................................... 6
Adjusting valve clearance ............................................................................................................................... 7
Testing compression pressure ........................................................................................................................ 9
Testing blow-by pressure ...............................................................................................................................11
Testing oil pressure ....................................................................................................................................... 12
Handling fuel system parts............................................................................................................................ 13
Releasing residual pressure in fuel system .................................................................................................. 13
Testing fuel pressure..................................................................................................................................... 14
Reduced cylinder mode operation ................................................................................................................ 15
No-injection cranking .................................................................................................................................... 15
Testing leakage-from pressure limiter and return rate from injector.............................................................. 16
Bleeding air from fuel circuit (for D475A-5)................................................................................................... 19
Bleeding air from fuel circuit (for PC2000) .................................................................................................... 22
Bleeding air from fuel circuit (Poor fuel spec.) .............................................................................................. 24
12V140E-3 Series
SEN00313-04
Testing fuel system for leakage..................................................................................................................... 26

Adjusting speed sensor................................................................................................................................. 27
Testing and adjusting alternator belt tension................................................................................................. 27
Handling controller high-voltage circuit ......................................................................................................... 28
12V140E-3 Series
SEN00313-04
Testing/Adjusting item
Symbol
799-101-1502 Digital thermometer
1 - 99.9 1,299C
Commercially
Thickness gauge
available
Adjusting valve clearance
1
D
2
1
2
Testing blow-by pressure E 3
4
5
1
2
1
G 2
3
Testing leakage through

pressure limiter and
return rate from injector
799-201-1590 Gauge
799-201-1450 Adapter
1
2
799-201-1511 Nozzle
799-201-1571 Tube
2
1
799-101-5002 Hydraulic tester
799-261-1204 Digital hydraulic tester
1 Pressure gauge: 60 MPa {600 kg/cm2}
799-401-2320 Gauge
799-101-5002 Hydraulic tester
799-261-1204 Digital hydraulic tester
795-471-1450 Adapter
799-101-5220 Nipple (10 x 1.25 mm)
1 8 x 1.25 (male) R1/8 (female)

1
Size: 10 x 1.25 mm
1
795-471-1310 Adapter
07002-11023
O-ring
Pressure gauge: 2.5, 6, 40, 60 MPa

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

{25, 60, 400, 600 kg/cm2}
1
2
6151-51-8490 Spacer
6141-71-1710 Joint
1 14
1 10
Commercially
Hose
available
1 Inside diameter: Approx. 11 mm
Commercially
Hose
available
1 Inside diameter: Approx. 17 mm
12V140E-3 Series
6261-71-6150 Gasket
799-201-1504 Blow-by checker kit
1 0 6.9 MPa {0 70 kg/cm2}

1
For 140E-3, 5
1
1 0 10 kPa {0 1,000 mmH2O}
799-401-2320 Gauge
795-502-1590 Compression gauge
Intake: 0.35 mm
Exhaust: 0.57 mm
Controller sensor
Actuator diagnosis
Remarks
799-401-2220 Hose
Testing exhaust
temperature
Testing fuel pressure
Part name
1 -101 200 kPa {-760 1,500 mmHg}
Testing oil pressure
Part No.
799-201-2202 Boost gauge kit
Testing air boost

pressure
Testing compression
pressure
1
Q'ty
Testing and adjusting tools list
Commercially
Measuring cylinder
available
Commercially
Stopwatch
available
07376-70315 Plug
1
1
1 Size: 03
799-601-4130 T-adapter
799-601-4330 Socket
1 For Ne sensor
1 For G (Bkup) sensor
799-601-4240 Socket
799-601-4250 Socket
1 For atmospheric pressure sensor

1 For boost pressure sensor
799-601-9420 T-adapter
799-601-4150 T-adapter
1 For common rail pressure sensor

1 For oil pressure sensor
Testing/Adjusting item
Symbol
Part No.
Part name
799-601-9430 Socket
799-601-9020 T-adapter
799-601-4260 T-adapter
1 For injector
1 For controller (4 - pole)
799-601-4211 T-adapter
799-601-4220 T-adapter

799-601-4350 T-box
799-601-9320 T-box
1 For 60 - pole type

1 For 24 - pole type
799-601-9310 Plate
795-799-5530 Socket
Remarks
For boost temperature sensor

For intake air sensor
For coolant temperature sensor
1 For fuel temperature sensor
Oil temperature sensor
1 For supply pump PCV
795-799-5540 Socket
Controller sensor
Actuator diagnosis
Q'ty
SEN00313-04
12V140E-3 Series
SEN00313-04
Testing air boost pressure

a
Testing tools for air boost pressure
Symbol
A
k
a
1.
Part No.
Part name
799-201-2202
Boost gauge kit
790-401-2220
Hose
Be careful not to touch any hot part when

removing or installing the testing tools.
The test point is subject to machine models.
Remove air boost pressure pickup plug ((L1)
on left bank or (R1) on right bank) from the bottom of the air intake connector.
4.
2.
Install nipple [1] of boost gauge kit A and connect 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
After finishing testing, remove the testing tools

and return the removed parts.
SEN00313-04
Testing exhaust temperature

a
Part No.
799-101-1502
1.
2.
Run the engine and test the exhaust temperature in the whole speed range.
machine.
4.

Part name
Digital thermometer
Remove and install the testing tools after

the exhaust manifold temperature has lowered.
Remove an exhaust temperature pickup plug
(1) of the subject section for measuring from
the top of the exhaust manifold.
a Subject section for measuring includes
front left, rear left, front right and rear right
(4 points in total).
Install sensor [1] of digital thermometer B and

connect it to thermometer [2].
a Installation example to the rear right-hand
side (RR)
3.
Testing tool for exhaust temperature
Symbol
For engines mounted with the exhaust

temperature sensor, connect temperature
gauge [2] to the sensor on machine.
12V140E-3 Series
SEN00313-04
Adjusting valve clearance

a
Adjusting tool for valve clearance
Symbol
Part No.
Commercially
available
Part name
Clearance gauge
5.
Hereafter crank the engine similar way in the

firing order. Match the stamped line of the
damper to the pointer and adjust the valve
clearance of each cylinder.
a Firing order
R1 L1 R5 L5 R3 L3 R6 L6
R2 L2 R4 L4
Valve clearance adjusting method

1.
Remove cylinder head cover.
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 specified clearance between the crosshead (4) and
rocker arm (3) and adjust the adjustment
screw to the degree that the clearance gauge
can be moved lightly.
a Valve clearance
Air Intake valve: 0.35 mm, Exhaust valve:
0.57 mm
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
SEN00313-04
6.
After finishing adjustment, return the removed

parts.
3 Cylinder head cover mounting bolt:
14.7 34.3 Nm {1.5 3.5 kgm}
12V140E-3 Series
SEN00313-04
Testing compression pressure

a
Testing tools for compression pressure
Symbol
1
D
k
1.
Part No.
Part name
795-502-1590
Compression gauge
795-471-1310
Adapter
6261-71-6150
Gasket
When measuring the compression pressure, take care not to burn yourself on the
exhaust manifold, muffler, etc. or get
caught in a rotating part.
Measure the compression pressure after the
engine is warmed up.
(Engine oil temperature: 40 60C).
4.
Install adapter D2 to the mounting hole on the

injector and compression gauge D1.
a Fit the gasket to the injector end without
fail
a Fix the adapter with the injector holder.
3 Holder mounting bolt:
58.8 73.5 Nm {6.0 7.5 kgm}
a Apply a little amount of engine oil to the
connecting parts of the adapter and gauge
so that air will not leak easily.
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.
6.
Connect the INSITE (bench test tool) to the

engine and set the engine in the no-injection
cranking mode.
k If the engine is not set in the no-injection cranking mode, it will start and will
be dangerous. Accordingly, be sure to
set the engine in this mode.
Remove cylinder head cover (1) of the cylinder

to be tested for compression pressure.
2.
Bring the cylinder to be tested to the compression 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 wiring harness on the injector side and the
bracket on the rocker housing side and
r e mo v e t he i n j ec to r w i r i ng h a r n es s
(Loosen the 2 terminal nuts alternately)
from the injector.
a Pass injector under the fuel path projected
sideways and pull up the injector through
wire (Do not pry the injector top up).
12V140E-3 Series
SEN00313-04
7.
Rotate the engine with the starting motor and

measure the compression pressure.
a Read the pressure gauge pointer when it
is stabilized.
8.

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

bolt.
5) Install rocker arm assembly.
3 Rocker arm assembly mounting bolt:
93 103 Nm {9.5 10.5 kgm}
a Adjust the valve clearance. For details,
see Adjusting valve clearance.
6) Install head cover.
3 Cylinder head cover mounting bolt:
27.5 34.3 Nm {2.8 3.5 kgm}
Install the injector wiring harness according to the following procedure

1) Install the injector wiring harness to the
cylinder head and fix the connector side
with the plate.Install O-ring (16).
2) Install cap (17) with clip on the injector
side of wiring harness.
Press wiring harness (18) between the
injector top and cap to the injector main
body without slack.
3) Tighten nut (19) on the injector side.
3 Nut: 2 0.2 Nm {0.2 0.02 kgm}
10
12V140E-3 Series
SEN00313-04
Testing blow-by pressure

a
a
a
a
1.
2.
3.
Run the engine at the rated output and test the

blow-by pressure.
machine.
4.

Testing tool for blow-by pressure
Symbol
Part No.
Part name
Q'ty
799-201-1504
Blow-by checker kit
799-201-1590
Gauge
799-201-1450
Adapter
799-201-1511
Nozzle
799-201-1571
Tube

Measure blow-by pressure after the engine is
warmed up.
(Engine coolant temperature: Min. 70C)
Breather is provided to each RH and LH
banks. Test the breather on either one of the
banks.
Install adaptor E3 and nozzle E4 to the tip of
each breather hose on the RH and LH.
Connect tube E5 and gauge E2 to either one of
the nozzles.Close the tube connecting mate of
other nozzle with a piece of short cut tube, etc.
12V140E-3 Series
11
SEN00313-04
Testing oil pressure

a
1
2
Part No.
Hydraulic tester
790-261-1204
Digital hydraulic tester
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.
12
Run the engine at the rated output and low idle

and test the oil pressure.
machine.
4.

Part name
799-101-5002
2.
3.
Testing tools for oil pressure
Symbol
F
Install nipples [1] and [2] of hydraulic tester F1

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

a
SEN00313-04
Precautions for testing and maintaining fuel

system
The common rail fuel injection system (CRI)
consists of more precise parts than the conventional fuel injection pump and nozzle. If foreign matter enters this system, it can cause a
trouble.
When testing and maintaining the fuel system,
take care more than the past. If dust, etc.
sticks to any part, wash that part thoroughly
with clean fuel.
Precautions for replacement of fuel filter cartridge
The fuel filter cartridge used must be a genuine
Komatsu part.
The fuel injection pump and nozzle of the common rail type fuel injection system (CRI) are
consisted of more precision parts than those
used for the current pumps and nozzles. This
system, therefore, employs a special filter with
highly efficient filtering performance to prevent
mixing of foreign substances. Thus, substituting it with a non-genuine filter could cause
troubles in the fuel system. It is strictly prohibited to use such part.
12V140E-3 Series
Releasing residual pressure in

fuel system
a
Pressure is generated in the low-pressure circuit and high-pressure circuit of the fuel system while the engine is running.
Low-pressure circuit:
Feed pump Fuel filter Supply pump
High-pressure circuit:
Supply pump Common rail Injector
The pressure in both low-pressure circuit and
high-pressure circuit lowers to a safety level
automatically 30 seconds after the engine is
stopped.
Before the fuel circuit is tested and its parts are
removed, the residual pressure in the fuel circuit must be released completely. Accordingly,
observe the following.
Before testing the fuel system or removing
its parts, wait at least 30 seconds after stopping the engine until the residual pressure
in the fuel circuit is released. (Do not start
the work just after stopping the engine
since there is residual pressure.)
13
SEN00313-04
Testing fuel pressure

a
1
2
3
4
1.
2.
14
3.
Testing tools for fuel pressure
Symbol
Part No.
Part name
799-101-5002
Hydraulic tester
790-261-1204
Digital hydraulic tester
795-471-1450
Adapter
799-101-5220
Nipple
07002-11023
O-ring
799-401-2320
Gauge
Run the engine at high idle and measure the

fuel pressure.
a If the fuel pressure is in the following
range, it is normal.
Engine speed
Fuel pressure
High idle
0.15 0.3 MPa

{1.5 3 kg/cm2}
Test only the fuel pressure in the low-pressure

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

after the priming pump are independent, test
each circuit.
5.

Install adapter G2 and connect to gauge G4.
12V140E-3 Series
Reduced cylinder mode

operation
a
1.
2.
3.
SEN00313-04
Reduced cylinder mode operation means to

run the engine with the fuel injectors of 1 or
more cylinders disabled electrically to reduce
the number of effective cylinders. The purposes and effects of this operation are as follows.
This operation is used to find out a cylinder
which does not output power normally (or,
combustion in it is abnormal).
When a cylinder is selected for the reduced
cylinder mode operation, if the engine speed
and output do not change from the normal
operation (all-cylinder operation), that cylinder
has 1 or more defects. The possible defects
are as follows.
q
Leakage through cylinder head gasket
q
Defective injection
q
Defective piston, piston ring, or cylinder
liner
q
Defective valve mechanism
(Moving valve system)
q
Defect in electrical system
Since the common rail fuel injection system
controls the injector of each cylinder electronically, the operator can perform the reduced cylinder mode operation easily with switches to
find out a defective cylinder.
a Perform the reduced cylinder mode operation with the engine mounted on the
machine or connected to INSITE (bench
test tool).
Before performing, see Testing method in
the shop manual for the machine or
INSITE (bench test tool).
12V140E-3 Series
No-injection cranking
a
No-injection cranking means to crank the

engine with the starting motor while all the
injections are stopped electrically. The purpose and effect of this operation are as follows.
When a machine or engine has been stored for
a long time, implementing the no-injection
cranking before starting the engine lubricates
the engine parts and thus prevents its seizure.
Perform the no-injection operation with the
engine mounted on the machine or connected
to INSITE (bench test tool).
Before performing, see Testing method in the
shop manual for the machine or INSITE
(bench test tool).
15
SEN00313-04
Testing leakage-from pressure limiter and return rate from injector
Type of engine having intake manifold equipped with return block
If the engine is of a type that returns the fuel

spilling from the injector from the return block
installed to the front of intake manifold, check
the engine according to the following (the figure showing the LH bank for PC2000).
Testing tools for pressure limiter leakage and
injector return rate
Symbol
16
Part No.
Part name
6151-51-8490
Spacer
6141-71-1710
Joint
Commercially
available
Inside diameter of the hose:

Approx. 11 mm
Commercially
available
Inside diameter of the hose:

Approx. 17 mm
Commercially
available
Measuring cylinder
Commercially
available
Stopwatch
07376-70315
Plug
Prepare an oil pan of about 20 l to receive the

fuel flowing out during the test.
1.
Preparatory work (case of the LH bank)

1) Remove tube (4) between common rail (3)
and supply pump (5).
2) Insert spacer H1 on supply pump (5) side
and tighten the removed joint bolt again.
3) Connect the return pipe to the fuel tank
again, too.
a Be sure to provide a gasket to both
ends of the spacer.
12V140E-3 Series
SEN00313-04
2.
4)
5)
Insert joint H2 on common rail (3) side and

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

1) Lay test hose H3 so that it will not slacken
and put its end in the oil pan.
2) Connect INSITE (bench test tool) to the
engine and set it so that it can check the
engine speed.
3) Start the engine and keep its speed to
1,600 rpm with no load.
4) After the engine speed is stabilized, test
the leakage in 1 minute with measuring
cylinder H5.
a You may test for 20 seconds and
judge by multiplying the result by 3.
a If the leakage from the pressure limiter is in the following range, it is normal.
5)
12V140E-3 Series
Engine speed
Leakage
(cc/min)
At rated output
Max. 10
After finishing testing, stop the engine.
17
SEN00313-04
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 injector.
1) Disconnect return hose (2) of return block
(1) and connect test hose H4.
a Apply plug H7 to the return hose side
to stop oil, and fix it to the fuel tank.
a Bind the connecting part of the test
hose with a wire, etc. to prevent it
from coming off.
2) Lay test hose H4 so that it will not slacken
and put its end in the oil pan.
6)
3)
4)
5)
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 procedure.
Connect INSITE (bench test tool) to the

engine and set it so that it can check the
engine speed.
Run the engine at the rated output.
After the engine speed is stabilized, test
the return rate in 1 minute with measuring
cylinder H5.
a You may test for 20 seconds and
judge by multiplying the result by 3.
a If the supply pump is not supplying
fuel, the engine speed may not rise.
In this case, record the engine speed,
too, during the test.
a If the return rate (spill) from the injector is in the following range, it is normal.
Rated output speed Limit of return rate (spill)
(rpm)
(cc/min)
18
1,600
960
1,700
1,020
1,800
1,080
1,900
1,140
2,000
1,200
12V140E-3 Series
SEN00313-04
Bleeding air from fuel circuit (for D475A-5)
a
a
1.
If fuel is used up or if a fuel circuit part is

removed and installed, bleed air from the fuel
circuit according to the following procedure.
The locations of the fuel circuit parts are subject to machine models (The figure showing
the LH bank for D475A-5).
Remove fuel pre-filter (6) and fill it with fuel.
a Fill the fuel filter with clean fuel and take
care that dirt will not enter it.
a Check that the cap is fitted to part (a)
(central hole) of the fuel pre-filter (6), and
then add fuel through part (b) (holes
around the central hole).
a After filling the fuel pre-filter (6) with fuel,
remove the cap from part (a).
a If clean fuel is not available, do not
remove the filter but fill it with the fuel by
operating priming pump (3).
12V140E-3 Series
2.
Don't fill fuel directly after removing main

filter (1).
Install fuel pre-filter (6) to the pre-filter head.

a Apply engine oil thinly over the packing on
the fuel pre-filter side.
19
SEN00313-04
a
After the packing of the fuel pre-filter

touches the sealing face of the filter head,
tighten the fuel filter 1/2 3/4 turns.
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}
20
12V140E-3 Series
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.
12V140E-3 Series
SEN00313-04
21
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Bleeding air from fuel circuit (for PC2000)
a
a
1.
22
If fuel is used up or if a fuel circuit part is

removed and installed, bleed air from the fuel
circuit according to the following procedure.
The locations of the fuel circuit parts are subject to machine models (The figure showing
the LH bank for PC2000).
Remove fuel pre-filter and fill it with fuel.
a Fill the fuel filter with clean fuel and take
care that dirt will not enter it.
a Check that the cap is fitted to part (a)
(central hole) of the fuel pre-filter, and then
add fuel through part (b) (holes around the
central hole).
a After filling the fuel pre-filter with fuel,
remove the cap from part (a).
a If clean fuel is not available, do not
remove the filter but fill it with the fuel by
operating priming pump (3).
2.
Don't fill fuel directly after removing main

filter (1).
Install fuel pre-filter to the filter head.

a Apply engine oil thinly over the packing on
the fuel pre-filter side.
12V140E-3 Series

a
SEN00313-04
After the packing of the fuel pre-filter

touches the sealing face of the filter head,
tighten the fuel filter 1/2 3/4 turns.
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.
12V140E-3 Series
23
SEN00313-04
Bleeding air from fuel circuit

(Poor fuel spec.)
Reference:
q
The electric priming pump switch is installed to
the chassis.
q
Each figure shows D475A-5E0 for an example.
a Bleed air from the fuel circuit in the following
cases according to this procedure.
q
When the fuel filter is replaced
q
When fuel is used up
q
When the engine is started for the first
time after the fuel piping or supply pump is
replaced
a If the fuel filter was replaced, do not fill the
main filter and prefilter with the fuel.
1.
Turn the starting switch to the "OFF" position.
2.
Check that the fuel valve on the fuel tank side

is open.
3.
Turn the left and right lever (1) of the air bleeding piping to the parallel position with the piping to open the circuit valve.
4.
Turn "ON" switch (3) of electric priming pump

(2) installed to the chassis.
a The electric priming pump operates and
lamp (4) blinks.
a
a
a
k
The electric priming pump has a timer in it

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

stuck near the air bleeding piping lever.
24
12V140E-3 Series
5.
After the specified time (approx. 7 minutes),

lamp (4) goes off and the electric priming pump
stops automatically.
a If only the fuel filter was replaced, the air
bleeding work is completed now.
6.
If the fuel was used up or the fuel piping or

supply pump was replaced and there is not fuel
in the fuel circuit, turn switch (3) "ON" after the
electric priming pump stops automatically.
7.
When lamp (4) goes off, the air bleeding work

is completed.
8.
Turn lever (1) of the air bleeding piping to the

cross position with the piping to close the circuit valve.
9.
Start the engine with the starting motor.

a Do not operate the starting motor continuously for more than 20 seconds.
q
After starting the engine, run it at low
idle for about 5 minutes to bleed all air
from the fuel circuit.
q
Stop the engine and check that the air
bleeding valve is closed.
12V140E-3 Series
SEN00313-04
10. If the engine does not start, try to start it again

according to the following procedure.
k When starting the engine, check that there
is no person around it.
a Carry out the work with the air bleeding
valve closed. (Do not open the air bleeding valve after step 7.)
a After the engine fails to start, wait for
about 2 minutes before trying to start
again.
1) Turn the electric priming pump switch ON.
2) While the electric priming pump is operating, crank the engine.
q
If the engine does not start, repeat the
above operation.
a Do not operate the starting motor continuously for more than 20 seconds.
a If the engine fails to start, wait for about 2
minutes and try to start again.
3) After starting the engine, run it at low idle
for about 5 minutes to bleed all air from
the fuel circuit.
4) Stop the engine and check that the air
bleeding valve is closed.
5) After the above operation, start the engine
normally.
25
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Testing fuel system for leakage 1

k
Very high pressure is generated in the highpressure circuit of the fuel system. If fuel
leaks while the engine is running, it is dangerous since it can catch fire.
After testing the fuel system or removing
its parts, test it for fuel leakage according
to the following procedure.
Clean and degrease the engine and the parts
around it in advance so that you can test it easily for fuel leakage.
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.
a Check mainly around the high-pressure
circuit parts coated with the color checker
for fuel leakage.
a If any fuel leakage is detected, repair it
and inspect again from step 1.
4.
Run the engine at low idle.
5.

leakage.
for fuel leakage.
6.
Run the engine at high idle.
7.

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.
26
9.

leakage.
for fuel leakage.
a If no fuel leakage is detected, check is
completed.
12V140E-3 Series
Adjusting speed sensor

a
a
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The G (Bkup) speed sensor and Ne speed

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

is free from steel chips and flaws, and then
install it again temporarily.
2 Threads: Gasket sealant (LG-6)
2.
Screw in sensor (1) until its tip touches the

tooth tip of flywheel ring gear (2).
3.
4.
Return sensor (1) by 3/4 1 turn.

a Clearance (a) of 1.1 1.5 mm will be
made between the sensor tip and gear
tooth tip.
While fixing sensor (1), tighten nut (3).
3 Nut: 49 68.6 Nm {5 7 kgm}
12V140E-3 Series
Testing and adjusting alternator

belt tension
1
Testing
Press the intermediate point of the belt between
alternator pulley and drive pulley with a finger and
measure deflection (a) of the belt.
a Pressing force: Approx. 59 Nm {Approx. 6 kg}
a Deflection (a): Approx. 20 mm (1 piece)
Adjusting
a If the deflection is out of the standard range,
adjust it according to the following procedure.
1.
Loosen nut (B) and bolt (2) alternately.
2.
Adjust belt tension using nut (A).
3.
Tighten bolt (2) to have adjust bolt (1) and

plate (3) made orthogonal to each other.
4.
Tighten nut (B) to fix plate (3).

a After adjusting, test the belt tension again.
27
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Handling controller high-voltage

circuit
1
1.
When disconnecting or connecting a connector

between engine controller and engine, be sure
to turn the starting switch OFF.
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.
28
12V140E-3 Series
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2009 KOMATSU
All Rights Reserved
30
12V140E-3 Series
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12V140E-3 Series
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ENGINE
Shop Manual
12V140E-3 Series

40 Troubleshooting
General Information on troubleshooting
Points to remember when troubleshooting .................................................................................................
Error codes and failure codes list................................................................................................................
Information in troubleshooting table ............................................................................................................
Connection table for connector pin numbers ..............................................................................................
T- branch box and T- branch adapter table ................................................................................................. 45
12V140E-3 Series
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40 Troubleshooting
Points to remember when troubleshooting

k
k
k
k
k
k
When troubleshooting a machine, stop it in a level ground, and check that the lock pin, chocks,
and parking brake are securely fitted.
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.
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.
Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
When disconnecting wiring, always disconnect the negative () terminal of the battery first.
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 connect
it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and the
prevent reoccurrence of the failure.When carrying out troubleshooting, and important point is of course to understand the structure and function. However, a short cut to effective troubleshooting is to ask the operator
various questions to form some idea of possible causes of the failure that would produce the reported symptoms.
1. When carrying out troubleshooting, do not hurry
to disassemble the components.
If components are disassembled immediately
after any failure occurs:
q Parts that have no connection with the failure
or other unnecessary parts will be disassembled.
q It will become impossible to find the cause of
the failure.
It will also cause a waste of manhours, parts, or
oil or grease, and at the same time, will also lose
the confidence of the user or operator.
For this reason, when carrying out troubleshooting, it is necessary to carry out thorough
prior investigation and to carry out troubleshooting in accordance with the fixed procedure.
2. Points to ask user or operator
1) Have any other problems occurred apart
from the problem that has been reported?
2) Was there anything strange about the
machine before the failure occurred?
3) Did the failure occur suddenly, or were there
problems with the machine condition before
this?
4) Under what conditions did the failure occur?
5) Had any repairs been carried out before the
failure? When were these repairs carried
out?
6) Has the same kind of failure occurred
before?
3. Check before troubleshooting
1) Check for symptoms of any abnormality in
the machine and engine.
2) Be sure to check the CHECKS BEFORE

STARTING items.
3) Check other inspection items, if necessary.
4) Some other maintenance items can be
checked externally, so check any item that is
considered to be necessary.
5) Check the controller for display of an error.
4. Confirming failure
Confirm the extent of the failure yourself, and
judge whether to handle it as a real failure or as
a problem with the method of operation, etc.
a When operating the machine or engine to reenact the troubleshooting symptoms, do not
carry out any investigation or measurement
that may make the problem worse.
5. Troubleshooting
Use the results of the investigation and inspection in Items 2 4 to narrow down the causes of
failure, then use the troubleshooting matrix to
locate the position of the failure exactly.
a The basic procedure for troubleshooting is as
follows.
1) Start from the simple points.
2) Start from the most likely points.
3) Investigate other related parts or information.
6. Measures to remove root cause of failure
Even if the failure is repaired, if the root cause of
the failure is not repaired, the same failure will
occur again. To prevent this, always investigate
why the problem occurred. Then, remove the
root cause.
12V140E-3 Series
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40 Troubleshooting
Error codes and failure codes list

*1 *3: Machine monitor in KES 6 digit display
INSITE
error code
Machine failure
code
111
CA111
ECM Critical Internal Failure (LH bank)
111
CB111
ECM Critical Internal Failure (RH bank)
115
CA115
Eng. Ne and G (Bkup) Speed Sensor Error (LH bank)
115
CB115
Eng. Ne and G (Bkup) Speed Sensor Error (RH bank)
122
CA122
Charge Air Press. Sensor High Error (LH bank only)
123
CA123
Charge Air Press. Sensor Low Error (LH bank only)
131
CA131
Throttle Sensor High Error (LH bank only)
132
CA132
Throttle Sensor Low Error (LH bank only)
135
CA135
Oil Press. Sensor High Error (LH bank only)
141
CA141
Oil Press. Sensor Low Error (LH bank only)
144
CA144
Coolant Temp. Sensor High Error (LH bank only)
145
CA145
Coolant Temp. Sensor Low Error (LH bank only)
153
CA153
Charge Air Temp. Sensor High Error (LH bank only)
154
CA154
Charge Air Temp. Sensor Low Error (LH bank only)
187
CA187
Sensor Sup. 2 Volt. Low Error (LH bank)
187
CB187
Sensor Sup. 2 Volt. Low Error (RH bank)
212
CA212
Eng. Oil Temp.Sensor High Error (LH bank only)
213
CA213
Eng. Oil Temp.Sensor Low Error (LH bank only)
221
CA221
Ambient Air Press. Sensor High Error (LH bank only)
222
CA222
Ambient Air Press. Sensor Low Error (LH bank only)
227
CA227
Sensor Sup. 2 Volt. High Error (LH bank)
227
CB227
Sensor Sup. 2 Volt. High Error (RH bank)
234
CA234
Eng. Over (LH bank only)
238
CA238
Ne Speed Sensor Sup. Volt. Error (LH bank)
238
CB238
Ne Speed Sensor Sup. Volt. Error (RH bank)
263
CA263
Fuel Temp. Sensor High Error (LH bank)
263
CB263
Fuel Temp. Sensor High Error (RH bank)
265
CA265
Fuel Temp. Sensor Low Error (LH bank)
265
CB265
Fuel Temp. Sensor Low Error (RH bank)
271
CA271
PCV1 Short Error (LH bank)
12V140E-3 Series
Failure phenomenon
SEN00315-01
40 Troubleshooting
INSITE
error code
Machine failure
code
271
CB271
PCV1 Short Error (RH bank)
272
CA272
PCV1 Open Error (LH bank)
272
CB272
PCV1 Open Error (RH bank)
273
CA273
PCV2 Short Error (LH bank)
273
CB273
PCV2 Short Error (RH bank)
274
CA274
PCV2 Open Error (LH bank)
274
CB274
PCV2 Open Error (RH bank)
322
CA322
Injector #1 (LA/B #1) System Open/Short Error (LH bank)
323
CA323
324
CA324
325
CA325
331
CA331
332
CA332
342
CA342
Caribration Code Incompatibility (LH bank)
342
CB342
Caribration Code Incompatibility (RH bank)
351
CA351
Inj. Drive Circuit Error (LH bank)
351
CB351
Inj. Drive Circuit Error (RH bank)
352
CA352
Sensor Sup. 1 Volt. Low Error (LH bank)
352
CB352
Sensor Sup. 1 Volt. Low Error (RH bank)
386
CA386
Sensor Sup. 1 Volt. High Error (LH bank)
386
CB386
Sensor Sup. 1 Volt. High Error (RH bank)
441
CA441
Battery Voltage Low Error (LH bank)
441
CB441
Battery Voltage Low Error (RH bank)
442
CA442
Battery Voltage High Error (LH bank)
442
CB442
Battery Voltage High Error (RH bank)
449
CA449
Rail Press. Very High Error (LH bank)
449
CB449
Rail Press. Very High Error (RH bank)
451
CA451
Rail Press. Sensor High Error (LH bank)
451
CB451
Rail Press. Sensor High Error (RH bank)
452
CA452
Rail Press. Sensor Low Error (LH bank)
452
CB452
Rail Press. Sensor Low Error (RH bank)
553
CA553
Rail Press. High Error 1 (LH bank)
Failure phenomenon
12V140E-3 Series
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40 Troubleshooting
INSITE
error code
Machine failure
code
553
CB553
Rail Press. High Error 1 (RH bank)
554
CA554
Rail Press. Sensor In Range Error (LH bank)
554
CB554
Rail Press. Sensor In Range Error (RH bank)
559
CA559
Rail Press. Low Error 1 (LH bank)
559
CB559
Rail Press. Low Error 1 (RH bank)
689
CA689
Eng. Ne Speed Sensor Error (LH bank)
689
CB689
Eng. Ne Speed Sensor Error (RH bank)
691
CA691
Intake Air Temp Sensor High Error (LH bank only)
692
CA692
Intake Air Temp Sensor Low Error (LH bank only)
731
CA731
Eng. G (Bkup) Speed Sensor Phase Error (LH bank)
731
CB731
Eng. G (Bkup) Speed Sensor Phase Error (RH bank)
757
CA757
All Continuous Data Lost Error (LH bank)
757
CB757
All Continuous Data Lost Error (RH bank)
778
CA778
Eng. G (Bkup) Speed Sensor Error (LH bank)
778
CB778
Eng. G (Bkup) Speed Sensor Error (RH bank)
781
CA781
Inter Multi-controller Communication Error (LH bank)
781
CB781
Inter Multi-controller Communication Error (RH bank)
1117
CA1117
Persistent Data Lost Error (LH bank)
1117
CB1117
Persistent Data Lost Error (RH bank)
1257
CA1257
Harness Key error (LH bank)
1257
CB1257
Harness Key error (RH bank)
1548
CB1548
Injector #7 (R/B #1) System Open/Short Error (RH bank)
1549
CB1549
1551
CB1551
1552
CB1552
1553
CB1553
1622
CB1622
1633
CA1633
KOMNET Data Time Error (LH bank)
2185
CA2185
Throttle Sens. Sup. Volt. High Error (LH bank only)
2186
CA2186
Throttle Sens. Sup. Volt. Low Error (LH bank only)
2249
CA2249
Rail Press. Very Low Error (LH bank)
2249
CB2249
Rail Press. Very Low Error (RH bank)
12V140E-3 Series
Failure phenomenon
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40 Troubleshooting
INSITE
error code
Machine failure
code
--*1
Eng. Overheat (LH bank only)
--*2
Eng. Oil Press. Low Speed Derate (LH bank only)
--*3
Eng. Oil Press. Low Torque Derate (LH bank only)
Failure phenomenon
a INSITE error code:

An error code of 3 or 4 digits displayed on the INSITE (bench test tool) when the occurrence condition of
the failure is confirmed with the INSITE.
a Machine failure code:
An error code of 5 or 6 digits displayed on the machine monitor when the occurrence condition of the failure
is confirmed with the machine monitor, etc. on the machine side.
12V140E-3 Series
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40 Troubleshooting
Information in troubleshooting table

a The following information is summarized in the troubleshooting table and the related electrical circuit diagram. Before carrying out troubleshooting, understand that information fully.
Error code
Failure code
Display on
INSITE
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Display on
applicable machine
Contents of trouble detected by engine controller

Action taken by engine controller to protect system or devices when engine controller detects
trouble
Phenomenon that appears on engine as trouble as result of action taken by engine controller
(shown above)
Information related to detected trouble or troubleshooting
Causes
Possible causes
and standard
value in normal
state
Trouble Problem that appears on engine
Standard value in normal state/Remarks on troubleshooting
<Contents of description>
q Standard value in normal state to judge possible causes
q Remarks on judgment
<Troubles in wiring harness>
q Disconnection
Connector is connected imperfectly or wiring harness is
broken.
q Ground fault
Wiring harness which is not connected to chassis ground
circuit is in contact with chassis ground circuit.
q Hot short
Wiring harness which is not connected to power source (24
V) circuit is in contact with power source (24 V) circuit.
q Short circuit
Independent wiring harnesses are in contact with each
other abnormally.
Possible causes of trouble

(Given numbers are refer<Precautions for troubleshooting>
ence numbers, which do not
(1) Method of indicating connector No. and handling of
indicate priority)
Tadapter
Insert or connect T-adapter as explained below for troubleshooting, unless otherwise specified.
q If connector No. has no marks of "male" and "female",
3
disconnect connector and insert T-adapters in both
male side and female side.
q If connector No. has marks of "male" and "female", disconnect connector and connect T-adapter to only male
side or female side.
(2) Entry order of pin Nos. and handling of tester leads
Connect positive (+) lead and negative (-) lead of tester as
explained below for troubleshooting, unless otherwise
specified.
q Connect positive (+) lead to pin No. or wiring harness
4
entered on front side.
q Connect negative (-) lead to pin No. or wiring harness
entered on rear side.
12V140E-3 Series
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40 Troubleshooting
Related circuit diagram
This drawing is a part of the electric circuit diagram related

to troubleshooting.
q Connector No.: Indicates (Model - Number of pins) and
(Color).
q "Connector No. and pin No." from each branching/merging point: Shows the ends of branch or source of merging
within the parts of the same wiring harness.
q Arrow(io): Roughly shows the location on the machine.
12V140E-3 Series
40 Troubleshooting
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Connection table for connector pin numbers

(Rev. 2009. 04)
a The terms of male and female refer to the pins, while the terms of male housing and female housing refer
to the mating portion of the housing.
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T- branch box and T- branch adapter table

(Rev. 2009. 03)
799-601-2600
799-601-3100
799-601-3200
799-601-3380
799-601-3410
799-601-3420
799-601-3430
799-601-3440
799-601-3450
799-601-3460
799-601-3510
799-601-3520
799-601-3530
799-601-2910
799-601-3470
799-601-2710
799-601-2720
799-601-2730
799-601-2740
799-601-2950
799-601-2750
799-601-2760
799-601-2770
799-601-2780
T-box(for ECONO)
T-box(for MS)
T-box(for MS)
Plate for MS (14-pin)
Adapter for BENDIX (MS)
Case
Adapter for MIC
Adapter for MIC
Adapter for MIC
Adapter for MIC
Adapter for MIC
Adapter for ECONO
Adapter for ECONO
Adapter for ECONO
Adapter for ECONO
24
24
17
17
5
10
5
17
19
14
MS-24P
MS-24P
MS-17P
MS-17P
MS-5P
MS-10P
MS-5P
MS-17P
MS-19P
MS-14P
5
13
17
21
9
2
3
4
8
MIC-5P
MIC-13P
MIC-17P
MIC-21P
MIC-9P
ECONO2P
ECONO3P
ECONO4P
ECONO8P
ECONO12
P
DLI-8P
DLI-12P
DLI-16P
ECONO12
P
12
799-601-2810 Adapter for DLI

8
12
16
799-601-2840 Extension cable (ECONO type)
12
Case
T-box(for DRC 60, ECONO)
Case
Adapter for X (T-adapter)
Adapter for X
Adapter for X
Adapter for X
Adapter for SWP
Adapter for SWP
Adapter for SWP
Adapter for SWP
Adapter for SWP
Adapter for M (T-adapter)
Adapter for M
Adapter for M
Adapter for M
Adapter for M
Adapter for M
12V140E-3 Series
q
q
q
q
q
q
q q
q q
q
q
q
q
q
q
q
q
q
q
q q
q q
q q q
X2P
X3P
X4P
SW6P
SW8P
SW12P
SW14P
SW16P
M2P
M3P
M4P
M6P
M8P
Out of kit
799-601-4201
799-601-9300
799-601-9200
799-601-4101
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q q
q q
q q
q q
q q
60
1
2
3
4
6
8
12
14
16
1
2
3
4
6
8
799-601-9100
799-601-9000
799-601-8000
q q
799-601-7500
799-601-7400
799-601-7100
799-601-7000
799-601-2800
21
37
37
799-601-2790 Adapter for ECONO
799-601-2850
799-601-4350
799-601-4360
799-601-7010
799-601-7020
799-601-7030
799-601-7040
799-601-7050
799-601-7060
799-601-7310
799-601-7070
799-601-7320
799-601-7080
799-601-7090
799-601-7110
799-601-7120
799-601-7130
799-601-7340
Identificati
on symbol
799-601-2700
Part name
T-adapter kit
799-601-2500
Part No.
Number of pins
a The vertical column indicates a part number of T-branch box or T-branch adapter while the horizontal column indicates a part number of harness checker assembly.
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
45
SEN00315-01
799-601-7140
799-601-7150
799-601-7160
799-601-7170
799-601-7330
799-601-7350
799-601-7180
799-601-7190
799-601-7210
799-601-7220
799-601-7230
799-601-7240
799-601-7270
799-601-7510
799-601-7520
799-601-7530
799-601-7540
799-601-7550
799-601-7360
799-601-7370
799-601-7380
799-601-9010
799-601-9020
799-601-9030
799-601-9040
799-601-9050
799-601-9060
799-601-9070
799-601-9080
799-601-9090
799-601-9110
799-601-9120
799-601-9130
799-601-9140
799-601-9210
799-601-9220
799-601-9230
799-601-9240
799-601-9250
799-601-9260
799-601-9270
799-601-9280
799-601-9290
799-601-9310
799-601-9320
799-601-9330
799-601-9340
799-601-9350
799-601-9360
799-601-9410*
Adapter for S
Adapter for S (White)
Adapter for S (Blue)
Adapter for S (Blue)
Adapter for AMP040
Adapter for AMP040
Adapter for AMP040
Adapter for AMP040
Short connector for X
Case
Case
Adapter for 070
Adapter for 070
Adapter for 070
Adapter for 070
Adapter for 070
Adapterfor relay
Adapterfor relay
Adapter for JFC
Adapter for DTM
Adapter for DT
Adapter for DT
Adapter for DT
Adapter for DT
Adapter for DT (Gray)
Adapter for DT (Black)
Adapter for DT (Green)
Adapter for DT (Brown)
Adapter for DT (Gray)
Adapter for DT (Black)
Adapter for DT (Green)
Adapter for DT (Brown)
Adapter for HD30-18
Adapter for HD30-18
Adapter for HD30-18
Adapter for HD30-18
Adapter for HD30-24
Adapter for HD30-24
Adapter for HD30-24
Adapter for HD30-24
Adapter for HD30-24
Plate for HD30 (24-pin)
T-box (for ECONO)
Case
Case
Adapter for DRC
Adapter for DRC
Socket for engine (CRI-T2)
Adapter for engine (CRI-T2)
799-601-9420 Adapter for engine (CRI-T3) PFUEL
Oil pressure sensor
799-601-9430*
Socket for engine (CRI-T3) PCV
46
24
q
q
q q q
q q q
q q q
q q
q
q
q
Out of kit
799-601-4201
799-601-4101
799-601-9300
799-601-9200
799-601-9100
q
q
799-601-9000
799-601-8000
q
q
q
q
799-601-7500
q
q
q
q
799-601-7400
07-10
07-12
07-14
07-18
07-20
REL-5P
REL-6P
DTM2
DT2
DT3
DT4
DT6
DT8GR
DT8B
DT8G
DT8BR
DT12GR
DT12B
DT12G
DT12BR
D18-8
D18-14
D18-20
D18-21
D24-9
D24-16
D24-21
D24-23
D24-31
q
q
q
q
799-601-7100
10
12
14
18
20
5
6
2
2
2
3
4
6
8
8
8
8
12
12
12
12
8
14
20
21
9
16
21
23
31
799-601-7000
S8P
S10P
S12P
S16P
S16PW
S12PW
A8P
A12P
A16P
A20P
799-601-2800
8
10
12
16
16
12
8
12
16
20
2
799-601-2700
Identificati
on symbol
799-601-2500
Part name
T-adapter kit
Number of pins
Part No.
40 Troubleshooting
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q q
q q
q
q
q
q
40
24
2
DRC-40
DRC-24
G
A3
q q
q q
12V140E-3 Series
SEN00315-01
40 Troubleshooting
799-601-9440* Socket for engine (CRI-T2)

795-799-5520* Socket for engine (HPI-T2)
Socket for engine (HPI-T2)
795-799-5530* Socket for engine (CRI-T3)
Temperature sensor
Socket for engine (HPI-T2)
795-799-5540*
Socket for engine (CRI-T3) TIM
795-799-5460 Cable for engine (HPI-T2)
799-601-4110 Adapter for engine (140-T3) PIM
799-601-4130 Adapter for engine (CRI-T3) NE, CAM
799-601-4140
Atomosphere pressure
799-601-4150 Adapter for engine (CRI-T3) POIL
799-601-4160
Oil pressure switch
799-601-4180 Adapter for engine (CRI-T3) PEVA
799-601-4190*
Common rail pressure
799-601-4230*
Air intake pressure/temperature
799-601-4240* Socket for engine (CRI-T3) PAMB
799-601-4250* Socket for engine (CRI-T3) PIM
799-601-4330* Socket for engine (CRI-T3) G
799-601-4340*
Pump actuator
Socket for engine (CRI-T3)(95)
799-601-4380*
Air intake pressure/temperature
799-601-4260 Adapter for controller (ENG)
799-601-4390* Socket for controller (95 ENG)
799-601-4280* Box for controller (PUMP)
799-601-9720 Adapter for controller (HST)
799-601-9890 Multi-adapter for DT2 4 and DTM2
q q
FCIB
q q
4160
q q
4180
q q
1,2,3L
q q
1,2,3,4C
q q
3
3
3
1,2,3A
1,2,3B
1,2,3,G
q q
q q
q q
2,PA
q q
1,2,3,4T
4
DTP4
50
DRC50
60
DRC60
60
121
16 HST16A
16 HST16B
26 HST26A
2,
3,
Out of kit
FCIG
799-601-4201
799-601-4101
q q
q q
799-601-9300
ITT3N
FCIN
799-601-9200
3
3
3
4
3
799-601-9100
q q
799-601-9000
799-601-8000
799-601-7500
q q
799-601-7400
799-601-7100
799-601-7000
1,2,3
S
799-601-2800
3
2
799-601-2700
Identificati
on symbol
799-601-2500
Part name
Number of pins
Part No.
T-adapter kit
q
q
q
q
q
q
q q
q
q
q
q
q
q
q
q
* Shows not T-adapter but socket.
12V140E-3 Series
47
SEN00315-01
40 Troubleshooting

2009 KOMATSU
All Rights Reserved
48
SEN00316-01
ENGINE
1SHOP MANUAL
12V140E-3 Series
40 Troubleshooting
Troubleshooting of mechanical system

(S-mode)
Method of using troubleshooting charts .......................................................................................................... 3
S-1 Starting performance is poor .................................................................................................................... 6
S-2 Engine does not start ............................................................................................................................... 7
S-3 Engine does not pick up smoothly.......................................................................................................... 10
S-4 Engine stops during operations ...............................................................................................................11
S-5 Engine does not rotate smoothly ............................................................................................................ 12
S-6 Engine lacks output (or lacks power) ..................................................................................................... 13
S-7 Exhaust smoke is black (incomplete combustion).................................................................................. 15
S-8 Oil consumption is excessive (or exhaust smoke is blue) ...................................................................... 16
S-9 Oil becomes contaminated quickly ......................................................................................................... 17
S-10 Fuel consumption is excessive............................................................................................................. 18
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) ................................................... 19
S-12 Oil pressure drops ................................................................................................................................ 20
S-13 Oil level rises (Entry of coolant or fuel)................................................................................................. 21
12V140E-3 Series
SEN00316-01
40 Troubleshooting
S-14 Coolant temperature becomes too high (overheating) ......................................................................... 22

S-15 Abnormal noise is made ....................................................................................................................... 23
S-16 Vibration is excessive ........................................................................................................................... 24
12V140E-3 Series
40 Troubleshooting
Method of using troubleshooting charts
SEN00316-01
The troubleshooting chart consists of the questions, check items, causes, and troubleshooting blocks.
The questions and check items are used to pinpoint
high probability causes by simple inspection or
from phenomena without using troubleshooting
tools.
Next, troubleshooting tools or direct inspection are
applied to check the narrowed causes in order from
the most probable one to make final confirmation
according to the troubleshooting procedure.
[Questions]:
Items to be drawn from the user or operator.
They correspond to A and B in the chart on the
right.
The items in A are basic ones.
The items in B can be drawn from the user or
operator, depending on their level.
[Check items]:
Simple check items used by the serviceman to
narrow down the causes.
They corresponds to C in the chart on the right.
[Causes]:
Items to be narrowed from the questions and
check items.
The serviceman narrows down the probable
causes from A, B, and C.
[Troubleshooting]:
Items to finally verify whether the narrowed
down causes are undoubtedly the real causes
using the troubleshooting tools and direct
inspections.
Items listed in the [Questions] and [Check items] and related to the [Causes] are marked with E, Q, or w.
E: Causes to be referred to for questions and check items
Q: Causes related to questions and check items
w: Causes highly probable among ones marked with Q
a When narrowing the "auses", apply the items marked with w before those marked with Q.
When narrowing the causes, do not apply the items marked with E. (If no items have other marks and
the causes cannot be narrowed, however, you may apply them.)
12V140E-3 Series
SEN00316-01
40 Troubleshooting
<Example of troubleshooting> Exhaust smoke is black

Let us assume that [Clogged air cleaner element] is taken to be the cause of black exhaust gas. Three symptoms have causal relationship with this problem: [Color of exhaust gas gradually became black], [Power was
lost gradually], and [Air cleaner clogging caution lamp is flashing].
12V140E-3 Series
40 Troubleshooting
SEN00316-01
If we look for the linkage of these three phenomena to possible causes, we find that they have causal relationship with five causes.
Let us explain here the method of using this causal relationship to pinpoint the most probable cause.
12V140E-3 Series
SEN00316-01
40 Troubleshooting
S-1 Starting performance is poor 1
Q w w
Q Q
Defective or deteriorated battery
Defective alternator (generator section)
Defective alternator (regulator section)
Defective intake air heater system
Defective injector
Stuck or seized supply pump plunger
Clogged feed pump gauze filter
Clogged fuel filter element
E E
E
w
Q Q Q Q
w
w w Q Q
w
w
w w
w
w
w
E w Q Q
w
w w
Q
w
w
Q Q Q Q
Q
w
Q
Q Q
q
q
q
q
q
q
q
q
Replace
Replace
Replace
Replace
Replace
Replace
Clean
Clean
q
Clean
Replace
Correct
Inspect air cleaner directly

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

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

q
Defective electrical system
q
Insufficient supply of fuel
q
Insufficient intake of air
q
Improper selection of fuel (particularly during winter)
q
Coolant in exhaust pipe
a The common rail fuel injection system (CRI) recognizes
the fuel injection timing electrically. Accordingly, even if
the starting operation is carried out, the engine may not
start until the crankshaft revolves 2 turns at maximum.
This phenomenon does not indicate a trouble, however.
*1: Code [559/CA559], [559/CB559] and code [2249/CA2249], [2249/CB2249] in E-mode
12V140E-3 Series
40 Troubleshooting
SEN00316-01
S-2 Engine does not start
Defective steering circuit wiring
Defective PTO or hydraulic pump

Carry out troubleshooting on
installed machine
w
w
w
Q
Q
w
w
Q
w
w
Q
q
q
When specific gravity of electrolyte and voltage of battery are measured, they are low
There is not voltage (20 - 30 V) between battery relay terminal B
and terminal E
When terminal B and terminal C of starting switch are connected,
engine starts
When terminal B and terminal C at safety relay outlet are connected, engine starts
q
q
q
When terminal B and terminal C at safety relay outlet are connected, engine does not start
Replace
Replace
Replace
Correct
Replace
q
Replace
Remedy
12V140E-3 Series
Defective starting motor (motor section)
Defective starting motor (safety relay section)
Defective starting switch
Defective battery relay
Inspect flywheel ring gear directly

Troubleshooting
Defective connection of battery terminal
E E
Battery electrolyte is low

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

connect cord, turn the
switch ON and carry out
troubleshooting

installed machine

Degree of machine opera- Operated for long period
tion
Condition of horn when
Horn does not sound
starting switch is turned
Horn volume is low
ON
Broken flywheel ring gear
Causes
Replace
Check items
Questions
a) Engine does not turn

General causes why engine does not turn
q
Engine seized inside
o See "S-4 Engine stops during operations".
q
Water hammer caused by coolant which entered cylinder
q
Defective electrical system
q
Problem in drive devices on applicable machine side
o Troubleshoot the applicable machine side
SEN00316-01
40 Troubleshooting
b) Engine turns but no exhaust smoke comes out

General causes why engine turns but no exhaust smoke
comes out
q
Fuel is not being supplied
q
Supply of fuel is extremely small
q
Improper selection of fuel (particularly in winter)
Defective injector
Defective operation of flow damper
Defective operation of overflow valve (Does not close)
Wrong connection of supply pump PCV
Defective supply pump PCV
Broken supply pump shaft spline
Seized, abnormally worn feed pump
E
w Q w w w
w E
Q Q
Q Q
E E
Q
Q
w Q
w w w w

Inspect fuel filter directly
Inspect feed pump directly
Carry out troubleshooting according to No-pressure feed by supply pump error
(*1) in E-mode
Carry out troubleshooting according to Abnormality in PCV1 (*2) or Abnormality
in PCV2 (*3) in E-mode
Inspect overflow valve directly
Engine can be started in reduced cylinder mode
q
q
q
q q
q
q
q
Replace
Replace
Replace
Correct
Replace
Replace
Replace
Replace
Clean
Replace
Correct
Correct
q q
Add
Remedy
Clogged fuel filter element
Leaking, clogging and entry of air to fuel piping
Insufficient fuel in tank

Degree of
E E
machine operation
Exhaust smoke suddenly stopped coming out (when starting again)
w
w
Manual
When fuel tank is inspected, it is found to be empty
w
Q w
Rust and water are found when fuel tank is drained
Q
When fuel filter is removed, there is no fuel in it
w Q
w
w
w Q
If air bleeding plug of fuel filter is removed, fuel does not flow
While engine is
Q Q
Q
out
cranked with
starting motor,
If spill hose from injector is disconnected, little fuel spills
Q
Replace
Troubleshooting
Check items
Questions
Use of improper fuel
Causes

12V140E-3 Series
40 Troubleshooting
SEN00316-01
c) Exhaust smoke comes out but engine does not start

(fuel is being injected)
General causes why exhaust smoke comes out but engine
does not start
q
Lack of rotating force due to defective electrical system
q
q
q
Improper selection of fuel
Defective intake air heater system
Defective coolant temperature sensor and/or wiring harness
Clogged injector and/or defective spray
Stuck and/or seized supply pump plunger
Clogged fuel filter and/or strainer
Leaking, clogging of fuel system, and entry of air
Worn piston ring and/or cylinder liner
Worn dynamic valve system (Valve, rocker lever, etc.)

Degree of machine
E
E E
E
operation
Suddenly failed to start
w
w
Q
Q
Q
Q Q
w
w w
Manual
w
When engine is preheated or when temperature is low, preheating monitor does not
w
indicate normally (if monitor is installed)
w
Q
w w
When fuel filter is removed, there is no fuel in it
w
w
w Q Q
Starting motor cranks engine slowly
w
When engine is cranked, abnormal sound is generated around cylinder head
w
Fuel does not flow out if air bleeding plug of fuel filter is
While engine is
Q
Q w w
removed
cranked with starting motor,
If spill hose from injector is disconnected, little fuel spills
Q Q
w
w
q
q
q
q
q
q
q
Replace
Replace
Replace
Clean
Replace
Clean
Clean
Correct
Clean
q
Replace
Replace
Remedy
Replace

q
Inspect dynamic valve system directly
q
q
Inspect fuel filter, strainer directly
Carry out troubleshooting according to No-pressure feed by supply pump error (*1)
in E-mode
When injector unit is tested, spray condition is bad
When specific gravity of electrolyte and voltage of battery are measured, they are low
Coolant temperature gauge does not indicate normally (if coolant temperature
gauge is installed)
When starting switch is turned to HEAT, intake air heater mount does not become
warm
Clean
Troubleshooting
Check items
Questions
Causes
12V140E-3 Series
SEN00316-01
40 Troubleshooting
S-3 Engine does not pick up smoothly
General causes why engine does not pick up smoothly

q
q
q
Defective spray condition of fuel
q
q
Controller is controlling in derate mode
(limiting injection rate (output) because of an error in electrical system)
E
w
Clogged injector and/or defective spray
Defective operation of flow damper (Maximum leakage from injector)
E E
Q Q
Q
w
w w w
w w
w
w
w
w
w w
w
w Q Q
Q
w
w Q
w
w
Q
Q
w w
Q w
q
q
q
Correct
Replace
Replace
Clean
Clean
q q
Clean
Replace
Replace
Adjusting
Replace

q
q
q
Inspect valve clearance directly
q
When turbocharger is rotated by hand, it is found to be heavy
q
Carry out troubleshooting according to No-pressure feed by supply pump error (*1) in
E-mode
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not
change on some cylinders
Remedy
Leaking, clogging of or entry of air to fuel piping
Seized turbocharger or interference of turbocharger
Improper valve clearance
E E
Correct

Degree of
machine operation Operated for long period
Engine pick-up suddenly became worse
Replacement of filters not carried out according to Operation and Maintenance Manual
Blue under light load
Color of exhaust
gas is
Black
When engine is cranked, interference sound is emitted from around turbocharger
High idle speed under no load is normal, but speed suddenly drops when load is applied
Clean
Troubleshooting
Check items
Questions
Causes
10
12V140E-3 Series
40 Troubleshooting
SEN00316-01
S-4 Engine stops during operations
General causes why engine stops during operations

q
Seized parts inside engine
q
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There is overheating
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Problem in drive devices on applicable machine side
o Troubleshoot the applicable machine side
Problem in drive devices on installed machine side
Broken auxiliary equipment (pump, compressor, etc.)
Broken supply pump shaft spline
Broken or seized feed pump
Leaking and/or clogged fuel piping
Broken or seized gear train
Broken or seized crankshaft bearing
Broken or seized piston and/or connecting rod
Broken dynamic valve system (valve, rocker arm, etc.)
Causes
EE
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Condition when engine Engine overheated and stopped

stopped
Engine stopped slowly
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Manual
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Engine stopped after hunting
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Fuel level monitor indicates low level (if monitor is installed)

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Check items
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Metal particles are found when oil pan is drained

Does not turn at all
When engine is
cranked by hand
Turns in opposite direction
Moves by amount of gear backlash
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Supply pump shaft does not turn
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Replace
Replace
Replace
Replace
Clean
Clean
Correct
Clean
Add
Replace
q
Replace
Remedy
Replace

Inspect piston and connecting rod directly
Inspect crankshaft bearing directly
Inspect gear train directly
Inspect feed pump directly
Carry out troubleshooting according to No-pressure feed by supply pump
error (*1) in E-mode
Engine rotates when pump auxiliary equipment (pump, compressor, etc.) is
removed
Replace
Troubleshooting
Engine turns, but stops when load is applied to machine
Questions
Abnormal noise was heard and engine stopped sudw w w w

denly

installed machine
Degree of machine
operation
12V140E-3 Series
11
SEN00316-01
40 Troubleshooting
S-5 Engine does not rotate smoothly
General causes why engine does not rotate smoothly

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Air in fuel system
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Defective speed sensor (Error at degree that it is not indicated)
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Defective G (Bkup) speed sensor or wiring harness
Defective Ne speed sensor and/or wiring harness
Clogged injector and/or defective spray (dirt in injector)
Defective operation of flow damper (Maximum leakage from injector)
Clogged fuel filter or strainer
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Carry out troubleshooting according to Abnormality in engine Ne speed sensor (*1) in Emode
Carry out troubleshooting according to Abnormality in engine Bkup speed sensor (*2) in Emode
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Correct
Correct
Correct
Replace
Replace
Replace
Clean
Add
Remedy
Leaking or clogging or entry of air to fuel piping
E E
Replace

Degree of machine
operation
Occurs at a certain speed range
Occurs at low idle
Condition of hunting
Occurs even when speed is raised
Occurs on slopes
Correct
Troubleshooting
Check items
Questions
Low setting of low idle speed
Causes
*1: Code [689/CA689] and [689/CB689] in E-mode

*2: Code [778/CA778] and [778/CB778] in E-mode
12
12V140E-3 Series
40 Troubleshooting
SEN00316-01
S-6 Engine lacks output (or lacks power)

General causes why engine lacks output
q
q
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q
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Overheat
o See "S-14 Coolant temperature becomes too
high (Overheating)"
q
(limiting injection rate (output) because of an
error in electrical system)
1
Defective fuel temperature sensor and/or wiring harness
Defective boost pressure sensor and/or wiring harness
Defective drive of injector (signal and/or solenoid)
Defective installation of boost pressure sensor (air leakage)
Clogged injector or defective spray (dirt in injector)
Leaking or clogged fuel piping
Air leakage from air intake piping
Causes
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12V140E-3 Series
E E
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High idle speed is too high

High idle speed under no load is normal, but speed suddenly drops when
load is applied
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Replace
Replace
Correct
Replace
Replace
Replace
Clean
Replace
Correct
Clean
Replace
Adjusting
Replace
q
Replace
Remedy


Inspect air intake piping directly
When boost pressure is measured, it is found to be low
Carry out troubleshooting according to No-pressure feed by supply
pump error (*1) in E-mode
When a cylinder is cut out for reduced cylinder mode operation, engine
speed does not change on some cylinders
Inspect boost pressure sensor mount directly
Carry out troubleshooting according to Abnormality in charge pressure
sensor (*2) in E-mode
Carry out troubleshooting according to Abnormality in fuel temperature
sensor (*3) in E-mode
E
Q
Correct
Suddenly
Power was lost
Gradually
Output becomes insufficient after short stop of operation
Color of exhaust Black
gas
When exhaust manifold is touched immediately after starting engine,
temperature of some cylinders is low
Clean
Troubleshooting
Check items
Questions
Degree of machine
operation
13
SEN00316-01
40 Troubleshooting

*2: Code [122/CA122] and code[123/CA123] in E-mode.
14
12V140E-3 Series
40 Troubleshooting
SEN00316-01
S-7 Exhaust smoke is black (incomplete combustion)
E
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Defective coolant temperature sensor or wiring harness
Improper fuel injection pressure
Improper injection timing
Clogged fuel spill piping (on cylinder head side)
Abnormally worn injector
Clogged or seized injector
E
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Replace
Adjusting
Adjusting
Correct
Replace
Replace
Replace
Replace
Correct
Adjusting
Replace
Replace

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When turbocharger is rotated by hand, it is fount to be heavy
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q
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When muffler is removed, exhaust sound improves
Carry out troubleshooting according to No-pressure feed by supply pump error
(*1) in E-mode
When a cylinder is cut out for reduced cylinder mode operation, engine speed
does not change on some cylinder
Inspect fuel spill piping (on cylinder head side) directly
Carry out troubleshooting according to Abnormality in coolant temperature sensor error (*2) in E-mode
Remedy
Crushed or clogged muffler
Leakage of air between turbocharger and cylinder head
Replace

Degree of
Suddenly became black
Color of exhaust Gradually became black
gas
Oil replenished more frequently
Suddenly
Power was lost
Gradually
Muffler is crushed
Air leaks between turbocharger and cylinder head, and clamp is loosened
Engine is operated in low-temperature mode at normal temperature
When exhaust manifold is touched immediately after starting engine, temperature
of some cylinders is low
Torque converter stall speed or pump relief speed is high
(Fuel is injected excessively)
Exhaust noise is abnormal
If spill hose from injector is disconnected, abnormally much fuel spills
Causes
Clean
Troubleshooting
Check items
Questions
General causes why exhaust smoke is black

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Excessive injection of fuel
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Overheat
o See "S-14 Coolant temperature becomes too high
(Overheating)"
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(limiting injection rate (output) because of an error in
electrical system)

*2: Code [144/CA144] and code[145/CA145] in E-mode
12V140E-3 Series
15
SEN00316-01
40 Troubleshooting
S-8 Oil consumption is excessive (or exhaust smoke is blue)
16
Oil leakage from oil pan, cylinder head, etc.
Oil leakage from oil drain plug
Oil leakage from oil piping
Oil leakage from oil filter
Oil leakage from oil cooler
Broken oil cooler
Broken piston ring
Clogged breather or breather hose
Turbocharger 1
Worn seal at blower end
Worn seal at turbocharger end
Worn or damaged rear oil seal
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Correct
Correct
Correct
Correct
Replace
Replace
Correct
Replace
Replace
Clean
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Replace
Remedy
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Replace
When intake manifold is removed, dust is found inside

When intake manifold is removed, inside is found contaminated abnormally
Excessive play of turbocharger shaft
Check breather and breather hose directly
Inspect rear oil seal directly
Pressure-tightness test of oil cooler shows there is leakage
There is external leakage of oil from engine
E E E
Replace

Degree of machine operOperated for long period
ation
Oil consumption suddenly increased
Oil becomes contaminated quickly
Outside of engine is contaminated with oil
There are loose piping clamps in intake system
Inside of turbocharger intake outlet pipe is contaminated with oil
Inside of turbocharger exhaust outlet pipe is contaminated with oil
There is oil in coolant
Oil level in clutch chamber or damper chamber on the installed machine side is
increasing
Exhaust smoke is blue under light load
Excessive
Amount of blow-by gas
None
Worn or damaged valve (stem, guide, seal)
Dust sucked in from intake system
Causes
Correct
Troubleshooting
Check items
Questions
General causes why oil consumption is excessive

q
Abnormal combustion of oil
q
Long-time operation of engine at low idle or high idle
(Do not run engine continuously at idle without load for
more than 20 minutes)
q
External leakage of oil
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Wear of parts in lubrication system
12V140E-3 Series
40 Troubleshooting
SEN00316-01
S-9 Oil becomes contaminated quickly
Exhaust smoke is bad
Clogged turbocharger lubrication drain tube
Defective oil filter safety valve
Clogged oil filter
Clogged oil cooler
Clogged breather and/or breather hose
Worn valve and/or valve guide
Defective seal at turbocharger turbine end
Causes

Degree of machine operation
E E E
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Even when engine oil temperature rises, oil filter clogging monitor indicates clogging (if monitor is
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installed)
Metal particles are found when oil filter is drained
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Inside of exhaust pipe is contaminated with oil
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Engine oil temperature rises quickly
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Color of exhaust gas
Black
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Excessive
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Amount of blow-by gas
None
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Excessive play of turbocharger shaft

Inspect breather and breather hose directly
Inspect oil cooler directly
Inspect oil filter directly
Spring of oil filter safety valve is hitched or broken
Inspect turbocharger lubrication drain tube directly
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Clean
Replace
Replace
Clean
Clean
Replace
Replace
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Remedy
12V140E-3 Series
See S-7
Replace
Troubleshooting
Check items
Questions
General causes why oil becomes contaminated

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Entry of exhaust gas into oil due to internal wear
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Clogging of lubrication passage
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Use of improper oil
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Operation under excessive load
17
SEN00316-01
40 Troubleshooting
S-10 Fuel consumption is excessive
General causes why fuel consumption is excessive

q
Leakage of fuel
q
Defective condition of fuel injection (fuel pressure, injection timing)
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Excessive injection of fuel
Defective coolant temperature sensor or wiring harness
Defective operation of injector
Defective spray by injector
Defective supply pump plunger
Defective common rail fuel pressure
E
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Remove and inspect head cover directly

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

Degree of
machine operation
More than other machines of same model
Condition of fuel
Gradually increased
consumption
Suddenly increased
There is external leakage of fuel from engine
Combustion is irregular
Engine oil level rises and oil smells of diesel fuel
When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low
Low idle speed is high
Torque converter stall speed or hydraulic pump relief speed is high
Color of exhaust Black
gas
White
Correct
Troubleshooting
Check items
Questions
Fuel leakage inside head cover
Causes

18
12V140E-3 Series
40 Troubleshooting
SEN00316-01
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)1
General causes why oil is mixed in coolant
q
Internal leakage in lubrication system
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Internal leakage in cooling system
Broken hydraulic oil cooler or power train oil cooler on installed machine side
Broken oil cooler core and/or O-ring
Insufficient protrusion of cylinder liner
Damaged cylinder liner O-ring and/or hole caused by pitting
Cracks inside cylinder block
Broken cylinder head and/or head gasket
Causes
Degree of machine
operation
Oil level
Suddenly increased
Q
Q
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Oil level has risen and oil is milky
There are excessive air bubbles in radiator, coolant spurts back
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Hydraulic oil or power train oil on installed machine side is milky
When hydraulic oil or power train oil is drained, water is found
q q
Inspect cylinder block and liner directly
Inspect cylinder liner directly
12V140E-3 Series
Replace
Replace
Replace
Remedy
Replace
Pressure-tightness test of cylinder head shows there is leakage
Carry out troubleshooting

on installed machine
Check items
Q Q
Gradually increased
Hard water is being used as coolant
Troubleshooting
Replace
Questions
19
SEN00316-01
General causes why oil pressure drops

q
Leakage, clogging, and/or wear of lubrication system
q
Defective oil pressure control
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Selection of oil by the temperature etc. specified in the Operation and Maintenance Manual is not observed
q
Deterioration of oil due to overheating
Defective oil level sensor and/or wiring harness
Defective oil pressure sensor and/or defective wiring harness
Leaking, crushed, clogged hydraulic piping
Clogged oil filter
Defective oil pump
Clogged and/or broken pipe in oil pan
Clogged strainer in oil pan
Defective oil pump relief valve
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Metal particles are found in oil filter

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Inspect oil pan strainer and pipe directly
Oil pump rotation is heavy, there is play in oil pump
Valve and spring of oil pump relief valve are fatigued and damaged
Inspect oil filter directly
Carry out troubleshooting according to Abnormality in oil pressure sensor (*1) in E-mode
If oil level sensor is replaced, oil level monitor indicates normally
See S-13
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Replace
Replace
Correct
Clean
Adjusting
Replace
Add
Remedy
Coolant and fuel mixing in oil
Lack of oil in oil pan
Clean

Degree of
Oil pressure monitor indicates low oil pressure (if monitor is installed)
Non-specified oil is being used
Replacement of filters not carried according to Operation and Maintenance Manual
Indicates pressure drop at low idling time
Oil pressure
Indicates pressure drop at low and high idling times
monitor
Indicates pressure drop on slopes
(if installed)
Indicates pressure drop occasionally
Oil level monitor indicates oil level drop (if monitor is installed)
Oil level in oil pan is low
External hydraulic piping is leaking or crushed
Oil is milky or smells of diesel oil
Clean
Troubleshooting
Check items
Questions
Worn journal of bearing
Causes
Clean
S-12 Oil pressure drops
40 Troubleshooting
20
12V140E-3 Series
40 Troubleshooting
SEN00316-01
S-13 Oil level rises (Entry of coolant or fuel)
General causes why oil level rises

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

Degree of
machine operation
Fuel consumption increasing
Coolant replenished more frequently
There is oil mixed in coolant
Oil smells of diesel fuel
Oil is milky
When engine is started, drops of water come from muffler
When radiator cap is removed and engine is run at low idle, an abnormal number of bubbles
appears, or coolant spurts back
Exhaust smoke is white
Water pump drain hole (breather hole) is clogged
When water pump drain hole (breather hole) is cleaned, coolant comes out
Oil level in clutch or damper chamber of installed machine is low
Oil level in hydraulic tank of installed machine is low
Defective seal of auxiliary equipment (pump, compressor)
w
Q
Q
Defects in supply pump
Defective thermostat seat
Clogged water pump drain hole (breather hole) and/or defective seal
Worn or damaged rear oil seal
Cracks inside cylinder block
Fuel leakage inside head cover
Broken oil cooler core and/or O-ring
E
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Q Q
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Q
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Remove and inspect head cover directly
Inspect cylinder block and/or liner directly
Inspect rear oil seal directly
Remove and inspect water pump directly
Remove and inspect thermostat cover directly
Remove and inspect supply pump directly
Inspect seal of auxiliary equipment directly
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Replace
Replace
Correct
Replace
Replace
Correct
Replace
Replace
Correct
q
Remedy
12V140E-3 Series
E E
Replace
Troubleshooting
Check items
Questions
Causes
21
SEN00316-01
40 Troubleshooting
S-14 Coolant temperature becomes too high (overheating)

General causes why coolant temperature becomes too high
q
Lack of cooling air (deformation, and/or damages of fan)
q
Drop in heat dissipation efficiency
q
Problem in coolant circulation system
q
Rise in oil temperature in power train on applicable
machine side
o Trouble shoot on the applicable machine side
Rise in power train oil temperature on applicable machine side
Defective coolant temperature gauge
Slipping fan belt and/or worn fan pulley
Defective radiator cap (pressure valve)
Clogged radiator core
Clogged or crushed radiator fins
Defective operation of thermostat
Broken water pump
Lack of coolant
Clogged or broken oil cooler
E E
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Replace
Correct
Replace
Correct
Correct
Replace
Replace
Add
Carry out troubleshooting

on installed machine
Replace

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

Degree of
machine operation
Sudden overheated
Condition for
Persistent overheating
Coolant tempera- Rises quickly
ture gauge
Does not go down from red range
(if installed)
Radiator coolant level monitor indicates drop of coolant level (if monitor is installed)
Engine oil level has risen and oil is milky
Fan belt tension is low
Milky oil is floating on coolant
There are excessive air bubbles in radiator and coolant spurts back
When light bulb is held behind radiator core, no light passes through
Radiator shroud, inside of underguard on applicable machine side are clogged with
dirt or mud
Coolant is leaking because of cracks in hose or loose clamps
Coolant flows out from radiator overflow hose
Fan belt whines under sudden acceleration
Power train oil temperature gauge enters red range faster than engine coolant temperature gauge (if oil temperature gauge and coolant temperature gauge are
installed) on the installed machine side
Replace
Troubleshooting
Check items
Questions
Causes
Remedy
22
12V140E-3 Series
40 Troubleshooting
SEN00316-01
S-15 Abnormal noise is made
12V140E-3 Series
Improper fuel injection timing (abnormality in coolant temperature sensor)
Dirt caught in injector
Clogged or seized injector
Deformed cooling fan and/or looseness or interference of fan belt
Removed or seized gear train bushing
Improper gear train backlash
Excessive wear of piston ring and/or cylinder liner
Defective inside of muffler (dividing board out of position)
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When turbocharger is rotated by hand, it is fount to be heavy

When muffler is removed, abnormal noise disappears
Inspect fan and fan belt directly
Abnormal noise is heard only when engine is started
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Correct
Correct
Replace
Correct
Replace
Replace
Replace
Replace
Replace
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Correct
Remedy
Broken dynamic valve system (valve and/or rocker lever)
Replace

Degree of
machine operation
Gradually increased
Condition of
abnormal noise
Suddenly increased
Air leaks between turbocharger and cylinder head
When engine is cranked, abnormal sound is generated around EGR gas piping
When engine is cranked, beat noise is emitted around muffler
Color of exhaust Blue under light load
gas
Black
Abnormal noise is loud when engine is accelerated
Interference or seizure of turbocharger
Leakage of air between turbocharger and cylinder head
Causes
Replace
Troubleshooting
Check items
Questions
General causes why abnormal noise is emitted

q
Abnormality due to defective parts
q
Abnormal combustion
q
Air leakage from air intake system
a Judge if the noise is an internal noise or an external noise
before starting troubleshooting.
a While the engine is not sufficiently warmed up, it is operated
in the low-temperature mode. Accordingly, the engine sound
rises slightly higher. This is no abnormality, however.
a When the engine is accelerated, the engine sound rises
slightly for approx. 3 seconds maximum. This is no abnormality, however.
23
SEN00316-01
40 Troubleshooting
S-16 Vibration is excessive

Degree of
Condition of vibra- Suddenly increased
tion
Gradually increased
Non-specified oil is being used
Oil pressure is low at low idle
Vibration occurs at mid-range speed
Vibration follows engine speed
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Exhaust smoke is black

Inspect main bearing and connecting rod bearing directly
Inspect camshaft bushing directly
Inspect engine mounting bolts and cushions directly
When alignment is checked, radial runout or facial runout is detected
Inspect front support spigot joint portion directly
Inspect output shaft or inside of damper directly
Broken output shaft and/or parts in damper on installed machine side
Worn front support spigot joint portion
Misalignment between engine and devices on installed machine side
Loose engine mounting bolts and/or broken cushions
Worn camshaft bushing
Improper gear train backlash
E
Q
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q
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Replace
Adjusting
Replace
Adjusting
Replace
Replace
Replace
q
Remedy
24
Worn main bearing and/or connecting rod bearing
Stuck dynamic valve system (valve, rocker lever, etc.)
Causes
Replace
Troubleshooting
Check items
Questions
General causes why vibration occurs

q
Defective parts (abnormal wear, breakage, etc.)
q
Misalignment between installed machine
q
Abnormal combustion
a If abnormal noise vibration occur, carry out troubleshooting for "S-15
Abnormal noise is emitted", too.
12V140E-3 Series
40 Troubleshooting
12V140E-3 Series
SEN00316-01
25
SEN00316-01
40 Troubleshooting

2009 KOMATSU
All Rights Reserved
26
12V140E-3 Series
SEN00317-03
12V140E-3 Series
SEN00317-03
ENGINE
Shop Manual
12V140E-3 Series

40 Troubleshooting
Troubleshooting of electrical system
(E-mode), Part 1
E-1 Code [111/CA111] ECM Critical Internal Failure (LH bank) ..................................................................
E-2 Code [111/CB111] ECM Critical Internal Failure (RH bank)..................................................................
E-3 Code [115/CA115] Eng. Ne and G (Bkup) Speed Sensor Error (LH bank)...........................................
E-4 Code [115/CB115] Eng. Ne and G (Bkup) Speed Sensor Error (RH bank) ..........................................
E-5 Code [122/CA122] Charge Air Press. Sensor High Error (LH bank only) ............................................ 10
E-6 Code [123/CA123] Charge Air Press. Sensor Low Error (LH bank only) ............................................. 12
E-7 Code [131/CA131] Throttle Sensor High Error (LH bank only) ............................................................ 14
E-8 Code [132/CA132] Throttle Sensor Low Error (LH bank only) ............................................................. 15
E-9 Code [135/CA135] Oil Press. Sensor High Error (LH bank only) ......................................................... 16
E-10 Code [141/CA141] Oil Press. Sensor Low Error (LH bank only) ........................................................ 18
E-11 Code [144/CA144] Coolant Temp. Sensor High Error (LH bank only)................................................ 20
12V140E-3 Series
SEN00317-03
40 Troubleshooting
E-12 Code [145/CA145] Coolant Temp. Sensor Low Error (LH bank only) ................................................ 22
E-13 Code [153/CA153] Charge Air Temp. Sensor High Error (LH bank only)........................................... 24
E-14 Code [154/CA154] Charge Air Temp. Sensor Low Error (LH bank only)............................................ 26
E-15 Code [187/CA187] Sensor Sup. 2 Volt. Low Error (LH bank)............................................................. 27
E-16 Code [187/CB187] Sensor Sup. 2 Volt. Low Error (RH bank) ............................................................ 27
E-17 Code [212/CA212] Eng. Oil Temp.Sensor High Error (LH bank only) ................................................ 28
E-18 Code [213/CA213] Eng. Oil Temp.Sensor Low Error (LH bank only) ................................................. 30
E-19 Code [221/CA221] Ambient Air Press. Sensor High Error (LH bank only) ......................................... 32
E-20 Code [222/CA222] Ambient Air Press. Sensor Low Error (LH bank only).......................................... 34
E-21 Code [227/CA227] Sensor Sup. 2 Volt. High Error (LH bank) ............................................................ 36
E-22 Code [227/CB227] Sensor Sup. 2 Volt. High Error (RH bank) ........................................................... 38
E-23 Code [234/CA234] Eng. Overspeed (LH bank only)........................................................................... 40
E-24 Code [238/CA238] Ne Speed Sensor Sup. Volt. Error (LH bank)....................................................... 42
E-25 Code [238/CB238] Ne Speed Sensor Sup. Volt. Error (RH bank) ...................................................... 44
E-26 Code [263/CA263] Fuel Temp. Sensor High Error (LH bank)............................................................. 46
E-27 Code [263/CB263] Fuel Temp. Sensor High Error (RH bank) ............................................................ 48
E-28 Code [265/CA265] Fuel Temp. Sensor Low Error (LH bank) ............................................................. 50
E-29 Code [265/CB265] Fuel Temp. Sensor Low Error (RH bank)............................................................. 50
E-30 Code [271/CA271] PCV1 Short Error (LH bank) ................................................................................ 52
E-31 Code [271/CB271] PCV1 Short Error (RH bank)................................................................................ 54
E-32 Code [272/CA272] PCV1 Open Error (LH bank) ................................................................................ 56
E-33 Code [272/CB272] PCV1 Open Error (RH bank) ............................................................................... 57
E-34 Code [273/CA273] PCV2 Short Error (LH bank) ................................................................................ 58
E-35 Code [273/CB273] PCV2 Short Error (RH bank)................................................................................ 60
E-36 Code [274/CA274] PCV2 Open Error (LH bank) ................................................................................ 62
E-37 Code [274/CB274] PCV2 Open Error (RH bank) ............................................................................... 63
E-38 Code [322/CA322] Injector #1 (L/B #1) System Open/Short Error (LH bank) .................................... 64
E-44 Code [342/CA342] Caribration Code Incompatibility (LH bank) ......................................................... 76
E-45 Code [342/CB342] Caribration Code Incompatibility (RH bank)......................................................... 76
E-46 Code [351/CA351] INJ. Drive Circuit Error (LH bank) ........................................................................ 78
E-47 Code [351/CB351] INJ. Drive Circuit Error (RH bank)........................................................................ 80
E-48 Code [352/CA352] Sensor Sup. 1 Volt. Low Error (LH bank)............................................................. 82
E-49 Code [352/CB352] Sensor Sup. 1 Volt. Low Error (RH bank) ............................................................ 82
E-50 Code [386/CA386] Sensor Sup. 1 Volt. High Error (LH bank) ............................................................ 84
E-51 Code [386/CB386] Sensor Sup. 1 Volt. High Error (RH bank) ........................................................... 86
E-52 Code [441/CA441] Battery Voltage Low Error (LH bank) ................................................................... 88
E-53 Code [441/CB441] Battery Voltage Low Error (RH bank)................................................................... 88
E-54 Code [442/CA442] Battery Voltage High Error (LH bank) .................................................................. 89
E-55 Code [442/CB442] Battery Voltage High Error (RH bank) .................................................................. 89
12V140E-3 Series
40 Troubleshooting
12V140E-3 Series
SEN00317-03
SEN00317-03
40 Troubleshooting
E-1 Code [111/CA111] ECM Critical Internal Failure (LH bank)

Error code
Failure code
111
CA111
Trouble Engine Controller Internal Failure (LH bank)

Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Abnormality occurred in controller.
None in particular.
Engine continues operation normally, but it may stop during operation or may not be able to start.
Different machine models may have different connector Nos.

Causes
Check fuse or circuit breaker on machine side directly for defect.

(If fuse is burnt or circuit breaker is turned OFF, circuit probably has
ground fault.)
a Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring harwithout turning starting switch ON.
ness
Wiring harness between PW L (female) (3),
ResisMax. 1
2 (Disconnection in wiring or (4) battery (+)
tance
defective contact in connecWiring harness between PW L (female) (1), Resistor)
Max. 1
(2) chassis ground
tance
Ground fault in wiring harwithout turning starting switch ON.
ness
3
Wiring harness between PW L(female) (3),
Resis(Short circuit with GND cirMin. 1 M
(4) battery (+)
tance
cuit)
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
4 Defective engine controller
PW L
Voltage
1 Defective fuse
Possible causes
and standard
value in normal
state
Between (3), (4) (1), (2)
20 30 V
12V140E-3 Series
40 Troubleshooting
SEN00317-03
Circuit diagram related to controller power supply
12V140E-3 Series
SEN00317-03
40 Troubleshooting
E-2 Code [111/CB111] ECM Critical Internal Failure (RH bank)

Error code
Failure code
111
CB111
Trouble
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Abnormality occurred in controller.
None in particular.

Causes
Possible causes
and standard
value in normal
state
Engine Controller Internal Failure (RH bank)
Check fuse or circuit breaker on machine side directly for possible

defect.
Defective fuse
(If fuse is burnt or circuit breaker is turned OFF, circuit probably
has ground fault.)
ness
Wiring harness between PW R (female) (3), ResisMax. 1
(Disconnection in wiring or (4) battery (+)
tance
defective contact in connecWiring harness between PW R (female) (1), Resistor)
Max. 1
(2) chassis ground
tance
ness
(Short circuit with GND cir- Wiring harness between PW R (female) (3), ResisMin. 1 M
(4) battery (+) and chassis ground
tance
cuit)
and carry out troubleshooting
Defective engine controller
PW R
Voltage
Between (3), (4) (1), (2)
20 30 V
12V140E-3 Series
40 Troubleshooting
SEN00317-03
12V140E-3 Series
SEN00317-03
40 Troubleshooting
E-3 Code [115/CA115] Eng. Ne and G (Bkup) Speed Sensor Error (LH
bank)
Error code
Failure code
115
CA115
Trouble Abnormality in engine Ne and G (Bkup) speed sensor (LH bank)

Contents of q Abnormality occurred in Ne speed sensor circuit and G (Bkup) speed sensor circuit simultaneously.
trouble
Action of
q Engine stop
controller
Phenomenon
q Engine cannot be started (engine has been stopped).
that appears on
q Engine stops (if engine has been running).
machine
Related
information
Causes
Possible causes
and standard
value in normal
state
Defective Ne speed sensor

system
Carry out troubleshooting for code [689/CA689].
Defective G (Bkup) speed

sensor system
Carry out troubleshooting for code [778/CA778].
Defective mount of Ne speed Check mount of Ne speed sensor directly for defect (defective
sensor
installation of sensor, internal defect of flywheel, etc.)
Check mount of G (Bkup) speed sensor directly for defect

Defective mount of G (Bkup)
(defective installation of sensor, internal defect of supply pump,
speed sensor
etc.)
Defective connection of sen- Check Ne speed sensor and G (Bkup) speed sensor directly for
sor (Wrong connection)
defective connection (wrong connection).
If causes 1 5 are not detected, engine controller may be defec6 Defective engine controller tive. (Since trouble is in system, troubleshooting cannot be carried
out.)
5
12V140E-3 Series
SEN00317-03
40 Troubleshooting
E-4 Code [115/CB115] Eng. Ne and G (Bkup) Speed Sensor Error (RH
bank)
Error code
Failure code
115
CB115
Trouble Abnormality in engine Ne and G (Bkup) speed sensor (RH bank)

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

Engine stops (if engine has been running).
Causes
Possible causes
and standard
value in normal
state
Defective Ne speed sensor

system
Carry out troubleshooting for code [689/CB689].
Defective G(Bkup) speed

sensor system
Carry out troubleshooting for code [778/CB778].
Defective mount of Ne speed Check mount of Ne speed sensor directly for defect (defective
sensor
installation of sensor, internal defect of flywheel, etc.)
Check mount of G (Bkup) speed sensor directly for defect

Defective mount of G (Bkup)
(defective installation of sensor, internal defect of supply pump,
speed sensor
etc.)
Defective connection (Wrong Check Ne speed sensor and G (Bkup) speed sensor directly for
connection)
defective connection (wrong connection).
If causes 1 5 are not detected, engine controller may be defec6 Defective engine controller tive. (Since trouble is in system, troubleshooting cannot be carried
out.)
5
12V140E-3 Series
SEN00317-03
40 Troubleshooting
E-5 Code [122/CA122] Charge Air Press. Sensor High Error (LH bank
only)
Error code
Failure code
Trouble
122
Contents of
trouble
Action of
controller
Phenomenon
that appears on
machine
Related
information
CA122
q
Charge pressure sensor circuit detects abnormally high pressure.
Sets charge pressure to fixed value (400 kPa {4.1 kg/cm2}) and continues operation.
Acceleration performance of engine drops.

Causes
Defective sensor power sup- If code [187/CA187] or [227/CA227] is indicated, carry out troubleply system
shooting for it first.
or start engine and carry out troubleshooting.
Defective charge pressure

2 sensor
(Internal trouble)
Possible causes
and standard
value in normal
state
Sensor detection of abnormally high charge pressure

(LH bank only)
Short circuit in wiring harness

3
(With another wiring harness)
PIM
Between (1) (2)
Power supply
4.75 5.25 V
Pressure sensor voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness
and controller, too, for another cause of trouble, and then judge.
without turning starting switch ON.
Wiring harness between LH J1 (female) (37)
Resis PIM (female) (1) and LH J1 (female) (47)
Min. 1
tance
PIM (female) (3)
Wiring harness between LH J1 (female)
Resis(37) PIM (female) (1) and LH J1 (female)
Min. 1
tance
(44) PIM (female) (2)
Resis PIM (female) (3) and LH J1 (female) (44)
Min. 1
tance
PIM (female) (2)
LH J1
Between (37) (47)
10
Voltage
Voltage
Power supply
4.75 5.25 V
12V140E-3 Series
40 Troubleshooting
SEN00317-03
Circuit diagram related to charge pressure sensor
12V140E-3 Series
11
SEN00317-03
40 Troubleshooting
E-6 Code [123/CA123] Charge Air Press. Sensor Low Error (LH bank
only)
Error code
Failure code
Trouble
123
Contents of
trouble
Action of
controller
Phenomenon
that appears on
machine
Related
information
Possible causes
and standard
value in normal
state
12
CA123
Sensor detection of abnormally low charge pressure

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

Carry out troubleshooting for E-5 Code [122/CA122].
12V140E-3 Series
40 Troubleshooting
12V140E-3 Series
SEN00317-03
13
SEN00317-03
40 Troubleshooting
E-7 Code [131/CA131] Throttle Sensor High Error (LH bank only)
Throttle sensor of decelerator pedal type (Case of D475-5)
Error code
Failure code
131
CA131
Trouble Throttle sensor detection of abnormally high level (LH bank only)
Contents of
trouble
Action of
controller
Phenomenon
that appears on
machine
Related
information
Throttle sensor circuit detection of abnormally high level.
Sets throttle angle with signal other than throttle sensor signal and continues operation.
(depending on each model)
Depends on machine model.

Causes
Defective sensor power sup- If code [2185/CA2185] or [2186/CA2186] is indicated, carry out
ply system
troubleshooting for it first.
Defective deceleration sen2 sor

(Internal trouble)
Possible causes
and standard
value in normal
state
Ground fault in wiring harness

3
(Short circuit with GND circuit)
DEC (male)
Resistance
Between (A) (C)
4.0 6.0 k
Between (B) (A)
0.25 5.0 k
Between (B) (C)
0.25 5.0 k

Wiring harness between OEM L(female)
ResisMin. 1 M
(22) DEC (female) (A) and chassis ground tance
Wiring harness between OEM L(female) (9)
DEC (female) (B) and chassis ground
Resistance
Min. 1 M
Wiring harness between OEM L(female)

ResisMin. 1 M
(23) DEC (female) (C) and chassis ground tance
OEM L
Voltage
Between (22) (23)
Power supply
4.75 5.25 V
Between (9) (23)
Signal
0.5 4.5 V
Circuit diagram related to deceleration pedal type throttle sensor (Case of D4755)
14
12V140E-3 Series
SEN00317-03
40 Troubleshooting
E-8 Code [132/CA132] Throttle Sensor Low Error (LH bank only)
Error code
Failure code
132
CA132
Trouble Throttle sensor detection of abnormally low level (LH bank only)
Contents of
trouble
Action of
controller
Phenomenon
that appears on
machine
Related
information
Signal voltage in throttle sensor circuit is abnormally low.
Varies by installed machine
Possible causes
and standard
value in normal
state
12V140E-3 Series
Causes

15
SEN00317-03
40 Troubleshooting
E-9 Code [135/CA135] Oil Press. Sensor High Error (LH bank only)
Error code
Failure code
Trouble
135
Contents of
trouble
Action of
controller
Phenomenon
that appears on
machine
Related
information
CA135
q
Signal voltage in oil pressure sensor circuit is abnormally high.
Set oil pressure to default value (250 kPa {2.5 kg/cm2}) and continue operation.

Causes
Defective oil pressure sen2 sor

(Internal trouble)
Possible causes
and standard
value in normal
state
Oil pressure sensor detection of abnormally high pressure

(LH bank only)

3

4
POIL
Between (1) (2)
Voltage
Power supply
4.75 5.25 V
Sensor voltage is measured with wiring harness connected.

Accordingly, if voltage is abnormal, check wiring harness and controller, too, for another cause of trouble, and then judge.
ResisMin. 1 M
(37) POIL (female) (1) and chassis ground tance
POIL (female) (2) and chassis ground
Resistance
Min. 1 M
Wiring harness between LH J1 (female) (13) ResisMin. 1 M

POIL (female) (3) and chassis ground
tance
Resis POIL (female) (1) and LH J1 (female) (47)
Min. 1 M
tance
POIL (female) (2)
POIL (female) (1) and LH J1 (female) (13)
POIL (female) (3)
Resistance
Min. 1 M

Resis POIL (female) (2) and LH J1 (female) (13)
Min. 1 M
tance
POIL (female) (3)
LH J1
Between (37) (47)
16
Voltage
Power supply
4.75 5.25 V
12V140E-3 Series
40 Troubleshooting
SEN00317-03
Circuit diagram related to oil pressure sensor
12V140E-3 Series
17
SEN00317-03
40 Troubleshooting
E-10 Code [141/CA141] Oil Press. Sensor Low Error (LH bank only)
Error code
Failure code
Trouble
141
Contents of
trouble
Action of
controller
Phenomenon
that appears on
machine
Related
information
Possible causes
and standard
value in normal
state
18
CA141
Oil pressure sensor detection of abnormally low pressure

(LH bank only)
Signal voltage in oil pressure sensor circuit is abnormally low.
Sets oil pressure to default value (250 kPa {2.5 kg/cm2}) and continues operation.
Causes

12V140E-3 Series
40 Troubleshooting
12V140E-3 Series
SEN00317-03
19
SEN00317-03
40 Troubleshooting
E-11 Code [144/CA144] Coolant Temp. Sensor High Error (LH bank only)
Error code
Failure code
Trouble
144
Contents of
trouble
Action of
controller
Phenomenon
that appears on
machine
Related
information
CA144
q
Signal voltage in coolant temperature sensor circuit is abnormally high.
Fixes coolant temperature at (90 C) and continues operation.

Causes
Defective coolant tempera1 ture sensor

(Internal trouble)
Possible causes
and standard
value in normal
state
Coolant temperature sensor detection of abnormally high temperature (LH bank only)

TWTR (male)
Coolant temperature
Resistance
Between (A) (B)
10 100 C
0.6 20 k

ness
ResisMax. 1
2 (Disconnection in wiring or (15) TWTR (female) (A)
tance
defective contact in connecWiring harness between LH J1 (female) (38) Resistor)
Max. 1
TWTR (female) (B)
tance
ness
3
Resis(Short circuit with GND cir(15) TWTR (female) (A) and chassis
Min. 1 M
tance
cuit)
ground
LH J1 (female)
Coolant temperature
Resistance
Between (15) (38)
20
10 100 C
0.6 20 k
12V140E-3 Series
40 Troubleshooting
SEN00317-03
Circuit diagram related to coolant temperature sensor
12V140E-3 Series
21
SEN00317-03
40 Troubleshooting
E-12 Code [145/CA145] Coolant Temp. Sensor Low Error (LH bank only)
Error code
Failure code
Trouble
145
Contents of
trouble
Action of
controller
Phenomenon
that appears on
machine
Related
information
Possible causes
and standard
value in normal
state
22
CA145
Coolant temperature sensor detection of abnormally low temperature (LH bank only)
Signal voltage in coolant temperature sensor circuit is abnormally low.
Fixes coolant temperature at (90 C) and continues operation.
Causes

12V140E-3 Series
40 Troubleshooting
12V140E-3 Series
SEN00317-03
23
SEN00317-03
40 Troubleshooting
E-13 Code [153/CA153] Charge Air Temp. Sensor High Error (LH bank
only)
Error code
Failure code
Trouble
153
Contents of
trouble
Action of
controller
Phenomenon
that appears on
machine
Related
information
CA153
q
Signal voltage in charge temperature sensor circuit is abnormally high.
Fixes charge temperature (intake air temperature) at (70 C) and continues operation.

Causes
Defective charge tempera1 ture sensor

(Internal trouble)
Possible causes
and standard
value in normal
state
Charge temperature sensor detection of abnormally high temperature (LH bank only)

Intake air temperaTIM (male)
Resistance
ture
Between (A) (B)
Between (23) (47)
24
10 100 C
0.5 20 k
Between (A) chasAll range

Min. 1 M
sis ground
ness
ResisMax. 1
2 (Disconnection in wiring or (23) TIM (female) (A)
tance
Max. 1
TIM (female) (B)
tance
ness
3
(Short circuit with GND cir- Wiring harness between LH J1 (female) (23) ResisMin. 1 M
TIM (female) (A) and chassis ground
tance
cuit)
Intake air tempera4 Defective engine controller
LH J1 (female)
Resistance
ture
10 100 C
0.5 20 k
12V140E-3 Series
40 Troubleshooting
SEN00317-03
Circuit diagram related to charge temperature sensor
12V140E-3 Series
25
SEN00317-03
40 Troubleshooting
E-14 Code [154/CA154] Charge Air Temp. Sensor Low Error (LH bank
only)
Error code
Failure code
Trouble
154
Contents of
trouble
Action of
controller
Phenomenon
that appears on
machine
Related
information
Possible causes
and standard
value in normal
state
26
CA154
Charge temperature sensor detection of abnormally low charge

temperature (LH bank only)
Signal voltage in charge temperature sensor circuit is abnormally low.
Fixes charge temperature (intake air temperature) at (70 C) and continues operation.
Causes

12V140E-3 Series
SEN00317-03
40 Troubleshooting
E-15 Code [187/CA187] Sensor Sup. 2 Volt. Low Error (LH bank)
Error code
Failure code
Trouble
187
Contents of
trouble
Action of
controller
CA187
q
Signal voltage in sensor power supply 2 (5 V) circuit is abnormally low.
Sets atmospheric pressure sensor to default value (52.44 kPa {0.5 kg/cm2}) and continues operation.
Sets oil pressure sensor to default value (250 kPa {2.5 kg/cm2}) and continues operation.
Fixes charge pressure sensor value (400 kPa {4.1 kg/cm2}) and continues operation.
Operates G (Bkup) sensor with signals of Ne speed sensor.
Output drops.
q
q
Phenomenon
that appears on
machine
Related
information
Power supply 2 sensor detection of abnormally low voltage

(LH bank)
Possible causes
and standard
value in normal
state
Causes

E-16 Code [187/CB187] Sensor Sup. 2 Volt. Low Error (RH bank)
Error code
Failure code
Trouble
187
Contents of
trouble
Action of
controller
Phenomenon
that appears on
machine
Related
information
CB187
Power supply 2 sensor detection of abnormally low voltage

(RH bank)
Signal voltage in sensor power supply 2(5 V) circuit is abnormally low.
Operate G (Bkup) sensor with signals of Ne speed sensor.
Output drops.
Possible causes
and standard
value in normal
state
12V140E-3 Series
Causes

Carry out troubleshooting for E-22 Code [227/CB227].
27
SEN00317-03
40 Troubleshooting
E-17 Code [212/CA212] Eng. Oil Temp.Sensor High Error (LH bank only)
Error code
Failure code
Trouble
212
Contents of
trouble
Action of
controller
Phenomenon
that appears on
machine
Related
information
CA212
q
Signal voltage in engine oil temperature sensor circuit is abnormally high.
Sets oil pressure to default value (100 C) and continues operation.

Causes
Defective oil temperature

1 sensor
(Internal trouble)
Possible causes
and standard
value in normal
state
Engine oil temperature sensor detection of abnormally high temperature (LH bank only)

TOIL (male)
Oil temperature
Resistance
Between (A) (B)
0 100 C
0.5 36 k

ness
Wiring harness between LH J1 (female) (17) ResisMax. 1
2 (Disconnection in wiring or TOIL (female) (A)
tance
Max. 1
TOIL (female) (B)
tance
ness
3
(Short circuit with GND cir- Wiring harness between LH J1 (female) (17) ResisMin. 1 M
TOIL (female) (A) and chassis ground
tance
cuit)
LH J1
Oil temperature
Resistance
(17) (47)
28
0 100 C
0.5 36 k
12V140E-3 Series
40 Troubleshooting
SEN00317-03
Circuit diagram related to engine oil temperature sensor
12V140E-3 Series
29
SEN00317-03
40 Troubleshooting
E-18 Code [213/CA213] Eng. Oil Temp.Sensor Low Error (LH bank only)
Error code
Failure code
Trouble
213
Contents of
trouble
Action of
controller
Phenomenon
that appears on
machine
Related
information
Possible causes
and standard
value in normal
state
30
CA213
Engine oil temperature sensor detection of abnormally low temperature (LH bank only)
Signal voltage in engine oil temperature sensor circuit is abnormally low.
Sets oil temperature to default value (100 C) and continues operation.

Causes

12V140E-3 Series
40 Troubleshooting
12V140E-3 Series
SEN00317-03
31
SEN00317-03
40 Troubleshooting
E-19 Code [221/CA221] Ambient Air Press. Sensor High Error (LH bank
only)
Error code
Failure code
Trouble
221
Contents of
trouble
Action of
controller
Phenomenon
that appears on
machine
Related
information
CA221
Atmospheric pressure sensor detection of abnormally high pressure (LH bank only)
Signal voltage in atmospheric pressure sensor circuit is abnormally high.
Sets atmospheric pressure to default value (52.44 kPa {0.5 kg/cm2}) and continues operation.
Output drops.

Causes
PAMB
Defective atmospheric pres2 sure sensor

(Internal trouble)
Possible causes
and standard
value in normal
state

3

4
Voltage
Between (1) (2)
Power supply
4.75 5.25 V
Between (3) (2)
Signal
0.5 4.5 V

PAMB (female) (1) and chassis ground
tance
Resistance
Min. 1 M

ResisMin. 1 M
tance
Resis PAMB (female) (1) and LH J1 (female)
Min. 1 M
tance
(38) PAMB (female) (3)
PAMB (female) (1) and LH J1 (female) (3)
PAMB (female) (2)
Resistance
Min. 1 M

Resis PAMB (female) (3) and LH J1 (female) (3)
Min. 1 M
tance
PAMB (female) (2)
32
LH J1
Voltage
Between (37) (38)
4.75 5.25 V
Between (3) (38)
0.5 4.5 V
12V140E-3 Series
40 Troubleshooting
SEN00317-03
Circuit diagram related to atmospheric pressure sensor
12V140E-3 Series
33
SEN00317-03
40 Troubleshooting
E-20 Code [222/CA222] Ambient Air Press. Sensor Low Error (LH bank
only)
Error code
Failure code
Trouble
222
Contents of
trouble
Action of
controller
Phenomenon
that appears on
machine
Related
information
Possible causes
and standard
value in normal
state
34
CA222
Atmospheric pressure sensor detection of abnormally low pressure

(LH bank only)
Signal voltage in atmospheric pressure sensor circuit is abnormally low.
Sets atmospheric pressure to default value (52.44 kPa {0.5 kg/cm2}) and continues operation.
Output drops.
Causes

12V140E-3 Series
40 Troubleshooting
12V140E-3 Series
SEN00317-03
35
SEN00317-03
40 Troubleshooting
E-21 Code [227/CA227] Sensor Sup. 2 Volt. High Error (LH bank)
Error code
Failure code
Trouble
227
Contents of
trouble
Action of
controller
CA227
q
Signal voltage in sensor power supply 2(5 V) circuit is abnormally high.
Sets oil pressure sensor to default value (250 kPa {2.5 kg/cm2}) and continues operation.
Fixes charge pressure sensor value (400 kPa {4.1 kg/cm2}) and continues operation.
Operates G (Bkup) sensor with signals of Ne speed sensor.
Output drops.
q
q
Phenomenon
that appears on
machine
Related
information
Causes
1 Defective related system
Possible causes
and standard
value in normal
state
Power supply 2 sensor detection of abnormally high voltage

(LH bank)
Defective sensor (Internal

trouble)

If another failure code is indicated, carry out troubleshooting for it.
Atmospheric presPAMB connector
Disconnect devices
sure sensor
at right in order. If
Oil pressure sensor
POIL connector
error code disapCharge pressure
pears subsequently,
PIM connector
sensor
that device has a
defect in it.
G (Bkup) sensor
G connector

ness
3 (Disconnection in wiring or respective sensors (female)
tance
Max. 1
respective sensors (female)
tance
Ground fault in wiring harWiring harness between LH J1 (female) (37)
Resisness
respective sensors (female) and chassis
Min. 1 M
4
tance
(Short circuit with GND cir- ground
cuit)
Resis respective sensors (female) and chassis
Min. 1 M
tance
ground
Short circuit in wiring harwithout turning starting switch ON.
ness
5
(37) respective sensors (female) and LH
Resis(With another wiring harMin. 1 M
J1 (female) (47) respective sensors
tance
ness)
(female)
LH J1
Voltage
Between (37) (47)
36
4.75 5.25 V
12V140E-3 Series
40 Troubleshooting
SEN00317-03
Circuit diagram related to sensor power supply 2 (5 V)
12V140E-3 Series
37
SEN00317-03
40 Troubleshooting
E-22 Code [227/CB227] Sensor Sup. 2 Volt. High Error (RH bank)
Error code
Failure code
Trouble
227
Contents of
trouble
Action of
controller
Phenomenon
that appears on
machine
Related
information
CB227
q
Signal voltage in sensor power supply 2 (5 V) circuit is abnormally high.
Operates G(Bkup) sensor with signals of Ne speed sensor.
Output drops.

Causes
Possible causes
and standard
value in normal
state

trouble)

3

4
38
Power supply 2 sensor detection of abnormally high voltage

(RH bank)

Disconnect devices
error code disapG (Bkup)speed senG connector
pears subsequently,
sor
that device has a
defect in it.
Wiring harness between RH J1 (female)
Resis(37) respective sensors (female) and
Min. 1 M
tance
chassis ground
Resis(47) respective sensors (female) and
Min. 1 M
tance
chassis ground
(37) respective sensors (female) and RH
ResisMin. 1 M
J1 (female) (47) respective sensors
tance
(female)
RH J1
Voltage
Between (37) (47)
4.75 5.25 V
12V140E-3 Series
40 Troubleshooting
SEN00317-03
12V140E-3 Series
39
SEN00317-03
40 Troubleshooting
E-23 Code [234/CA234] Eng. Overspeed (LH bank only)

Error code
Failure code
234
CA234
Trouble Engine overspeed (LH bank only)

Contents of
trouble
Action of
controller
Phenomenon
that appears on
machine
Related
information
Engine speed is above operating range.
Limits fuel injection rate until engine speed lowers to operating range.
Engine speed fluctuates.
Causes
Possible causes
and standard
value in normal
state
40
2 Improper way of use
Way of use may be improper. Teach proper way of use to operator.
If causes 1 2 are not detected, engine controller may be defective. (Since trouble is in system, troubleshooting cannot be carried
out.)
12V140E-3 Series
40 Troubleshooting
12V140E-3 Series
SEN00317-03
41
SEN00317-03
40 Troubleshooting
E-24 Code [238/CA238] Ne Speed Sensor Sup. Volt. Error (LH bank)
Error code
Failure code
238
CA238
Trouble Ne Speed Sensor Sup. Volt. Error (LH bank)

Contents of
trouble
Action of
controller
Phenomenon
that appears on
machine
Related
information
Abnormality occurred in Ne speed sensor power supply (5 V) circuit.
Controls Ne speed sensor with signals of G (Bkup) speed sensor.
q
q
Running engine stops (when G (Bkup) speed sensor is also abnormal).

Stopped engine cannot be started (when G (Bkup) speed sensor is also abnormal).

Causes
Possible causes
and standard
value in normal
state

Disconnect devices
Defective Ne speed sensor at right in order. If
1
error code disap(Internal trouble)
Ne speed sensor
NE connector
pears subsequently,
that device has a
defect in it.
ness
2 (Disconnection in wiring or Ne (female) (1)
tance
Max. 1
Ne (female) (2)
tance
Ground fault in wiring harWiring harness between LH J1 (female) (16) Resisness
Min. 1 M
3
tance
(Short circuit with GND cir- Ne (female) (1) and chassis ground
cuit)

4
42

Ne (female) (2) and chassis ground
tance
Resis Ne (female) (1) and LH J1 (female) (48)
Min. 1 M
tance
Ne (female) (2)
LH J1
Voltage
Between (16) (48)
4.75 5.25 V
12V140E-3 Series
40 Troubleshooting
SEN00317-03
Circuit diagram related to Ne speed sensor power supply
12V140E-3 Series
43
SEN00317-03
40 Troubleshooting
E-25 Code [238/CB238] Ne Speed Sensor Sup. Volt. Error (RH bank)
Error code
Failure code
238
CB238
Trouble Ne Speed Sensor Sup. Volt. Error (RH bank)

Contents of
trouble
Action of
controller
Phenomenon
that appears on
machine
Related
information
Abnormality occurred in Ne speed sensor power supply (5 V) circuit.
q
q


Causes
Possible causes
and standard
value in normal
state

Disconnect devices
Defective Ne speed sensor at right in order. If
1
error code disap(Internal trouble)
Ne speed sensor
NE connector
pears subsequently,
that device has a
defect in it.
ness
ResisMax. 1
2 (Disconnection in wiring or (16) Ne (female) (1)
tance
defective contact in connecWiring harness between RH J1 (female)
Resistor)
Max. 1
(48) Ne (female) (2)
tance
Min. 1 M
3
tance
(Short circuit with GND cir- Ne (female) (1) and chassis ground
cuit)

4

ResisMin. 1 M
(48) Ne (female) (2) and chassis ground
tance
Resis(16) Ne (female) (1) and RH J1 (female)
Min. 1 M
tance
Voltage
LH J1 (16) RH J1 (48)
4.75 5.25 V
44
12V140E-3 Series
40 Troubleshooting
SEN00317-03
Circuit diagram related to Ne speed sensor power supply
12V140E-3 Series
45
SEN00317-03
40 Troubleshooting
E-26 Code [263/CA263] Fuel Temp. Sensor High Error (LH bank)
Error code
Failure code
Trouble
263
Contents of
trouble
Action of
controller
Phenomenon
that appears on
machine
Related
information
CA263
q
Signal voltage in fuel temperature sensor circuit is abnormally high.
Fixes fuel temperature at (95 C) and continues operation.

Causes
Defective fuel temperature

1 sensor
(Internal trouble)
Possible causes
and standard
value in normal
state
Fuel temperature sensor detection of abnormally high temperature

(LH bank only)

LH TFUEL (male)
Fuel temperature
Resistance
Between (A) (B)
10 100 C
0.6 20 k

Disconnection in wiring harWiring harness between LH J1 (female)
Resisness
Max. 1
2
tance
(Disconnection or defective (30) LH TFUEL (female) (A)
contact in connector)
LH TFUEL (female) (B)
tance
Ground fault in wiring harWiring harness between LH J1 (female) (30)
ness
ResisMax.
3
LH TFUEL (female) (A) and chassis
(Short circuit with GND cirtance
1 M
ground
cuit)
LH J1 (female)
Fuel temperature
Resistance
Between (30) (47)
10 100 C
0.6 20 k
46
12V140E-3 Series
40 Troubleshooting
SEN00317-03
Circuit diagram related to fuel temperature sensor
12V140E-3 Series
47
SEN00317-03
40 Troubleshooting
E-27 Code [263/CB263] Fuel Temp. Sensor High Error (RH bank)
Error code
Failure code
Trouble
263
Contents of
trouble
Action of
controller
Phenomenon
that appears on
machine
Related
information
CB263
q
Signal voltage in fuel temperature sensor circuit is abnormally high.

Causes
Defective fuel temperature

1 sensor
(Internal trouble)
Possible causes
and standard
value in normal
state
Fuel temperature sensor detection of abnormally high temperature

(RH bank only)

RH TFUEL (male)
Fuel temperature
Resistance
Between (A) (B)
10 100 C
0.6 20 k

ness
ResisMax. 1
2 (Disconnection in wiring or (30) RH TFUEL (female) (A)
tance
Resistor)
Max. 1
(47) RH TFUEL (female) (B)
tance
Ground fault in wiring harWiring harness between RH J1 (female)
ness
ResisMax.
3
(30) RH TFUEL (female) (A) and chassis
(Short circuit with GND cirtance
1 M
ground
cuit)
RH J1 (female)
Fuel temperature
Resistance
Between (30) (47)
10 100 C
0.6 20 k
48
12V140E-3 Series
40 Troubleshooting
SEN00317-03
Circuit diagram related to fuel temperature sensor
12V140E-3 Series
49
SEN00317-03
40 Troubleshooting
E-28 Code [265/CA265] Fuel Temp. Sensor Low Error (LH bank)
Error code
Failure code
Trouble
265
Contents of
trouble
Action of
controller
CA265
Fuel temperature sensor detection of abnormally low temperature

(LH bank)
Signal voltage in fuel temperature sensor circuit is abnormally low.
Substitutes with coolant temperature sensor. If coolant temperature sensor is also in abnormal
state.
Sets oil temperature to default value (95 C) and continues operation.
Phenomenon
that appears on
machine
Related
information
Possible causes
and standard
value in normal
state
Causes

E-29 Code [265/CB265] Fuel Temp. Sensor Low Error (RH bank)
Error code
Failure code
Trouble
265
Contents of
trouble
Action of
controller
CB265
Fuel temperature sensor detection of abnormally low temperature

(RH bank)
Signal voltage in fuel temperature sensor circuit is abnormally low.
Substitutes with coolant temperature sensor. If coolant temperature sensor is also in abnormal
state.
Phenomenon
that appears on
machine
Related
information
Possible causes
and standard
value in normal
state
50
Causes

12V140E-3 Series
40 Troubleshooting
12V140E-3 Series
SEN00317-03
51
SEN00317-03
40 Troubleshooting
E-30 Code [271/CA271] PCV1 Short Error (LH bank)

Error code
Failure code
271
CA271
Trouble PCV1 Short circuit Error (LH bank)

Contents of
trouble
Action of
controller
Phenomenon
that appears on
machine
Related
information
There is short circuit in PCV1 circuit of supply pump.
None in particular.

Causes

Defective supply pump

1 PCV1
(Internal trouble)
Possible causes
and standard
value in normal
state

2
Hot short in wiring harness

(Contact with 24 V)
LH PCV1 (male)
Resistance
Between (1) (2)
2.35.3
Between (1), (2) chassis

Min. 1 M
ground
ResisMin. 1 M
LH PCV1 (female) (1) and chassis ground
tance
Wiring harness between LH J1 (female)(5) ResisMin. 1 M
tance
Voltage Max. 1 V
Voltage Max. 1 V
LH J1 (female)
Resistance
Between (4) (5)
2.3 5.3

ground
Min. 1 M
52
12V140E-3 Series
40 Troubleshooting
SEN00317-03
Circuit diagram related to supply pump PCV1
12V140E-3 Series
53
SEN00317-03
40 Troubleshooting
E-31 Code [271/CB271] PCV1 Short Error (RH bank)

Error code
Failure code
271
CB271
Trouble PCV1 Short circuit Error (RH bank)

Contents of
trouble
Action of
controller
Phenomenon
that appears on
machine
Related
information
None in particular.

Causes


1 PCV1
(Internal trouble)
Possible causes
and standard
value in normal
state

2

(Contact with 24 V)
RH PCV1 (male)
Resistance
Between (1) (2)
2.35.3

Min. 1 M
ground
Wiring harness between RH J1 (female) (4)
ResisMin. 1 M
RH PCV1 (female) (1) and chassis ground tance
Wiring harness between RH J1 (female) (5) ResisMin. 1 M
Voltage Max. 1 V
RH PCV1 (female) (1) and chassis ground
Voltage Max. 1 V
RH J1 (female)
Resistance
Between (4) (5)
2.3 5.3

ground
Min. 1 M
54
12V140E-3 Series
40 Troubleshooting
SEN00317-03
12V140E-3 Series
55
SEN00317-03
40 Troubleshooting
E-32 Code [272/CA272] PCV1 Open Error (LH bank)

Error code
Failure code
272
CA272
Trouble PCV1 Disconnection Error (LH bank)

Contents of
trouble
Action of
controller
Phenomenon
that appears on
machine
Related
information
There is disconnection in PCV1 circuit of supply pump.
None in particular.

Causes


1 PCV1
(Internal disconnection)
Possible causes
and standard
value in normal
state
LH PCV1 (male)
Resistance
Between (1) (2)
2.3 5.3

Min. 1 M
ground
ness
ResisWiring harness between LH J1 (female) (4)
Max. 1
2 (Disconnection in wiring or LH PCV1 (female) (1)
tance
defective contact in connecWiring harness between LH J1 (female) (5)
Resistor)
Max. 1
LH PCV1 (female) (2)
tance
LH J1 (female)
Resistance
Between (4) (5)
2.3 5.3

ground
Min. 1 M
56
12V140E-3 Series
SEN00317-03
40 Troubleshooting
E-33 Code [272/CB272] PCV1 Open Error (RH bank)

Error code
Failure code
272
CB272
Trouble PCV1 Disconnection Error (RH bank)

Contents of
trouble
Action of
controller
Phenomenon
that appears on
machine
Related
information
None in particular.

Causes


1 PCV1
Possible causes
and standard
value in normal
state
RH PCV1 (male)
Resistance
Between (1) (2)
2.3 5.3

Min. 1 M
ground
ness
ResisWiring harness between RH J1 (female) (4)
Max. 1
2 (Disconnection in wiring or RH PCV1 (female) (1)
tance
defective contact in connecWiring harness between RH J1 (female) (5)
Resistor)
Max. 1
RH PCV1 (female) (2)
tance
RH J1(female)
Resistance
Between (4) (5)
2.3 5.3

ground
Min. 1 M
12V140E-3 Series
57
SEN00317-03
40 Troubleshooting
E-34 Code [273/CA273] PCV2 Short Error (LH bank)

Error code
Failure code
273
CA273
Trouble PCV2 Short circuit Error (LH bank)

Contents of
trouble
Action of
controller
Phenomenon
that appears on
machine
Related
information
None in particular.

Causes


1 PCV2
(Internal trouble)
Possible causes
and standard
value in normal
state

2

(Contact with 24 V)
LH PCV2 (male)
Resistance
Between (1) (2)
2.3 5.3

Min. 1 M
ground
ResisMin. 1 M
tance
tance
Voltage Max. 1 V
Voltage Max. 1 V
LH J1 (female)
Resistance
Between (9) (10)
2.3 5.3

ground
Min. 1 M
58
12V140E-3 Series
40 Troubleshooting
SEN00317-03
12V140E-3 Series
59
SEN00317-03
40 Troubleshooting
E-35 Code [273/CB273] PCV2 Short Error (RH bank)

Error code
Failure code
273
CB273
Trouble PCV2 Short circuit Error (RH bank)

Contents of
trouble
Action of
controller
Phenomenon
that appears on
machine
Related
information
None in particular.

Causes


1 PCV2
(Internal trouble)
Possible causes
and standard
value in normal
state

2

(Contact with 24 V)
RH PCV2 (male)
Resistance
Between (1) (2)
2.3 5.3

Min. 1 M
ground
Wiring harness between RH J1 (female) (9) ResisMin. 1 M
Wiring harness between RH J1(female) (10) ResisMin. 1 M
Voltage Max. 1 V
(10) RH PCV2 (female) (2) and chassis
Voltage Max. 1 V
ground
RH J1 (female)
Resistance
Between (9) (10)
2.3 5.3

ground
Min. 1 M
60
12V140E-3 Series
40 Troubleshooting
SEN00317-03
12V140E-3 Series
61
SEN00317-03
40 Troubleshooting
E-36 Code [274/CA274] PCV2 Open Error (LH bank)

Error code
Failure code
274
CA274
Trouble PCV2 Disconnection Error (LH bank)

Contents of
trouble
Action of
controller
Phenomenon
that appears on
machine
Related
information
None in particular.

Causes

1 PCV2
Possible causes
and standard
value in normal
state

LH PCV2 (male)
Resistance
Between (1) (2)
2.3 5.3

ness
ResisMax. 1
2 (Disconnection in wiring or LH PCV2 (female) (1)
tance
Max. 1
LH PCV2 (female) (2)
tance
LH J1 (female)
Resistance
Between (9) (10)
2.3 5.3

ground
Min. 1 M
62
12V140E-3 Series
SEN00317-03
40 Troubleshooting
E-37 Code [274/CB274] PCV2 Open Error (RH bank)

Error code
Failure code
274
CB274
Trouble PCV2 Disconnection Error (RH bank)

Contents of
trouble
Action of
controller
Phenomenon
that appears on
machine
Related
information
None in particular.

Causes

1 PCV2
Possible causes
and standard
value in normal
state

RH PCV2 (male)
Resistance
Between (1) (2)
2.3 5.3

ness
ResisMax. 1
2 (Disconnection in wiring or RH PCV2 (female) (1)
tance
Resistor)
Max. 1
(10) RH PCV2 (female) (2)
tance
RH J1 (female)
Resistance
Between (9) (10)
2.3 5.3

ground
Min. 1 M
12V140E-3 Series
63
SEN00317-03
40 Troubleshooting
E-38 Code [322/CA322] Injector #1 (L/B #1) System Open/Short Error (LH
bank)
Error code
Failure code
Trouble
322
Contents of
trouble
Action of
controller
Phenomenon
that appears on
machine
Related
information
CA322
Disconnection or short circuit in injector #1 (L/B #1) system (LH

bank)
There is disconnection or short circuit in injector in injector #1 circuit.
None in particular.
q
q
Output drops.
Idle speed is unstable.

Causes

Possible causes
and standard
value in normal
state
Defective injector #1
(Internal trouble)
LH CN1 (male)
Resistance
Between (1) (2)
0.4 1.1

Min. 1 M
ground
ness
2 (Disconnection in wiring or LH CN1 (female) (1)
tance
defective contact in connecWiring harness between LH J1 (female)
Resistor)
Max. 1
(53) LH CN1 (female) (2)
tance
Min. 1 M
3
LH CN1 (female) (1) and chassis ground
tance
(Short circuit with GND cirWiring harness between LH J1 (female)
cuit)
Resis(53) LH CN1 (female) (2) and chassis
Min. 1 M
tance
ground
Defective another cylinder
Prepare with starting switch OFF, then carry out troubleshooting
4
injector or wiring harness
LH J1 (female)
Resistance
Between (45) (53)
0.4 1.1

ground
Min. 1 M
64
12V140E-3 Series
40 Troubleshooting
SEN00317-03
Circuit diagram related to injector #1
12V140E-3 Series
65
SEN00317-03
40 Troubleshooting
E-39 Code [323/CA323] Injector #5 (L/B #5) System Open/Short Error

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

(LH bank)
There is disconnection or short circuit in injector #5 circuit.
None in particular.
q
q
Output drops.

Causes

Possible causes
and standard
value in normal
state
(Internal trouble)
LH CN5 (male)
Resistance
Between (1) (2)
0.4 1.1

Min. 1 M
ground
ness
tance
Max. 1
LH CN5 (female) (2)
tance
Ground fault in wiring harWiring
harness between LH J1 (female) (46) Resisness
Min. 1 M
3
LH
CN5
(female) (1) and chassis ground
tance
(Short circuit with GND cir-
cuit)


If multiple failure codes are displayed for injector malfunction, carry

out troubleshooting for them, too.
LH J1 (female)
Resistance
Between (46) (60)
0.4 1.1

ground
Min. 1 M
66
Resistance
Min. 1 M
12V140E-3 Series
40 Troubleshooting
SEN00317-03
12V140E-3 Series
67
SEN00317-03
40 Troubleshooting

(LH bank)
Error code
Failure code
Trouble
324
Contents of
trouble
Action of
controller
Phenomenon
that appears on
machine
Related
information
CA324
Disconnection or short circuit in injector #3 (L/B #3) system

(LH bank)
None in particular.
q
q
Output drops.

Causes

Possible causes
and standard
value in normal
state
(Internal trouble)
LH CN3 (male)
Resistance
Between (1) (2)
0.4 1.1

Min. 1 M
ground
ness
tance
Max. 1
LH CN3 (female) (2)
tance
Min. 1 M
3
tance
(Short circuit with GND cirWiring harness between LH J1 (female)
cuit)
Min. 1 M
tance
ground
4
LH J1 (female)
Resistance
Between (55) (52)
0.4 1.1

ground
Min. 1 M
68
12V140E-3 Series
40 Troubleshooting
SEN00317-03
12V140E-3 Series
69
SEN00317-03
40 Troubleshooting

(LH bank)
Error code
Failure code
Trouble
325
Contents of
trouble
Action of
controller
Phenomenon
that appears on
machine
Related
information
CA325

bank)
None in particular.
q
q
Output drops.

Causes

Possible causes
and standard
value in normal
state
(Internal trouble)
LH CN6 (male)
Resistance
Between (1) (2)
0.4 1.1

Min. 1 M
ground
ness
ResisMax. 1
2 (Disconnection in wiring or (57) LH CN6 (female) (1)
tance
Max. 1
LH CN6 (female) (2)
tance
Ground fault in wiring harWiring harness between LH J1 (female)
Resisness
(57) LH CN6 (female) (1) and chassis
Min. 1 M
3
tance
(Short circuit with GND cir- ground
cuit)
Min. 1 M
tance
ground
4
LH J1 (female)
Resistance
Between (57) (59)
0.4 1.1

ground
Min. 1 M
70
12V140E-3 Series
40 Troubleshooting
SEN00317-03
12V140E-3 Series
71
SEN00317-03
40 Troubleshooting

(LH bank)
Error code
Failure code
Trouble
331
Contents of
trouble
Action of
controller
Phenomenon
that appears on
machine
Related
information
CA331

bank)
None in particular.
q
q
Output drops.

Causes

Possible causes
and standard
value in normal
state
(Internal trouble)
LH CN2 (male)
Resistance
Between (1) (2)
0.4 1.1

Min. 1 M
ground
ness
tance
defective contact in connecWiring harness between LH J1 (female)
Resistor)
Max. 1
(51) LH CN2 (female) (2)
tance
Min. 1 M
3
LH
CN2
tance
cuit)



LH J1 (female)
Resistance
Between (54) (51)
0.4 1.1

ground
Min. 1 M
72
Resistance
Min. 1 M
12V140E-3 Series
40 Troubleshooting
SEN00317-03
12V140E-3 Series
73
SEN00317-03
40 Troubleshooting
E-43 Code [332/CA332] Injector #4 (L/B #4) System Open/Short Error (LH
bank)
Error code
Failure code
Trouble
332
Contents of
trouble
Action of
controller
Phenomenon
that appears on
machine
Related
information
CA332
Disconnection or short circuit in injector #4 (L/B #4) system(LH

bank)
None in particular.
q
q
Output drops.

Causes

Possible causes
and standard
value in normal
state
(Internal trouble)
LH CN4 (male)
Resistance
Between (1) (2)
0.4 1.1

Min. 1 M
ground
ness
ResisMax. 1
2 (Disconnection in wiring or (56) LH CN4 (female) (1)
tance
Max. 1
LH CN4 (female) (2)
tance
Min. 1 M
3
LH
CN4
tance
cuit)



LH J1 (female)
Resistance
Between (56) (58)
0.4 1.1

ground
Min. 1 M
74
Resistance
Min. 1 M
12V140E-3 Series
40 Troubleshooting
SEN00317-03
12V140E-3 Series
75
SEN00317-03
40 Troubleshooting
E-44 Code [342/CA342] Caribration Code Incompatibility (LH bank)

Error code
Failure code
342
CA342
Trouble Engine Controller data matching failure (LH bank)

Contents of
trouble
Action of
controller
Phenomenon
that appears on
machine
Related
information
Matching error occurred in engine controller data.
None in particular.
Possible causes
and standard
value in normal
state
Causes

E-45 Code [342/CB342] Caribration Code Incompatibility (RH bank)

Error code
Failure code
342
CB342
Trouble Engine Controller data matching failure (RH bank)

Contents of
trouble
Action of
controller
Phenomenon
that appears on
machine
Related
information
Possible causes
and standard
value in normal
state
76
Matching error occurred in engine controller data.
None in particular.
Causes

12V140E-3 Series
40 Troubleshooting
12V140E-3 Series
SEN00317-03
77
SEN00317-03
40 Troubleshooting
E-46 Code [351/CA351] INJ. Drive Circuit Error (LH bank)

Error code
Failure code
351
CA351
Trouble Injector drive circuit error (LH bank)

Contents of
trouble
Action of
controller
Phenomenon
that appears on
machine
Related
information
Abnormality occurred in injector drive circuit.
Limits output and continues operation (Limits common rail pressure).
Output drops.

Causes
Possible causes
and standard
value in normal
state
If another failure code (code of abnormality in injector system) is

indicated, carry out troubleshooting for it.
2 Defective fuse
Check fuse or circuit breaker on installed machine side directly for

possible defect.
ground fault.)

ness
Wiring harness between PW L (female) (3),
ResisMax. 1
tance
defective contact in connecWiring harness between PW L (female) (1),
Resistor)
Max. 1
(2) chassis ground
tance
ness
4
Resis(Short circuit with GND cir- Wiring harness between PW L (female) (3),
Min. 1 M
tance
cuit)
PW L
Voltage
Between (3), (4) (1), (2)
78
20 30 V
12V140E-3 Series
40 Troubleshooting
SEN00317-03
12V140E-3 Series
79
SEN00317-03
40 Troubleshooting
E-47 Code [351/CB351] INJ. Drive Circuit Error (RH bank)

Error code
Failure code
351
CB351
Trouble Injector drive circuit error (RH bank)

Contents of
trouble
Action of
controller
Phenomenon
that appears on
machine
Related
information
Abnormality occurred in injector drive circuit.
Output drops.

Causes
Possible causes
and standard
value in normal
state
If another failure code (code of abnormality in injector system) is

indicated, carry out troubleshooting for it.
2 Defective fuse
Check fuse or circuit breaker on installed machine side directly for

possible defect.
ground fault.)

ness
Wiring harness between PW R (female) (3), ResisMax. 1
tance
defective contact in connecWiring harness between PW R (female) (1), Resistor)
Max. 1
(2) chassis ground
tance
ness
4
Wiring harness between PW R (female) (3), Resis(Short circuit with GND cirMin. 1 M
tance
cuit)
PW R
Voltage
Between (3), (4) (1), (2)
80
20 30 V
12V140E-3 Series
40 Troubleshooting
SEN00317-03
12V140E-3 Series
81
SEN00317-03
40 Troubleshooting
E-48 Code [352/CA352] Sensor Sup. 1 Volt. Low Error (LH bank)
Error code
Failure code
Trouble
352
Contents of
trouble
Action of
controller
Phenomenon
that appears on
machine
Related
information
CA352
Power supply 1 sensor detection of abnormally low voltage (LH

bank)
Output drops.
Possible causes
and standard
value in normal
state
Causes

E-49 Code [352/CB352] Sensor Sup. 1 Volt. Low Error (RH bank)
Error code
Failure code
Trouble
352
Contents of
trouble
Action of
controller
Phenomenon
that appears on
machine
Related
information
Possible causes
and standard
value in normal
state
82
CB352
Power supply 1 sensor detection of abnormally low voltage (RH

bank)
Output drops.
Causes

12V140E-3 Series
40 Troubleshooting
12V140E-3 Series
SEN00317-03
83
SEN00317-03
40 Troubleshooting
E-50 Code [386/CA386] Sensor Sup. 1 Volt. High Error (LH bank)
Error code
Failure code
Trouble
386
Contents of
trouble
Action of
controller
Phenomenon
that appears on
machine
Related
information
CA386
q
Output drops.

Causes
Possible causes
and standard
value in normal
state


Disconnect devices at
right in order. If error
2
LH common rail
trouble)
code disappears subLH PFUEL connector
pressure sensor
sequently, that device
has a defect in it.
Disconnection in wiring har- Wiring harness between LH J1 (female) (33)
ResisMax. 1
ness
LH PFUEL (female) (1)
tance
3 (Disconnection in wiring or
ResisMax. 1
defective contact in connec LH PFUEL (female) (2)
tance
tor)
ResisMax. 1
tance
ResisGround fault in wiring harMin. 1 M
LH PFUEL (female) (1) and chassis ground tance
ness
4
Resis(Short circuit with GND cir- Wiring harness between LH J1 (female) (25)
Min. 1 M
cuit)

5
84
Power supply 1 sensor detection of abnormally high voltage (LH

bank)

ResisMin. 1 M
Resis LH PFUEL (female) (1) and LH J1 (female)
Min. 1 M
tance
(25) LH PFUEL (female) (2)
Resis LH PFUEL (female) (1) and LH J1 (female)
Min. 1 M
tance
ResisMin. 1 M
LH PFUEL (female) (2) and LH J1 (female)
tance
LH J1
Voltage
Between (33) (47)
4.75 5.25V
12V140E-3 Series
40 Troubleshooting
SEN00317-03
12V140E-3 Series
85
SEN00317-03
40 Troubleshooting
E-51 Code [386/CB386] Sensor Sup. 1 Volt. High Error (RH bank)
Error code
Failure code
Trouble
386
Contents of trouble
Action of
controller
Phenomenon that
appears on
machine
Related information
CB386
Power supply 1 sensor detection of abnormally high voltage (RH

bank)
Output drops.

Causes
Defective related system

a Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Disconnect devices at
Defective sensor(Interright in order. If error
nal trouble)
code disappears subsequently, that device
has a defect in it.
RH common rail
pressure sensor
RH PFUEL
connector

ResisMax. 1
RH PFUEL (female) (1)
tance
Possible causes
and standard value
in normal state
Disconnection in wiring harness

3 (Disconnection in wirWiring harness between RH J1 (female) (25) ResisMax. 1
ing or defective contact
tance
in connector)
Wiring harness between RH J1 (female) (47) ResisMax. 1
tance
Wiring harness between RH J1 (female) (33) ResisGround fault in wiring
Min. 1 M
RH PFUEL (female) (1) and chassis ground
tance
harness
4
Resis(Short circuit with GND Wiring harness between RH J1 (female) (25)
Min. 1 M
tance
circuit)
Short circuit in wiring

harness
5
(With another wiring
harness)
86

ResisMin. 1 M
tance
ResisRH PFUEL (female) (1) and RH J1 (female)
Min. 1 M
tance
(25) RH PFUEL (female) (2)
Wiring harness between wiring RH J1 (female)
(33) RH PFUEL (female) (1) and RH J1
(female) (47) RH PFUEL (female) (3)
Resistance
Min. 1 M

ResisMin. 1 M
RH PFUEL (female) (2) and RH J1 (female)
tance
a Prepare with starting switch OFF, then turn starting switch ON and
Defective engine concarry out troubleshooting.
troller
RH J1
Voltage
Between (33) (47)
4.75 5.25V
12V140E-3 Series
40 Troubleshooting
SEN00317-03
12V140E-3 Series
87
SEN00317-03
40 Troubleshooting
E-52 Code [441/CA441] Battery Voltage Low Error (LH bank)

Error code
Failure code
441
CA441
Trouble Supply voltage abnormally low (LH bank)

Contents of
trouble
Action of
controller
Phenomenon
that appears on
machine
Related
information
Abnormally low supply voltage in circuit.
None in particular.
Possible causes
and standard
value in normal
state
Causes

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

Error code
Failure code
441
CB441
Trouble Supply voltage abnormally low (RH bank)

Contents of
trouble
Action of
controller
Phenomenon
that appears on
machine
Related
information
Possible causes
and standard
value in normal
state
88
None in particular.
Causes

12V140E-3 Series
SEN00317-03
40 Troubleshooting
E-54 Code [442/CA442] Battery Voltage High Error (LH bank)

Error code
Failure code
442
CA442
Trouble Supply voltage abnormally high (LH bank)

Contents of
trouble
Action of
controller
Phenomenon
that appears on
machine
Related
information
None in particular.
Possible causes
and standard
value in normal
state
Causes

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

Error code
Failure code
442
CB442
Trouble Supply voltage abnormally high (RH bank)

Contents of
trouble
Action of
controller
Phenomenon
that appears on
machine
Related
information
None in particular.
Possible causes
and standard
value in normal
state
12V140E-3 Series
Causes

89
SEN00317-03
40 Troubleshooting

2009 KOMATSU
All Rights Reserved
90
SEN00318-03
ENGINE
1SHOP MANUAL
12V140E-3 Series
40 Troubleshooting
Troubleshooting of electrical system

(E-mode), Part 2
E-56 Code [449/CA449] Rail Press. Very High Error (LH bank) ..................................................................... 3
E-57 Code [449/CB449] Rail Press. Very High Error (RH bank) .................................................................... 3
E-58 Code [451/CA451] Rail Press. Sensor High Error (LH bank) ................................................................. 4
E-59 Code [451/CB451] Rail Press. Sensor High Error (RH bank) ................................................................ 6
E-60 Code [452/CA452] Rail Press. Sensor Low Error (LH bank).................................................................. 8
E-61 Code [452/CB452] Rail Press. Sensor Low Error (RH bank) ................................................................. 8
E-62 Code [553/CA553] Rail Press. High Error 1 (LH bank) .......................................................................... 9
E-63 Code [553/CB553] Rail Press. High Error 1 (RH bank)........................................................................ 10
E-64 Code [554/CA554] Rail Press. Sensor In Range Error (LH bank).........................................................11
E-65 Code [554/CB554] Rail Press. Sensor In Range Error (RH bank) ........................................................11
E-66 Code [559/CA559] Rail Press. Low Error 1 (LH bank) ......................................................................... 12
E-67 Code [559/CB559] Rail Press. Low Error 1 (RH bank) ........................................................................ 16
E-68 Code [689/CA689] Eng. Ne Speed Sensor Error (LH bank) ................................................................ 20
E-69 Code [689/CB689] Eng. Ne Speed Sensor Error (RH bank)................................................................ 22
12V140E-3 Series
SEN00318-03
40 Troubleshooting
E-70 Code [691/CA691] Intake Air Temp Sensor High Error (LH bank only) ................................................ 24
E-71 Code [692/CA692] Intake Air Temp Sensor Low Error (LH bank only)................................................. 26
E-72 Code [731/CA731] Eng. G (Bkup) Speed Sensor Phase Error (LH bank)............................................ 27
E-73 Code [731/CB731] Eng. G (Bkup) Speed Sensor Phase Error (RH bank) ........................................... 27
E-74 Code [757/CA757] All Continuous Data Lost Error (LH bank).............................................................. 28
E-75 Code [757/CB757] All Continuous Data Lost Error (RH bank) ............................................................. 28
E-76 Code [778/CA778] Eng. G (Bkup) Speed Sensor Error (LH bank)....................................................... 30
E-77 Code [778/CB778] Eng. G (Bkup) Speed Sensor Error (RH bank) ...................................................... 32
E-78 Code [781/CA781] Inter Multi-controller Communication Error (LH bank) ........................................... 34
E-79 Code [781/CB781] Inter Multi-controller Communication Error (RH bank)........................................... 36
E-80 Code [1117/CA1117] Persistent Data Lost Error (LH bank) .................................................................. 37
E-81 Code [1117/CB1117] Persistent Data Lost Error (RH bank) ................................................................. 37
E-82 Code [1257/CA1257] Harness Key error (LH bank) ............................................................................. 38
E-83 Code [1257/CB1257] Harness Key error (RH bank) ............................................................................ 39
E-84 Code [1548/CB1548] Injector #7 (R/B #1) System Open/Short Error (RH bank) ................................. 40
E-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
12V140E-3 Series
40 Troubleshooting
SEN00318-03
E-56 Code [449/CA449] Rail Press. Very High Error (LH bank)
Error code
Failure code
449
CA449
Contents of
trouble
Action of
controller
Trouble
Common rail pressure abnormally high Error 2 (LH bank)
Common rail pressure sensor circuit detected abnormally high pressure (level 2).
Phenomenon
that appears on Output drops.
machine
Related
information
Possible causes
and standard
value in normal
state
Causes

E-57 Code [449/CB449] Rail Press. Very High Error (RH bank)
Error code
Failure code
449
CB449
Contents of
trouble
Action of
controller
Trouble
Common rail pressure abnormally high Error 2 (RH bank)
Phenomenon
machine
Related
information
Possible causes
and standard
value in normal
state
12V140E-3 Series
Causes

SEN00318-03
40 Troubleshooting
E-58 Code [451/CA451] Rail Press. Sensor High Error (LH bank)
Error code
Failure code
451
CA451
Contents of
trouble
Action of
controller
Trouble
Common rail pressure sensor detected abnormally high pressure

(LH bank)
Signal voltage in common rail pressure sensor circuit is abnormally high.

Phenomenon
machine
Related
information
Causes
1
Defective common rail pres2 sure sensor

(Internal trouble)
LH PFUEL
Voltage
Between (1) (3)
Power supply
4.75 5.25 V
Between (2) (3)
Signal
0.25 4.6 V

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes
and standard
value in normal
state

defective contact in connector)

Resistance
Max. 1 z

Resistance
Max. 1 z

Resistance
Max. 1 z

4

LH PFUEL (female) (1) and chassis
ground
Resistance
Min. 1 Mz

ground
Resistance
Min. 1 Mz

ground
Resistance
Min. 1 Mz
12V140E-3 Series
40 Troubleshooting
SEN00318-03
Causes

Possible causes
and standard
value in normal
state

5

LH PFUEL (female) (1) and LH J1
(female) (25) LH PFUEL (female) (2)
Resistance
Min. 1 Mz

Resistance
Min. 1 Mz

Resistance
Min. 1 Mz

LH J1
Voltage
Between (33) (47)
4.75 5.25 V
Between (25) (47)
0.25 4.6 V
Circuit diagram related to common rail pressure sensor
12V140E-3 Series
SEN00318-03
40 Troubleshooting
E-59 Code [451/CB451] Rail Press. Sensor High Error (RH bank)
Error code
Failure code
451
CB451
Contents of
trouble
Action of
controller
Trouble
Common rail pressure sensor detected abnormally high pressure

(RH bank)
Signal voltage in common rail pressure sensor circuit is abnormally high.

Phenomenon
machine
Related
information
Causes
1
Defective sensor power sup- If code [352/CB352] or [386/CB386] is indicated, carry out troubleply system
Defective common rail pres2 sure sensor

(Internal trouble)
RH PFUEL
Voltage
Between (1) (3)
Power supply
4.75 5.25 V
Between (2) (3)
Signal
0.25 4.6 V

Possible causes
and standard
value in normal
state


Resistance
Max. 1 z

Resistance
Max. 1 z

Resistance
Max. 1 z

4

(33) RH PFUEL (female) (1) and chassis
ground
Resistance
Min. 1 Mz

ground
Resistance
Min. 1 Mz

ground
Resistance
Min. 1 Mz
12V140E-3 Series
40 Troubleshooting
SEN00318-03
Causes

Possible causes
and standard
value in normal
state

5

Resistance
Min. 1 Mz

Resistance
Min. 1 Mz

Resistance
Min. 1 Mz

RH J1
Voltage
Between (33) (47)
4.75 5.25 V
Between (25) (47)
0.25 4.6 V
Circuit diagram related to common rail pressure sensor
12V140E-3 Series
SEN00318-03
40 Troubleshooting
E-60 Code [452/CA452] Rail Press. Sensor Low Error (LH bank)
Error code
Failure code
452
CA452
Contents of
trouble
Action of
controller
Trouble
Common rail pressure sensor detected abnormally low pressure

(LH bank)
Signal voltage in common rail pressure sensor circuit is abnormally low.

Phenomenon
machine
Related
information
Possible causes
and standard
value in normal
state
Causes

E-61 Code [452/CB452] Rail Press. Sensor Low Error (RH bank)
Error code
Failure code
452
CA452
Contents of
trouble
Action of
controller
Trouble
Common rail pressure sensor detected abnormally low pressure

(RH bank)
Signal voltage in common rail pressure sensor circuit is abnormally low.

Phenomenon
machine
Related
information
Possible causes
and standard
value in normal
state
Causes

12V140E-3 Series
40 Troubleshooting
SEN00318-03
E-62 Code [553/CA553] Rail Press. High Error 1 (LH bank)

Error code
Failure code
553
CA553
Contents of
trouble
Action of
controller
Trouble
Common rail pressure abnormally high Error 1 (LH bank)
None in particular.
Phenomenon
machine
Related
information
Causes
Possible causes
and standard
value in normal
state
2 Use of improper fuel
Check fuel used directly.

(High viscosity)
Defective electrical system of Common rail pressure sensor may have electric trouble.
common rail pressure sensor Carry out troubleshooting for code [451/CA451] (E-58).
Defective mechanical system

4 of common rail pressure sen- Check mechanical system of common rail pressure sensor directly.
sor
5 Defective overflow valve
Check overflow valve directly for broken spring, worn seat, and
stuck ball.
6 Clogging of overflow piping
Check overflow piping directly for clogging.
7 Defective pressure limiter
Check pressure limiter directly for mechanical defect.
12V140E-3 Series
SEN00318-03
40 Troubleshooting
E-63 Code [553/CB553] Rail Press. High Error 1 (RH bank)

Error code
Failure code
553
CB553
Contents of
trouble
Action of
controller
Trouble
Common rail pressure abnormally high Error 1 (RH bank)
None in particular.
Phenomenon
machine
Related
information
Causes
Possible causes
and standard
value in normal
state
10
Check fuel used directly.

(High viscosity)
Defective electrical system of Common rail pressure sensor may have electric trouble.
common rail pressure sensor Carry out troubleshooting for code [451/CB451] (E-59).
Defective mechanical system

4 of common rail pressure sen- Check mechanical system of common rail pressure sensor directly.
sor
5 Defective overflow valve
Check overflow valve directly for broken spring, worn seat, and
stuck ball.
6 Clogging of overflow piping
Check overflow piping directly for clogging.
Check pressure limiter directly for mechanical defect.
12V140E-3 Series
40 Troubleshooting
SEN00318-03
E-64 Code [554/CA554] Rail Press. Sensor In Range Error (LH bank)
Error code
Failure code
554
CA554
Contents of
trouble
Action of
controller
Trouble
Common rail pressure sensor detection of in range abnormality

(LH bank)
In range error occurred in common rail pressure sensor circuit.

Phenomenon
machine
Related
information
Possible causes
and standard
value in normal
state
Causes

E-65 Code [554/CB554] Rail Press. Sensor In Range Error (RH bank)
Error code
Failure code
554
CB554
Contents of
trouble
Action of
controller
Trouble
Common rail pressure sensor detected In range abnormality

(RH bank)
In range error occurred in common rail pressure sensor circuit.

Phenomenon
machine
Related
information
Possible causes
and standard
value in normal
state
12V140E-3 Series
Causes

11
SEN00318-03
40 Troubleshooting
E-66 Code [559/CA559] Rail Press. Low Error 1 (LH bank)

Error code
Failure code
559
CA559
Contents of
trouble
Action of
controller
Trouble
Supply pump no-pressure feed error 1 (LH bank)
Supply pump does not feed fuel (level 1).

Limits common rail pressure.
Phenomenon
machine
Related
information
Causes
Improper fuel may be used. Check fuel used directly.
Loosening of fuel pipe and

leaked fuel
Fuel pipe may be loosened or fuel may be leaked. Check fuel pipe
directly.
4 Clogging of filter/strainer
a For contents of troubleshooting, see Note 2.
Clogging of fuel tank air

5
breather
Fuel tank air breather may be clogged. Clean air breather and
check the hose directly.
Possible causes
and standard
value in normal
state
Supply pump PCV may have electric trouble. Carry out troubleDefective supply pump PCV
shooting for following codes [271/CA271] (E-30), [272/CA272] (Eelectrical system
32), [273/CA273] (E-34), [274/CA274] (E-36).
Defective low-pressure circuit device
a For contents of troubleshooting, see Note 1. For checking of

fuel low-pressure circuit, see Testing and adjusting, Testing fuel
pressure.
Pressure in fuel low-pressure
circuit
a For testing of return (spill) limit from injector, see Testing and
adjusting, Testing leakage from pressure limiter and return rate
from injector.
8 Defective injector
Speed at rated operation
Return (Spill) limit from injector
1,600 rpm
960 cc/min
1,700 rpm
1,020 cc/min
1,800 rpm
1,080 cc/min
1,900 rpm
1,140 cc/min
2,000 rpm
1,200 cc/min
a For testing of leakage from pressure limiter, see Testing and

from injector.
Leakage from pressure limiter
10 Defective supply pump
12
Max. 0.15 0.29 MPa

{Max. 1.5 3.0 kg/cm2}
Max. 10 cc/min (at rated output)
If causes 1 9 are not detected, supply pump may be defective.
12V140E-3 Series
40 Troubleshooting
SEN00318-03
Note 1: When low-pressure circuit is defective, check the following:

q
Fuel level
q
Clogged fuel tank breather
q
Water separator/Prefilter filled with water
q
Clogged fuel filter
q
Clogged screen in water separator
q
Stuck or worn feed pump, clogged filter
q
Leaked or clogged low-pressure fuel pipe
q
Bypass valve malfunction, defective assembly of other parts (See Fig.1.)
q
Fuel in oil pan (fuel leakage in head cover)
Fig. 1: Locations of overflow valve (1), bypass valve (2), and fuel inlet joint (3)
q
Overflow valve (1): Spring is seen through both holes.
q
Bypass valve (2): Spring is seen through hole on nut side.
q
Fuel inlet joint (3): Gauze filter is seen through both holes.
Note 2: Check, clean, and replace the filters and strainers according to the following procedure.
q
Fuel filter: Replace (Replace both prefilter and main filter.)
q
Water separator: Disassemble and check. If screen (4) is clogged, clean it.
q
Gauze filter: Disassemble and check. Clean, if clogged.
q
Upstream strainer of gauze filter: Disassemble and check. Clean, if clogged.
12V140E-3 Series
13
SEN00318-03
40 Troubleshooting
Check sheet for no-pressure feed

Model
Machine serial No.
Work No.
#
Date of check
Engine
Engine serial No.
Service meter
#
Worker's name
A. Visual check
1
Fuel leakage to outside
Clogging of fuel tank breather
Good NG
B. Check with machine monitor

(Fault history function, monitoring function, and reduced cylinder mode function)
3
Check of error/failure code
Good NG
/
Check of monitoring information

Code
*1
Displayed item
Engine speed
Unit
Standard value
(Reference
value)
Low idle
rpm
<By models>
High idle
rpm
<By models>
Equivalent to rating <By models>
rpm
<By models>
Checking condition
Measured
Good NG
value
Low idle
High idle
100
mm3
MPa
*5
Common rail fuel pressure Equivalent to rating <By models>
MPa
Low idle
Fuel injection timing comHigh idle
mand
CA
*6
CA
CA
*7
Boost pressure
kPa
*8
Engine coolant temperature
Low idle
*9
Fuel temperature
Low idle
Unit
Standard value
(Reference
value)
*2
Throttle opening
*3
Fuel injection command
*4

command
Check of reduced cylinder mode operation (Engine speed)

Func
tion
5
*10
14
Reduced cylinder
Checking condition
Measured
Good NG
value
No. 1 cylinder
Low idle
rpm
No. 2 cylinder
Low idle
rpm
No. 3 cylinder
Low idle
rpm
No. 4 cylinder
Low idle
rpm
No. 5 cylinder
Low idle
rpm
No. 6 cylinder
Low idle
rpm
12V140E-3 Series
40 Troubleshooting
C. Check of fuel circuit pressure

6
Fuel low-pressure circuit pressure
SEN00318-03
Checking condition
High idle
Unit
Standard value
(Reference
value)
MPa
{kg/cm2}
Min. 0.15
{Min. 1.5}
Measured
Good NG
value
D. Check of strainers and filters

7
Visual check of strainers
Visual check of gauze filter
Visual check of fuel filter
Good NG
10 Visual check of bypass valve
Unit
Standard value
(Reference
value)
11 Leakage through pressure limiter No load, at rated output
cc/min
Max. 10
Equivalent to rating
<By models> 1,600 rpm
cc/min
960
cc/min
1,020
cc/min
1,080
cc/min
1,140
cc/min
1,200
E. Check of leakage and return

rate
12 Return rate from injector
Checking condition
Measured
Good NG
value
Speed:
Return
rate:
*1 *10:
When inspecting with INSITE (bench test tool), see Operation and Maintenance Manual (Testing
method).
When inspecting with the monitoring function of the machine, use the codes specified for each machine
model.
Equivalent to rating <By models>:
When inspecting the engine unit on the bench, operate it under a load equivalent to the rating. When
the engine is installed to the machine, however, the operation load equivalent to the rating depends on
the machine model.
12V140E-3 Series
15
SEN00318-03
40 Troubleshooting
E-67 Code [559/CB559] Rail Press. Low Error 1 (RH bank)

Error code
Failure code
559
CB559
Contents of
trouble
Action of
controller
Trouble
Supply pump no-pressure feed error 1 (RH bank)

Phenomenon
machine
Related
information
Causes
Improper fuel may be used. Check fuel used directly.
Loosening of fuel pipe and

leaked fuel
Fuel pipe may be loosened or fuel may be leaked. Check fuel pipe
directly.
4 Clogging of filter/strainer
a For contents of troubleshooting, see Note 2.
Clogging of fuel tank air

5
breather
Fuel tank air breather may be clogged. Clean air breather and
check the hose directly.
Possible causes
and standard
value in normal
state
Supply pump PCV may have electric trouble. Carry out troubleDefective supply pump PCV
shooting for following codes [271/CB271] (E-31), [272/CB272] (Eelectrical system
33), [273/CB273] (E-35), [274/CB274] (E-37).
Defective low-pressure circuit device
a For contents of troubleshooting, see Note 1. For checking of

fuel low-pressure circuit, see Testing and adjusting, Testing fuel
pressure.
Pressure in fuel low-pressure
circuit
a For testing of return (spill) limit from injector, see Testing and
from injector.
8 Defective injector
Speed at rated operation
Return (Spill) limit from injector
1,600 rpm
960 cc/min
1,700 rpm
1,020 cc/min
1,800 rpm
1,080 cc/min
1,900 rpm
1,140 cc/min
2,000 rpm
1,200 cc/min
a For testing of leakage from pressure limiter, see Testing and

from injector.
Leakage from pressure limiter
10 Defective supply pump
16
Max. 0.15 0.29 MPa

{Max. 1.5 3.0 kg/cm2}
Max. 10 cc/min (at rated output)
If causes 1 9 are not detected, supply pump may be defective.
12V140E-3 Series
40 Troubleshooting
SEN00318-03
Note 1: When low-pressure circuit is defective, check the following:

q
Fuel level
q
Clogged fuel tank breather
q
Water separator/Prefilter filled with water
q
Clogged fuel filter
q
Clogged screen in water separator
q
Stuck or worn feed pump, clogged filter
q
Leaked or clogged low-pressure fuel pipe
q
Bypass valve malfunction, defective assembly of other parts (See Fig.1.)
q
Fuel in oil pan (fuel leakage in head cover)
Fig. 1: Locations of overflow valve (1), bypass valve (2), and fuel inlet joint (3)
q
Overflow valve (1): Spring is seen through both holes.
q
Bypass valve (2): Spring is seen through hole on nut side.
q
Fuel inlet joint (3): Gauze filter is seen through both holes.
Note 2: Check, clean, and replace the filters and strainers according to the following procedure.
q
Fuel filter: Replace (Replace both prefilter and main filter.)
q
Water separator: Disassemble and check. If screen (4) is clogged, clean it.
q
Gauze filter: Disassemble and check. Clean, if clogged.
q
Upstream strainer of gauze filter: Disassemble and check. Clean, if clogged.
12V140E-3 Series
17
SEN00318-03
40 Troubleshooting
Check sheet for no-pressure feed

Model
Machine serial No.
Work No.
#
Date of check
Engine
Engine serial No.
Service meter
#
Worker's name
A. Visual check
1
Fuel leakage to outside
Clogging of fuel tank breather
Good NG
B. Check with machine monitor

(Fault history function, monitoring function, and reduced cylinder mode function)
3
Check of error/failure code
Good NG
/
Check of monitoring information

Code
*1
Displayed item
Engine speed
Unit
Standard value
(Reference
value)
Low idle
rpm
<By models>
High idle
rpm
<By models>
rpm
<By models>
Checking condition
Measured
Good NG
value
Low idle
High idle
100
mm3
MPa
*5
Common rail fuel pressure Equivalent to rating <By models>
MPa
Low idle
Fuel injection timing comHigh idle
mand
CA
*6
CA
CA
*7
Boost pressure
kPa
*8
Engine coolant temperature
Low idle
*9
Fuel temperature
Low idle
Unit
Standard value
(Reference
value)
*2
Throttle opening
*3
Fuel injection command
*4

command
Check of reduced cylinder mode operation (Engine speed)

Func
tion
5
*10
18
Reduced cylinder
Checking condition
Measured
Good NG
value
No. 1 cylinder
Low idle
rpm
No. 2 cylinder
Low idle
rpm
No. 3 cylinder
Low idle
rpm
No. 4 cylinder
Low idle
rpm
No. 5 cylinder
Low idle
rpm
No. 6 cylinder
Low idle
rpm
12V140E-3 Series
40 Troubleshooting
C. Check of fuel circuit pressure

6
Fuel low-pressure circuit pressure
SEN00318-03
Checking condition
High idle
Unit
Standard value
(Reference
value)
MPa
{kg/cm2}
Min. 0.15
{Min. 1.5}
Measured
Good NG
value
D. Check of strainers and filters

7
Visual check of strainers
Visual check of gauze filter
Visual check of fuel filter
Good NG
10 Visual check of bypass valve
Unit
Standard value
(Reference
value)
11 Leakage through pressure limiter No load, at rated output
cc/min
Max. 10
cc/min
960
cc/min
1,020
cc/min
1,080
cc/min
1,140
cc/min
1,200
E. Check of leakage and return

rate
12 Return rate from injector
Checking condition
Measured
Good NG
value
Speed:
Return
rate:
*1 *10:
When inspecting with INSITE (bench test tool), see Operation and Maintenance Manual (Testing
method).
When inspecting with the monitoring function of the machine, use the codes specified for each machine
model.
Equivalent to rating <By models>:
When inspecting the engine unit on the bench, operate it under a load equivalent to the rating. When
the engine is installed to the machine, however, the operation load equivalent to the rating depends on
the machine model.
12V140E-3 Series
19
SEN00318-03
40 Troubleshooting
E-68 Code [689/CA689] Eng. Ne Speed Sensor Error (LH bank)

Error code
Failure code
689
CA689
Contents of
trouble
Action of
controller
Trouble
Engine Ne Speed Sensor detected abnormality (LH bank)
Abnormality occurred in engine Ne speed sensor circuit.

Phenomenon
that appears on
machine
Related
information
Causes
1
Defective sensor power sup- If code [238/CA238] is indicated, carry out troubleshooting for it
ply system
first.


Ne (female) (1)
Resistance
Max. 1 z

Ne (female) (2)
Resistance
Max. 1 z

Ne (female) (3)
Resistance
Max. 1 z
3
Possible causes
and standard
value in normal
state

Resistance
Min. 1 Mz

Resistance
Min. 1 Mz

Resistance
Min. 1 Mz

4

Ne (female) (1) and LH J1 (female) (48)
Ne (female) (2)
Resistance
Min. 1 Mz

Ne (female) (2)
Resistance
Min. 1 Mz

Ne (female) (3)
Resistance
Min. 1 Mz
Defective mount of sensor or Check Ne speed sensor directly for defective mount (defective
5 defective rotation sensing
clearance) or check rotation sensing part (flywheel) directly for
part
defect.
Defective engine Ne speed
sensor
If causes 1 5 are not detected, engine Ne speed sensor may be

defective. (Since trouble is in system, troubleshooting cannot be
carried out.)
out.)
20
12V140E-3 Series
40 Troubleshooting
SEN00318-03
Circuit diagram related to engine Ne speed sensor
12V140E-3 Series
21
SEN00318-03
40 Troubleshooting
E-69 Code [689/CB689] Eng. Ne Speed Sensor Error (RH bank)

Error code
Failure code
689
CB689
Contents of
trouble
Action of
controller
Trouble
Engine Ne Speed Sensor detected abnormality (RH bank)
Abnormality occurred in engine Ne speed sensor circuit.

Phenomenon
that appears on
machine
Related
information
Causes
1
Defective sensor power sup- If code [238/CB238] is indicated, carry out troubleshooting for it
ply system
first.


Ne (female) (1)
Resistance
Max. 1 z

Resistance
Max. 1 z

Resistance
Max. 1 z
3
Possible causes
and standard
value in normal
state

Resistance
Min. 1 Mz

Resistance
Min. 1 Mz

Resistance
Min. 1 Mz

4

Ne (female) (1) and RH J1 (female) (48)
Ne (female) (2)
Resistance
Min. 1 Mz

Ne (female) (1) and RH J1(female) (27)
Ne (female) (3)
Resistance
Min. 1 Mz

(48) Ne (female) (2) and RH J1 (female)
Resistance
Min. 1 Mz
Defective mount of sensor or Check Ne speed sensor directly for defective mount (defective
5 defective rotation sensing
clearance) or check rotation sensing part (flywheel) directly for
part
defect.
sensor
If causes 1 5 are not detected, engine Ne speed sensor may be

defective. (Since trouble is in system, troubleshooting cannot be
carried out.)
out.)
22
12V140E-3 Series
40 Troubleshooting
SEN00318-03
Circuit diagram related to engine Ne speed sensor
12V140E-3 Series
23
SEN00318-03
40 Troubleshooting
E-70 Code [691/CA691] Intake Air Temp Sensor High Error (LH bank
only)
Error code
Failure code
691
CA691
Contents of
trouble
Action of
controller
Trouble
Intake air temperature sensor detected abnormally high temperature (LH bank)
Intake air temperature sensor circuit detected abnormally high temperature.

Fixes intake air temperature at (25 C) and continues operation.
Phenomenon
that appears on
machine
Related
information
Causes

Defective charge tempera1 ture sensor

(Internal trouble)
Possible causes
and standard
value in normal
state
TAM1
Intake air
temperature
Resistance
Between (A) (B)
10 100 C
0.5 20 kz
Between (A)
chassis ground
All range
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshootDisconnection in wiring haring without turning starting switch ON.
ness
Resis2 (Disconnection in wiring or
Max. 1 z
TAM1 (female) (A)
tance
Resistor)
Max. 1 z
TAM1 (female) (B)
tance
3
TAM1 (female) (A) and chassis ground
Resistance
Max. 1 Mz
24
TAM1 (male)
Intake air
temperature
Resistance
Between (43) (47)
10 100 C
0.5 20 kz
12V140E-3 Series
40 Troubleshooting
SEN00318-03
Circuit diagram related to intake air temperature sensor
12V140E-3 Series
25
SEN00318-03
40 Troubleshooting
E-71 Code [692/CA692] Intake Air Temp Sensor Low Error (LH bank
only)
Error code
Failure code
692
CA692
Contents of
trouble
Action of
controller
Trouble
Intake air temperature sensor detected abnormally low temperature (LH bank only)
Intake air temperature sensor circuit detected abnormally low temperature.

Fixes intake air temperature at (25 C) and continues operation.
Phenomenon
that appears on
machine
Related
information
Possible causes
and standard
value in normal
state
26
Causes

12V140E-3 Series
40 Troubleshooting
SEN00318-03
E-72 Code [731/CA731] Eng. G (Bkup) Speed Sensor Phase Error (LH
bank)
1
Error code
Failure code
731
CA731
Contents of
trouble
Action of
controller
Trouble
Engine G (Bkup) speed sensor abnormal phase (LH bank)
Engine G (Bkup) sensor circuit detected abnormality in phase.

Controls with signals of engine Ne speed sensor.
Phenomenon
Running engine stops (when Ne speed sensor is also abnormal).
that appears on
Stopped engine cannot be started (when Ne speed sensor is also abnormal).
machine
Related
information
Possible causes
and standard
value in normal
state
Causes

sensor system
Engine Ne speed sensor may be defective.

Carry out troubleshooting for [689/CA689] (E-68).

sensor system
Common rail pressure sensor may have electric trouble.

Carry out troubleshooting for code [778/CA778] (E-76).
E-73 Code [731/CB731] Eng. G (Bkup) Speed Sensor Phase Error (RH
bank)
1
Error code
Failure code
731
CB731
Contents of
trouble
Action of
controller
Trouble
Engine G (Bkup) speed sensor abnormal phase (RH bank)
Engine G (Bkup) sensor circuit detected abnormality in phase.

Controls with signals of engine Ne speed sensor.
Phenomenon
that appears on
machine
Related
information
Possible causes
and standard
value in normal
state
Causes
1
sensor system
2
12V140E-3 Series

sensor system

Engine Ne speed sensor may be defective.
Carry out troubleshooting for [689/CB689] (E-69).
Common rail pressure sensor may have electric trouble.
Carry out troubleshooting for code [778/CB778] (E-77).
27
SEN00318-03
40 Troubleshooting
E-74 Code [757/CA757] All Continuous Data Lost Error (LH bank)
Error code
Failure code
757
CA757
Contents of
trouble
Action of
controller
Trouble
All Engine Controller Data Lost Error (LH bank)
All data in engine controller are lost.

None in particular.
Phenomenon
that appears on Engine continues operation normally, but it may stop during operation or may not be able to start.
machine
Related
information
Possible causes
and standard
value in normal
state
Causes

E-75 Code [757/CB757] All Continuous Data Lost Error (RH bank)
Error code
Failure code
757
CB757
Trouble
All Engine Controller Data Lost Error (RH bank)
Contents of
trouble
Action of c
ontroller
None in particular.
Phenomenon
that appears on Engine continues operation normally, but it may stop during operation or may not be able to start.
machine
Related
information
Possible causes
and standard
value in normal
state
28
Causes

12V140E-3 Series
40 Troubleshooting
12V140E-3 Series
SEN00318-03
29
SEN00318-03
40 Troubleshooting
E-76 Code [778/CA778] Eng. G (Bkup) Speed Sensor Error (LH bank) 1
Error code
Failure code
778
CA778
Contents of
trouble
Action of
controller
Trouble
Engine G (Bkup) speed sensor abnormal (LH bank)
Abnormality occurred in engine G (Bkup) speed sensor circuit.

Controls with signals of Ne speed sensor.
Phenomenon
that appears on
machine
Related
information
Causes
1


LH G (female) (1)
Resistance
Max. 1 z

LH G (female) (2)
Resistance
Max. 1 z

LH G (female) (3)
Resistance
Max. 1 z
3
Possible causes
and standard
value in normal
state

LH G (female) (1) and chassis ground
Resistance
Min. 1 Mz

Resistance
Min. 1 Mz

Resistance
Min. 1 Mz

4

LH G (female) (1) and LH J1
(female) (47) LH G (female) (2)
Resistance
Min. 1 Mz

Resistance
Min. 1 Mz

Resistance
Min. 1 Mz
Defective mount of sensor or Check G (Bkup) speed sensor directly for defective mount (defec5 defective rotation sensing
tive clearance) or check rotation sensing part (in supply pump)
part
directly for defect.
6

sensor system
30
If causes 1 5 are not detected, engine G (Bkup) speed sensor

may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
out.)
12V140E-3 Series
40 Troubleshooting
SEN00318-03
Circuit diagram related to engine G (Bkup) speed sensor system
12V140E-3 Series
31
SEN00318-03
40 Troubleshooting
E-77 Code [778/CB778] Eng. G (Bkup) Speed Sensor Error (RH bank) 1
Error code
778
Contents of
trouble
Action of
controller
Phenomenon
that appears on
machine
Related
information
Possible causes
and standard
value in normal
state
32
Failure code
CB778
Trouble
Engine G (Bkup) speed sensor abnormal (RH bank)
Abnormality occurred in engine G (Bkup) speed sensor circuit.

Controls with signals of Ne speed sensor.
Causes
Defective sensor power sup- If code [187/CB187] or [227/CB227] is indicated, carry out trouble1
ply system
Disconnection in wiring har- Wiring harness between RH J1 (female)
ResisMax. 1 z
ness
(37) RH G (female) (1)
tance
Resisdefective contact in connecMax. 1 z
tance
tor)
ResisMax. 1 z
tance
Resis(37) RH G (female) (1) and chassis
Min. 1 Mz
tance
Ground fault in wiring harground
ness
3
(Short circuit with GND cirResis(47) RH G (female) (2) and chassis
Min. 1 Mz
cuit)
tance
ground
Resis(26) RH G (female) (3) and chassis
Min. 1 Mz
tance
ground
Resis(37) R G (female) (1) and RH J1
Min. 1 Mz
tance
Short circuit in wiring har(female) (47) RH G (female) (2)
ness
4
(With another wiring harResis(37) R G (female) (1) and RH J1
Min. 1 Mz
ness)
tance
(female) (26) RH G (female) (3)
Resis(47) R G (female) (2) and RH J1
Min. 1 Mz
tance
(female) (26) RH G (female) (3)
Defective mount of sensor or Check G (Bkup) speed sensor directly for defective mount (defec5 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 cansensor system
not be carried out.)
If causes 1 6 are not detected, engine controller may be defec7 Defective engine controller
tive. (Since trouble is in system, troubleshooting cannot be carried
out.)
12V140E-3 Series
40 Troubleshooting
SEN00318-03
Circuit diagram related to engine G (Bkup) speed sensor system
12V140E-3 Series
33
SEN00318-03
40 Troubleshooting
E-78 Code [781/CA781] Inter Multi-controller Communication Error (LH

bank)
1
Error code
Failure code
781
CA781
Contents of
trouble
Action of
controller
Trouble
Inter multi-controller communication error (LH bank)
Communication error occurred between engine controllers (LH bank)

None in particular.
Phenomenon
Single-bank operation
that appears on
Engine cannot be started with the key ON
machine
Related
information
Causes
ness
Max. 1 z
RH J1 (female) (8)
tance
Resistor)
Max. 1 z
RH J1 (female) (6)
tance
Possible causes
and standard
value in normal
state

2
RH J1 (female) (8) and chassis ground
Resistance
Min. 1 Mz

RH J1 (female) (6) and chassis ground
Resistance
Min. 1 Mz
34
LH J1 (female)
Resistance
Between (8) (6)
54 66 z

ground
Min. 1 Mz
12V140E-3 Series
40 Troubleshooting
SEN00318-03
Circuit diagram related to inter multi-controller communication
12V140E-3 Series
35
SEN00318-03
40 Troubleshooting
E-79 Code [781/CB781] Inter Multi-controller Communication Error (RH

bank)
1
Error code
Failure code
781
CB781
Contents of
trouble
Action of
controller
Trouble
Inter multi-controller communication error (RH bank)
Communication error occurred between engine controllers (LH bank)

None in particular.
Phenomenon
Single-bank operation
that appears on
Engine cannot be started with the key ON
machine
Related
information
Possible causes
and standard
value in normal
state
36
Causes

12V140E-3 Series
40 Troubleshooting
SEN00318-03
E-80 Code [1117/CA1117] Persistent Data Lost Error (LH bank)

Error code
Failure code
1117
CA1117
Contents of
trouble
Action of
controller
Trouble
Engine Controller Data Lost Error (LH bank)

None in particular.
Phenomenon
that appears on
machine
Related
information
Possible causes
and standard
value in normal
state
Causes

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

Error code
Failure code
1117
CB1117
Contents of
trouble
Action of
controller
Trouble
Engine Controller Data Lost Error (RH bank)

None in particular.
Phenomenon
that appears on
machine
Related
information
Possible causes
and standard
value in normal
state
12V140E-3 Series
Causes

37
SEN00318-03
40 Troubleshooting
E-82 Code [1257/CA1257] Harness Key error (LH bank)

Error code
Failure code
1257
CA1257
Contents of
trouble
Action of
controller
Trouble
Multi-controller identification harness key error (LH bank)
Collation of identification harness between respective bank controllers fail (LH bank)
Stops operation
Phenomenon
that appears on Engine cannot be started with the key ON
machine
Related
information
Causes
Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
ness
Resisdefective contact in connec- Wiring harness between OEM L (female) (7)
Max. 1 z
OEM
L
(female)
(34)
tance
tor)
Possible causes
and standard
value in normal
state

2
Between wiring harness OEM L (female) (8)
and chassis ground
Resistance
Min. 1 Mz
Between wiring harness OEM L (7) and

chassis ground
Resistance
Max. 1 z
Between wiring harness OEM L (8) and

chassis ground
Resistance
Min. 1 Mz
Circuit diagram related to multi-controller identification harness key
38
12V140E-3 Series
40 Troubleshooting
SEN00318-03
E-83 Code [1257/CB1257] Harness Key error (RH bank)

Error code
Failure code
1257
CB1257
Contents of
trouble
Action of
controller
Trouble
Multi-controller identification harness key error (RH bank)
Collation of identification harness between respective bank controllers fail (RH bank)
Stops operation
Phenomenon
that appears on Engine cannot be started with the key ON
machine
Related
information
Causes
Wrong connection of harness
1
Connector connection error Between OEM R (female) (7) OEM R
ResisMin. 1 Mz
(female) (34) terminals
tance
Possible causes
and standard
value in normal
state

2
Between wiring harness OEM R (female) (8)
and chassis ground
Resistance
Min. 1 Mz
Between wiring harness OEM R (7) and

chassis ground
Resistance
Min. 1 Mz
Between wiring harness OEM R (8) and

chassis ground
Resistance
Min. 1 Mz
Circuit diagram related to multi-controller identification harness key
12V140E-3 Series
39
SEN00318-03
40 Troubleshooting
E-84 Code [1548/CB1548] Injector #7 (R/B #1) System Open/Short Error

(RH bank)
1
Error code
Failure code
1548
CB1548
Contents of
trouble
Action of
controller
Trouble
Disconnection or short circuit in injector #7 (R/B #1) system

(RH bank)

None in particular.
Phenomenon
Output drops.
that appears on
machine
Related
information
Causes

Possible causes
and standard
value in normal
state
(Internal trouble)
RH CN1 (male)
Resistance
Between (1) (2)
0.4 1.1 z

ground
Min. 1 Mz
ness
Max. 1 z
(45) RH CN1 (female) (1)
tance
Resistor)
Max. 1 z
tance
3

(45) RH CN1 (female) (1) and chassis
ground
Resistance
Min. 1 Mz

ground
Resistance
Min. 1 Mz
40
RH J1 (female)
Resistance
Between (45) (53)
0.4 1.1 z

ground
Min. 1 Mz
12V140E-3 Series
40 Troubleshooting
SEN00318-03
Circuit diagram related to injector #7 (R/B #1) system
12V140E-3 Series
41
SEN00318-03
40 Troubleshooting

(RH bank)
1
Error code
Failure code
1549
CB1549
Contents of
trouble
Action of
controller
Trouble

(RH bank)

None in particular.
Phenomenon
Output drops.
that appears on
machine
Related
information
Causes

Possible causes
and standard
value in normal
state
(Internal trouble)
RH CN2 (male)
Resistance
Between (1) (2)
0.4 1.1 z

ground
Min. 1 Mz
ness
Max. 1 z
tance
Resistor)
Max. 1 z
tance
3

ground
Resistance
Min. 1 Mz

ground
Resistance
Min. 1 Mz
42
RH J1 (female)
Resistance
Between (54) (51)
0.4 1.1 z

ground
Min. 1 Mz
12V140E-3 Series
40 Troubleshooting
SEN00318-03
12V140E-3 Series
43
SEN00318-03
40 Troubleshooting
E-86 Code [1551/CB1551] Injector #10 (R/B #4) System Open/Short

Error (RH bank)
Error code
Failure code
1551
CB1551
Contents of
trouble
Action of
controller
Trouble

(RH bank)

None in particular.
Phenomenon
Output drops.
that appears on
machine
Related
information
Causes

Possible causes
and standard
value in normal
state

(Internal trouble)
RH CN4 (male)
Resistance
Between (1) (2)
0.4 1.1 z

ground
Min. 1 Mz
ness
Max. 1 z
tance
Resistor)
Max. 1 z
tance
3

ground
Resistance
Min. 1 Mz

ground
Resistance
Min. 1 Mz
44
RH J1 (female)
Resistance
Between (56) (58)
0.4 1.1 z

ground
Min. 1 Mz
12V140E-3 Series
40 Troubleshooting
SEN00318-03
12V140E-3 Series
45
SEN00318-03
40 Troubleshooting

Error (RH bank)
Error code
Failure code
1552
CB1552
Contents of
trouble
Action of
controller
Trouble

(RH bank)

None in particular.
Phenomenon
Output drops.
that appears on
machine
Related
information
Causes

Possible causes
and standard
value in normal
state

(Internal trouble)
RH CN5 (male)
Resistance
Between (1) (2)
0.4 1.1 z

ground
Min. 1 Mz
ness
Max. 1 z
tance
Resistor)
Max. 1 z
tance
3

ground
Resistance
Min. 1 Mz

ground
Resistance
Min. 1 Mz
46
RH J1 (female)
Resistance
Between (46) (60)
0.4 1.1 z

ground
Min. 1 Mz
12V140E-3 Series
40 Troubleshooting
SEN00318-03
12V140E-3 Series
47
SEN00318-03
40 Troubleshooting

Error (RH bank)
Error code
Failure code
1553
CB1553
Contents of
trouble
Action of
controller
Trouble

(RH bank)

None in particular.
Phenomenon
Output drops.
that appears on
machine
Related
information
Causes

Possible causes
and standard
value in normal
state

(Internal trouble)
RH CN6 (male)
Resistance
Between (1) (2)
0.4 1.1 z

ground
Min. 1 Mz
ness
Max. 1 z
tance
Resistor)
Max. 1 z
tance
3

ground
Resistance
Min. 1 Mz

ground
Resistance
Min. 1 Mz
48
RH J1 (female)
Resistance
Between (57) (59)
0.4 1.1 z

ground
Min. 1 Mz
12V140E-3 Series
40 Troubleshooting
SEN00318-03
12V140E-3 Series
49
SEN00318-03
40 Troubleshooting

(RH bank)
1
Error code
Failure code
1622
CB1622
Contents of
trouble
Action of
controller
Trouble

(RH bank)

None in particular.
Phenomenon
Output drops.
that appears on
machine
Related
information
Causes

Possible causes
and standard
value in normal
state
(Internal trouble)
RH CN3 (male)
Resistance
Between (1) (2)
0.4 1.1 z

ground
Min. 1 Mz
ness
Max. 1 z
tance
Resistor)
Max. 1 z
tance
3

ground
Resistance
Min. 1 Mz

ground
Resistance
Min. 1 Mz
50
RH J1 (female)
Resistance
Between (55) (52)
0.4 1.1 z

ground
Min. 1 Mz
12V140E-3 Series
40 Troubleshooting
SEN00318-03
12V140E-3 Series
51
SEN00318-03
40 Troubleshooting
E-90 Code [1633/CA1633] KOMNET Datalink Timeout Error (LH bank) 1

Error code
Failure code
1633
CA1633
Contents of
trouble
Action of
controller
Trouble
KOMNET error (LH bank)
Abnormality occurred in circuit of KOMNET communication with machine (LH bank).

Normal control (communication function disabled)
Phenomenon
that appears on Different problems occur on different machine models.
machine
Related
information
Causes


Possible causes
and standard
value in normal
state
Wiring harness between OEM L (female)

(46) OEM R (female) (46)
Resistance
Max. 1 z

Resistance
Max. 1 z

(46) OEM L (female) (47)
Resistance
108
132 z
2

(46) OEM R (female) (46) and chassis
ground
Resistance
Min. 1 Mz

(47) OEM R (female) (47) and chassis
ground
Resistance
Min. 1 Mz
52

(46) OEM L (female) (47)
Resistance
108
132z
Wiring harness between OEM R (female)

Resistance
108
132 z
12V140E-3 Series
40 Troubleshooting
SEN00318-03
KOMNET-related circuit diagram
12V140E-3 Series
53
SEN00318-03
40 Troubleshooting
E-91 Code [2185/CA2185] Throttle Sens. Sup. Volt. High Error (LH bank
only)
1
Error code
Failure code
2185
CA2185
Contents of
trouble
Action of
controller
Trouble
Throttle sensor detection of abnormally high supply voltage

(LH bank only)
High voltage abnormality occurred to throttle sensor power supply (5 V) circuit.

Phenomenon
that appears on Depends on machine model.
machine
Related
information
Causes

Defective deceleration sen1 sor

(Internal trouble)
Possible causes
and standard
value in normal
state
Decelerator sensor
DEC connector
ness
Max. 1 z
(22) DEC (female) (A)
tance
defective contact in connecWiring harness between OEM L (female)
Resistor)
Max. 1 z
(23) DEC (female) (C)
tance
3

4
54
Disconnect devices
error code disappears subsequently,
that device has a
defect in it.
(22) DEC (female) (A) and chassis ground
Resistance
Min. 1 Mz

(23) DEC (female) (C) and chassis ground
Resistance
Min. 1 Mz
(22) DEC (female) (A) and OEM L
(female) (23) DEC (female) (C)
Resistance
Min. 1 Mz

OEM L
Voltage
Between (22) (23)
4.75 5.25 V
12V140E-3 Series
40 Troubleshooting
SEN00318-03
Circuit diagram related to deceleration pedal type throttle sensor (Case of D475-5)
12V140E-3 Series
55
SEN00318-03
40 Troubleshooting
E-92 Code [2186/CA2186] Throttle Sens. Sup. Volt. Low Error (LH bank
only)
1
Error code
Failure code
2186
CA2186
Contents of
trouble
Action of
controller
Trouble
Throttle sensor detected abnormally low supply voltage

(LH bank only)
Low-voltage abnormality occurred to throttle sensor power supply (5V) circuit.

Phenomenon
that appears on Depends on machine model.
machine
Related
information
Possible causes
and standard
value in normal
state
56
Causes

12V140E-3 Series
40 Troubleshooting
SEN00318-03
E-93 Code [2249/CA2249] Rail Press. Very Low Error (LH bank)
Error code
Failure code
2249
CA2249
Contents of
trouble
Action of
controller
Trouble
Supply pump no-pressure feed error 2 (LH bank)

Phenomenon
machine
Related
information
Possible causes
and standard
value in normal
state
Causes

E-94 Code [2249/CB2249] Rail Press. Very Low Error (RH bank)
Error code
Failure code
2249
CB2249
Contents of
trouble
Trouble
Supply pump no-pressure feed error 2 (RH bank)
Action of ontrol Limits common rail pressure.

ler
Phenomenon
machine
Related
information
Possible causes
and standard
value in normal
state
12V140E-3 Series
Causes

57
SEN00318-03
40 Troubleshooting
E-95 Code [ *1/] Eng. Overheat (LH bank only)

Error code
Failure code
*1
Contents of
trouble
Action of
controller
Trouble
Engine overheat (LH bank only)
Engine coolant temperature is above operating range.

Limits output and continues operation.
Phenomenon
machine
Related
information
Possible causes
and standard
value in normal
state
Causes
This defective phenomenon is indicated only on the installed

Carry out troubleshooting on machine when it was detected.
1
machine side
Accordingly, contents of troubleshooting differ by the machine
model. See Shop manual for machine.
E-96 Code [ *2/] Eng. Oil Press. Low Speed Derate (LH bank only) 1
Error code
Failure code
*2
Contents of
trouble
Action of
controller
Trouble
Engine oil pressure low and speed derate (LH bank only)
Engine oil pressure is below operating range.

Limits output and continues operation (Limits fuel injection rate and engine speed).
Phenomenon
machine
Related
information
Possible causes
and standard
value in normal
state
58
Causes

1
machine side
12V140E-3 Series
40 Troubleshooting
SEN00318-03
E-97 Code [ *3/] Press. Low Torque Derate (LH bank only)
Error code
Failure code
*3
Contents of
trouble
Action of
controller
Trouble
Engine oil pressure low and torque derate (LH bank only)
Engine oil pressure is below operating range.

Limits output and continues operation (Limits fuel injection rate and engine speed).
Phenomenon
machine
Related
information
Possible causes
and standard
value in normal
state
Causes

1
machine side
12V140E-3 Series
59
SEN00318-03
40 Troubleshooting

2009 KOMATSU
All Rights Reserved
60
12V140E-3 Series
SEN00320-03
ENGINE
1SHOP MANUAL
12V140E-3 Series

General information on disassembly and
assembly
How to read this manual ................................................................................................................................. 2
Coating materials list....................................................................................................................................... 4
Special tool list ................................................................................................................................................ 7
Sketches of special tools ................................................................................................................................ 9
12V140E-3 Series
SEN00320-03
How to read this manual

1.
(Rev. 2009.01)
1
Removal and installation of assemblies

Special tools
q
Special tools which are necessary for
r e m o v a l o r i n s ta l l a t i o n o f pa r ts a r e
described as A1,X1 etc. and their parts
numbers, part names and quantities are
described in the special tool list.
q
Also the following information is described
in the special tool list.
1) Necessity
t : Special tools that cannot be substituted and should always be used
q : Special tools that will be useful if available and are substitutable with tools
available on the market
2) Distinction of new and existing special tools
N:
Tools newly developed for this
model. They have a new part number respectively.
R:
Tools made available by redesigning the existing tools which were
developed for other models. Each
of them has a new part number
assigned by setting forward the
part number of the existing tool.
Blank: Tools already available for other
models. They can be used without
any modification.
3) Circle mark Q in sketch column:
q
The sketch of the special tool is presented in the section of "Sketches of
special tools".
q
Part No. of special tools starting with
79*T-***-****:
means that they are not available
from Komatsu Ltd. (i.e. tools to be
made locally).
Removal
q
In "Removal" section, the work procedures,
precautions and know-how to do the work, and
the amount of oil and coolant to be drained are
described.
q
Common tools that are necessary for removal
are described as [1], [2] etc. and their part
numbers, part names and quantities are not
described.
q
Various symbols used in "Removal" section
are explained and listed below.
k
: Precautions related to work safety
a: Guidance or precautions for the work

[*1] : This mark shows that instructions or precautions for parts installation work are given in
"Installation" section.
6
: Amount of oil or coolant to be drained
: Weight of part or component
Installation
q
Unless otherwise instructed, installation of parts
is to be done in the reverse order to removal.
q
Instructions and precautions for parts installation is shown with the mark ([*1], [*2]...) which
corresponds to the mark in "Removal" section.
q
Common tools that are necessary for installation are described as [1], [2] etc. and their
part numbers, part names and quantities are not
described.
q
Marks shown in the "Installation" section stand
for the following.
k

2
: Type of coating material
: Tightening torque
: Amount of oil or coolant to be replenished
Sketches of special tools

q
Various special tools are illustrated for the local
manufacture.
12V140E-3 Series
2.
SEN00320-03
Disassembly and assembly of assemblies

Special tools
q
Special tools which are necessary for disassembly and assembly of parts are
described as A1,X1 etc. and their part
numbers, part names and quantities are
described in the special tool list.
q
Also the following information is described
in the special tool list.
1) Necessity
t : Special tools that cannot be substituted
and should always be used.
q : Special tools that will be useful if available and are substitutable with tools
available on the market.
2) Distinction of new and existing special tools
N
: Tools newly developed for this
model. They have a new part
number respectively.
R
: Tools made available by redesigning the existing tools which were
developed for other models. Each
of them has a new part number
assigned by setting forward the
part number of the existing tool.
Blank : Tools already available for other
models. They can be used without
any modification.
3) Circle mark Q in sketch column:
q
The sketch of the special tool is presented in the section of "Sketches of
special tools".
q
Part No. of special tools starting with
79*T-***-****:
means that they are not available
from Komatsu Ltd. (i.e. tools to be
made locally).
Disassembly
q
In "Disassembly" section, the work procedures,
the amount of oil and coolant to be drained are
described.
q
Common tools that are necessary for disassembly are described as [1], [2] etc. and
their part numbers, part names and quantities
are not described.
q
The meanings of the symbols used in "Disassembly" section are as follows.
k

6:
Amount of oil or coolant drained
Assembly
q
In "Assembly" section, the work procedures,
the amount of oil and coolant to be replenished
are described.
q
Common tools that are necessary for assembly are described as [1], [2] etc. and their
part numbers, part names and quantities are
not described.
q
The meanings of the symbols used in "Assembly" section are as follows.
k

2
: Type of coating material
: Tightening torque
: Amount of oil or coolant to be replenished

q
Various special tools are illustrated for the local
manufacture.
12V140E-3 Series
SEN00320-03
Coating materials list
(Rev. 2009.02)
1
a The recommended coating materials such as adhesives, gasket sealants, and greases used for disassembly and assembly are listed below.
a For coating materials not listed below, use the equivalent of products shown in this manual.
Category
Komatsu
code
Part number
Q'ty
Container
Main features and applications
LT-1A
790-129-9030
150 g
Tube
Used to prevent rubber gaskets, rubber cushions, and cork plugs from coming out.
LT-1B
790-129-9050
20 g
(2 pcs.)
Used for plastic (except polyethylene,

polypropylene, tetrafluoroethylene and vinyl
Polyethylene
chloride), rubber, metal, and non-metal parts
container
which require immediate and strong adhesion.
LT-2
09940-00030
50 g
Polyethylene Features: Resistance to heat and chemicals.

container Used to fix and seal bolts and plugs.
Adhesive
LT-3
LT-4
790-129-9040
250 g
Holtz MH 705
790-129-9120
75 g
ThreeBond
1735
Gasket sealant
790-129-9140
Can
Used to stick and seal metal, glass, and plastics.
Polyethylene
Used to seal plugs.
container
Tube
Heat-resistant seal used to repair engines.
50 g
Quick-setting adhesive.
Polyethylene Setting time: Within 5 sec. to 3 min.
container Used mainly to stick metals, rubbers, plastics,
and woods.
Quick-setting adhesive.
Quick-setting type.
Polyethylene
(max. strength is obtained after 30 minutes)
container
Used mainly to stick rubbers, plastics, and
metals.
Aron-alpha
201
790-129-9130
2g
Loctite
648-50
79A-129-9110
50 cc
Features: Resistance to heat and chemicals.

Polyethylene
Used for fitted portions used at high temperacontainer
tures.
1 kg
Used to seal various threaded portions, pipe

Polyethylene
joints, and flanges.
container Used to seal tapered plugs, elbows, and nipples of hydraulic piping.
LG-5
790-129-9080
LG-6
790-129-9160
200 g
Tube
Features: Silicon-based heat and cold-resistant sealant.

Used to seal flange surfaces and threaded
portions.
Used to seal oil pan, final drive case, etc.
LG-7
790-129-9170
1 kg
Tube
Features: Silicon-based quick-setting sealant.

Used to seal flywheel housing, intake manifold, oil pan, thermostat housing, etc.
Tube
Features: Silicon-based, heat and cold-resistant, vibration-resistant, impact-resistant sealant.

Used to seal transfer case, etc.
Tube
Used for rough surfaces such as the circle

gear top seal which does not need to be
clamped, water resistance of the clearance at
the welded area, etc.
Can be coated with paint.
LG-8
ThreeBond
1207B
LG-9
ThreeBond
1206D
790-129-9060
Adhesive: 1 kg
(Set of adhesive
Hardener: 500 g
and hardener)
419-15-18131
790-129-9310
100 g
200 g
12V140E-3 Series
Gasket sealant
CateKomatsu code
gory
Part number
Q'ty
Container
LG-10
ThreeBond
1206E
790-129-9320
200 g
Tube
Used as lubricant/sealant when the radiator

hoses are inserted.
Can be coated with paint.
LG-11
ThreeBond
1121
790-129-9330
200 g
Tube
Feature: Can be used together with gaskets.

Used for covers of the transmission case and
steering case etc.
ThreeBond
1211
790-129-9090
100 g
Tube
Gasket sealant used to repair engine.
Tube
Used to prevent scuffing and seizure of press-fitted portions, shrink-fitted portions, and threaded
portions.
Used to lubricate linkages, bearings, etc.
Can
Spray type
Thin molybdenum disulphide films are made on
metal surfaces to prevent the metals from scuffing each other.
Applicable for the propeller shaft splines, needle
bearings, pins and bolts of various links, etc.
Can
Feature: Seizure and scuffing prevention compound with metallic super-fine-grain, etc.
Used for the mounting bolt in the high temperature area of the exhaust manifold and the turbocharger, etc.
Various
Various
Feature: Lithium grease with extreme pressure

lubrication performance.
General purpose type.
Seizure
prevention
compound
Molybdenum
disulfide
lubricant
LM-P
LC-G
NEVER-SEEZ
09940-00040
09995-00250
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
G2-LI
SYG2-160LI
G0-LI
SYGA-160CNLI
*: For cold district
SYG0-400LI-A (*)
SYG0-160CNLI
(*)
Molybdenum
SYG2-400M
disulfide grease SYG2-400M-A
LM-G (G2-M)
SYGA-16CNM
Grease
SEN00320-03
SYG2-400T-A
SYG2-16CNT
SYG0-400T-A (*)
*: For cold district SYG0-16CNT (*)
Hyper White
Grease G2-T,
G0-T (*)
SYG2-400B
Biogrease
G2-B, G2-BT (*) SYGA-16CNB
*: For use at high SYG2-400BT (*)
temperature and SYGA-16CNBT
under high load
(*)
G2-S
ThreeBond
1855
G2-U-S
ENS grease
12V140E-3 Series
427-12-11871
200 g
190 g
Used for parts under heavy load.

Caution:
400 g x 10 Bellows-type Do not apply grease to rolling bearings like
400 g x 20 container
swing circle bearings, etc. and spline.
The grease should be applied to work equipment
16 kg
Can
pins at their assembly only, not applied for
greasing afterwards.
400 g
16 kg
400 g
16 kg
200 g
2 kg
Bellows-type
container
Can
Seizure resistance, heat resistance and water

resistance higher than molybdenum disulfide
grease.
Not conspicuous on machine since color is
white.
Bellows-type Since this grease is decomposed by natural baccontainer

teria in short period, it has less effects on microorganisms, animals, and plants.
Can
Tube
Feature: Silicone grease with wide using temperature range, high resistance to thermal-oxidative degradation and performance to prevent
deterioration of rubber and plastic parts.
Used for oil seals of the transmission, etc.
Can
Feature: Urea (organic system) grease with heat

resistance and long life. Enclosed type.
Used for rubber, bearing and oil seal in damper.
Caution: Do not mix with lithium grease.
SEN00320-03
Part number
SUNSTAR
PAINT PRIMER
580 SUPER
SUNSTAR
PAINT PRIMER
435-95
Container
20 ml
Glass
container
Used as primer for cab side.

(Using limit: 4 months after date of manufacture)
20 ml
Glass
container
Used as primer for glass side.

20 ml
Glass
container
417-926-3910
22M-54-27230
Used as primer for painted surface on cab

side.
Used as primer for black ceramic-coated
surface on glass side and for hard polycarbonate-coated surface.
SUNSTAR
GLASS
PRIMER
435-41
22M-54-27240
150 ml
Can
SUNSTAR
SASH PRIMER
GP-402
22M-54-27250
20 ml
Glass
container
Used as primer for sash (Almite).

SUNSTAR
PENGUINE
SEAL 580
SUPER S or
W
417-926-3910
320 ml
Polyethylene
container
S is used for high-temperature season

and W for low-temperature season as
adhesive for glass.
Sika Japan,
Sikaflex 256HV
20Y-54-39850
310 ml
Polyethylene
container
Used as adhesive for glass.

SUNSTAR
PENGUINE
SUPER 560
22M-54-27210
320 ml
Ecocart
(Special
container)
SUNSTAR
PENGUINE
SEAL No. 2505
417-926-3920
320 ml
Polyethylene
container
SEKISUI
SILICONE
SEALANT
20Y-54-55130
333 ml
Polyethylene
container
Used to seal front window.

Cartridge
Used to seal joint of glasses.

Translucent white seal.
GE TOSHIBA
SILICONES
TOSSEAL 381
22M-54-27220
333 ml
Adhesive for cab glass
Caulking material
Adhesive
Primer
SUNSTAR
GLASS
PRIMER 580
SUPER
Q'ty
Adhesive for cab glass
CateKomatsu code
gory
Used as adhesive for glass.

Used to seal joints of glass parts.
12V140E-3 Series
SEN00320-03
Special tool list
(Rev. 2009.01)
1
Part No.
Engine repair stand
t 1
790-901-1800
Bracket assembly
t 1
790-901-1810
Bracket
t 1
790-901-1820
Bracket
t 1
790-901-1830
Bracket
t 1
790-901-1840
Bracket
t 1
790-901-1510
Plate
t 4
02100-01038
Bolt
t 36
01252-11050
Bolt
t 16
01643-31645
Washer
t 12
01643-31032
Washer
t 16
01602-21648
Washer
t 24
795-102-2102
Spring pusher
t 1
795-102-2110
Handle
t 1
795-102-2120
Bracket
t 1
795-102-4210
Bracket
t 1
01016-50830
Bolt
t 1
01580-10806
Nut
t 1
01144-31270
Stud
t 1
01580-11210
Nut
t 1
790-501-4000
Disassembly and
assembly of engine
assembly
Disassembly and
assembly of cylinder
head
Part name
Q'ty
Symbol
Removal and
installation of piston ring
795-100-1191
Piston ring tool
t 1
Measurement of
cylinder liner projection
795-502-1121
Holder
t 1
Removal of cylinder liner
795-236-1000
Liner puller
t 1
Installation of cylinder
liner
795-230-5472
Liner driver
t 1
Angle tightening of bolt
795-331-1110
Wrench
t 1
Installation of piston
795-236-1500
Piston holder
t 1
12V140E-3 Series
New/Remodel
Sketches
Work item
Necessity
a Tools with part number 79*T-***-**** means that they are not available from Komatsu Ltd. (i.e. tools to be
made locally).
a Necessity
: t . . . . . . Special tools that cannot be substituted and should always be used
: q . . . . . . Special tools that will be useful if available and are substitutable with tools available on the market
a New/Remodel: N. . . . . . Tools newly developed for this model. They have a new part number respectively.
: R. . . . . . Tools made available by redesigning the existing tools which were developed for
other models. Each of them has a new part number assigned by setting forward
the part number of the existing tool.
: Blank . . Tools already available for other models. They can be used without any modification.
a Tools marked with Q in the sketch column are presented in the sketches of the special tools (See "Sketches of special tools")
Remarks
Installation of rear oil

seal
Press fitting of valve

stem seal
Adjusting valve
clearance
Removal of front and

rear oil seal
New/Remodel
Sketches
Installation of front oil

seal
Symbol
795T-621-1430
Plate
t 1
795T-621-1441
Push tool
t 1
01050-32280
Bolt
t 3
01582-02218
Nut
t 3
01640-22232
Washer
t 3
795T-621-1531
Push tool
t 1
01050-32050
Bolt
t 5
01640-02032
Washer
t 5
795T-621-1540
Push tool
t 1
Q For PC2000-8
01050-32060
Bolt
t 5
For PC2000-8
01640-02032
Washer
t 5
For PC2000-8
795-130-1720
Push tool
t 1
Thickness gauge
q 1
Seal puller
q 1
Part No.
Commercially
available
795-931-1100
Part name
Necessity
Work item
Q'ty
SEN00320-03
Remarks
IN: 0.35 mm, EX: 0.57 mm
12V140E-3 Series
SEN00320-03
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
J Plate
J Push tool
12V140E-3 Series
SEN00320-03
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
K Push tool
K Push tool (For PC2000-8)
10
12V140E-3 Series
12V140E-3 Series
SEN00320-03
11
SEN00320-03

2011 KOMATSU
All Rights Reserved
12
12V140E-3 Series
SEN00321-01
ENGINE
1SHOP MANUAL
12V140E-3 Series

Disassembly and assembly, Part 1 ................................................................................................................. 2
General disassembly of engine ............................................................................................................ 2
12V140E-3 Series
SEN00321-01
General disassembly of engine 1

a
a
1.
2.
The shapes, quantity, locations, etc. of the

parts depend on each applicable machine.
Take care.
When a part is provided on both sides of the
bank, one side alone is shown as an example.
Except where otherwise specified, contents of
the work shall be the same on both sides of the
bank.
Preparation work
Before disassembling the engine, check its
parts for cracking, damage, etc. and clean the
entire engine carefully for accurate inspection
of its parts and quick disassembly and assembly.
a Before cleaning the engine, carefully seal
or remove the openings, electric parts,
and wiring connectors so that water will
not enter them.

Remove engine harness (1) and then remove
starting motor assemblies (2) and (3).
a Remove the assembly at the top first
being followed by that at the bottom.
5.
Alternator
1) Remove auxiliary equipment belt (1).
2) Remove alternator (2).
Installation to engine repair stand

1) Install the engine assembly (1) to tool A.
4 Engine assembly:
Approx. 3,800 kg
2)
3.
4.
Drain the engine coolant and engine oil.

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

Disconnect the connector and terminal and
then remove engine harness (1) from the
engine assembly.
12V140E-3 Series
6.
SEN00321-01
Fuel filter and filter head assembly, and

priming pump
1) Remove fuel tubes (1) and (2).
2) Remove fuel filter and filter head assembly (3).
3) Remove priming pump (4).
9.
7.
Air intake connector

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

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

Remove spill tube (1).
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 positions of clamps (1) (3) using paint.
3) Remove clamps (1) (3).
4) Remove high-pressure pipes (5) and (6).
12V140E-3 Series
SEN00321-01
12. High-pressure pipe (between common rail

fuel injector)
2)
Apply a marking to every installation positions of clamps (2) and (3) using paint.
3)
4)
5)
13. Air intake manifold assembly

1) Remove support (1).
2)
3)
Remove bracket.
Remove all clamps (2) and (3).
Remove 6 high-pressure pipes (4).
Lift air intake manifold (2) temporarily and

then remove the mounting bolts.
Lift off air intake manifold assembly (2).
4 Air intake manifold assembly:
45 kg
12V140E-3 Series
SEN00321-01
16. Exhaust manifold assembly

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

Remove exhaust connectors (1) and (2).
2)
3)
15. Turbocharger assembly

1) Remove 2 water pipes and 2 oil pipes.
a When the air-cooled turbocharger is
used, the oil pipes alone are provided.
2) Lift turbocharger assembly (1) temporarily
and then remove the mounting bolts.
3) Lift off turbocharger assembly (1).
4 Turbocharger assembly: 35 kg
12V140E-3 Series
Lift exhaust manifold assembly (5) temporarily and then remove the mounting bolts.
Lift off exhaust manifold assembly (5).
4 Exhaust manifold assembly: 25 kg
17. Common rail

1) Remove fuel tube (1).
2) Remove common rail (2).
SEN00321-01
18. Supply pump assembly

1) Remove oil tube (1)
2) Remove supply pump assembly mounting bolt (2).
3) Remove supply pump assembly (3).
3)
Remove water 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).
12V140E-3 Series
22. Plate and block

Remove plates (1) and (2) and block (3).
SEN00321-01
25. Head cover

Remove head cover (1).
a Repeat the same procedure on every cylinder up to removal of the cylinder head
assembly.
23. Fuel tube

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

1) Remove bracket (1) and then remove oil
filler tube (2).
2) Loosen the sleeve nut at the base and
then remove oil level gauge (3).
3)
12V140E-3 Series
Remove air intake rocker arm (4), spacer

(5) and exhaust rocker arm (6) from rocker
shaft (7).
SEN00321-01
27. Push rod

Remove push rod (1).
28. Injector harness

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

1) Remove holder mounting bolt (1).
2)
Insert a small L-bar [1] under the fuel connector and pry out fuel injector (2) slowly.
a Do not grip the solenoid valve at the
top of the injector to pull off the injector.
30. Crosshead
Remove crosshead (1).
31. Cylinder head assembly

1) Remove the water tube.
2) Lift off cylinder head assembly (1).
4 Cylinder head assembly: 25 kg
12V140E-3 Series

a
3)
4)
When removing the cylinder head

assembly without removing the fuel
injector, be sure to prevent its interference with the floor surface since the
injector tip protrudes through the bottom of the cylinder head.
Remove the cylinder head gasket.

Disassemble the cylinder head assembly
1] Using tool B, compress the valve
spring to remove cotter (2).
2] Remove upper seat (3), outer spring
(4), and inner spring (5).
3]
4]
SEN00321-01
Remove lower seat (6).

Raise the cylinder head and remove
valve (7).
12V140E-3 Series
32. Oil pan

1) Support the front and rear side of oil pan
(1) with block [1].
2) Remove all oil pan mounting bolts.
3) Separate the gasket sealant.
4) Lift the engine and then remove oil pan
(1).
4 Oil pan: 90 kg
33. Suction pie and under plate

1) Fix under plate (1) temporarily using several oil pan mounting bolts.
2) Remove stay (2) and then remove suction
pipe (3).
SEN00321-01
3)
4)
Support under plate (1) using jack [1].

Remove the bolts used for temporary fixing and then lower the jack carefully to
remove under plate (1).
4 Under plate: 25 kg
34. Relief valve

1) Remove relief valve (1).
2)
Install the engine again to tool A.
36. Breather
Remove breather (1), blowby pipe (2) and
plate (3).
a Remove the plate on the left bank alone.
37. Thermostat case

1) Remove water outlets (1).
2) Remove thermostat case (2).
3)
Remove thermostat (3) from thermostat

case (2).
35. Alternator bracket

Remove alternator bracket (1).
10
12V140E-3 Series
38. Front engine hanger

Remove front engine hanger (1).
SEN00321-01
2]
3]
4]

1) Remove coolant temperature sensor (1).
2) Remove thermostat housing (2).
Remove shaft (5), thrust plate (6) and

gear (7) as a unit.
Remove gear (7) from shaft (5).
Pull off oil seal (9) and bushing (10)
from housing (8).
41. Flywheel assembly

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

1) Remove pulley (1).
2) Remove accessory drive (2).
3)
Disassemble the accessory drive according to the following procedure.

1] Pull off hub (3) and then remove
thrust plate (4).
12V140E-3 Series
11
SEN00321-01
42. Flywheel housing

1) Remove burring tool (1) and Ne speed
sensor (2).
2)
Remove engine speed sensor (3).
3)
Lift flywheel housing (4) temporarily and

then remove the mounting bolt.
Lift off the flywheel housing (4).
4 Flywheel housing: 230 kg
4)
43. Rear oil seal

Remove rear oil seal (1) from the flywheel
housing.
44. Damper and crank pulley assembly

1) Lift damper and crank pulley assembly (1)
temporarily and then remove the mounting
bolts.
2) Lift off damper and crank pulley assembly
(1).
4 Damper and crank pulley assembly: 75 kg
45. Front support

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

Lift off gear case cover (1).
a As a cover for carrying a unit is put on the
machine in the figure below, the shape of
actual machine is partially different from it.
4 Gear case cover:75 kg
SEN00321-01
3)
Remove thrust plate (4) from the shaft.

a A indicates the oil channel.
47. Front oil seal

Remove front oil seal (1) from the gear case
cover.
49. Supply pump gear

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

1) Remove plate (1).
2) Remove idler gears (large) (2) and (3).
50. Idler gear (Small)

1) Remove plate (1).
2) Remove idler gear (small) (2).
12V140E-3 Series
13
SEN00321-01
51. Oil pump assembly

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

1) Remove oil tube (1)
a Remove the oil tube on the left bank
alone.
2) Remove supply pump drive case (2).
53. Oil cooler (Front side)

Remove oil cooler (front side) (1)
54. Cam follower assembly

1) Remove plate (1) and cam follower cover
(2).
14
55. Camshaft assembly

1) Turn cam gear (1) to remove mounting
bolt (2) through lightening hole.
12V140E-3 Series
SEN00321-01
a
a
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.
Be sure to remove the piston cooling nozzle before removing the piston connecting
rod assembly.
When removing the nozzle, turn it 90 so
that it may not hit the piston.
58. Piston and connecting rod assembly

1) Prior to the removal, measure the side
clearance of the connecting rod using dial
gauge [1] in order to use it as a rough
standard in the assembly.
a Check the stamped No. of the connecting rod cap.
q
Make sure that the cap No. and
cylinder No. are the same.
q
The No. must be stamped on the
cam side.
a If the cylinder No. is not stamped,
write it using an electric pen prior
to the removal (it is not acceptable to stamp the number).
56. Timing gear case

1) Lift timing gear case (1) temporarily and
then remove the mounting bolt.
2) Lift off timing gear case (1).
4 Gear case cover: 55 kg
2)
3)
Rotate the crankshaft in order to drive the

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

Remove piston cooling nozzle (1).
12V140E-3 Series
15
SEN00321-01
4)
5)
6)
7)
8)
16
Hit the connecting rod head lightly using a

plastic hammer to loosen the connecting
rod cap and connecting rod.
Scrub the carbon off the top wall of the
liner using fine sandpaper.
Turn the crankshaft until the piston comes
to the top dead center and then remove
the connecting rod cap (2).
Push in and piston and connecting rod

assembly using pushing bar [1] from the
oil pan side and then remove the assembly while supporting piston (3) from the
cylinder head side.
a Take care not to damage the inside of
the cylinder with a corner of the connecting rod.
Remove other piston and connecting rod
assemblies according to the above procedure.
a Keep the sliding portion and bearing
of the piston in a safe place to protect
them from damage.
a Assemble the connecting rod and cap
temporarily and keep them along with
the connecting rod bearing on a cylinder to cylinder basis.
9)
Disassemble the piston and connecting

rod assembly according to the following
procedure.
1] Remove snap ring (4)
2] Support connecting rod (5) with hand
and then remove piston pin (6) to disconnect piston (7) from the connecting rod.
a When the piston pin is firmly
fixed and unremovable, heat it
(roughly 5 minutes at 100C)
using an industrial dryer.
3] Remove the snap ring on the other
side.
4]
5]
Using tool C, remove piston ring (8).

Remove oil ring expander (9)
a Keep the piston, connecting rod,
connecting rod bearing, piston
ring, and piston pin on a cylinder
to cylinder basis.
12V140E-3 Series
59. Crankshaft
1) Before removing crankshaft, measure the
end play of the crankshaft using dial
gauge [1] in order to use it as a rough
standard in the assembly.
2)
3)
Remove mounting bolts (2) of main cap

(1).
Insert the bolts in the bolt hole of the main
cap (1) and remove the cap, while shaking
it.
SEN00321-01
4)
Lift off crankshaft (4).

a Use care in lifting the crankshaft so
that it may not hit and get damage
from the cylinder block.
4 Crankshaft: 210 kg
5)
Remove upper thrust bearing (5) from

No.7 journal.
Remove upper bearing (6).
a Apply marking to the assembly positions of the main cap, main bearing
and thrust bearing using paint or tags
and then keep them on a cap to cap
basis.
6)
Lower thrust bearing (3) is assembled

to No. 7 main cap. Record its assembly position after removal.
12V140E-3 Series
17
SEN00321-01
60. Cylinder liner

1) Before removing cylinder liner (1), measure its projection using tool D and dial
gauge [1].
a Before measuring projection of the
liner, tighten the liner with plate [2] so
that it may not be lifted by the O-ring.
3 Plate mounting bolt:
69 98 Nm {7 10 kgm}
2)
18
61. Cylinder block

Lift off the cylinder block from tool A.
4 Cylinder block: 850 kg
Using tool E, remove cylinder liner (1).
12V140E-3 Series
12V140E-3 Series
SEN00321-01
19
SEN00321-01

2011 KOMATSU
All Rights Reserved
20
12V140E-3 Series
SEN00322-04
ENGINE
1SHOP MANUAL
12V140E-3 Series

General assembly of engine ........................................................................................................................... 2
12V140E-3 Series
SEN00322-04
5]
General assembly of engine

a
a
The shapes, quantity, locations, etc. of the

parts depend on each applicable machine.
Take care.
When a part is provided on both sides of the
banks, one side alone will be shown as an
example. Except where otherwise noted, the
same work procedure shall be employed for
the both banks.
Clean each part carefully, and check it for
bruise, flaw, cavity, etc. Make sure each oil or
coolant path is through.
Tightening bolts by plastic-region turning angle

method
a Bolts tightened by plastic-region turning angle
method
q
Cylinder head mounting bolt
q
Main cap mounting bolt
q
Connecting rod cap mounting bolt
a If the plastic-region turning angle method is
applied, the tightened bolts have permanent
strain. Accordingly, the allowable number of
using times of each bolt is limited. Observe the
following precautions.
q
Check each mounting bolt head for punch
marks. If there were punch marks more
than the specified numbers, replace the
bolt.
1.
Cylinder block
1) Lift the cylinder block and then set it on
tool A.
4 Cylinder block: 850 kg
2) Before inserting the cylinder liners, prepare the cylinder block according to the
1] Remove the rust and scales from
faces A and B with sandpaper, etc.
until the machined surfaces are
exposed.
2] Polish parts B, R and r with sandpaper of about No. 200 until they
become smooth.
If part R is sharpened or burrs are
present there, finish it with a scraper
or sandpaper.
Finish this surface particularly
smoothly so that it will not damage
the O-ring.
3] If face R is so pitted that it cannot be
repaired, replace the cylinder block.
4] If faces A and parts R and r are pitted, finish them smoothly.
2.
Check the counterbored part and

remove burrs. If chips or dust is on
face C, the liner does not fit and coolant may leak and the projection of the
liner may become improper consequently.
a If the counterbored part is drooping, corroded, or pitted, repair it.
Cylinder liner
a Replace the O-ring and clevis seal with
new ones.
1) Check that the cylinder liner O-ring groove
and periphery of the liner are not roughened because of rusting or pitting. If those
parts are roughened, replace the cylinder
liner.
2) Install clevis seal (1), O-rings (2) and (3) to
the cylinder liner.
a Check that there is not a burr, dust,
etc. in the groove of the liner.
a Fit the clevis seal with the chamfered
side down. When fitting it, press it
against the seal groove all round so
that it will not be twisted.
a When installing O-rings (2) and (3),
refer to the following.
q
O-ring (2): Black
q
O-ring (3): Orange
2 Clevis seal and O-ring:
Rubber lubricant (RF-1)
a RF-1: DAIDO CHEMICAL INDUSTRY
CO., LTD.
If RF-1 is not available, apply clean
engine oil (EO30).
a Since the clevis seal and O-ring are
swollen and deteriorated by oil, apply
a small amount of oil to them thinly
with a brush just before fitting them.
12V140E-3 Series
3)
After fitting the liner O-ring, check it for

twist. If it is twisted, correct it with a
smooth rod (about 10 mm in diameter).
SEN00322-04
Gasket sealant application diameter: 0.8 1.6 mm
When applying the gasket sealant, make sure overlapping b

between the coating at start and
the end complies with the following dimension.
Gasket
sealant
overlapping
dimension b: 6 6 mm
4)
Install the cylinder liner according to the

1] Using cloth, wipe dirt and oil completely off the contact faces between
the counterbored part of the cylinder
block and liner flange.
2] Apply silicon-based gasket sealant to
the counterbored mating parts a of
the cylinder block and cylinder liner.
2 Cylinder block:
Gasket sealant (LG-6)
12V140E-3 Series
After applying the gasket sealant,

finish the cylinder liner installation within 50 minutes.
When the bottom contact face of
the counterbored liner flange is
modified and shim (2) is used.
SEN00322-04
1]
2]
5)
Immediately before press-fitting of the

liner, apply a small amount of engine oil to
the liner O-ring, crevice seal and contact
face of the cylinder block.
2 Clevis seal, O-ring and cylinder
block: Engine oil (EO30)
a Apply the engine oil, using hands,
uniformly on the entire contact face of
the cylinder block.
6)
Direct stamping "T" on the top face of the

liner toward the engine front side and then
insert cylinder liner (1) to the cylinder
block while taking care so that the O-ring
may not be damaged.
Push in cylinder liner keeping weight on
both hands.
a If the liner does not enter the cylinder
block smoothly when pushed with
weight on both hands, stop the work
since the O-ring is potentially damaged. In this case, check the cylinder
block for burrs.
7)
Coat the bottom side of shim

(2) with a small amount of
gasket sealant LG-6 and
then assemble the shim.
Then apply gasket sealant
LG-6 according to the same
procedure as that employed
when the shim is not used.
8)
Using tool F, press-fit cylinder liner (1) to

the cylinder block.
9)
To prevent the gasket sealant from projecting through the clearance between the
block and liner after the cylinder head is
tightened, tighten the cylinder head temporarily with the used head gasket
inserted.
a At this time, observe the following
tightening torque and tightening
order.
3 Temporary tightening torque:
137 157 Nm {14 16 kgm}
a Installation of No. 7 bolt is not necessary.
10) Remove the cylinder head and wipe off

the gasket sealant projected from the
counterbored part.
a Be sure to perform steps 9) and 10)
above since the projected gasket
sealant can deform the grommet of
the head gasket.
11) After press-fitting the cylinder liner, measure its projection using tool D.
a Before measuring projection of the
liner, tighten it with plate [1] so that it
may not be lifted by the O-ring.
q
Measuring position:
4 positions at a, b, c and d.
12V140E-3 Series
SEN00322-04
a
a
a
Plate mounting bolt:

686 980 Nm {7 10 kgm}
Standard cylinder projection:
0.07 0.15 mm
If the projection is out of the standard,
correct it according to the maintenance standard.
If the gasket sealant is projected from
the fitting parts of the cylinder block
and cylinder liner up to the top of the
cylinder block, wipe it off.
2)
3)
3.
Crankshaft
1) Fit upper main bearing (6) to the cylinder
block, matching the projection of the
former to the notch of the latter.
Drive in the roll pin in such that its projection from the block end face may become
2.7 3.4 mm and then install upper thrust
bearing (5).
a Install the thrust bearing with the
grooved surface on the crankshaft
side.
2 Thrust bearing sliding surface:
Engine oil (EO30)
Before assembling crankshaft, confirm the
following items.
q
Presence/absence of abnormality in
the front and rear threaded portions.
(Make sure the bolt can be smoothly
screwed in with hand.)
q
Presence/absence of scratches or
dents on the pin and main journal.
q
Presence/absence of dusts in the oil
hole.
a
a
Upper bearing: With oil hole A

No. 4 bearing is wider than others.
Thus, care must be taken to prevent
an assembly error.
a Bearing with a
No. 4 bearing: 52 mm
Bearings other than No. 4: 48 mm
a Before fitting the bearing, make sure
that its back side is free from foreign
matter.
2 Bearing inner surface:
Engine oil (EO30)
a Don't apply the engine oil to the bearing backside.
12V140E-3 Series
4)
Lift crankshaft (4) and then install it on the

cylinder block.
a When installing the crankshaft, take
care not to hit its sliding surfaces
against the cylinder block.
4 Crank shaft: 210 kg
2 Cylinder block journal:
Engine oil (EO30)
SEN00322-04
5)
Install the projection of lower bearing (7)

locating it to the notch of main cap (1) and
install.
a Before fitting the bearing, make sure
that its back side is free from foreign
matter.
2 Inside of bearing:
Engine oil (EO30)
a Don't apply the engine oil to the bearing backside.
6)
7)
8)
a
a
a
Lower bearing: Without oil hole

No. 4 bearing is wider than others. Thus, care
must be used to prevent an assembly error.
Bearing with a
No. 4 bearing: 52 mm
Bearings other than No. 4: 48 mm
9)
Drive the roll pin of cap No. 7 so that it will

be projected by 2.7 3.4 mm from the cap
end and then install lower thrust bearings
(3) to both sides.
a Install the thrust bearing with the
grooved surface on the crankshaft
side.
2 Thrust bearing sliding surface:
Engine oil (EO30)
Apply the engine oil to the surface of the
journal of the crankshaft. Then install the
main cap after making sure that the No.
being stamped on respective main caps
(1) is matching the cylinder block No.
2 Crankshaft journal:
Engine oil (EO30)
a When installing the main cap, direct
its cast part number side toward the
front of the engine.
Apply engine oil to the threaded portion of
the main cap mounting bolt and washer
and then drive in the bolts alternately until
the main cap is completely fitted.
2 Main cap mounting bolt:
Engine oil (EO30)
Tighten main cap mounting bolts (2)

a Tighten the bolts from the center one
to the outer ones in order.
12V140E-3 Series
SEN00322-04
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.
When tool G is not used, apply

marking b to the main cap and
bolt with paint, and then retighten
the bolt by 90 (+30/0).
10) Make punch mark c on the mounting bolt
head.
a When a new bolt is used, do not
make a punch mark on its head.
Piston and connecting rod assembly

1) Assemble the piston and connecting rod
1] Fit in oil ring expander (9) to the oil
ring groove.
2] Using tool C, assemble the oil ring,
second ring and top ring, in this order.
a
a
a
11) Check that the crankshaft turns smoothly.
a Standard crankshaft starting torque:
Max. 147 Nm {15 kgm}
12) Measure the end play of the crankshaft
with dial gauge [1].
a End play standard value:
0.140 0.320 mm
a If the end play is out of the standard,
correct it. For details, see "Structure,
function and maintenance standard".
12V140E-3 Series
Assemble respective piston rings

as shown in the figure.
When assembling the respective
rings to the piston, direct their
stamped side upward.
Take the expander out of the oil
ring and fit it to the piston first
and then assemble the oil ring. At
this time, make sure that the
expander is fitted to the ring
groove perfectly.
Make sure that the coil butt joint
of the expander is situated in a
position 180 to the oil ring abutment joint.
SEN00322-04
3]
Install snap ring (10) to one side of

piston (7).
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.
Apply engine oil to the piston pin boss
and inner surface of the connecting
rod bushing and then insert piston pin
(6) while directing the connecting rod
upward.
2 Piston pin: Engine oil (EO30)
Install snap ring (4) on the opposite
side.
a Turn the snap ring to make sure
that the left and right side snap
rings are completely fitted in the
ring groove.
a Also make sure that the connecting rod moves lightly.
5]
6]
7]
Install the projection of connecting

rod upper bearing (11) locating it to
the notch of the connecting rod.
a Before fitting the bearing, make
sure that its back side is free
from foreign matter.
a Don't apply the oil to the bearing
backside.
a Make sure that the connecting
rod small end bushing are large
end bearing hole are aligned with
the connecting rod oil hole.
a Before assembling the connecting rod, check the connecting rod
oil hole for settled dusts.
2 Connecting rod bearing inner
surface: Engine oil (EO30)
8]
Install the projection of connecting

rod lower bearing (12) locating it to
the notch of the connecting rod cap.
a Before fitting the bearing, make
sure that its back side is free
from foreign matter. Don't apply
the engine oil to the backside.
12V140E-3 Series
2)
Apply the engine oil to the cylinder liner.

a Apply the engine oil uniformly on the
entire circumference with hands.
2 Cylinder liner: Engine oil (EO30)
3)
Turn the crankshaft to drive the pin journal

of the target cylinder of insertion to the top
dead center position.
After confirming No. of the piston and connecting rod assembly, insert the assembly
to the cylinder block directing it in the
direction shown in the figure.
a Set the direction of the cylinder block
in such that the cylinder may face
sideways. This process is needed to
prevent sudden insertion of the piston
and connecting rod assembly to the
cylinder.
a On each bank, install notch A for the
piston cooling nozzle and chamfered
side B of the connecting rod. In this
case, their positional relation with
front direction F of the engine must be
as shown in the figure.
4)
12V140E-3 Series
SEN00322-04
5)
Align the abutment joint of respective piston rings as well as the piston to the position shown in the figure.
Make sure that the coil butt joint of the oil ring
is situated in a position 180 to the abutment
joint
2 Piston ring, piston and crank journal:
Engine oil (EO30)
6) Using tool H, compress the piston ring and
then push in the piston head with a
wooden bar and the like.
SEN00322-04
7)
Using the connecting rod puller [1] shown

in the figure, pull the connecting rod until it
is closely contacted against the pin journal.
a Make sure the connecting rod bearing
is not displaced.
a The connecting rod puller [1] is made
by welding bar b to unnecessary connecting rod bolt a.
a Total length of connecting rod puller l:
Approx. 500 mm.
2 Crank pin journal:
Engine oil (EO30)
When assembling a new connecting

rod, record its cylinder No. on the
connecting rod cap using a electric
pen (stamping is not acceptable). It is
strictly prohibited to change the combination of the connecting rod and
cap through this operation.
11) Apply the engine oil to the threaded portion and washer of the connecting rod.
2 Connecting rod bolt and washer
Engine oil (EO30)
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) alternately until the connecting rod cap is
closely contacted.
10
12V140E-3 Series
SEN00322-04
a
13) Turn the crankshaft 180 and insert the

piston and connecting rod assembly on
one bank according to the steps 1) 12).
14) Tighten the mounting bolts in the order
indicated in the figure according to the following procedure.
3 Connecting rod bolt:
1st time: 69 78 Nm {7 8 kgm}
2nd time:
69 78 Nm {7 8 kgm} (again)
3rd time: Using tool G, retighten the
bolt by 90 (+30/0).
After assembling the connecting rod,

make sure that the crankshaft rotates
normally.
16) Measure the side clearance of the connecting rod with dial gauge [1].
q
Standard side clearance:
0.3 0.454 mm
a When the side clearance is out of the
standard, remove the connecting rod
cap and check the connecting rod for
assembly errors, presence of burrs or
pinching of foreign substances.
5.
12V140E-3 Series
When tool G is not used, apply marking b to

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

1) Install piston cooling nozzle (1).
a After completely inserting the spigot
joint portion to the block side mounting hole, tighten the mounting bolt.
3 Piston cooling nozzle mounting
bolt: 54 20 Nm {5.5 2.0 kgm}
a Prior to the installation, check the
nozzle for damages or internal clogging .
11
SEN00322-04
a
2)
Make sure prior to the installation that

the notch for preventing interference
of the piston cooling nozzle is provided on the piston skirt portion.
7.
Camshaft assembly
1) Insert the camshaft assembly (3) to the
cylinder block along with the cam gear.
a Install it carefully turning the cam
shaft so that the cam bushing may
not be damaged.
a Use care when inserting the cam
shaft so that your fingers may not be
pinched.
2 Camshaft: Engine oil (EO30)
Turn the crankshaft slowly to make sure

that interference is not observed between
piston cooling nozzle (1) and piston (2) or
connecting rod (3).
2)
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.
8.
12
Turn the cam gear (1) and tighten mounting bolt (2) through the lightening hole
a Replace the current mounting bolt
with a new one.
3 Cam shaft mounting bolt:
88 34 Nm {9.0 3.5 kgm}
Cam follower assembly

1) Assemble the cam follower according to
the following procedure.
1] Install snap ring (7) to shaft (6).
2] Install cam follower (5) to shaft (6).
2 Cam follower bushing inner
surface: Engine oil (EO30)
3] Install snap rings (4).
12V140E-3 Series
9.
2)
Install cam follower assembly (3).

3 Cam follower assembly mounting
bolt:
44.1 58.8 Nm {4.5 6.0 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
other sections.
3 Cam follower cover mounting bolt:
34.3 44.1 Nm {3.5 4.5 kgm}
SEN00322-04
10. Supply pump drive case

1) Install supply pump drive case (2).
2) Install oil tube (1).
a Install the oil tube on the left bank
alone.
3 Oil tube joint bolt:
7.9 12.7 Nm {0.8 1.3 kgm}
11. Oil pump assembly

Install oil pump assembly (1).
3 Oil pump mounting bolt:
54 20 Nm {5.5 2.0 kgm}
Oil cooler (front side)

Install oil cooler (front side) (1)
12V140E-3 Series
13
SEN00322-04
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 position when adjusting respective gears.
2) Install thrust plate (4) to the shaft.
a Install the plate in such that oil groove
A may be set on the idler gear side.
2 Thrust plate: Engine oil (EO30)
13. Supply pump gear

1) Install key (2) to the shaft.
3)
2)
14
Install idler gears (large) (2) and (3).

2 Idler gear bushing inner surface:
Engine oil (EO30)
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 purpose retention tool and fixing the supply pump gear.
3 Supply pump gear mounting nut:
176 196 Nm {18 20 kgm}
12V140E-3 Series
4)
SEN00322-04
2)
Install water pump assembly (2) temporarily.
3)
Measure the backlash and end play of

each gear with the dial gauge.
a Symbols in the figure correspond to
"Position" field in the following table.
Install idler gears (large) (2) and (3) in

such that their counter marks as well
as that of respective gears may come
to the positions shown in the figure.
Install plate (1) and then tighten the

mounting bolt.
a Install the plate setting its "OUT"
marking on the outside.
2 Plate sliding surface:
Engine oil (EO30)
3 Idler gear (large) mounting bolt:
98.0 122.5 Nm {10.0 12.5 kgm}
15. Check of timing gear for backlash and end

play
1) Attach gear (1) to the compressor and
then install them temporarily. (When the
engine is equipped with the compressor)
12V140E-3 Series
15
SEN00322-04
1]
Position
AA
B1B1
B2B2
CC
DD
EE
FF
GG
HH
LL
RR
Note):
5
6
7
Backlash of each gear
(mm)
Standard
Measuring points
value
Right idler gear (small) and
0.130 0.390
right sub idler gear
(0.125 0.363)
Right sub idler gear and right 0.051 0.469
supply pump gear
(0.125 0.363)
Left sub idler gear and left
0.051 0.469
supply pump gear
(0.125 0.363)
Left sub idler gear and left
0.129 0.391
cam gear
(0.125 0.363)
Right idler gear (small) and
0.129 0.391
right cam gear
(0.125 0.363)
Right idler gear (large) and
0.052 0.481
water pump drive gear
Right idler gear (large) and
0.137 0.421
oil pump gear
Left supply pump gear and
0.106 0.381
compressor gear
(0.138 0.354)
Right cam gear and acces0.085 0.492
sory drive gear
(0.138 0.354)
Crank gear and left idler gear
0.141 0.425
(large)
Crank gear and right idler
0.141 0.425
gear (large)
The standard value enclosed in ( ) indicates
the backlash between spur gears
2]
Position
1
2
3
4
When cover (2) was removed, apply the

gasket sealant in the position shown in the
figure before installing it again.
2 Cover: Gasket sealant (LG-7)
q
Application diameter: 2.0 mm
End play of each gear
Gear name
Idler gear (large) end play
Idler gear (small) end play
Supply pump gear end play
Oil pump gear end play
Accessory drive gear end
play
Crank gear end play
Cam gear end play
(mm)
Standard value
0.07 0.18
0.07 0.18
0.07 0.20
0.03 0.088
0.1 0.4
0.14 0.32
0.10 0.25
16. Gear case cover

Lift and install gear case cover (1).
a As a cover for carrying a unit is put on the
machine in the figure below, the shape of
actual machine is partially different from it.
16
17. Front oil seal

1) Clean, degrease and then dry the contact
surface between the front cover and front
seal.
2) Using a clean cloth, remove foreign matter
deposited on the crankshaft flange.
a Clean foreign matter deposited on the
seal lip surface (surface around the
crankshaft) and then degrease and
dry the surface.
12V140E-3 Series
SEN00322-04
3)
Check the crankshaft end face corner

and lip siding surface for scratches
due to the housing, burrs or rusts.
When installing front oil seal (2), do not
apply oil or grease to the shaft and seal
lip. Wipe off the oil from the shaft.
2 Inner circumference of front oil
seal: Gasket sealant (LG-7 or
equivalent)
1] The surface having the parts number
(PN) marking must face to the outside
of engine.
18. Front support

Install front support (1).
a Prior to the installation, fill the oil hole with
grease.
a Volume of grease filled: 20 cc
2 Front support: Grease (G2-LI)
2]
Tighten nuts [1] using the tool J

(plate), and press oil seal (8) to the
crank shaft end surface.
19. Damper and crank pulley assembly

1) When the damper and crank pulley are
separated, assemble them again by tightening the mounting bolts in the order indicated in the figure.
2 Damper mounting bolt and washer:
Engine oil (EO30)
3 Damper mounting bolt:
98 122 Nm {10 12.5 kgm}
3]
Tighten nuts [1] using the tool J

(push tool), press oil seal (8) in the
front case until it becomes the dimension (a) as shown in the figure.
a Oil seal press fit dimensions
(a): 17 mm
(from crank shaft end surface)
(b): 25.1 mm
(from front cover end surface)
12V140E-3 Series
17
SEN00322-04
2)
Lift and install damper and crank pulley

assembly (1).
a Install the assembly aligning it to the
dowel pin of the crankshaft.
4 Damper and crank pulley assembly: 75 kg
Tighten the mounting bolts in 3 steps

according to the order indicated in the
figure.
2 Flywheel housing mounting bolt:
Engine oil (EO30)
3 Flywheel housing mounting bolt:
1st time:
343 49 Nm {35 5 kgm}
2nd time: Loosen it fully
3rd time:
411.6 19.6 Nm {42 2 kgm}
Tighten the mounting bolts in 3 steps

according to the order indicated in the
figure.
2 Damper and crank pulley pump
assembly mounting bolt and
washer: Engine oil (EO30)
3 Damper and crank pulley assembly
mounting bolt
1st time:
73.5 19.6 Nm {7.5 2 kgm}
2nd time:
245 19.6 Nm {25 2 kgm}
3rd time:
744.8 19.6 Nm {76 2 kgm}
2)
3)
After the installation, cut off the gasket

projecting from the oil pan mounting surface to make height of the gasket and
mounting surface even.
Install burring tool (1) and Ne speed sensor (2).
20. Flywheel housing

1) Lift and install flywheel housing (4).
4 Flywheel housing: 230 kg
18
12V140E-3 Series
21. Rear oil seal

1) Clean, degrease and then dry the contact
surface between the flywheel housing and
rear seal.
2) Using a clean cloth, remove foreign matter
a Clean foreign matter deposited on the
dry the surface.
a Check the crankshaft end face corner
3) When installing rear oil seal (3), do not
apply oil or grease to the shaft and seal
lip. Wipe off the oil from the shaft.
1] The surface having the parts number
(PN) marking must face to the outside
of engine.
SEN00322-04
4)
PC2000-8
a Check the Teflon seal (Laydown lip
seal) by checking the wear of the
shaft and replace it with the Standard
seal.
a
a
2]
Clean, degrease and then dry the

contact surface between the flywheel
housing and rear seal.
Clean foreign matter deposited on the
dry the surface.
Check the crankshaft end face corner
Using the K (push tool), press oil

seal (3) in the flywheel housing until it
becomes the dimension (a) or (B) as
shown in the figure.
(a): 5 mm (from flywheel housing end surface)
12V140E-3 Series
19
SEN00322-04
5)
Installation procedure of standard seal

a Do not apply any grease, oil and others to the seal lip surface (a).
a Never remove inside plastic cylinder
(3) of the standard spare seal before
installing the seal.
4]
5]
1]
Set the large inside diameter side (b)

of plastic inside cylinder (3) to the end
of crankshaft (4).
a Extremely take care not to mistake the direction of the plastic
inside cylinder.
6]
7]
2]
3]
20
Hold the metal ring of rear oil seal (1)

with both hands and push it in firmly.
After pushing in the rear oil seal,
remove plastic inside cylinder (3).
a When removing the inside cylinder, take care not to damage the
seal lip.
Apply rear seal (2) on the end of

crankshaft (4).
a Install the rear seal in the correct
direction.
Manually push the metal ring of rear
seal (2) evenly, and insert in its position.
Using the tool K, further press and
insert rear seal (2) evenly.
Using the tool K, press rear seal (2)

by tightening bolts equally.
a Press rear seal (2) until tool K
reaches crankshaft (4).
q Press fit method of oil seal
(from flywheel housing end
surface)
(a): 13.5 mm
q Press fit method of oil seal
(from crankshaft end surface)
(b): 25.7 mm
a After having pressed the rear
seal, remove the red sealant
form outer edge.
12V140E-3 Series
SEN00322-04
a
Tighten the mounting bolts in the following order.

2 Flywheel assembly mounting bolt:
Engine oil (EO30)
3 Flywheel mounting bolt
1st time:
98 19.6 Nm {10 2 kgm}
2nd time:
294 19.6 Nm {30 2 kgm}
3rd time:
539 19.6 Nm {55 2 kgm}
22. Flywheel assembly

1) Lift and install flywheel assembly (1).
a Install the assembly aligning it to the
dowel pin of the crankshaft.
4 Flywheel assembly: 130 kg
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
When tightening the mounting bolt, fix

the space flywheel and flywheel
housing using plate [1] in order to prevent the crankshaft from turning.
12V140E-3 Series
21
SEN00322-04
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 position and then tighten the locknut.
3 Engine speed sensor locknut:
49 68.6 Nm {5 7 kgm}
2)
3)
Install accessory drive (2).

Install pulley (1).

1) Install thermostat housing (2).
2) Install water temperature sensor (1).
23. Accessory drive assembly

1) Assemble the accessory drive.
1] Pull off bushing (10) and oil seal (9) to
housing (8).
a Press-fit the bushing 2 mm
deeper from the end face.
2 Bushing inner surface:
Engine oil (EO30)
a Press-fit the oil seal 1.5 mm
deeper from the end face.
2 Seal lip: Grease (G2-LI)
a Fill 50 80% of the lip open
space with the grease.
2] Press-fit gear to (7) to shaft (5).
3] Assemble thrust plate (6) to the shaft
and gear assembly and then insert
the housing from the rear side.
4] Assemble thrust plate (4) to the shaft
and then press-fit hub (3).
a Use care in above operation so
that the seal lip may not be damaged.
22
25. Front engine hanger

Install front engine hanger (1).
12V140E-3 Series
26. Thermostat case

1) Install thermostat (3) to thermostat case
(2).
2)
3)
Install thermostat case (2).

Install water outlet (1).
27. Breather
Install breather (1), blow-by pipe (2) and plate
(3).
3 Breather mounting bolt:
24.5 29.4 Nm {2.5 3.0 kgm}
a Install plate (3) to the left side bank alone.
12V140E-3 Series
SEN00322-04
28. Alternator bracket

Install alternator bracket (1).
29. Relief valve

1) Remove engine assembly (1) from tool A
and then support it using block [1].
a Make sure the engine is supported
stably.
2) Install relief valve (1).
30. Suction pie and under plate

1) Using jack [1], install under plate (1) and
then fix it temporarily using the oil pan
mounting bolt.
4 Under plate: 25 kg
23
SEN00322-04
2)
Install suction pipe (3) and stay (2).
33. Common rail

1) Install bracket (3).
2) Install common rail (2).
a Install the common rail at this point
since positioning of the high-pressure pipe is needed when installing
the fuel injector.
3 Common rail mounting bolt:
59 74 Nm {4 5 kgm}
31. Oil pan

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

1) Assemble the cylinder head assembly
1] Install valve (7).
2] Install lower seat (6).
2)
Install the engine assembly to tool A

again.
32. Oil level gauge and oil filler tube

2) Install oil level gauge (3) and then tighten
the sleeve nut at the base.
3) Install oil filler tube (2).
3]
24
Using tool L, install stem seal (8).

a Drive in tool L until its lower end
a is contacted against lower seat
(6).
12V140E-3 Series
SEN00322-04
4)
4]
5]
2)
3)
Install inner spring (5), outer spring

(4) and upper seat (3).
Using tool B, compress the valve
spring to install cotter (2).
a After the installation, hit the valve
stem lightly with the plastic hammer to make sure the cotter is
installed stably.
Install the cylinder head gasket.

Lift and install cylinder head assembly (1).
4 Cylinder head assembly: 30 kg
12V140E-3 Series
Tighten the mounting bolts according to

the following procedure.
1] Tighten mounting bolts (No. 1 7)
temporarily.
2] Tighten the mounting bolts (No. 1 6)
in 3 steps according to the order indicated in the figure.
a When a bolt with 5 punch marks,
which indicates the tightening
frequency up to today, in its head
is found, replace it with a new
one.
2 Cylinder head assembly mounting bolt: Molybdenum disulfide lubricant (LM-P)
3 Cylinder head assembly mounting
bolt (No. 1 6)
1st time:
137 157 Nm {14 16 kgm}
2nd time:
284 294 Nm {29 30 kgm}
3rd time: 90 (+30/0)
When tool G is not used in tightening of the 3rd time, check the
rotating angle after applying
marking b to the cylinder head
and bolt head using paint.
25
SEN00322-04
3]
4]
Tighten the mounting bolt (No. 7) with

the following torque.
2 Cylinder head assembly mounting bolt:
Molybdenum disulfide lubricant (LM-P)
3 Cylinder head assembly mounting bolt (No. 7):
66.2 7.4 Nm {6.75 0.75 kgm}
After the tightening, stamping punch
mark a to the head of mounting bolts
(No. 1 6).
2)
Insert fuel injector (2) to the cylinder head

along with holder (3).
3)
Install spherical washer (7) and then

tighten holder mounting bolt (1) temporarily.
2 Special washer: Engine oil (EO30)
Tighten sleeve nut (5) of the high-pressure
pipe temporarily.
a Also tighten the sleeve nut on the
common rail side temporarily to proceed with the positioning.
a See "High-pressure pipe" for precautions on this operation.
Tighten holder mounting bolt (1) with the
specified torque.
3 Holder mounting bolt:
58.8 73.5 Nm {6 7.5 kgm}
a Leave sleeve nut (5) being tightened
temporarily in above operation as is.
This nut is to be tightened with the
specified torque in the next step.
4)
5)
Install the water tube.

3 Water tube joint bolt:
9.8 12.7 Nm {1.0 1.3 kgm}
35. Fuel injector

a Check that the inside of the injector sleeve
is free from dirt.
1) Install O-rings (4) and (5) and gasket (6) to
the fuel injector.
2 O-ring: Engine oil (EO30)
26
5)
12V140E-3 Series
SEN00322-04
a
36. High-pressure pipe (between common rail fuel injector)

k Install the high-pressure pipe and
clamp paying attention to the following
points.
q
It is strictly prohibited to reuse a highpressure pipe by modifying its bend
or using the pipe in an unintended
location.
q
The clamp used must be a legitimate
one. And it must be installed in the
specified position with the specified
torque.
q
After installing the high-pressure pipe
and clamp, make sure that 10 mm
m i n im u m c l e a r a n c e i s p r o v 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.
q
Check the taper seal of the connecting part (Part a: Part of 2 mm from the
end) for visible lengthwise slit b and
dent c.
q
Check part d (end of the taper seal:
Part at 2 mm from the end) for
stepped-type wear (fatigue) which
your nail can feel.
2)
3)
4)
5)
1)
After installing fuel injector (5) and common rail (6) temporarily to high-pressure
pipe (4), tighten the sleeve nut with the
specified torque.
a Control the torque by using a spanner
type torque wrench (commercially
available) for the tightening.
3 High-pressure
pipe sleeve nut
(injector side):
39.2 49 Nm {4 - 5 kgm}
3 High-pressure
pipe sleeve nut
(common rail side):
39.2 - 49 Nm {4 5 kgm}
12V140E-3 Series
6)
7)
After the tightening, make sure the Oring is not projecting from the sleeve
nut.
Manually tighten and install temporarily

the stay and top and bottom clamps of
high-pressure pipe clamp (7).
Tighten the top and bottom clamps permanently.
a Before tightening the stay permanently, deflect the rubber fist.
3 Top and bottom clamp bolt:
9.8 1 Nm {1 0.1 kgm}
Tighten the stay permanently.
Manually tighten and install temporarily
the stay and top and bottom clamps of the
high-pressure pipe.
Install the high-pressure pipe clamp and
gate type frame temporarily.
a First tighten the high-pressure pipe
clamp permanently, and then tighten
the gate type frame permanently to
the common rail mounting bolt.
3 Gate type frame mounting bolt:
9.8 1 Nm {1 0.1 kgm}
Tighten the high-pressure pipe clamp permanently.
3 High pressure pipe clamp bolt:
9.8 1 Nm {1 0.1 kgm}
27
SEN00322-04
8)
9)
Tighten the clamp stay permanently.

a Tighten the clamp of the air intake
manifold after installing the manifold.
Install the rubber cover to the sleeve nut

on the high-pressure pipe.
a Direct the slit downward when installing the rubber cover.
q
Injector side (8): Bottom
q
Common rail side (9): Cylinder
block side
37. Crosshead
1) Install crosshead (1).
2 Crosshead sliding portion:
Engine oil (EO30)
2)
28
When installing the high-pressure pipe without

removing the fuel injector (for example, when
replacing only the high-pressure pipe with new
one), follow the procedure below.
q
Tighten sleeve nut (10) by 2 turns with the
hand into the threads of the fuel injector
and then tighten it with the spanner.
a If sleeve nut (10) does not catch the
threads, it will help to turn the spanner
while pressing sleeve nut (8) end with a
small rod, etc. toward the injector.
Adjust the crosshead according to the following procedure.

1] Loosen locknut (2) and then loosen
adjustment screw (3) to a position
where it does not valve stem (4).
2] Maintain the contact with valve stem
(5) on the push rod side by pressing
the contact face against the rocker
arm using a finger.
3] Tighten adjustment screw (3) to confirm the position where adjustment
screw (3) is contacted against valve
stem (4).
4] Drive in adjustment screw (3) further
by 20 from the contacting position
against valve stem (4).
5] Tighten locknut (2) while suppressing
move of adjustment screw (3).
3 Locknut:
58.8 5.9 Nm {6.0 0.6 kgm}
12V140E-3 Series
38. Injector harness

1) Push connector (3) out of the cylinder
head and then install injector harness (4)
in the cylinder head.
2) Tighten injector terminal mounting nut (1)
and clamp mounting bolt (2).
a Alternately tighten injector terminal
mounting nuts (1).
3 Injector terminal mounting nut:
2 0.2 Nm {0.2 0.02 kgm}
a After tighten the injector terminal
mounting nut, push the harness
against the injector body to eliminate
sagging.
SEN00322-04
40. Rocker arm assembly

1) Assemble the rocker arm assembly
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).
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)
12V140E-3 Series
29
SEN00322-04
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:
93 103 Nm {9.5 10.5 kgm}
a Tighten locknut (1) after adjustment of
the valve clearance is completed.
2)
3)
41. Adjusting valve clearance

1) Rotate the crankshaft forward and drive
right No.1 cylinder to the compression top
dead center, while watching move of the
intake valve on right No. 6 cylinder. Then
locate the stamped line of R1.6 TOP of
vibration damper (1) to pointer (2).
a Crank the engine using the burring
tool (B) being provided in the front
right side of the flywheel housing.
a The intake valve of right No. 6 cylinder will start moving as right No. 1 cylinder is driven to vicinity of the
compression top dead center. (Open)
a Figure shows the cylinder No. and
their firing order (circled numbers
indicate the firing order).
30
4)
Loosen locknut (6) of adjustment screw

(5) of the right No. 1 cylinder and then
i n s e rt c l ea r a n c e g a ug e M , whic h is
adjusted to the specified thickness,
between crosshead (4) and rocker arm
(3). Then using the adjustment screw,
adjust the clearance to a degree that
allows only slight move of the gauge.
a Standard valve clearance:
q
Intake valve: 0.35 0.02 mm
q
Exhaust valve: 0.57 0.02 mm
Tighten locknut (6) to secure adjustment
screw (5).
3 Locknut tightening torque:
52.9 64.7 Nm {5.4 6.6 kgm}
a After tightening the locknut, check the
valve clearance again.
Repeat the same procedure for other
engines, too, in the order of firing. Namely,
crank the engine and then locate the
stamped of the damper to the pointer to
adjust the valve clearance of respective
cylinders.
a Firing order
R1 - L1 - R5 - L5 - R3 - L3 - R6 - L6 R2 - L2 - R4 - L4
12V140E-3 Series
SEN00322-04
42. Head cover

Install head cover (1).
3 Head cover mounting bolt:
14.7 34.3 Nm {1.5 3.5 kgm}
43. Fuel tube

Install fuel tube (1).
3 Fuel tube joint bolt:
9.8 12.7 Nm {1.0 1.3 kgm}
44. Plate and block

Install block (3) and plates (2) and (1).
12V140E-3 Series
31
SEN00322-04
45. Oil cooler (rear side)

1) Install oil cooler (2).
2) Install oil manifold (1).
46. Water pump assembly

1) Install housing (5) to water pump (4).
32
2)
Install water pump assembly (3).
3)
Install water connector (2).
4)
Install block (1).
47. Corrosion resister and filter head assembly

Install corrosion resister and filter head assembly (1).
48. Exhaust manifold assembly

1) Install the gasket.
a Install the gasket directing its "OUT"
marking to the exhaust manifold side.
2) Lift and install exhaust manifold assembly
(5).
4 Exhaust manifold assembly: 25 kg
12V140E-3 Series
SEN00322-04

a Tighten it once and then tighten again
with the same torque.
2 Exhaust manifold assembly mounting bolt:
Molybdenum disulfide lubricant
(LM-P)
3 Exhaust manifold assembly mounting bolt:
44.1 53.9 Nm {4.5 5.5 kgm}
3)
Turbocharger assembly: 35 kg
Turbocharger assembly mounting
bolt and nut:
Molybdenum disulfide lubricant
(LM-P)
Turbocharger assembly mounting
bolt:
44.1 53.9 Nm {4.5 5.5 kgm}
Install bracket (4), water pipe (3), muffler

bracket (2) and insulating plate (1).
2)
49. Turbocharger assembly

1) Lift and install turbocharger assembly (1).
a Tighten turbocharger assembly
mounting bolt according to the procedure below.
1] Tighten mounting bolts at each connecting portion temporarily for positioning.
2] Tighten
turbocharger
assembly
mounting bolts in the following order.
1st time: [1],[2],[3] and [4]
2nd time: [1],[3],[2]and [4]
12V140E-3 Series
Install water pipes (2) and (3) and oil pipes

(4) and (5).
a As for the air-cooled turbocharger,
install the oil pipes alone.
3 Water connector (Block side):
78.5 103 Nm {8 10.5 kgm}
3 Water pipe flare nut (Water connector side):
24.5 59 Nm {2.5 6 kgm}
3 Water pipe joint bolt (Turbocharger
side):
24.5 34.3 Nm {2.5 3.5 kgm}
3 Water
connector (Turbocharger
side): 29.4 39.2 Nm {3 4 kgm}
3 Water pipe flare nut (Water connector side):
29.4 39.2 Nm {3 4 kgm}
33
SEN00322-04
50. Exhaust connector

Install exhaust connectors (1) and (2).
51. Air intake manifold assembly

1) Install the gasket.
a Install the gasket setting its "UP"
marking upward and also directing
this side to the intake manifold.
2) Lift and install air intake manifold assembly (2).
4 Intake manifold assembly: 45 kg
3)
Install support (1).
52. High-pressure pipe clamp

Install brackets (1) and (2) to the exhaust manifold and then tighten high-pressure pipe clamp
bolt (3).
3 High pressure pipe clamp bolt:
9.8 1 Nm {1 0.1 kgm}

3 Intake manifold assembly mounting
bolt: 58.8 73.5 Nm {6 7.5 kgm}
34
12V140E-3 Series
SEN00322-04
53. Spill tube

Install spill tube (1).
3 Spill tube joint bolt
Cylinder head side:
9.8 12.7 Nm {1.0 1.3 kgm}
Intake manifold side:
19.6 29.4 Nm {2.0 3.0 kgm}
Tighten mounting bolt (2) with the

specified torque after tightening the
sleeve nut of the high-pressure pipe
(between supply pump and common
rail).
2 Supply pump assembly mounting
bolt: Adhesive (LT-2)
54. Supply pump assembly and high-pressure

pipe (between supply pump - common rail)
k Install the high-pressure pipe and
clamp paying attention to the following
points.
q
It is strictly prohibited to reuse a highpressure pipe by modifying its bend
or using the pipe in an unintended
location.
q
The clamp used must be a legitimate
one. And it must be installed in the
specified position with the specified
torque.
q
After installing the high-pressure pipe
and clamp, make sure that 10 mm
m i n im u m c l e a r a n c e i s p r o v 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) temporarily.
a Align and insert the unequal spline
portion of the supply pump side to
unequal spline portion A of the supply
pump drive case side.
a When it is difficult to insert the supply
pump , turn the crankshaft to change
position of unequal spline portion A.
2)
3)
4)
5)
12V140E-3 Series
After installing high-pressure pipes (4) and

(5) to supply pump (1) and common rail
(3) temporarily, tighten the sleeve nut with
the specified torque.
a Control the torque by using a spanner
type torque wrench (commercially
available part) for the tightening.
3 High-pressure
pipe sleeve nut
(supply pump side):
39.2 49 Nm {4 5 kgm}
3 High-pressure
pipe sleeve nut
(common rail side):
39.2 58.8 Nm {4 6 kgm}
Tighten supply pump assembly mounting
bolt (2).
Tighten the mounting bolt across the supply pump assembly bottom face and
bracket.
3 Supply pump mounting bolt (Bottom side):
19.6 29.4 Nm {2.0 3.0 kgm}
Install oil tube (6).
3 Oil tube joint bolt:
9.8 12.7 Nm {1.0 1.3 kgm}
35
SEN00322-04
55. Fuel pipe

1) Install priming pump (4).
a If the air bleeding plug is removed,
tighten the pump with the following
torque.
24.5 34.3 Nm {2.5 3.5 kgm}
2) Install fuel pipes (1) (3).
3 Fuel pipe joint bolt (Common rail
side):
17.7 22.6 Nm {1.8 2.3 kgm}
3 Fuel pipe joint bolt (Supply pump
side):
14.8 19.6 Nm {1.5 2.0 kgm}
6)
7)
36
Install high-pressure pipe clamp (7)

1] Manually tighten and install temporarily the stay and top and bottom
clamps of the high-pressure pipe
clamp.
2] Tighten the top and bottom clamps
permanently.
a Use care in the tightening so that
excessive force may not be
applied to the supply pump side
install position.
9.8 1 Nm {1 0.1 kgm}
3] Tighten respective stays permanently.
q
Supply pump side (8): Bottom
q
Common rail side (9): Facing
inward (Opposed)
56. Air intake connector

Install air intake connector (1).
12V140E-3 Series
57. Air inlet pipe

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
58. Engine controller and controller cooler

1) Install controller cooler (4).
2) Install fuel hoses (2) and (3).
3) Install engine controller (1).
3 Engine controller mounting bolt:
23.5 Nm {2.4 kgm}
12V140E-3 Series
SEN00322-04
59. Fuel filter and filter head assembly

1) Install fuel filter and filter head assembly
(3).
2) Install fuel tubes (1) and (2).
3 Fuel tube joint bolt:
24.5 34.3 Nm {2.5 3.5 kgm}
60. Alternator
1) Install alternator (2).
2) Install auxiliary equipment belt (1).
3) Adjust tension of the auxiliary equipment
belt.
a Adjust its deflection to 20 mm when
the pushing force of 58.8 Nm {6 kgm}
is applied to the belt center through a
finger.
3 Adjuster lock bolt:
53.9 122.6 Nm {5.5 12.5 kgm}
37
SEN00322-04
61. Starting motor assembly

Install staring motor assemblies (3) and (2) and
then connect wiring harness (1) to them.
a Install the top assembly first being followed by the bottom one.
3 Starting motor B terminal nut:
19.6 25.5 Nm {2 2.6 kgm}
1)
2)
62. Engine wiring harness
Install engine wiring harness (1) on the engine
assembly and then connect the connector and
terminal.
3)
4)
5)
6)
7)
63. Checking for fuel leakage
a When removal and installation of fuel supply pump (1), common rail (2), or highpressure pipes (3) and (4) were conducted, check fuel leakage according to
the following procedure after assembling
the engine.
a Here, high-pressure pipes (3) and (4)
denote every fuel pipe (the figure shows
an example).
8)
9)
38
Clean and degrease the engine and the

parts around it in advance so that you can
test it easily for fuel leakage.
Spray color checker (developer) over the
fuel supply pump, common rail, fuel injector, and joints of the high-pressure piping.
Run the engine at speed below 1,000 rpm
and stop it after its speed is stabilized.
Check the fuel piping and devices for fuel
leakage.
a Check mainly around the high-pressure circuit parts coated with the color
checker for fuel leakage.
a If any fuel leakage is detected, repair
it and check again from step 1).
Run the engine at low idle.
leakage.
Run the engine at high idle.
leakage.
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.
12V140E-3 Series

a
a
SEN00322-04
If any fuel leakage is detected, repair

If no fuel leakage is detected, check
is completed.
12V140E-3 Series
39
SEN00322-04

2011 KOMATSU
All Rights Reserved
40
12V140E-3 Series
SEN00876-03
ENGINE
1SHOP MANUAL
12V140E-3 Series

Removal and installation fuel supply pump unit .............................................................................................. 2
Removal and installation oil seal unit .............................................................................................................. 5
12V140E-3 Series
SEN00876-03
Removal and installation fuel

supply pump unit
a
Figure shows an example of the left side bank.

Except where otherwise noted, the same work
procedure shall be employed for the both
banks.
Removal
1.
2.
Remove the connectors (in 3 places).

Remove fuel return hose (3) between common
rail (1) and supply pump (2). [*1]
a A fuel return pipe is provided on the right
side bank. Since it does not allow removal
halfway, the whole set of the pipe must be
removed.
6.
7.
3.
4.
5.
Remove fuel tube (5) between priming pump

(4) and supply pump (2). [*2]
Remove fuel tube and hose assembly (7)
between supply pump (2) and controller cooler
(6).
8.
Remove oil tube (9) between supply pump (2)

and the cylinder block. [*4]
Disconnect fuel tube (10) between the fuel filter and supply pump (2) from the supply pump
side. [*5]
Remove supply pump mounting bracket (11).

[*6]
Remove 2 high-pressure pipes (8) between

supply pump (2) and common rail (1). [*3]
12V140E-3 Series
9.
Remove 4 mounting bolts (12) and then

remove supply pump assembly (2). [*7]
SEN00876-03
Installation
q
Carry out installation in the reverse order to
removal.
[*1]
Fuel return hose (3) joint bolt (Common rail

side): 17.7 22.6 Nm {1.8 2.3 kgm}
[*2]
10. Remove nut (12), coupling (13) and key (14)

from supply pump assembly (2). [*8]
Fuel tube (5) joint bolt:

24.5 34.3 Nm {2.5 3.5 kgm}
[*3], [*7]
Install the supply pump and high-pressure pipe by
finalizing their position the following procedure.
1) Install supply pump assembly (2) temporarily.
a Align the unequal spline portion of the
supply pump side to unequal spline
portion A of the supply pump drive
case side and then insert the supply
pump..
a When it is difficult to insert the supply
pump , turn the crankshaft to change
position of unequal spline portion A.
Tighten mounting bolt (12) with the

specified torque after tightening the
sleeve nut of the high-pressure pipe
(between supply pump and common
rail).
2 Supply pump assembly mounting
bolt: Adhesive (LT-2)
12V140E-3 Series
SEN00876-03
2)
3)
4)
After installing high-pressure pipes (8) on

supply pump (2) and common rail (1) temporarily, tighten the sleeve nut with the
specified torque.
a Use a spanner type torque wrench
(commercially available part) should
be used for the tightening to ensure
observance of the specified torque.
3 High-pressure
pipe sleeve nut
(Supply pump side):
39.2 49 Nm {4 5 kgm}
3 High-pressure
pipe sleeve nut
(Common rail side):
39.2 58.8 Nm {4 6 kgm}
Install the clamp of the high-pressure pipe
1] Manually tighten and install temporarily the stay and top and bottom
clamps of the high-pressure pipe.
2] Tighten the top and bottom clamps
permanently.
a Take care in the tightening so
that excessive force may not be
applied to the supply pump side
install position.
9.8 1 Nm {1 0.1 kgm}
3] Tighten respective stays permanently.
q
Supply pump side: Bottom side
q
Common rail side:
Faced inward (Opposed)
[*4]
Oil tube (9) joint bolt:

9.8 12.7 Nm {1.0 1.3 kgm}
[*5]
Fuel tube (10) joint bolt:

24.5 34.3 Nm {2.5 - 3.5 kgm}
[*6]
Supply pump mounting bolt (Pump bottom

side): 19.6 29.4 Nm {2.0 3.0 kgm}
[*8]
Nut (12):
176 196 Nm {18 20 kgm}
12V140E-3 Series
Removal and installation oil seal

unit
1
SEN00876-03
a
CS: Crankshaft
Rear oil seal

a For the work up to removal of the flywheel, see
the shop manual for the applicable machine.
1.
Remove rear seal (3).
Take care in the removal not to damage

the seal installation position on the flywheel housing and the seal contact face
on the crankshaft.
Before removing, slightly drive the seal in
once to free it from fixation.
1) Replace the tip of tool N with the hook
type one.
2) Hitch the hook to the hoop of rear
seal (3).
3) Remove rear seal with impact of slide
hammer (SH).
Tool N
12V140E-3 Series
SEN00876-03
Installation
1. Clean, degrease and then dry the contact surface between the flywheel housing and rear
seal.
2.
Using a clean cloth, remove foreign matter

a Clean foreign matter deposited on the seal
lip surface (surface around the crankshaft)
and then degrease and dry the surface.
a Check the crankshaft end face corner and
lip siding surface for scratches due to the
housing, burrs or rusts.
3.
When installing rear oil seal (3), do not apply

oil or grease to the shaft and seal lip. Wipe off
the oil from the shaft.
1) The surface having the parts number (PN)
marking must face to the outside of
engine.
2)
Using the K (push tool), press oil seal (3)

in the flywheel housing until it becomes
the dimension (a) or (b) as shown in the
figure.
(a): 5 mm (from flywheel housing
end surface)
Carry out the following work in the shop

manual of the applicable machine.
12V140E-3 Series
Removal (PC2000-8)
a For the work up to removal of the flywheel, see
1.
Remove rear seal (2).

a Take care in the removal not to damage
the seal installation position on the flywheel housing and the seal contact face
on the crankshaft.
a Before removing, slightly drive the seal in
once to free it from fixation.
a When rear seal (2) is fixed too hard to the
flywheel housing (FWH), carry out the following procedure.
1) Replace the tip of tool N with the drill
type one.
2) Drill through a hole of approx. 3 mm
dia. on rear seal (2).
3) Insert the top end of tool N into the
drilled hole, and remove the rear seal
by the impact of slide hammer (SH).
(Apply the slide hammer evenly not to
tilt the rear seal.)
a Remove the metal powders completely.
a Take care not to damage crankshaft (4).
SEN00876-03
Installation
a Check the Teflon seal (Laydown lip seal) by
checking the wear of the shaft and replace it
with the Standard seal.
a
a
a
Clean, degrease and then dry the contact

surface between the flywheel housing and
rear seal.
Clean foreign matter deposited on the seal
Check the crankshaft end face corner and
Tool A3
12V140E-3 Series
SEN00876-03
1.
Installation procedure of standard seal

a Do not apply any grease, oil and others to
the seal lip surface (a).
a Never remove inside plastic cylinder (3) of
the standard spare seal before installing
the seal.
4)
5)
6)
1)
2)
3)
Set the large inside diameter side (b) of

plastic inside cylinder (3) to the end of
crankshaft (4).
a Extremely take care not to mistake
the direction of the plastic inside cylinder.
7)
Using the tool K, press rear seal (2) by

tightening bolts equally.
a Press rear seal (2) until tool K
reaches crankshaft (4).
q
Press fit method of oil seal (from
flywheel housing end surface)
(a): 13.5 mm
q
Press fit method of oil seal (from
crankshaft end surface)
(b): 25.7 mm
a After having pressed the rear seal,
remove the red sealant form outer
edge.
Hold the metal ring of rear oil seal (1) with

both hands and push it in firmly.
After pushing in the rear oil seal, remove
plastic inside cylinder (3).
a When removing the inside cylinder,
take care not to damage the seal lip.
Apply rear seal (2) on the end of crankshaft (4).

a Install the rear seal in the correct
direction.
Manually push the metal ring of rear seal
(2) evenly, and insert in its position.
Using the tool K, further press and insert
rear seal (2) evenly.
Carry out the following work in the shop manual of the applicable machine.
12V140E-3 Series
Front oil seal

Removal
a For the work up to removal of the damper, see
1. Remove front oil seal (1) according to the following procedures.
SEN00876-03
Installation
1. Clean, degrease and then dry the contact surface between the front cover and front seal.
2.
Using a clean cloth, remove foreign matter

a Clean foreign matter deposited on the seal
a Check the crankshaft end face corner and
3.
When installing front oil seal (2), do not apply

oil or grease to the shaft and seal lip. Wipe off
the oil from the shaft.
2
1)
2)
3)
Inner circumference of front oil seal:

Gasket sealant (LG-7 or equivalent)
1)
The surface having the parts number (PN)

marking must face to the outside of
engine.
2)
Tighten nuts [1] using the tool J (plate),

and press oil seal (8) to the crank shaft
end surface.
Replace the tip of tool N with the hook

type one.
Hitch the hook to the hoop of front seal
(2).
Remove front seal with impact of slide
hammer (SH).
Tool A3
CS: Crankshaft
12V140E-3 Series
3)
SEN00876-03
Tighten nuts [1] using the tool J (push

tool), press oil seal (8) in the front case
until it becomes the dimension (a) as
shown in the figure.
(a): 17 mm (from crank shaft end surface)
(b): 25.1 mm (from front cover end
surface)
Carry out the following work in the shop manual of the applicable machine.
12V140E-3 Series
10
12V140E-3 Series
SEN00876-03
11
SEN00876-03

2011 KOMATSU
All Rights Reserved
12
12V140E-3 Series
SEN05155-00
ENGINE
1SHOP MANUAL
2
3
12V140E-3 Series
90 Repair and replacement of

parts
1
Information related to repair and
replacement
Flowchart ........................................................................................................................................................ 2
Special tool table............................................................................................................................................. 4
12V140E-3 Series
SEN05155-00
Flowchart
Repair of cylinder block top and counterbore by grinding
a
a
For removal, installation, disassembly and assembly of the engine, see the Shop Manual, "Disassembly
and assembly".
If the judgment of No. 9 is NO, examine A. If the result is NO again, examine B.
12V140E-3 Series
12V140E-3 Series
SEN05155-00
SEN05155-00
Special tool table

Replacement/Repair item
1
Symbol
Q'ty
1
79A-471-1050 Pump assembly
795-100-1522 Push tool
795-411-1310 Push tool
795-100-4801 Seat puller
For valve seat insert
790-101-5001 Push tool kit
KIT
E 2
790-101-5081 Plate
For intake valve
790-101-5071 Plate
For exhaust valve
795-100-3005 Seat cutter
KIT
795-100-3100 Body assembly
795-100-3200 Micrometer
795-100-3300 Gauge
795-100-3401 Tool head
795-100-3601 Head support
795-100-3710 Cutter
For oversize machining
795-100-3720 Cutter
For 30
795-100-3730 Cutter
For 45
795-100-4211 Pilot
10.000 mm
795-100-4221 Pilot
10.010 mm
795-100-4231 Pilot
10.020 mm
795-100-4241 Pilot
10.030 mm
795-140-6410 Guide puller
795-130-1310 Guide driver
1
Replacement of valve seat
insert
F
Repair of valve by grinding
Commercially
Valve refacer
available
Check of main bearing mounting hole inside diameter
Commercially
Alignment bar
available
790-101-2800 Bearing puller
790-101-2300 Push puller
795-240-6401 Push tool
795-240-6411 Push tool
795-240-6420 Push tool
795-240-6431 Block
795-240-6440 Nut
795-213-1200 Push tool
795-213-1250 Bar
795-213-1210 Push tool
M 3
795-213-1240 Collar
795-213-1230 Guide
792-103-0400 Grip
Replacement of crankshaft
gear
K
L
Replacement of connecting
rod small end bushing
Replacement of cam bushing
Remarks
795-611-1300 Coolant tester
Replacement of crosshead
guide
Part name
Pressure test of cylinder head

Replacement of valve guide
Part No.
KIT
KIT
KIT
12V140E-3 Series
Replacement/Repair item
Repair of counterbore portion
12V140E-3 Series
Symbol
SEN05155-00
Part No.
Part name
Q'ty
Remarks
79A-513-1710 Basic machine
79A-513-1780 Guide plate
79A-513-1820 Cutter plate
79A-513-1860 Cutter
79A-513-1940 Cutter set gauge
79A-513-1950 Micrometer
79A-513-1960 Driver plate
79A-513-2090 Driver shaft
79A-513-2110 Driver handle
10 79A-513-2120 Service package
11 79A-513-2130 Case
12 79A-513-2140 Basic machine
13 79A-513-2160 Cutter plate
14 79A-513-2230 Cutter
15 79A-513-2240 Remover pin
16 79A-513-2250 Case
17 79A-513-2260 Service package
18 79A-513-2270 Compound
LOCTITE
19 79A-513-2280 Primer
LOCTITE
20 79A-513-2320 Bushing
12
SEN05155-00

2009 KOMATSU
All Rights Reserved
12V140E-3 Series
SEN05156-01
ENGINE
1SHOP MANUAL
2
3
12V140E-3 Series

parts
1
Part names related to cylinder head ............................................................................................................... 2
Testing and inspection of cylinder head .......................................................................................................... 3
Pressure test of cylinder head ........................................................................................................................ 5
Replacement of valve guide............................................................................................................................ 5
Replacement of valve seat insert.................................................................................................................... 6
Replacement of crosshead guide ................................................................................................................. 13
Repair of cylinder head mounting face by grinding ....................................................................................... 14
Repair of valve by grinding ........................................................................................................................... 15
12V140E-3 Series
SEN05156-01
Part names related to cylinder head
1.
2.
3.
4.
5.
6.
7.
Cylinder head
Crosshead guide
Valve guide
Valve seat insert (intake side)
Valve (intake valve)
Valve (exhaust valve)
Valve seat insert (exhaust side)
12V140E-3 Series
SEN05156-01
Testing and inspection of cylinder head
1
Unit: mm
Inspection item
Criteria
Remedy
Presence of crack (External dye check)

Presence of water leakage during air pressure test (0.29
Water leakage from and crack
0.34 MPa {3.0 3.5 kg/cm2}, 30 sec)
of cylinder head
Water pressure test (0.34 0.39 MPa {3.5 4.0 kg/cm2}, 10
min)
Distortion of cylinder head top
and bottom
Tolerance
Repair limit
0 0.06
0.09
Repair by welding or
replace cylinder
head
Repair by grinding or
replace cylinder
head
Projection of injector nozzle
a See Fig. A
Allowable range of projection (a): 2.3 2.9
Replace copper gasket, injector or cylinder head
Damage of valve contact surface of valve seat insert or

looseness of valve seat insert
Repair valve seat

insert contact surface or replace valve
seat insert
Valve sinking quantity (both

intake and exhaust valves)
Presence of dent on valve seat insert contact surface

Check of valve seat insert contact surface
Airtightness test
Hit cylinder head lightly to check for looseness
a See Fig. B
Sink (b)
Standard value
Repair limit
0 0.1
0.7
Replace valve or
valve seat insert
a See Fig. C
Valve head thickness (d)
Valve head thickness
Valve
Standard value
Repair limit
Intake
2.4
1.9
Exhaust
2.15
1.6
Valve seat contact surface angle (c)

Intake valve: 30
Exhaust valve: 45
Abnormality in valve
Replace valve
Deformation of head into dish shape

Presence of crack or dent on seat contact surface of valve
Airtightness test
Play when new cotter pin is inserted in cotter groove
Uneven wear or bend of valve stem
Repair valve stem
Presence of dent at valve stem end

Valve
Outside diameter of valve stem
Projection of valve guide

Outside diameter of crosshead guide
Projection of crosshead guide
12V140E-3 Series
Repair limit
Intake
10
9.940 9.955
Exhaust
10
9.911 9.926
Valve
Inside diameter of valve guide
Standard size Standard value
Replace valve
Repair limit
Intake
10
9.989 10.011
Exhaust
10
9.989 10.011
Replace valve guide
a See Fig. D
Allowable range of projection (e): 22 0.2
Standard size
Standard value
Repair limit
11
11.000 11.011
10.95
a See Fig. E
Allowable range of projection (f): 49 0.25
Replace crosshead
guide
Repair crosshead
guide
SEN05156-01
Illustrations related to testing and inspection table

Fig. A
Fig. D
a:
1.
2.
3.
e:
Projection
Injector
Copper gasket
Cylinder head
Projection
Fig. E
Fig. B
f:
1.
2.
b:
Projection
Crosshead guide
Cylinder head
Sink
Fig. C
c:
d:
Valve seat contact surface angle

Valve head thickness
12V140E-3 Series
Pressure test of cylinder head

a
SEN05156-01
Replacement of valve guide

a
Pressure test tools
Symbol
Part No.
Part name
790-553-1601
79A-471-1050 Pump assembly
Valve guide replacement tools
Symbol
Coolant tester
Part No.
Part name
795-100-1522
Push tool
795-411-1310
Push tool
Pulling out of valve guide

q
If the cylinder head parts were repaired, perform the test according to the following procedure.
Water pressure test

1.
Combine tools A and B and connect the hose

to the cylinder head.
2.
Apply water pressure (0.34 0.39 MPa {3.5

4.0 kg/cm2}) for about 10 minutes and check
around the cylinder head for leakage.
a
k
Warm the whole cylinder head and then perform the test with hot water at 80 95 C.
Pay fully attention to handling the cylinder
head and water whose temperature are
high, and take care not to get burnt.
Using tool C1, pull out the valve guide.
Press fitting of valve guide

1.
Machine the valve guide hole of the cylinder

head to the dimension below.
q
Inside diameter: 17(+0.011/0) mm
2.
Press fit the valve guide until the tool C2 end

touches the cylinder head.
3.
Check that the projection of the valve guide is

within the standard value.
Projection tolerance of valve guide:
22 0.2 mm
Air pressure test

1.
Connect the air compressor hose to the cylinder head.
2.
Put the cylinder head in a water tub, apply air

pressure (0.29 0.34 MPa {3.0 3.5 kg/cm2}
for about 30 seconds, and check for air leakage.
If any crack is detected in the cylinder head by

the above tests, replace the cylinder head.
12V140E-3 Series
SEN05156-01
Replacement of valve seat insert 1

a
Valve seat insert replacement tools
Symbol
Part No.
795-100-4801
Part name
Seat puller
790-101-5001
Push tool kit
790-101-5081
Plate
790-101-5071
Plate
795-100-3005
Seat cutter
795-100-3710
Cutter
795-100-3720
Cutter
795-100-3730
Cutter
795-100-4211
Pilot
Pulling out of valve seat insert

k
k
k
Keep the air pressure at 0.5 0.6 MPa {5 6

kg/cm2} during the work.
When replacing the grinding stone, stop
the air.
Before starting the grinding work, perform
a trial operation of the grinder for 1 minute
and ensure that the grinder is normal.
a After replacing the grinding stone, perform
a trial operation for 3 minutes.
Ensure that the grinding stone is free from
damage and install it to the grinder shaft
with no play.
When using the grinder, put on safety
glasses.
When pulling out with seat puller of tool D

1. Install grinding stone (4) to grinder (1).
2.
While matching the groove of sleeve (2), insert

the grinder in holder (3).
(Adjust the grinder position with set screw (5).)
3.
Adjust the position of grinder (1) so that the

center of grinding stone (4) will be at the center
of valve seat insert (a) and then tighten set
screw (5) to fix grinder (1).
4.
Rotate grinding stone (4) and move it slowly

until it touches valve seat insert (a).
5.
While lightly pressing grinding stone (4)

against the inside surface of valve seat insert
(a), make a groove about 1 mm deep all
around the inside surface of valve seat insert
(a).
12V140E-3 Series
6.
Push in 3 claws (10) of puller head (9) of tool D

with the hand and put them in valve seat insert
(a).
7.
Tighten screw (12) to press 3 claws (10)

against the inside groove of valve seat insert
(a).
a If screw (12) is tightened too strongly, the
insert will be broken and become difficult
to pull out. Accordingly, stop tightening
when 3 claws (10) reach the groove fully.
8.
Put bridge (8) in the outside of puller head (9),

place plates (11) and (7) on the bridge, and
tighten nut (6) to pull out valve seat insert (a).
12V140E-3 Series
SEN05156-01
When pulling out valve seat insert (a) by welding a bar to it

1. Weld bar (b) (Length: 0.1 0.5 mm shorter
than valve seat inside diameter, Diameter:
Approx. 10 mm) to the inside of valve seat
insert (a).
a Take care that welding spatters will not
stick to the head.
2.
After the temperature of the welded parts has

decreased to around the ambient temperature,
insert an unnecessary valve (c) in the reverse
direction and hit its head with a small hammer
to pull out valve seat insert (a).
a If a large impact is given, the welded parts
may come off. Take care.
SEN05156-01
Press fitting of valve seat insert

When press fitting hole for valve seat insert (a)
is not repaired by cutting
1. Using tools E1 and E2 or tools E1 and E3,
press fit standard valve seat insert (a) with
press (d).
a Do not press fit with a hammer.
a Press fitting force of valve seat insert (a)
Intake side:
Approx. 14.7 kN {Approx. 1.5 ton}
Exhaust side:
Approx. 14.7 kN {Approx. 1.5 ton}
2.
Measure sinking quantity (f) of valve seat

insert (a) from cylinder head bottom (e).
a Sinking quantity (f) of valve seat insert (a)
Intake side: 2.2 mm
Exhaust side: 2.4 mm
12V140E-3 Series
12V140E-3 Series
SEN05156-01
SEN05156-01
Oversize machining of valve seat insert

mounting hole
q
Using tool F1 and attached cutter F2, increase

the valve seat insert mounting hole to the next
oversize.
Limit the increase of the mounting hole diameter to 1.0 mm. If the hole diameter needs to be
increased more than 1.0 mm, replace the cylinder head.
Machining dimensions of valve seat insert and mounting hole

Intake valve side
Unit: mm
Valve seat insert
Valve seat insert size
d1
Valve seat insert mounting hole

c1
d2
d3
c2
Standard
55.0
+0.111
+0.086
8.8
0
0.1
55.0
+0.019
+0
58.00 0.2
11
0
0.1
0.25 OS
55.25
+0.111
+0.086
8.8
0
0.1
55.25
+0.019
+0
58.25 0.2
11
0
0.1
0.50 OS
55.5
+0.111
+0.086
8.92
0
0.1
55.5
+0.019
+0
58.50 0.2
11.12
0
0.1
0.75 OS
55.75
+0.111
+0.086
9.05
0
0.1
55.75
+0.019
+0
58.75 0.2
11.25
0
0.1
1.00 OS
56.0
+0.111
+0.086
9.18
0
0.1
56.0
+0.019
+0
59.00 0.2
11.38
0
0.1
OS: Oversize
Exhaust valve side

Unit: mm
Valve seat insert
Valve seat insert size
10
d1

c1
d2
d3
c2
Standard
52.0
+0.080
+0.070
8.6
0
0.1
52.0
+0.019
+0
55.00 0.2
11
0
0.1
0.25 OS
52.25
+0.080
+0.070
8.6
0
0.1
52.25
+0.019
+0
55.25 0.2
11
0
0.1
0.50 OS
52.5
+0.080
+0.070
8.72
0
0.1
52.5
+0.019
+0
55.50 0.2
11.12
0
0.1
0.75 OS
52.75
+0.080
+0.070
8.85
0
0.1
52.75
+0.019
+0
55.75 0.2
11.25
0
0.1
1.00 OS
53.0
+0.080
+0.070
8.98
0
0.1
53.0
+0.019
+0
56.00 0.2
11.38
0
0.1
OS: Oversize
12V140E-3 Series
Valve seat insert
SEN05156-01
Finish machining of valve contact surface of valve seat insert

1.
a
Using tool F1 and attached cutters F3 and F4,

machine the valve contact surface of the valve
seat insert to the following dimensions.
Select tool F5 which will be inserted in the
valve guide with no clearance.
g:
Cylinder head bottom
a
a
Inside finished surface roughness: Max. 12.5 S

Mounting hole bottom surface roughness:
Max. 12.5 S
Concentricity of valve guide hole and valve
seat insert hole: Max. 0.07 mm (TIR)
Squareness of valve guide hole to valve seat
insert hole bottom: Max. 0.03 mm (TIR)
TIR is an abbreviation for Total Indicator Reading, which is the difference between the maximum and minimum readings in runout.
measurement.
a
a
a
12V140E-3 Series
EV: Exhaust valve

IV: Intake valve
h: Finish machining width
11
SEN05156-01
2.
Fit the contact surface of the valve seat insert

to the valve by using compound.
1) Thinly apply rough compound mixed with
oil to the seat surface of a valve and insert
that valve in the valve guide.
2) Install the fitting rod to the valve head and
lightly hit valve against the valve seat
while rotating it with both hands to fit the it
to the valve seat.
3) After the valve and valve seat are fitted
and their surfaces become smooth, wipe
off the compound.
4) Apply fine compound and fit the valve and
valve seat again similarly to the above
until they are fitted to each other without
breakage.
Final inspection
q
q
q
q
q
Thinly apply red lead to the valve seat insert

contact surface of a new valve and insert that
valve in the valve guide.
Lightly press the valve against the valve seat
insert and rotate it 10.
Check the valve seat insert contact surface of
the valve and ensure that the contact is even
and is not broken.
Or , make marks (m) (about 20 places) on the
valve seat insert contact surface of a new
valve with a pencil and insert that valve in the
valve guide.
Ensure that all the pencil marks (m) have been
erased evenly.
When master valve is used
EV:
IV:
j:
k:
Exhaust valve
Intake valve
Cylinder head bottom
Contact width against valve
Concentricity of contact surfaces of valve

guide and valve seat insert: Max. 0.07 mm
(TIR)
TIR is an abbreviation for Total Indicator Reading, which is the difference between the maxim u m an d m i n i m u m r e a d i n g s i n r u n o u t .
measurement.
12
12V140E-3 Series
Replacement of crosshead guide1

a
Crosshead guide replacement tools
Symbol
G
Part No.
SEN05156-01
Press fitting of crosshead guide

q
Part name
795-140-6410
Guide puller
795-130-1310
Guide driver
a
a
Pulling out of crosshead guide

q
1.
Using tool G2, insert crosshead guide (a) in

cylinder head (b) and press fit it with a copper
or plastic hammer until the projection is within
the tolerance.
Projection tolerance of crosshead guide:
49 0.25 mm
Diameter of cylinder head crosshead guide hoe:
11 0.027/0.054 mm
Using tool G1, pull out crosshead guide (a)

from cylinder head (b).
Hold crosshead guide (a) with collet (4) of the
puller.
2.
Tighten collet (4) with bolt (1) to lock sleeve

(2).
3.
Rotate nut (3) and pull out the crosshead

guide.
4.
Remove burrs and fins from and clean the

crosshead guide mounting portion.
12V140E-3 Series
13
SEN05156-01
Repair of cylinder head mounting

face by grinding
1
Grinding
1.
Remove the valve seat insert.

q
For the removal procedure, see "Replacement of valve seat insert".
2.
Remove the distortion and corrosion of the cylinder head by grinding within the tolerance of
cylinder head height (a).
q
Stamp "R" on the left side of the cylinder
head.
Standard cylinder head height (a):

140 0.05 mm
Limit after grinding: 139.65 mm
Grinding depth by 1 grinding: 0.10 0.15 mm
Ground surface roughness: Max. 8S
Flatness (Distortion): Max. 0.05 mm
Grinding depth limit: 0.3 mm
Difference in head height (a) for 1 unit:
Max. 0.15 mm
a
a
a
a
a
a
3.
Press fit the valve seat insert of the next oversize.

q
For the press fitting procedure, see
"Replacement of valve seat insert".
Check after repair by grinding

q
14
Measure the sinking quantity of the valve and

projection of the injector and ensure that they
are within the standard values and then adjust
if necessary.
Valve sinking quantity Standard: 0 0.1 mm
12V140E-3 Series
Repair of valve by grinding

a
SEN05156-01
Valve grinding tool
Symbol
Part No.
Commercially
available
Part name
Valve refacer
Grinding of seat contact surface of

valve
q
Using tool H, grind the seat contact surface of

the valve.
Seat contact surface angle of valve (a)

Intake valve: 30 015'
Exhaust valve: 45 015'
Check after grinding

q
Apply dial gauge (1) to the facial runout measuring point of seat contact surface (c) of the
valve and rotate the valve to measure its facial
runout while pressing it toward left (d).
Intake valve: Max. 0.045 mm (TIR)
Exhaust valve: Max. 0.030 mm (TIR)
TIR is an abbreviation for Total Indicator Reading, which is the difference between the maximum and minimum readings in runout.
measurement.
Measure the valve head thickness, sinking

quantity of the valve, and contact of the seat
contact surface of the valve, and ensure that
they are within the standard values.
Allowable limit of valve head thickness (b)
Intake valve:
Min. 1.9 mm (Standard size: 2.4 mm)
Exhaust valve:
Min. 1.6 mm (Standard size: 2.15 mm)
Valve sinking quantity Standard: 0 0.1 mm
Allowable limit: 0.7 mm
12V140E-3 Series
e:
Block
Check the contact of the seat contact surface

of the valve by either of the following methods.
Thinly apply red lead to the seat contact surface of the ground valve and insert that valve
in the valve guide.
Check the valve seat insert contact surface of
the valve and ensure that the contact is even
and is not broken.
Make marks (f) (about 20 places) on the seat
contact surface of the ground valve with a pencil and insert that valve in the valve guide.
Ensure that all the pencil marks (f) have been
erased evenly.
q
q
q
q
15
SEN05156-01

2010 KOMATSU
All Rights Reserved
16
12V140E-3 Series
SEN05157-00
ENGINE
1SHOP MANUAL
2
3
12V140E-3 Series

parts
1
Part names related to cylinder block............................................................................................................... 3
Testing and inspection of cylinder block.......................................................................................................... 4
Part names related to crankshaft .................................................................................................................... 7
Testing and inspection of crankshaft............................................................................................................... 8
Part names related to connecting rod ............................................................................................................. 9
Testing and inspection of connecting rod...................................................................................................... 10
Replacement of flywheel ring gear.................................................................................................................11
Replacement of crankshaft gear ................................................................................................................... 12
Replacement of camshaft gear ..................................................................................................................... 13
Replacement of main bearing metal cap ...................................................................................................... 14
Replacement of connecting rod small end bushing ...................................................................................... 16
Replacement of cam bushing ....................................................................................................................... 17
Repair of cylinder block top by grinding ........................................................................................................ 19
12V140E-3 Series
SEN05157-00
Repair of counterbore by grinding................................................................................................................. 20

Check and identification after repair by grinding ........................................................................................... 22
Gasket sealant application procedure........................................................................................................... 23
Repair standard for cylinder liner O-ring ....................................................................................................... 25
Repair of crankshaft by grinding ................................................................................................................... 26
Improvement of surface roughness of crankshaft journal ............................................................................. 32
12V140E-3 Series
Part names related to cylinder block
1.
2.
3.
4.
5.
6.
7.
SEN05157-00
Cylinder liner
Clevis seal
Cylinder liner O-ring
Cylinder block
Main bearing metal cap bolt
Main bearing metal cap
(No. 1, 2, 3, 5 and 6 are same)
Camshaft bushing
12V140E-3 Series
SEN05157-00
Testing and inspection of cylinder block
1
Unit: mm
Inspection item
Criteria
Remedy
Crack
Presence of crack (External dye check)

Cylinder head bolt hole etc.
Repair of contact of packing
a See Fig. A
Water leakage caused by corrosion
Replace cylinder
block
a See Fig. B
Standard value
Clearance to cylinder liner
Standard size
Bore of
cylinder block
Outside
diameter of
cylinder liner
Standard
clearance
158.00
158.04
157.897
157.927
0.073
0.143
158.00
Inside diameter of camshaft
bushing
Projection of cylinder liner
Depth and bottom corrosion

counterbore
Inside diameter
Standard size
Standard value
Repair limit
65
65.00 65.06
65.10
a See Fig. D
Presence of corrosion
Standard size
Standard value
11
11.00 11.05
Tolerance
Repair limit
Max. 0.09
Max. 0.05
0.135
0.100
a See Fig. E
Main bearing mounting hole
diameter
Standard size
Standard value
Tighten main bearing metal
156.990
cap bolt to specified torque
157
157.025
Measure in rage of 10 on
General concentricity
upper and lower sides of
main bearing metal cap
Concentricity of adjacent holes
Repair by cutting
and add shim
Repair by cutting
Repair limit
Max. 0.020
Replace cylinder
block
Max. 0.013
a See Fig. F
Fit of main bearing metal cap
and cylinder block
(Interference)
Replace camshaft
bushing
Replace cylinder
liner or repair cylinder block
a See Fig. C
Allowable range: 0.07 0.15
Distortion and wear of cylinder All cylinder block

head mounting face
top of 1 cylinder
Replace cylinder
liner or cylinder block
Journal
Standard fit
(Interference)
Allowable clearance
No. 1 6
0.083 0.144
No. 7
0.038 0.099
a See Fig. G
Cylinder liner
Inside diameter of counterbore

and outside diameter of
cylinder liner flange
Upper section
170.2
170.10
170.20
Lower section
161.2
161.25
161.29
Replace cylinder
liner
Cylinder block
Repair limit
Upper section
170.2
170.200
170.263
Lower section
161.2
161.170
161.230
Repair limit
Repair cylinder block

and sleeve
12V140E-3 Series
SEN05157-00
Illustrations related to testing and inspection table

Fig. A
Fig. D
a:
f:
Packing portion
Depth of counterbore
Fig. B
Fig. E
b:
g:
Clearance
Inside diameter
Fig. C
Fig. F
c:
d:
e:
h:
Cylinder liner
Cylinder block
Projection
12V140E-3 Series
Fit
SEN05157-00
Fig. G
Method of checking main bearing metal inside

diameter with alignment bar
q
When checking the main bearing metal inside

diameter with tool J (alignment bar), follow the
procedure below.
Unit: mm
Specified dimension
Diameter
i:
j:
157
0.014
0.039
Roundness
0.005
Straightness
0.010
Length
Min. 1,300
Upper section
Lower section
1.
Set the cylinder block on the stand with the

main bearing metal cap side up.
2.
Apply engine oil to the inside of the main bearing metal hole of the cylinder block.
a Leave the main bearing metal cap
removed.
3.
Set tool J (alignment bar) to the main bearing

metal hole of the cylinder block.
4.
Install the main bearing metal cap and tighten

it to the following torque.
5.
Check that tool J (alignment bar) moves

smoothly.
12V140E-3 Series
SEN05157-00
Part names related to crankshaft 1
1.
2.
3.
4.
Crankshaft
Main bearing metal (upper) (All other than No.
4 are the same)
Main bearing metal (lower) (All other than No.
4 are the same)
Thrust metal (All of upper x 1 and lower x 2 are
the same)
12V140E-3 Series
SEN05157-00
Testing and inspection of crankshaft
1
Unit: mm
Inspection item
Criteria
Remedy
Crack
Check for crack by magnaflux inspection
Replace camshaft
Damage
Flaw
Presence of damage in journal Seizure
Discoloration
If damaged slightly,
repair with oilstone
or by lapping. If
seized, replace
crankshaft
Damage of tap holes at front and rear ends
Repair or replace
crankshaft
Clogging of oil hole

End play of crankshaft
Thrust metal thickness
Outside diameter of crankpin

journal
Presence of clogged oil hole

Repair limit
0.140 0.320
0.50
Size
Standard size
Standard
4.000
0.25 OS
4.125
Outside diameter of crank

main journal
Roundness of crank main

journal
Clearance in crank main
journal
Bend of crankshaft
(Total indicator reading)
Tolerance
Replace thrust metal

or replace with oversize parts
Repair limit
3.79
3.92
0.07
0.12
0.50 OS
4.250
0.75 OS
4.375
1.00 OS
4.500
Size
Standard size
Standard
100.00
99.88
0.25 OS
99.75
99.63
0.50 OS
99.50
0.75 OS
99.25
1.00 OS
99.00
4.04
Replace thrust metal

or replace with oversize crankshaft
4.17
4.29
Tolerance
Repair limit
0.030
0.030
99.38
99.13
Replace with undersize parts or replace

crankshaft
98.88
Standard
Repair limit
0 0.010
0.010
0.046 0.116
0.260
Roundness of crankpin journal
Clearance in crankpin journal
Repair
Standard value
Size
Standard size
Standard
148.00
0.25 OS
147.75
0.50 OS
147.50
0.75 OS
147.25
1.00 OS
147.00
Tolerance

connecting rod bearing metal
Repair limit
147.97
147.72
0.030
0.030
147.47
147.22

crankshaft
146.97
Standard
Repair limit
0 0.010
0.010
No. 4 only
0.130 0.195
0.250
Other than
No. 4
0.100 0.165
0.220

main bearing metal
Standard
Repair limit
Concentricity of all
main journals
Max. 0.15
0.15
Concentricity of
adjacent journals
Max. 0.07
0.07
Replace camshaft
a OS: Oversize
12V140E-3 Series
Part names related to connecting rod
1.
2.
3.
4.
5.
6.
7.
8.
SEN05157-00
Connecting rod bolt

Washer
Cap
Dowel pin
Bearing metal (lower)
Bearing metal (upper)
Rod
Small end bushing
12V140E-3 Series
SEN05157-00
Testing and inspection of connecting rod
1
Unit: mm
Inspection item
Criteria
Remedy
Crack
Check for crack by dye check or magnaflux inspection

a See Fig. H
Parallelism and twist of small Presence of bend (after small end bushing is installed)
and large end holes of
Parallelism: 0.10
connecting rod
Twist: 0.25
Tolerance
Standard
Standard
Allowable
Clearance between connecting
size
clearance clearance
Shaft
Hole
rod small end bushing and pis0.006
+0.049
0.030
ton pin
52
0.11
0.006
+0.030
0.055
Large end hole diameter
Without bearing metal.
Inside surface roughness of large
end hole: Max. 3.2 S
Clearance to crankshaft bearing
Connecting rod large end hole
(with bearing metal)
diameter
Wave of large end hole: Max. 0.004
(All width)
Standard
size
106
Replace connecting
rod
Replace small end
bushing
Surface roughness
of inside of small end
bushing: Max. 3.2S
Tolerance
+0.026
0.004
Allowable Replace bearing
clearance metal or connecting
rod
0.26
Standard
clearance
0.046
0.126
Even if dimensions of each part are within allowable limits, if any
clearance exceeds allowable clearance, replace parts (bearing
metal etc.)
Size
Standard size
Tolerance
Repair limit
Standard
3.000
2.91
0.125 US
3.125
3.04
Replace bearing
Bearing metal thickness
0.025
metal
0.250 US
3.250
3.16
0.035
0.375 US
3.375
3.29
0.500 US
3.500
3.40
Replace bearing
Flaw on inside of or seizure of Presence of flaw and seizure
metal and connecting
bearing metal
rod
Standard size
Tolerance
Distance between large and
Replace connecting
0.05
end small end holes
rod
305
0.05
Replace connecting
a See Fig. J
rod
Presence of lateral grinding mark
Streak and bruise on H-portion Presence of lateral streak
If there is bruise,
of connecting rod
replace connecting
rod regardless of
size of bruise
Presence of fretting on mating face
If fretting is felt with
Fretting on cap mating face
Mating face roughness: Max. 6.3 S
nail, replace connecting rod
Fitted area of mating face: Min. 70%
Scuffing on cap bolt seat surface
Repair with oilstone
Scuffing on bolt seat surface
Scuffing on bolt seat surface
Replace bolt
Scuffing on washer surface
Replace washer
Deformation of dowel pin
Presence of deformation of dowel pin

Presence of deformation of dowel pin hole
Replace connecting
rod
Damage of bolt
Presence of crack and damage on threaded portion of bolt

Presence of bend of bolt
Replace bolt
a
a
a
a
10
US: Undersize
If all the items of this criteria (particularly the wave of the large end hole) cannot be measured after the
connecting rod is rebuilt, do not rebuild since the accuracy of the connecting rod large end hole after
rebuilding cannot be confirmed.
When reusability is judged, if there are honing marks left on the inside of the connecting rod large end
hole, it is not required to measure the surface roughness of the inside and wave of the large end hole.
Do not reuse the connecting rod cap mounting bolt more than 5 times.
Each time the bolt is used, make a punch mark on it.
12V140E-3 Series
Fig. H
SEN05157-00
Replacement of flywheel ring gear1

k
Take care not to throw down the flywheel

and get hurt by mistake.
Removal of gear
Make a notch at the tooth bottom of the gear
with a grinder and break the gear to remove
with a chisel.
a:
Measured value
Fig. J
b:
c:
d:
Take care in handling the grinder and

chisel.
Press fitting of gear

1. Check the gear mounting face. If there is a
flaw, repair with an oilstone.
2.
Heat the gear at the specified shrink fit temperature for a certain time.
a Gear shrink fit temperature: Max. 200 C
Heating time: Min. 50 min
3.
Press fit the gear with the chamfered side

directed toward the flywheel until its side is fitted with the flywheel.
Inspection range
Streaks
Lengthwise direction
12V140E-3 Series
11
SEN05157-00
Replacement of crankshaft gear 1

a
Crankshaft gear replacement tools
Symbol
K
Part No.
Part name
790-101-2800
Bearing puller
790-101-2300
Push puller
4.
Using the drive tool, press fit the gear with the
timing mark out until its side is fitted with the
crankshaft flange.
a Press fit the gear quickly before it cools
down.
Removal of gear
q
Make a notch at the tooth bottom of the gear
with a grinder, assemble tools K1 and K2, and
rotate the nut to pull out the gear.
a If the gear cannot be pulled out by the above
method, make a notch at the tooth bottom of
the gear with a grinder, heat the gear with a
gas burner, and drive out the gear with a copper rod etc.
a Take care not to damage the crankshaft.

1. Check the gear mounting face, key way, flange
surface, etc. If there is a flaw, repair with an oilstone.
2.
Drive a new key into the key way of the crankshaft.
3.
a Gear shrink fit temperature: 200 C
12
12V140E-3 Series
Replacement of camshaft gear

k
SEN05157-00
When setting the camshaft assembly on the

press stand, take care not to catch your fingers between the press stand and the gear.
Removal of gear
Set the camshaft assembly on the press stand and
press the camshaft to pull out the gear.

1. Check the gear mounting face, key way, flange
surface, etc. If there is a flaw, repair with an oilstone.
2.
Drive a new key into the key way of the camshaft.
3.
Install the thrust plate.
4.
a Gear shrink fit temperature: 220 240 C
5.
Using the drive tool, press fit the gear with the
timing mark out until its side is fitted with the
camshaft flange.
a Press fit the gear quickly before it cools
down.
12V140E-3 Series
13
SEN05157-00
Replacement of main bearing

metal cap
a
Repair parts
Part name
6215-99-4160 No. 1, 2, 3, 5, 6 main bearing metal cap

6215-99-4170 No. 4 main bearing metal cap
6215-99-4180 No. 7 main bearing metal cap
Inside machining of main bearing metal cap

1. Remove the cylinder liner.
2.
Apply dial gauges to the inside of the 2 main

bearing metal caps at the longest pitch among
the caps to be used to center the arbor of the
boring machine.
5.
While checking the inside diameter of main

bearing metal cap (1), cut little by little.
a Cut to the degree that the boring bar tool
almost touches the inside of cylinder block
(2).
a Inside diameter of main bearing metal cap
q
Machining dimension
Tolerance: 157 +0.025/0 mm
q
After machining, remove the main bearing
metal cap, assemble it again, and check
its inside diameter.
Tolerance: 157 +0.025/0.010 mm
(Range to upper and lower 10 from mating face of main bearing metal cap)
a Finished surface roughness: Max. 10 S
a Do not cut the inside surface of the cylinder block.
When replacing the main bearing metal cap,

work on the semi-finished cap according to the
following procedure and install it.
Part No.
4.
Install the replacement main bearing metal cap

to the cylinder block and tighten it to the specified torque.
a Match the notches of the cylinder block
and main bearing metal cap to each other.
2 Main bearing metal cap mounting bolt:
Apply engine oil to threaded portion and
seat.
a Tighten with the angle tightening wrench
at the 3rd time.
3 Main bearing metal cap mounting bolt:
Unit: Nm {kgm}
Step
3.
Range
1st time
284 {29}
270 299
{27.5 30.5}
2nd time
569 {58}
559 579
{57.0 59.0}
3rd time
90 tightening
90 +30
+00
Set the cylinder block mounting jig on the table

of the horizontal boring machine and install the
cylinder block by fitting its cylinder liner mounting hole to the datum line of the jig.
14
Target
The cylinder block in the illustration has 6

cylinders.
12V140E-3 Series
SEN05157-00
Side machining of main bearing metal cap

(Machine only No. 7 main bearing metal cap)
1. Insert cast iron bushing (3) and pass arbor (4)
through it.
2.
Install facing tool (5) to the arbor.
3.
Cut main bearing metal cap (1) to the degree

that facing tool almost touches the cylinder
block surface.
4.
Cut the opposite side similarly.

a Thrust metal mounting surface roughness:
Max. 12.5 S
a Do not cut the cylinder block.
a Tolerance of main bearing metal cap
width: 51 0/0.030 mm
12V140E-3 Series
15
SEN05157-00
Replacement of connecting rod

small end bushing
1
Press fitting of bushing

1. Set the connecting rod to block (3) of tool L.
2.
Install the bushing to push tool (1), set push

tool (4), and fix them with nut (2).
a Match the oil holes of the bushing and
connecting rod to each other.
3.
Drive push tool (1) with the press to press fit

the bushing.
a Since the bushing is semi-finished, its
inside diameter is small and the piston pin
does not go through it.
After press fitting the bushing, machine its
inside with a reamer or a honing machine
according to the maintenance standard.
a After machining, remove all the chips from
the oil hole and oil groove.
a The inside surface roughness of the
machined bushing must be maximum of
3.2 S.
Connecting rod small end bushing replacement tool
Symbol
Part No.
795-240-6401
Part name
Push tool (KIT)
Pulling out of bushing

1. Set the connecting rod to block (3) of tool L.
2.
16
Using push tool (1) and nut, drive out the busing with the press.
a After removing the bushing, remove sharp
edges and burrs from and clean the bushing mounting hole.
12V140E-3 Series
Replacement of cam bushing

a
3.
Pulling out of No. 3, No. 4 and No. 5 bushings

1) Assemble bar (1), push tool (2), collar (3)
and guide (4) .
2) While hitting bar (1), drive out the bushing
4.
After removing the bushing, remove burrs and

foreign matter from and clean the bushing
mounting hole.
Cam bushing replacement tools
Symbol
Part No.
795-213-1200
SEN05157-00
Part name
Push tool (KIT)
Before replacing the cam bushing, remove the

plug at the rear of the cylinder block.
Removal
1. Pulling out of No. 1 and No. 7 bushings
1) Assemble push tool (2), collar (3) and bar
(1) of tool M.
2.
Pulling out of No. 2 and No. 6 bushings

1) Assemble bar (1), push tool (2), collar (3)
and guide (4) .
12V140E-3 Series
17
SEN05157-00
Installation
a Cam bushing installation drawing
a Press fit the cam bushing, while checking its
direction so that its mating part will be on the
upper side of its center after installed.
1.
Press fitting of No. 3, No. 4 and No. 5 bushings

1) Install bar (1), push tool (2), collar (3) and
guide (4) to the bushing.
2) Press fit the bushing until the oil holes of
th e c y l i n d e r b l o c k a n d b u s h i n g a r e
matched to each other.
3.
Press fitting of No. 1 and No. 7 bushings

1) Install bar (1), push tool (2) and collar (3)
to the bushing.
t h e c y l i n d e r b l o c k a nd b u s h i n g ar e
4.
Measurement after bushing is press fitted

1) Using dial inside gauge (a), measure the
inside diameter of the bushing.
2)
2.
18
Press fitting of No. 2 and No. 6 bushings

1) Install bar (1), push tool (2), collar (3) and
guide (4) to the bushing.
th e c y l i n d e r b l o c k a n d b u s h i n g a r e
Measure the clearance between the bushing and shaft. If it is out of the allowable
range or the shaft does not go through
smoothly, repair the inside of the bushing
with a reamer.
a After repairing the inside of the bushing with a reamer, remove all the
chips from the oil hole and oil groove.
a Inside diameter of cam bushing:
65 +0.06/0 mm
a Clearance to camshaft journal:
0.016 0.096 mm
12V140E-3 Series
Repair of cylinder block top by

grinding
SEN05157-00
Repair by grinding
If there is distortion or corrosion on the cylinder
block top, remove it by grinding.
a If the cylinder liner contact surface of counterbore portion (b) is blackened and grained (particularly in the forward and backward directions
of the cylinder block) more than a half of the
contact surface or the cylinder block top needs
to be ground, repair the counterbore portion.
a Rough criteria for repairing cylinder block top
by grinding
q
The cylinder block top is worn and corroded in
the shape of the trace of the head gasket.
q
Quantity (a) of the above wear is 0.15 mm or
more.
Grinding of top
q
Measure the wear quantity and distortion of the
cylinder block top. If the measured value is
larger than the allowable limit, repair the cylinder block top by grinding within the allowable
limit of cylinder block height (H).
Unit: mm
Standard
size
Repair limit
Flatness of cylinder block

top (per cylinder)
Max. 0.05
0.10
Cylinder block height (H)
471.5 0.04
471.06
Cylinder block top surface

roughness
12V140E-3 Series
Max. 12.5S
When repairing with grinding stone (Reference)

Grinding speed: 1,650 1,950 m/min
Table speed: 15 30 m/min
Grinding depth by 1 grinding: 0.025 mm
Cross feed for 1 grinding: 1 2 mm
Grinding stone: A461 V
Grinding fluid: Water soluble grinding fluid
19
SEN05157-00
Repair of counterbore by grinding 1
Counterbore grinding tool
Symbol
a
q
q
Part No.
Part name
79A-513-1780 Guide plate
79A-513-1860 Cutter
79A-513-1940 Cutter set gauge
79A-513-1950 Micrometer
79A-513-1960 Driver plate
79A-513-2090 Driver shaft
79A-513-2110
10
79A-513-2120 Service package
11
79A-513-2130 Case
12
13
14
79A-513-2230 Cutter
15
79A-513-2240 Remover pin
16
79A-513-2250 Case
17
79A-513-2260 Service package
18
79A-513-2270 Compound
19
79A-513-2280 Primer
20
79A-513-2320 Bushing
q
q
Machine only the hatched part of counterbore

portion depth (e).
Set the machining margin of counterbore portion depth (e) so that cylinder liner projection (f)
will be within the standard value.
If counterbore portion depth (e) exceeds the
standard dimension and the counterbore portion needs to be ground within the allowable
limit, set the machining margin so that 1 shim
shown below will be used for 1 cylinder.
Remove burrs and sharp edges from the
tapered portion etc.
(g) is a line parallel with the cylinder center.
Driver handle
After repairing the top of cylinder block (a) by

grinding, measure the counterbore portion
depth and repair the counterbore by grinding
within the allowable limit of counterbore depth
(e) if necessary.
Rough criteria for repairing counterbore portion
by grinding
A dimension is out of the standard dimension.
The cylinder liner contact surface (a) of the
counterbore portion is blackened and grained
(particularly in the forward and backward directions) more than a half of the whole area.
If counterbore portion depth (e) after the repair
is 11.05 12.525 mm, adjust cylinder liner projection (f) to 0.07 0.15 mm with shims.
Unit: mm
Counterbore portion depth (e)

Cylinder liner projection (f)
Counterbore surface roughness
Grinding shape
20
Standard
size
Repair limit
11 +0.05
+0
12.525
0.07 0.15
Max. 12.5S
See figure below
12V140E-3 Series
SEN05157-00
Shims for adjusting counterbore depth (reference)

Unit: mm
Part No.
Weight
(kg)
6210-29-2260
1.50
0.025
0.023
6210-29-2250
0.80
0.025
0.012
6210-29-2240
0.50
0.025
0.008
6210-29-2230
0.26
0.025
0.004
6210-29-2220
0.20
0.020
0.003
6210-29-2210
0.16
0.016
0.002
a
q
q
When grinding the counterbore portion, use

tool N.
Remarks
Outside diameter (i) and inside diameter (j) of

shim (1)
i: 169 0.15 mm
j: 161.3 + 0.030/0 mm
12V140E-3 Series
21
SEN05157-00
Check and identification after

repair by grinding
After repairing by grinding, check the flat portions around the water and oil holes on the cylinder block top for flaw.
Remove all burrs and sharp edges.
After grinding the top, if cylinder block height
(H) is larger than the standard dimension and
within allowable limit (471.06 471.45 mm), be
sure to use the oversize head gasket.
q
q
Unit: mm
Spare parts used
Head gasket
Part No.
Plate thickness
Standard
6210-17-1814
2.0
Oversize
6210-19-1814
2.4
The 2 letters of "OS" are stamped on the plate

for identification.
After repairing, stamp the contents of repair on
the cylinder block top (rear of the left bank) (a).
Stamp method is shown in the following table.
Oversize head
gasket
Shim
Stamp
Unnecessary
OS
SH
WS
(Stamp letter size shall be 5 10 mm)
22
12V140E-3 Series
Gasket sealant application

procedure
q
SEN05157-00
When press fitting the cylinder liner again after

pulling it out, apply gasket sealant (LG-6) to
the cylinder block top deck (cylinder liner
flange contact surface of the cylinder block)
When using shim for the deck, apply the gasket sealant similarly.
1.
Wipe off dirt, oil etc. from cylinder block top (c)
and the cylinder liner flange contact surface
with cloths.
2.
Apply LG-6 to gasket sealant application area

(a).
q
String diameter: 2 3 mm
q
Overlap length of starting and ending
points (b): 6 6 mm
a When using shim for the deck
q
Thinly apply LG-6 to the underside (e) of
shim (1) and fit the shim to the cylinder
block deck.
q
Then, apply LG-6 as when no shim is
used.
3.
Press fit cylinder liner to the cylinder block.

At this time, apply a little amount of rubber
lubricant (RF-1) to cylinder block contact surface (d) of the O-ring and seal of the cylinder
liner.
a Apply the engine oil just before press fitting the cylinder liner.
a RF-1: Product of DAIDO CHEMICAL
INDUSTRY CO., LTD.
If RF-1 cannot be obtained, apply clean
engine oil SAE No. 30.
a Since the clevis seal and O-ring are
swelled and deteriorated with oil, apply a
little amount of oil with a brush just before
installing.
12V140E-3 Series
4.
Set the cylinder liner to the cylinder block,

install the used head gasket, and tighten the
cylinder head temporarily.
At this time, tighten the bolts in the following
order.
3 Tightening torque:
147 10 Nm {15 1 kgm}
23
SEN05157-00
5.
24
Loosen the cylinder head mounting bolts,

remove the cylinder head, and wipe off the
excessive gasket sealant projected from the
counterbore portion.
a If the gasket sealant sticks to grommet (1)
of the head gasket, it deforms the grommet into a heart shape and can cause
coolant leakage into water hole (2).
Accordingly, wipe off the gasket sealant
thoroughly.
a When installing the cylinder head after
performing step "4.5", use a new head
gasket.
12V140E-3 Series
SEN05157-00
Repair standard for cylinder liner

O-ring
1
After repairing the bushing at the cylinder liner Oring portion of the cylinder block, finish to the following dimensions.
a Concentricity of (6) to standard (A): Max. 0.05
mm
Unit: mm
No.
Finish dimension
167
161.45 0.25
160.67 0.064
176 0.25
184.94 0.18
158 +0.040
+0
159.03 (Gauge diameter)
12V140E-3 Series
25
SEN05157-00
Repair of crankshaft by grinding 1

q
When the crankshaft is worn, seized or damaged slightly and needs to be repaired, grind it
to one of the following undersizes.
Undersizes: 0.25, 0.50, 0.75, 1.00 mm
If the crankshaft is bent or worn unevenly, it
should not be repaired but should be replaced.
(Repairing the crankshaft requires high technologies)
Finish fillet portion (R), shoulder portion (r) and
area (R) around the hole of the crankshaft with
extreme care.
Finish the oil holes of the main journal and pin

journal to the dimensions shown below.
Main journal portion
Finish dimensions of fillet portion

Finish
dimension
Pin journal portion
(a)
R1
4 +0.4
+0
r1
R2
Main journal (b)
r2
26
3.5 0
0.5
6
Unit: mm
Surface
roughness
3.2S
3.2S
12V140E-3 Series
Pin journal portion
SEN05157-00
Inspection before repair by grinding

Visual check
Check for crack, damage, discoloration by seizure,
wear, etc. and judge if the crankshaft can be
repaired by grinding.
Hardness check of journal surface
Standard value: 63 69 Hs
If the hardness is below the allowable limit, discard
the crankshaft.
Check during and after repair by grinding
Check of fillet R portion
q
Check that each fillet R portion is connected to
the journal shoulder smoothly.
q
Using the fillet R gauges, check that the R
dimension is between the minimum value
gauge and maximum value gauge.
q
(a) is the contact point of minimum value
gauge.
q
(b) is the contact point of maximum value
gauge.
Unit: mm
Fillet R
The outside surface roughness of the pin journal and main journal must be maximum of 0.8
S.
Equipment necessary for grinding

q
Magnaflux inspection machine
q
Shore hardness tester
q
Etching kit
q
Crankshaft grinding machine
q
Crankshaft grinding polishing machine
q
Surface roughness gauge
q
Fillet R gauge
12V140E-3 Series
Min. radius
Max. radius
Pin journal
4.0
4.4
Main journal
3.0
3.5
Check for seizure mark by etching

After repairing by grinding, check that there is
no grinding seizure mark by etching inspection.
q
If any seizure mark is detected, grind about
0.02 mm again to the next undersize dimension.
q
After checking, neutralize and clean the
checked surface and apply rust preventive oil.
q
Magnaflux inspection
Before using the repaired crankshaft, check it
by magnaflux inspection to ensure that it has
no crack.
q
Extremely closely check journal fillet portion (c)
which is in each dangerous area of the crankshaft shown in the figure.
q
After the magnaflux inspection, be sure to
demagnetize the crankshaft.
q
27
SEN05157-00
Measurement of bend (Measurement of alignment)

q
Measure the bend of the ground crankshaft
and ensure that it is within the standard value.
q
Measure the bend (alignment) at the following
4 places.
Tolerance of overall length alignment:
Max. 0.15 mm
Tolerance of adjacent alignment:
Max. 0.07 mm
Tolerance of front end alignment:
Max. 0.03 mm
Tolerance of rear end alignment:
Max. 0.03 mm
Grinding of main journal

a Grind all the main journals to the same undersize.
a When grinding, leave the polish finishing margin of 0.007 0.008 mm.
a Stamp undersize dimension (a) on the ground
crankshaft as shown in the figure to prevent
installation of bearing metals of a different size.
28
Undersize dimensions of main journal

Unit: mm
a
q
q
q
Size
Standard size
Standard
148.00
0.25 US
147.75
0.50 US
147.50
0.75 US
147.25
1.00 US
147.00
Tolerance
0
0.030
US: Undersize
Roundness, cylindricality (TIR) and surface
roughness of main journal
Tolerance: Max. 0.010 mm
Surface roughness: Max. 0.8 m
M: Main journal
P: Crankpin journal
Grinding of thrust surface

a It is not always required to grind the thrust surfaces of front (b) and rear (c) to the same
undersize dimension.
a Stamp the undersize dimension on the ground
installation of a wrong thrust metal.
a If thrust surface (a) was repaired by grinding,
ensure that the end play of the crankshaft is
within the allowable range.
(See Disassembly and assembly, "General
assembly")
12V140E-3 Series
SEN05157-00
Oversize dimensions of thrust surface

Unit: mm
Rear thrust surface
Front thrust surface
Standard
0.125 OS
0.25 OS
0.375 OS
0.50 OS
a
q
Standard
0.125 OS
0.25 OS
0.375 OS
Standard size
+0.050
59.000 +0
+0.050
59.125 +0
+0.050
59.250 +0
+0.050
59.375 +0
Repair limit
59.060
59.185
59.310
59.435
Standard size
Repair limit
Standard size
Repair limit
Standard size
Repair limit
Standard size
Repair limit
+0.050
59.125 +0
+0.050
59.250 +0
59.185
+0.050
59.250 +0
59.310
+0.050
59.375 +0
59.310
+0.050
59.375 +0
59.435
+0.050
59.500 +0
59.435
+0.050
59.500 +0
59.560
+0.050
59.625 +0
59.560
59.685
+0.050
59.375 +0
+0.050
59.500 +0
59.435
+0.050
59.500 +0
59.560
+0.050
59.625 +0
59.560
+0.050
59.625 +0
59.685
+0.050
59.750 +0
59.685
+0.050
59.750 +0
59.810
+0.050
59.875 +0
59.810
59.935
0.50 OS
+0.050
59.500 +0
59.560
+0.050
59.625 +0
59.685
+0.050
59.750 +0
59.810
+0.050
59.875 +0
59.935
+0.050
60.000 +0
60.060
OS: Oversize
Squareness of thrust surface (TIR)
Tolerance: 0.02 mm
TIR is an abbreviation for Total Indicator Reading, which is the difference between the maxim u m a nd m i n i m u m r e a d i n gs i n r u n ou t .
measurement.
Grinding of pin journal

a Grind all the pin journals to the same undersize.
a When grinding, leave the polish finishing margin of 0.007 0.008 mm.
a Stamp undersize dimension (a) on the ground
installation of bearing metals of a different size.
Undersize dimensions of pin journal
Unit: mm
a
q
Size
Standard size
Tolerance
Standard
100.000
0.25 US
99.750
0.50 US
99.500
0.75 US
99.250
1.00 US
99.000
M: Main journal
P: Crankpin journal
0
0.030
US: Undersize
Roundness, cylindricality (TIR) and surface
roughness of pin journal
Tolerance: Max. 0.010 mm
Surface roughness: Max. 0.8 m
12V140E-3 Series
29
SEN05157-00
Grinding of sides of main journal and pin journal

q
When repairing the worn surfaces of the main
journal and pin journal, limit the grinding quantity to the minimum.
q
Width of crankshaft main journal
#1 standard: 57 +0.1/0 mm
#2, 3, 5, 6 standard: 55 +0.1/0 mm
#4 standard: 59 +0.1/0 mm
#7 standard: 59 +0.05/0 mm
q
Width of crankshaft pin journal
Standard: 92 +0.054/0 mm
Dressing of grinding stone

Dress the grinding stone for each journal.
q
Adjust the grinding stone edge to the arc of the
fillet with the grinding stone modifying device.
q
Test and correct the grinding stone edge by
grinding a piece of wood on trial, while checking with ball gauges.
q
Work after repair by grinding

q
Ensure again that each dimension is as specified.
q
Clean each part thoroughly and apply rust-preventive oil.
q
When storing the crankshaft for a long period,
support it on 3 points or keep it erected with a
sling.
Balancing (Reference)
Avoid performing repair that may affect the crankshaft balancing, as much as possible.
q
Allowable limit of unbalance:
0.0098 Nm {100 gcm}
q
Limits for reading balance accurately
Bend of crankshaft: 0.07 mm (TIR)
Rotation speed of crankshaft: Max. 325 rpm
q
Correct the balance by drilling holes in or grind
the counterweight, if necessary.
Drilling direction: Radial direction
Hole diameter: Max. 15 mm
Hole depth: Max. 50 mm
Number of holes: Max. 6/counterweight
Center of hole:
Match to the center of the counterweight.
(Deviation: Max. 0.5 mm)
Distance between holes:
Thickness must be at least 5 mm.
a TIR is an abbreviation for Total Indicator Reading, which is the difference between the maxim u m an d m i n i m u m r e a d i ng s i n r u no u t .
measurement.
Prevention of grinding seizure

q
Apply the plunge grinding method.
q
Use all the width of the grinding stone.
q
Avoid grinding the boss surface as much as
possible.
q
Apply cooling oil sufficiently.
q
Set the standard peripheral speed of the grinding stone to 2,000 m/min when the crankshaft
rotation speed is 40 rpm.
Finishing of surface
See "Improvement of surface roughness of crankshaft journal".
q
Surface roughness standard (Pin journal and
main journal)
Journal surface: Max. 0.8S
Thrust surface: Max. 1.6S
End taper portions, boss portions and fillet portions of pin and main journals: Max. 3.2S
q
Polish finishing margin: 0.007 0.008 mm
30
12V140E-3 Series
Measuring procedure for bend and outside

diameter of journal portion
1. Support both end centers of the crankshaft
with a lathe.
Apply the dial gauge probe to the central journal (No. 4) perpendicularly from side so that
deflection caused by the own weight of the
crankshaft will not affect the measurement and
then set the gauge to 0 at the top.
Rotate the crankshaft 1 turn and read the minimum and maximum values.
a If a lathe is not available, support the No.
1 and No. 7 journals on V-blocks.
2.
SEN05157-00
Measuring points of journal

Pin journal: 5 places in directions X and Y
Main journal: 3 places in directions X and Y
Measure the outside diameters of the main

journal and pin journal with a micrometer or an
air micrometer.
12V140E-3 Series
31
SEN05157-00
Improvement of surface
roughness of crankshaft journal 1
q
If the surface roughness of the journal portions

of the crankshaft is out of the standard or the
journal surface has a flaw, bruise or rust which
can be removed, improve the surface roughness.
1.
Cleaning and blowing air

Before starting grinding, brush the oil holes
and blow air into them.
2.
3.
Check the surface roughness with the standard piece.

a Measure the surface roughness of the
journal by comparing it with the standard
piece.
Surface roughness standard (Pin journal
and main journal)
Journal surface: Max. 0.8S
Round part: Max. 3.2S
4.
If the surface roughness does not satisfy the

standard, make round polishing with the sandpaper (#500) again between both ends.
a After improving the surface roughness, be
sure to brush the oil holes and blow air
into them.
a Ensure that the there is no flaw or bruise
on the journal portion and the round part
of each fillet.
If there is any flaw or bruise, polish again
from step 1.
Improvement of surface roughness of journal

portions
When improving with special polishing machine

q
Use the special polishing machine shown
below.
1.
Set the rotation speed of the polishing machine

to 40 50 rpm.
Improve the surface roughness by making
round polishing with sandpaper (belt type)
between both ends of each journal.
a Use sandpaper (belt type) of #320.
a Move the sandpaper smoothly without
stopping at a place.
a Do not use honing oil.
2.
Replace the sandpaper with one of #500.

Apply honing oil to the journal surface. Make
round polishing with the sandpaper between
both ends of the journal, while operating handle (1) to move the sandpaper by the play.
a Move the sandpaper smoothly without
stopping at a place.
If the special polishing machine is not available,

use the following clamp jig for polishing to
improve the surface roughness.
1.
32
Using the crankshaft grinding machine, rotate

the crankshaft to polish.
q
Sandpaper: #800
q
Grinding oil:
Honing oil (Diesel fuel oil may be used)
q
Rotation speed of crankshaft: 40 rpm
12V140E-3 Series
2.
SEN05157-00
While moving the polishing jig in the axial

direction by the play of the journal width
(approx. 5 mm), polish the journal.
a Finish polishing each journal in about 6
minutes. Each time honing of 1 journal is
finished, replace the sandpaper with new
one.
a When honing the pin journal, set it to the
center of rotation.
Assembly and using procedure of clamp jig for

polishing
1. Assemble the clamp jigs for the pin journal and
main journal as shown in the following figure.
2.
Cut off sandpaper (#800) (a, b) to the shapes

shown below.
q
(a) is for the pin journal and its size is as
follows;
L: 200 mm, W:108 mm
q
(b) is for the main journal and its size is as
follows.
L: 170 mm, W: 70 mm
a Make slits (c) 20 mm long on both sides of
the sandpaper at intervals of 10 mm and
cut off one part at each end (d).
12V140E-3 Series
3.
Insert 2 pieces of upper and lower sandpapers

(a) or (b) in slit (e) and fix the ends with tape
(f).
Fold slit portion (d) of the sandpaper along the

round part of the clamp.
5.
Hold the journal with the clamp and fix the

lever ends with rubber tube (g) etc.
33
SEN05157-00
Clamp jig for polishing

a Make the polishing jig according to the following drawings.
Clamp jig for polishing (for pin journal)
Plate 1 (Use 2 pieces for 1 jig)
Lever 2 (Use 2 pieces for 1 jig)
34
12V140E-3 Series
SEN05157-00
Clamp jig for polishing (for main journal)

Plate 1 (Use 2 pieces for 1 jig)
Lever 2 (Use 2 pieces for 1 jig)
12V140E-3 Series
35
SEN05157-00

2009 KOMATSU
All Rights Reserved
36
12V140E-3 Series

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SEN00291-14

00 Index and foreword

00 Index and foreword

Composition of shop manual

Shop Manual, contents binder, binder label and tabs

00 Index and foreword

10 Structure, function and maintenance standard

20 Standard value table

30 Testing and adjusting

50 Disassembly and assembly

90 Repair and replacement of parts

00 Index and foreword

00 Index and foreword

00 Index and foreword

Lubrication system diagram.....................................................................................................

20 Standard value table

00 Index and foreword

00 Index and foreword

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

00 Index and foreword

50 Disassembly and assembly

00 Index and foreword

Parts related to cylinder block

00 Index and foreword

00 Index and foreword

KOMATSU 12V140E-3 Series engine

00 Index and foreword

Foreword and general information

00 Index and foreword

Important safety notice

If welding repairs are needed, always

Prohibition of operation and handling by

6 Safety check before starting work

Wearing protective goggles

Wearing shielding goggles and protectors

9 Good physical condition and preparation

Precautions against work which you are

00 Index and foreword

Preparations for work

Precautions during work

When removing a cover which is under

Precautions for sling work and making

00 Index and foreword

When installing wire ropes to an angular

11) Do not use twisted or kinked wire ropes.

00 Index and foreword

If the load is unstable or the wire rope

Precautions for using mobile crane

Selecting wire ropes

The allowable load is one-sixth of the

00 Index and foreword

Example of O-ring (Fitted to every joint of

For tightening torque, see the precautions for

00 Index and foreword

How to read the shop manual

Revision and distribution

00 Index and foreword

Revised edition mark

Weight of parts of component or parts. Caution necessary when

Places that require special attention for tightening torque during

00 Index and foreword

Explanation of terms for maintenance standard

Standard size and tolerance