DongCo SEN00291-04
DongCo SEN00291-04
DongCo SEN00291-04
ENGINE
12V140E -3 SERIES
SEN00294-04
ENGINE
1SHOP MANUAL
12V140E-3 Series
Index
Composition of shop manual................................................................................................................ 2
Table of contents .................................................................................................................................. 3
12V140E-3 Series
SEN00294-04
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
SEN00291-04
SEN00292-04
SEN00294-04 q
SEN00296-02 q
01 Specification
Specification and technical data
SEN00301-02
SEN00303-02 q
SEN00304-02
SEN00307-02 q
SEN00309-02 q
SEN00310-03
SEN00311-03 q
SEN00312-00
SEN00313-00
40 Troubleshooting
General information on troubleshooting
Troubleshooting of mechanical system (S-mode)
Troubleshooting of electrical system (E-mode), Part 1
Troubleshooting of electrical system (E-mode), Part 2
SEN00314-00
SEN00315-00
SEN00316-00
SEN00317-00
SEN00318-00
SEN00319-00
SEN00320-00
SEN00321-00
SEN00322-00
SEN00876-00
12V140E-3 Series
SEN00294-04
Table of contents
12V140E-3 Series
SEN00294-04
6
7
8
9
10
12
12
14
32
37
39
40
40
42
44
45
47
50
50
52
54
55
12V140E-3 Series
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12V140E-3 Series
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62
64
66
67
68
70
72
74
76
78
80
80
82
84
86
86
88
90
92
92
93
93
12V140E-3 Series
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E-89 Code [1622/CB1622] Injector #9 (R/B #3) System Open/Short Error (RH bank) ...........
E-90 Code [1633/CA1633] KOMNET Datalink Timeout Error (LH bank) ................................
E-91 Code [2185/CA2185] Throttle Sens. Sup. Volt. High Error (LH bank only).....................
E-92 Code [2186/CA2186] Throttle Sens. Sup. Volt. Low Error (LH bank only)......................
E-93 Code [2249/CA2249] Rail Press. Very Low Error (LH bank) ..........................................
E-94 Code [2249/CB2249] Rail Press. Very Low Error (RH bank) ..........................................
E-95 Code [ *1/] Eng. Overheat (LH bank only) ................................................................
E-96 Code [ *2/] Eng. Oil Press. Low Speed Derate (LH bank only) .................................
E-97 Code [ *3/] Press. Low Torque Derate (LH bank only) ..............................................
50
52
54
56
57
57
58
58
59
12V140E-3 Series
SEN00294-04
2007 KOMATSU
All Rights Reserved
Printed in Japan 06-07 (02)
12V140E-3 Series
SEN00296-02
ENGINE
1SHOP MANUAL
12V140E-3 Series
12V140E-3 Series
SEN00296-02
Safety notice
(Rev. 2007/03)
General precautions
k Mistakes in operation are extremely
dangerous. Read the Operation and
Maintenance Manual carefully before
operating the machine.
1) Before carrying out any greasing or
repairs, read all the safety plates stuck to
the machine. For the locations of the
safety plates and detailed explanation of
precautions, see the Operation and Maintenance Manual.
2) Decide a place in the repair workshop to
keep tools and removed parts. Always
keep the tools and parts in their correct
places. Always keep the work area clean
and make sure that there is no dirt, water,
or oil on the floor. Smoke only in the areas
provided for smoking. Never smoke while
working.
3) When carrying out any operation, always
wear safety shoes and helmet. Do not
wear loose work clothes, or clothes with
buttons missing.
q
Always wear safety glasses when hitting parts with a hammer.
q
Always wear safety glasses when
grinding parts with a grinder, etc.
4) When carrying out any operation with 2 or
more workers, always agree on the operating procedure before starting. Always
inform your fellow workers before starting
any step of the operation. Before starting
work, hang UNDER REPAIR 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)
Safety points
1 Good arrangement
2 Correct work clothes
3 Following work standard
4 Making and checking signs
5
2.
12V140E-3 Series
3)
4)
3.
12V140E-3 Series
SEN00296-02
8)
9)
10)
11)
12)
13)
14)
15)
16)
SEN00296-02
4.
8)
12V140E-3 Series
SEN00296-02
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.
12V140E-3 Series
7.
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
SEN00296-02
8.
Precautions for disconnecting and connecting hoses and tubes in air conditioner
circuit
1) Disconnection
k Collect the air conditioner refrigerant (R134a) from the air conditioner circuit in advance.
a Ask professional traders for collecting
and filling operation of refrigerant
(R134a).
a Never release the refrigerant (R134a)
to the atmosphere.
k If the refrigerant gas (R134a) gets
in your eyes, you may lose your
sight. Accordingly, when collecting or filling it, you must be qualified for handling the refrigerant
and put on protective goggles.
2)
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,
ZEXEL: ZXL100PG (equivalent to
PAG46)) to its O-rings.
12V140E-3 Series
1.
SEN00296-02
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.
12V140E-3 Series
SEN00296-02
3.
4.
Filing method
File by the brochures in the correct order of the form number printed in the shop manual composition
table.
q
Revisions
Revised brochures are shown in the shop manual composition table.
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
Tightening
torque
Coat
Oil, coolant
Drain
Remarks
Special safety precautions are necessary when performing work.
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
SEN00296-02
The maintenance standard values necessary for judgment of products and parts are described by the following terms.
1.
Example:
Standard size
120
Tolerance
0.022
0.126
Example:
Standard size
60
12V140E-3 Series
Tolerance
Shaft
Hole
0.030
+0.046
0.076
+0
SEN00296-02
2.
5.
3.
4.
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.
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
10
12V140E-3 Series
SEN00296-02
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.
12V140E-3 Series
11
SEN00296-02
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)
5)
12V140E-3 Series
3.
SEN00296-02
3]
12V140E-3 Series
13
SEN00296-02
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)
12V140E-3 Series
SEN00296-02
Disconnection
Connection (Example of
incomplete setting of (a))
15
SEN00296-02
4)
16
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.
12V140E-3 Series
SEN00296-02
17
SEN00296-02
2.
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.
18
12V140E-3 Series
5.
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
SEN00296-02
19
SEN00296-02
1.
2.
20
12V140E-3 Series
3.
SEN00296-02
114 engine
3)
107 engine
2)
12V140E-3 Series
21
SEN00296-02
4)
4.
1)
2)
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
SEN00296-02
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.
(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
Insulator
Conductor
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
SEN00296-02
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
24
12V140E-3 Series
3.
SEN00296-02
(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.
(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
SEN00296-02
[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
26
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
3)
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.
SEN00296-02
12V140E-3 Series
27
SEN00296-02
4)
5)
28
12V140E-3 Series
SEN00296-02
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
SEN00296-02
Type 2
1.
Disconnection
1) Hold the tightening portion and push body
(7) straight until sliding prevention ring (6)
contacts contact surface (a) of the hexagonal portion at the male end. (Fig. 6)
2) While holding the condition of Step 1), turn
lever (8) to the right (clockwise). (Fig. 7)
3) While holding the condition of Steps 1)
and 2), pull out whole body (7) to disconnect it. (Fig. 8)
2.
Connection
q
Hold the tightening portion and push body
(7) straight until sliding prevention ring (6)
contacts contact surface (a) of the hexagonal portion at the male end. (Fig. 9)
30
12V140E-3 Series
SEN00296-02
Type 3
1.
Disconnection
1) Hold the tightening portion and push body
(9) straight until sliding prevention ring (8)
contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 10)
2) While holding the condition of Step 1),
push cover (10) straight until it contacts
contact surface (b) of the hexagonal portion at the male end. (Fig. 11)
3) While holding the condition of Steps 1)
and 2), pull out whole body (9) to disconnect it. (Fig. 12)
2.
Connection
q
Hold the tightening portion and push body
(9) straight until the sliding prevention ring
contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 13)
12V140E-3 Series
31
SEN00296-02
a Fig. A
Tightening torque
Nm
kgm
11.8 14.7
1.2 1.5
27 34
2.8 3.5
59 74
6.0 7.5
98 123
10.0 12.5
153 190
15.5 19.5
235 285
23.5 29.5
320 400
33.0 41.0
455 565
46.5 58.0
610 765
62.5 78.0
785 980
80.0 100.0
1,150 1,440
118 147
1,520 1,910
155 195
1,960 2,450
200 250
2,450 3,040
250 310
2,890 3,630
295 370
32
Tightening torque
Nm
5.9 9.8
13.7 23.5
34.3 46.1
74.5 90.2
kgm
0.6 1.0
1.4 2.4
3.5 4.7
7.6 9.2
a Fig. B
12V140E-3 Series
2.
3.
Tightening torque
Nm
kgm
59 74
6.0 7.5
98 123
10.0 12.5
235 285
23.5 29.5
Nominal No.
02
03,04
05,06
10,12
14
4.
SEN00296-02
Thread diameter
mm
14
20
24
33
42
Thread diameter
mm
8
10
12
14
16
18
20
24
30
33
36
42
52
12V140E-3 Series
36
33
SEN00296-02
5.
Table of tightening torques for hoses (taper seal type and face seal type)
a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the
torque below.
a Apply the following torque when the threads are coated (wet) with engine oil.
Tightening torque Nm {kgm}
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}
mm
6
8
10
12
14
14
18
22
24
30
33
36
42
Tightening torque
Bolts and nuts
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
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
34
Thread size
(mm)
Face seal
Nominal No. Thread diameNumber of
ter (mm) (Refthreads, type of
erence)
thread
9/16-18UN
14.3
11/16-16UN
17.5
13/16-16UN
20.6
1-14UNS
25.4
1-3/16-12UN
30.2
Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts)
a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114
engine series to the torque below.
Thread size
7.
Taper seal
Tightening torque
Nm
82
10 2
12 2
24 4
36 5
kgm
0.81 0.20
1.02 0.20
1.22 0.20
2.45 0.41
3.67 0.51
12V140E-3 Series
8.
SEN00296-02
Table of tightening torques for 102, 107 and 114 engine series (Taper screws)
a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114
engine series to the torque below.
Thread size
inch
1/16
1/8
1/4
3/8
1/2
3/4
1
12V140E-3 Series
Tightening torque
Nm
31
82
12 2
15 2
24 4
36 5
60 9
kgm
0.31 0.10
0.81 0.20
1.22 0.20
1.53 0.20
2.45 0.41
3.67 0.51
6.12 0.92
35
SEN00296-02
Conversion table
2.
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
SEN00296-02
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
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
SEN00296-02
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
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
SEN00296-02
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
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
SEN00296-02
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
SEN00296-02
41
SEN00296-02
2007 KOMATSU
All Rights Reserved
Printed in Japan 06-07 (02)
42
12V140E-3 Series
SEN00303-02
ENGINE
1SHOP MANUAL
12V140E-3 Series
01 Specification
12V140E-3 Series
SEN00303-02
01 Specification
Outline
1. Applicable machine
Engine
SAA12V140E-3
Machine model
D475A-5E0
Bulldozer
HD785-7
Dump truck
PC2000-8
Hydraulic excavator
WA800-3E0, WA900-3E0
Wheel loader
12V140E-3 Series
01 Specification
SEN00303-02
2. Outline of engine
q
1)
2)
3)
4)
12V140E-3 Series
6)
7)
8)
9)
SEN00303-02
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
mm
2,171.5
mm
Rated output
kW{HP}/rpm
671 {899}/2,000
(Gross)
Max. torque
Nm{kgm}/rpm
3,825 {390}/1,400
(Gross)
rpm
2,150 50
rpm
620 + 80/0
g/kWh
{g/HPh}
210 {156.7}
Dry weight
kg
3,600
DENSO ECD-U2
Electronic control type
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
12V140E-3 Series
01 Specification
SEN00303-02
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)
rpm
2,250 25
rpm
650 20
g/kWh
{g/HPh}
207 {154}
Dry weight
kg
3,600
DENSO ECD-U2
Electronic control type
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
12V140E-3 Series
SEN00303-02
01 Specification
Engine name
SAA12V140E-3
Machine model
PC2000-8
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)
rpm
1,980 25
rpm
825 25
g/kWh
{g/HPh}
207 {154}
Dry weight
kg
3,600
DENSO ECD-U2
Electronic control type
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
mm
l {cc}
12V140E-3 Series
01 Specification
SEN00303-02
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)
rpm
2,200 (+10/-20)
rpm
680 + 50/0
g/kWh
{g/HPh}
215 {160}
Dry weight
kg
3,600
DENSO ECD-U2
Electronic control type
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
12V140E-3 Series
SEN00303-02
01 Specification
Engine name
SAA12V140E-3
Machine model
WA900-3E0
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)
rpm
2,200 + 10/0
rpm
680 + 50/0
g/kWh
{g/HPh}
215 {160}
Dry weight
kg
3,600
DENSO ECD-U2
Electronic control type
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
mm
l {cc}
12V140E-3 Series
01 Specification
12V140E-3 Series
SEN00303-02
SEN00303-02
General view
01 Specification
1.
2.
Center of crankshaft
Rear face of flywheel housing
10
12V140E-3 Series
01 Specification
SEN00303-02
1.
2.
Center of crankshaft
Center of engine
12V140E-3 Series
11
SEN00303-02
01 Specification
1.
2.
Center of crankshaft
Rear face of flywheel housing
12
12V140E-3 Series
01 Specification
SEN00303-02
1.
2.
Center of crankshaft
Center of engine
12V140E-3 Series
13
SEN00303-02
01 Specification
1.
2.
Center of crankshaft
Rear face of flywheel housing
14
12V140E-3 Series
01 Specification
SEN00303-02
1.
2.
Center of crankshaft
Center of engine
12V140E-3 Series
15
SEN00303-02
01 Specification
1.
2.
Center of crankshaft
Rear face of flywheel housing
16
12V140E-3 Series
01 Specification
SEN00303-02
1.
2.
Center of crankshaft
Center of engine
12V140E-3 Series
17
SEN00303-02
01 Specification
Dimensions table
Unit: mm
Engine
SAA12V140E-3
18
Machine model
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
SEN00303-02
Weight table
1
Unit: kg
No.
Item
Main parts
SAA12V140E-3
Turbocharger
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
Crankshaft assembly
10
Camshaft assembly
11
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
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
SEN00303-02
01 Specification
SAA12V140E-3
20
1
Machine model
Page
D475A-5E0
21
HD785-7
22
PC2000-8
23
WA800-3E0
24
WA900-3E0
25
12V140E-3 Series
01 Specification
SEN00303-02
12V140E-3 Series
21
SEN00303-02
01 Specification
22
12V140E-3 Series
01 Specification
SEN00303-02
12V140E-3 Series
23
SEN00303-02
01 Specification
24
12V140E-3 Series
01 Specification
SEN00303-02
12V140E-3 Series
25
SEN00303-02
01 Specification
2007 KOMATSU
All Rights Reserved
Printed in Japan 06-07 (02)
26
12V140E-3 Series
SEN00307-02
ENGINE
1SHOP MANUAL
12V140E-3 Series
12V140E-3 Series
SEN00307-02
Crankshaft........................................................................................................................................... 26
Camshaft............................................................................................................................................. 28
Cam follower, push rod ....................................................................................................................... 29
Piston, piston ring, and piston pin ....................................................................................................... 30
Connecting rod.................................................................................................................................... 32
Flywheel and flywheel housing ........................................................................................................... 34
Vibration damper................................................................................................................................. 35
Timing gear ......................................................................................................................................... 36
Valve system ....................................................................................................................................... 38
Valve and valve guide ......................................................................................................................... 40
Rocker arm and shaft.......................................................................................................................... 42
Crosshead and guide.......................................................................................................................... 43
12V140E-3 Series
SEN00307-02
A:
B:
C:
D:
12V140E-3 Series
1.
2.
3.
4.
SEN00307-02
Air cleaner
ERB type
[Air cleaner of automatic exhaust gas discharge type (Radial seal type)]
A:
B:
C:
Air inlet
To turbocharger (Intake air)
To muffler (Dust)
1.
2.
3.
4.
Pre-cleaner
Air cleaner casing
Outer element
Inner element
Engine
Machine model
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
SEN00307-02
FRG type
[Air cleaner of cyclone pack type with evacuator valve (Radial seal type)]
1.
2.
3.
4.
5.
Inlet
Outlet
Guide vane
Primary element
Safety element
Engine
Machine model
SAA12V140E-3 HD785-7
6.
7.
8.
9.
10.
Type
Evacuator valve
Number of
elements
Automatic discharge
1 Inner element,
1 Outer element
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
Evacuator valve
Dust pan
Guide plate (Sleeve)
Body
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.
SEN00307-02
Turbocharger
Water-cooled type
Type: KTR110L
12V140E-3 Series
A:
B:
C:
D:
E:
F:
G:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Blower housing
V-band
Diffuser plate
Center housing
Shroud
Turbine housing
Blower impeller
Seal ring
Thrust metal
Journal bearing
Seal ring
Turbine impeller
Specifications
Model:
Overall length:
Overall width:
Overall height:
Weight:
SEN00307-02
12V140E-3 Series
SEN00307-02
Model: KTR110L
12V140E-3 Series
SEN00307-02
Unit: mm
No.
Check item
12V140E-3 Series
Criteria
Remedy
Standard
Repair limit
0.08 0.13
0.18
0.43 0.68
0.84
Replace thrust
parts
Replace
bearing parts
Replace
bearing parts
SEN00307-02
Turbocharger mounting
a
a
A:
B:
1.
2.
Exhaust manifold
Turbocharger
10
12V140E-3 Series
Aftercooler
SEN00307-02
Air-cooled type
a
a
A:
B:
1.
2.
3.
4.
5.
Upper tank
Core
Lower tank
Fin
Tube
12V140E-3 Series
11
SEN00307-02
Muffler
a
a
A:
1.
2.
Turbocharger
Muffler
12
12V140E-3 Series
12V140E-3 Series
SEN00307-02
13
SEN00307-02
Engine unit
Cylinder head
A:
B:
Air intake
Exhaust gas
C:
D:
To fuel tank
To radiator
1.
2.
3.
4.
5.
Spill pipe
Air bleeding pipe
Cylinder head
Head cover
Head cover bolt
6.
7.
8.
9.
10.
14
12V140E-3 Series
SEN00307-02
Specifications
Cylinder head
Direct injection type
4-valve type
Split-type 1 cylinder, 1 cylinder head
Centralized cooling system for valve bridge and
injector
Cylinder head bolt: Plastic-region tightening
Valve seat
Valve seat inserts are press fitted to both intake and
exhaust valves
Rocker cover
O-ring seal
Injector
Installation: Dry type (without sleeve)
12V140E-3 Series
15
SEN00307-02
Unit: mm
No.
Check item
Projection of nozzle
5
6
16
Criteria
Remedy
Tolerance
Repair limit
0 0.06
0.09
Engine
Standard
SAA12V140E-3
2.3 2.9
Bolt No.
Procedure
1st phase
[1] [6]
2nd phase
3rd phase
[7]
Tighten in order
137 157 {14 16} shown above. If
216 {22}
284 294 {29 30} there are 5 punch
marks, replace
Retighten by 90
90(+30/0)
the bolt.
68.6 {7}
58.8 73.5 {6 7.5}
147 {15}
66.7 {6.8}
37.3 {3.8}
32.4 {3.3}
Retighten
12V140E-3 Series
12V140E-3 Series
SEN00307-02
17
SEN00307-02
Cylinder block
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
18
Cylinder block
Cylinder liner
Clevis seal
O-ring
O-ring
Main bearing metal cap bolt
Main bearing metal cap
Main bearing metal
Piston cooling nozzle
Thrust bearing metal
12V140E-3 Series
Specifications
Cylinder block
Crankshaft: 7 bearings
Camshaft: High cam type, 7 bearings
Main bearing cap bolt: Plastic-region tightening
SEN00307-02
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 and
Tufftride
12V140E-3 Series
19
SEN00307-02
20
12V140E-3 Series
SEN00307-02
Unit: mm
No.
Check item
0 0.09
0.135
Standard size
Tolerance
157
+0.025
0.010
0.050
0.060
Other
than No.4
4.5
0.065
0.075
Inside diameter of
main bearing metal
No.4 only
(When tightening
bolt with specified
Other
torque)
than No.4
Standard size
Tolerance
Repair limit
148
+0.175
+0.130
148.23
148
+0.145
+0.100
148.20
Standard size
Tolerance
69
+0.025
+0.025
Standard size
Tolerance
Repair limit
65
+0.040
+0.025
65.15
Procedure
1st time
284 {29}
2nd time
569 {58}
3rd time
Retighten by 90
90(+30/0)
65.7 {6.7}
Repair by
grinding or
replace
Replace or correct main bearing metal cap
Correct
No.4 only
Repair limit
10S or less
Remedy
Tolerance
Thickness of main
bearing metal
Criteria
Correct or
replace block
Replace
cam bushing
Retighten
Reassemble
12V140E-3 Series
21
SEN00307-02
Cylinder liner
Unit: mm
No.
1
Check item
Criteria
22
Standard size
Tolerance
Repair limit
+0.020
140
140.12
+0.020
+0.040
140
140.14
+0.021
Repair limit: 0.02
Repair limit: 0.02
Standard size
Tolerance
0.10
170.2
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
0.024
0.049
S
L
Remedy
161.2
158
12V140E-3 Series
12V140E-3 Series
SEN00307-02
23
SEN00307-02
1.
2.
3.
4.
5.
6.
7.
8.
9.
24
10.
11.
12.
13.
12V140E-3 Series
Specifications
SEN00307-02
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
25
SEN00307-02
Crankshaft
26
12V140E-3 Series
SEN00307-02
Unit: mm
No.
1
Check item
End play
Criteria
Standard value
Repair limit
0.140 0.315
0.50
Rank
Standard size
S.T.D.
148
0.25 U.S.
147.75
0.50 U.S.
147.50
0.75 U.S.
147.25
1.00 U.S.
147.00
Surface roughness of
crankpin journal
Bend of crankshaft
12V140E-3 Series
147.98
147.73
0.020
0.020
147.48
147.23
146.98
No.4 only
0.130 0.195
0.25
0.100 0.165
0.22
S.T.D.
100
0.25 U.S.
99.75
0.50 U.S.
89.50
0.75 U.S.
99.25
1.00 U.S.
99.00
Tolerance
Repair limit
89.88
89.63
0.020
0.020
89.38
89.13
88.88
Clearance limit
0.046 0.116
0.17
Repair limit
0.09
0.05
Procedure
5
Repair limit
Standard clearance
Tolerance
Journal
Rank
Outside diameter of crank
pin journal
Remedy
Replace connecting
rod bearing metal
Replace
1st time
74 {7.5}
54 93 {5.5 9.5}
2nd time
245 {25}
3rd time
745 {76}
Retighten
27
SEN00307-02
Camshaft
Unit: mm
No.
1
Check item
Bend of camshaft
Height of cam
Remedy
Standard
Repair limit
0.1 0.25
0.36
Standard size
Tolerance
65
0.016
0.036
Standard clearance
Clearance limit
0.016 0.096
0.15
End play
Clearance of
camshaft journal
28
Criteria
Replace
Standard size
Tolerance
Repair limit
Intake
55.48
0.1
55.08
Exhaust
55.75
0.1
55.35
Replace
12V140E-3 Series
SEN00307-02
Unit: mm
No.
Check item
Remedy
Standard size
Tolerance
Repair limit
22
0.021
0.034
21.92
22
+0.021
+0.021
22.07
31.7
+0.05
+0.02
31.50
12.7
+0.038
+0.013
12.78
12.63
0.006
12.56
Criteria
12V140E-3 Series
Standard size
Tolerance
12.7
0.20
0.20
13.4
0.20
0.20
Replace
29
SEN00307-02
30
12V140E-3 Series
SEN00307-02
Unit: mm
No.
Check item
Criteria
Rank
Standard size
Tolerance
Repair limit
140
0.120
0.135
139.830
140
0.105
0.120
139.845
No.
Measuring point
Standard size
Tolerance
No.1 ring
2.9
0.015
0.035
No.2 ring
2.41
0.010
0.035
Oil ring
0.010
0.030
No.1 ring
No.2 ring
4
No.
2 4 Clearance between piston
ring and piston ring groove
12V140E-3 Series
Oil ring
Replace piston
Replace piston
ring
Replace piston
No.1 ring
No.2 ring
Oil ring
0.035 0.060
0.14
No.1 ring
0.42 0.57
(Tension:
16.5 23.5 N
{1.68 2.40 kg})
2.0
0.65 0.80
No.2 ring
(Tension:
(Identification
16.2 24.2 N
2RN white mark)
{1.65 2.47 kg})
1.5
0.30 0.50
(Tension:
70.1 94.6 N
{7.15 9.65 kg})
1.0
Remedy
Oil ring
Standard size
Tolerance
52
0.006
0.006
52
+0.045
+0.035
Standard clearance
Clearance limit
0.035 0.051
0.10
Replace piston
or piston ring
Replace piston
ring or cylinder
liner
Replace piston
pin
Replace piston
Replace piston
or piston pin
31
SEN00307-02
Connecting rod
32
12V140E-3 Series
SEN00307-02
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Tolerance
Repair limit
52
+0.049
+0.030
52.09
Replace bushing
(Refilled part is
semi-finished part)
Standard clearance
Clearance limit
0.030 0.055
0.11
Standard size
Tolerance
57.4
+0.030
+0.030
Tighten
connecting
rod
cap
with
specified
torque
and
measure
and Z directions)
Inside diameter of
connecting rod large
end
Standard size
Tolerance
Repair limit
100
+0.096
+0.046
100.15
3.0
0.025
0.035
Item
Standard
Repair limit
Parallelism (a)
0 0.10
0.15
Twist (b)
0 0.25
0.30
Dimensions (c)
340
Procedure
1st time
74 {7.5}
69 78
{7 8}
2nd time
Retighten 90
90(+30/0)
Roughness
3.2S
Swell
Replace bushing
or piston pin
Replace connecting rod (Correction
not allowed)
Replace bearing
metal
Replace bearing
metal
Replace connecting rod
Tighten in order
shown in figure
Replace
Do not use a connecting rod cap mounting bolt more than 5 times.
Each time the bolt is used, make a punch mark on its head.
12V140E-3 Series
33
SEN00307-02
Unit: mm
No.
Check item
Criteria
Facial runout of
flywheel housing
Radial runout of
flywheel housing
34
Remedy
Reassemble
Procedure
1st time
343 {35}
2nd time
412 {42}
1st time
98 {10}
78 118 {8 12}
2nd time
294 {30}
3rd time
539 {55}
Tighten in order
shown in above
figure
12V140E-3 Series
Vibration damper
1.
2.
3.
4.
5.
6.
Vibration damper
Pin (between adapter and vibration damper)
Adapter
Pin (between adapter and crankshaft)
Bolt (between adapter and crankshaft)
Bolt (between adapter and vibration damper)
12V140E-3 Series
SEN00307-02
35
SEN00307-02
Timing gear
36
12V140E-3 Series
SEN00307-02
Unit: mm
No.
Check item
Criteria
Position
Measuring point
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
Tolerance
Standard
size
Replace
0.6
Standard
clearance
Clearance
limit
+0.034
+0.009
0.025 0.063
0.20
+0.055
+0.055
0.016 0.084
0.20
Shaft
Hole
56
0.016
0.029
56
0.016
0.029
Standard
Repair limit
0.09 0.26
0.4
0.07 0.18
0.4
0.07 0.20
0.4
0.03 0.088
0.4
0.1 0.4
0.4
Repair limit
Replace
bushing
Replace
thrust bearing
12V140E-3 Series
37
SEN00307-02
Valve system
38
12V140E-3 Series
1.
2.
3.
4.
5.
6.
7.
8.
Cam gear
Thrust plate
Camshaft
Cam follower
Cam roller
Rocker arm shaft
Cam follower shaft
Rocker arm adjustment screw
9. Locknut
10. Push rod
11. Rocker arm
SEN00307-02
Valve timing
Specifications
Camshaft
Drawn steel bar (Machining)
Journal and cam sections: Induction hardening
12V140E-3 Series
39
SEN00307-02
40
12V140E-3 Series
SEN00307-02
Unit: mm
No.
1
Check item
Sinking distance of 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
2.15
1.75
Valve
Standard size
Tolerance
Intake
30
15'
Exhaust
45
15'
Intake
10
0.045
0.060
Exhaust
10
0.074
0.089
Before head is
press fitted
10
+0.019
+0.001
Standard size
Tolerance
After head is
press fitted
10
Valve
Standard clearance
Clearance limit
0.034 0.071
0.22
Exhaust
0.063 0.100
0.24
Tolerance
22.0
0.2
Spring
Standard size
Repair limit
Outer
81.7
72.0
Inner
Spring
Installed
length
Outer
51.0
Inner
Perpendicularity of valve
spring
12V140E-3 Series
46.0
Replace valve
+0.011
0.009
Intake
Correct or replace
valve or valve seat
Replace valve or
valve seat
Replace valve
Exhaust
Valve seat angle
Remedy
Valve
Criteria
Replace valve or
valve guide
Replace valve
Correct
{38.5}
215.6 10.8
{22.0 1.1}
192.1
{19.6}
41
SEN00307-02
Unit: mm
No.
Check item
Outside diameter of rocker
arm shaft
42
Valve clearance
(When cold)
Tightening torque
for locknut of rocker arm
adjustment screw
Remedy
Standard size
Tolerance
32.0
0.0065
32.0
+0.087
+0.035
Standard clearance
Clearance limit
0.0285 0.0935
0.13
Criteria
Valve
Standard
Tolerance
Intake
0.35
0.02
Exhaust
0.57
0.02
58.8 {6}
Tighten
12V140E-3 Series
SEN00307-02
Unit: mm
No.
1
Check item
Depth of crosshead stem
receiver
Inside diameter of crosshead
Outside diameter of crosshead guide
Projection of crosshead
guide
12V140E-3 Series
Criteria
Remedy
Standard size
Tolerance
Repair limit
6.2
+0.3
+0.3
6.61
11.04
0.02
11.17
11
+0.011
+0.011
10.95
49.0
0.25
Replace
Correct
43
SEN00307-02
2007 KOMATSU
All Rights Reserved
Printed in Japan 06-07 (02)
44
12V140E-3 Series
SEN00309-02
ENGINE
1SHOP MANUAL
12V140E-3 Series
12V140E-3 Series
SEN00309-02
12V140E-3 Series
12V140E-3 Series
SEN00309-02
SEN00309-02
Lubrication system
SEN00309-02
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
12V140E-3 Series
SEN00309-02
Oil pump
A:
B:
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
SEN00309-02
Oil cooler
Specifications
Oil cooler
Heat dissipation surface area: 0.986 m2
Element: 12 stages
12V140E-3 Series
SEN00309-02
Oil filter
A:
B:
1.
2.
3.
Safety valve
Filter head
Cartridge
Specifications
Oil filter
Filtration area: 1.62 m2(0.42 m2 x 4)
Rated flow: 330l/min
Safety valve
Cracking pressure: 196 20 kPa {2.0 0.2 kg/cm2}
12V140E-3 Series
SEN00309-02
1.
2.
3.
Specifications
Main relief valve
Cracking pressure:
1,196 49 kPa {12.2 0.5 kg/cm2}
Valve spring
Main relief valve
Valve body
Unit: mm
No.
Check item
12V140E-3 Series
Criteria
Remedy
Tolerance
Standard size Outside diam- Inside diameeter of valve
ter of body
Standard
clearance
33
0.040
0.060
0.040 0.076
Free length
Installed
length
75.8
59.8
0.016
0.016
Replace valve or
body
353 {36}
Correct or
replace spring
SEN00309-02
A:
B:
C:
D:
1.
2.
3.
4.
5.
10
Specifications
Oil cooler bypass valve
Cracking pressure (differential pressure):
392 20 kPa {4.0 0.2 kg/cm2}
Regulator valve
Cracking pressure: 402 49 kPa {4.1 0.5 kg/cm2}
12V140E-3 Series
SEN00309-02
Unit: mm
No.
Check item
Criteria
Tolerance
Standard size Outside diam- Inside diameeter of valve
ter of body
Standard
clearance
22
0.020
0.041
0.020 0.074
Free length
Installed
length
111.5
75
12V140E-3 Series
Remedy
+0.033
+0.033
Replace valve or
body
239 {24.4}
Correct or
replace spring
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}
Replace valve or
body
Replace spring
Correct or
replace spring
11
SEN00309-02
Fuel system
12
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
SEN00309-02
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
SEN00309-02
1
1. Fuel system
Configuration
The CRI system is divided by the function into
the fuel system and control system.
14
12V140E-3 Series
SEN00309-02
2. Control system
12V140E-3 Series
15
SEN00309-02
16
12V140E-3 Series
SEN00309-02
6.
7.
8.
9.
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.
1.
2.
3.
4.
5.
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
17
SEN00309-02
Operation
18
12V140E-3 Series
SEN00309-02
2) Feed pump
q
q
q
q
12V140E-3 Series
19
SEN00309-02
2. Common rail
Structure
q
Common rail (4) distributes the high-pressure
fuel from the high-pressure pump to the injectors of the cylinders.
q
Common rail (4) is equipped with common rail
fuel pressure sensor (2), flow dampers (1), and
pressure limiter (3).
q
The fuel injection pipes are connected to flow
dampers (1) to send the high-pressure fuel to
the injectors.
q
The piping of the pressure limiter (3) is
returned to the fuel tank.
1)
Flow damper
Function
The flow dampers damp the pressure pulses in
the high pressure piping and supply the fuel to
the injectors with stable pressure.
q
If excessive fuel flows out, the flow dampers
block the fuel passage to prevent abnormal
outflow of the fuel.
q
If the fuel flows out abnormally, high pressure
is applied to the piston, which moves to the
right until it reaches the seat to stop the fuel.
q
20
2)
q
Pressure limiter
If abnormally high pressure is generated, the
pressure limiter opens to release that pressure.
If the common rail fuel pressure reaches about
140 MPa {1,430 kg/cm2}, the pressure limiter
operates (Opens).
If the common rail fuel pressure lowers to 30
MPa {310 kg/cm2}, the pressure limiter resets
itself (close) to maintain the pressure.
12V140E-3 Series
3)
q
SEN00309-02
12V140E-3 Series
21
SEN00309-02
3. Injector
Outline
q
The function of the injector is to inject the high
pressure fuel from the common rail into each
combustion chamber of the engine in the optimum timing, by the optimum quantity, at the
optimum injection rate, and under the optimum
spray condition.
q
The TWV (2-way solenoid valve) controls the
start and finish of fuel injection by controlling
the pressure in the control chamber.
q
The orifice limits the opening speed of the nozzle and controls the fuel injection rate.
q
The hydraulic piston transmits the force generated by the pressure in the control chamber to
the needle valve of the nozzle.
q
The nozzle sprays the fuel.
22
12V140E-3 Series
SEN00309-02
Structure
1.
2.
3.
4.
5.
6.
Inlet connector
Terminal
Upper body
Solenoid
Valve body
Orifice (out)
The injector consists of the nozzle section, orifice to control the fuel injection rate, hydraulic
piston section, and 2-way solenoid valve section.
12V140E-3 Series
7.
8.
9.
10.
11.
12.
Orifice (in)
Pressure control chamber
Command piston
Spring
Pressure pin
Nozzle assembly
23
SEN00309-02
A:
B:
No fuel injection
Start of fuel injection
C:
D:
1.
2.
3.
4.
Nozzle
Control piston
Orifice (in)
Orifice (out)
5.
6.
7.
8.
Valve body
Solenoid
Spring
Pressure control chamber
3)
Operation
1)
q
q
2)
q
q
q
24
12V140E-3 Series
SEN00309-02
12V140E-3 Series
25
SEN00309-02
26
2)
q
q
12V140E-3 Series
3)
q
A:
B:
SEN00309-02
4)
5)
Pressure inlet
Mounting screw: M5
Tightening torque:
4.5 0.5 Nm {0.46 0.05 kgm}
The following graph shows the output characteristics of the atmospheric pressure sensor.
12V140E-3 Series
27
SEN00309-02
6)
q
28
7)
q
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
12V140E-3 Series
SEN00309-02
9)
q
29
SEN00309-02
Various controls
30
12V140E-3 Series
SEN00309-02
12V140E-3 Series
31
SEN00309-02
Fuel piping
Left bank
a
a
1.
2.
3.
4.
5.
6.
32
12V140E-3 Series
7.
8.
9.
10.
11.
12.
PCV
Fuel injection pipe (No.1 cylinder)
Fuel injection pipe (No.2 cylinder)
Fuel injection pipe (No.3 cylinder)
Fuel injection pipe (No.4 cylinder)
Fuel injection pipe (No.5 cylinder)
12V140E-3 Series
SEN00309-02
13.
14.
15.
16.
17.
18.
33
SEN00309-02
Right bank
a
a
1.
2.
3.
34
12V140E-3 Series
4.
5.
6.
7.
8.
9.
12V140E-3 Series
SEN00309-02
10.
11.
12.
13.
14.
15.
PCV
High-pressure pump
Feed pump
Oil pump (For pump lubricating oil)
Fuel return pipe
Common rail
35
SEN00309-02
36
12V140E-3 Series
Fuel filter
A:
B:
Fuel inlet
Fuel outlet
1.
2.
3.
SEN00309-02
Specifications
Filtration area: 1.0 m2
12V140E-3 Series
37
SEN00309-02
Pre-fuel filter
A:
B:
Fuel inlet
Fuel outlet
1.
2.
3.
Specifications
Filtration area: 2.12 m2
38
12V140E-3 Series
SEN00309-02
Priming pump
1.
2.
3.
4.
5.
6.
7.
8.
Spring
Cover
Shaft
Bushing
Diaphragm
Diaphragm cover
Body
Check valve
12V140E-3 Series
9.
10.
11.
12.
13.
14.
15.
16.
Valve stopper
Packing
Check valve body
Lever pin
E-ring
Washer
Bolt
Lever
39
SEN00309-02
Cooling system
40
12V140E-3 Series
A:
SEN00309-02
Lubricating oil
1.
2.
Radiator
Cooling fan
2A. Hydraulic fan motor
3. Water pump
4. Oil cooler (For engine)
5. Corrosion resistor
6. Thermostat housing
7. Oil cooler (For power train)
8. Oil cooler bypass circuit (For power train)
9. Air bleeding
10. Turbocharger
12V140E-3 Series
41
SEN00309-02
Water pump
A:
B:
C:
1.
2.
3.
4.
5.
6.
7.
8.
Pump shaft
Water seal
Pump body
Water pump drive gear (Number of teeth: 25)
Ball bearing
Oil seal
Impeller
Pump cover
Specifications
Water pump
Type: Centrifugal, gear-driven
Revolving speed: Engine speed x 1.80
42
12V140E-3 Series
SEN00309-02
A.
B:
C:
1.
2.
3.
Oil cooler
Thermostat housing
Water pump
12V140E-3 Series
43
SEN00309-02
Thermostat
A:
B:
C:
To radiator
To water pump (When bypassing)
To thermostat
1.
2.
3.
Thermostat housing
Thermostat
Cylinder block
Specifications
Valve cracking temperature: 76.5 2C
Temperature at full opening: 90C
Lift at full opening: Min. 10 mm
Q'ty: 3
Unit: mm
No.
44
Check item
Criteria
Remedy
Opening/Closing of
thermostat
Move valve in fully open condition (in water tank of 90C) to water
tank of 71C and keep it for 4 -5 minutes.
Valve must fully close.
Replace
12V140E-3 Series
SEN00309-02
Corrosion resistor
A:
B:
Coolant inlet
Coolant outlet
1.
2.
3.
4.
Head
Element case (Cartridge)
Inhibitor (Solid anti-corrosion agent)
Valve
12V140E-3 Series
Specifications
Corrosion resistor
Filtration area: 0.373 m2x 2
Quantity of anti-corrosion agent: 1,000 g x 2
45
SEN00309-02
1.
2.
3.
4.
46
12V140E-3 Series
SEN00309-02
1.
2.
3.
4.
5.
6.
7.
Crankshaft pulley
Fan belt
Tension pulley
Adjustment bolt
Tension pulley bracket
Fan pulley
Fan
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
47
SEN00309-02
Tension pulley
SAA12V140E-3 (HD785-7, WA800-3E0, WA900-3E0)
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
48
12V140E-3 Series
SEN00309-02
12V140E-3 Series
49
SEN00309-02
Electrical equipment
Alternator
1.
2.
3.
4.
5.
Alternator
Alternator pulley
Terminal B
Terminal R
Terminal E
Engine
6.
Machine model
Type
D475A-5E0
HD785-7
Open type (brushless) manuSAA12V140E-3
PC2000-8
factured by NIKKO DENKI
WA800-3E0, WA900-3E0
50
Pulley
SpecificaOutside
Number
tions
diameter
of stages
(mm)
24V, 90A
95
Weight
(kg)
19
12V140E-3 Series
SEN00309-02
Alternator mounting
a:
1.
2.
3.
4.
5.
Adjustment bolt
Alternator pulley
Alternator
Alternator drive belt
Accessory pulley
12V140E-3 Series
51
SEN00309-02
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
52
Number
of pinion
teeth
11
Weight
Type of
(kg)
connector
18
DT
12V140E-3 Series
SEN00309-02
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
Starting motor assembly
Magnetic switch
Terminal B
Terminal C
Safety relay
Engine
Machine model
SAA12V140E-3
PC2000-8
12V140E-3 Series
7.
8.
9.
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
53
SEN00309-02
Starting aid
Electric heater
1.
2.
3.
4.
Body
Heater coil
Terminal
Connection diagram
54
Specifications
Type of heater: Electrical intake air heater
Rated voltage: 22 V (DC)
Load current: 175 A
12V140E-3 Series
SEN00309-02
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
55
SEN00309-02
2007 KOMATSU
All Rights Reserved
Printed in Japan 06-07 (02)
56
12V140E-3 Series
SEN00311-03
ENGINE
1SHOP MANUAL
12V140E-3 Series
12V140E-3 Series
SEN00311-03
Performance
Category
Necessary
speed for
starting
Body
Lubrication system
Cooling system
Machine model
D475A-5E0
Standard value
for new machine
rpm
rpm
660 40
660 40
rpm
Min. 110
rpm
Min. 100
Measurement conditions
Service limit
value
Air intake
resistance
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
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
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
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
Engine oil temperature: Min. 80C
SAE0W30E0S
SAE5W40E0S
SAE10W30DH
SAE15W40DH
SAE30DH
Function of
radiator pressure valve
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
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
Measurement conditions
Air intake
resistance
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
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
Engine oil temperature: Min. 80C
SAE0W30E0S
SAE5W40E0S
SAE10W30DH
SAE15W40DH
SAE30DH
Function of
radiator pressure valve
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
Measurement conditions
Air intake
resistance
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
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}
0.06
{0.6}
90 110
120
0.15
0.3
kPa
{kg/cm2}
At rated output
Engine oil temperature: Min. 80C
Oil pressure
At low idle
Engine oil temperature: Min. 80C
SAE0W30E0S
SAE5W40E0S
SAE10W30DH
SAE15W40DH
SAE30DH
Function of
radiator pressure valve
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
rpm
680 (+50/0)
680 (+50/0)
rpm
Min. 110
rpm
Min. 100
Measurement conditions
Service limit
value
Air intake
resistance
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
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
Engine oil temperature: Min. 80C
SAE0W30E0S
SAE5W40E0S
SAE10W30DH
SAE15W40DH
SAE30DH
Function of
radiator pressure valve
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
rpm
680 (+50/0)
680 (+50/0)
rpm
Min. 110
rpm
Min. 100
Item
Measurement conditions
Service limit
value
Air intake
resistance
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
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
Engine oil temperature: Min. 80C
SAE0W30E0S
SAE5W40E0S
SAE10W30DH
SAE15W40DH
SAE30DH
Function of
radiator pressure valve
Fan speed
At rated speed
rpm
1,005
1,005
Alternator belt
tension
mm
20
20
12V140E-3 Series
SEN00311-03
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.
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}
kW
{HP}
651 691
{873 926}
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
660 40 rpm
This table shows the standard values obtained by using the JIS correction coefficients.
Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.
This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Use ASTM No.1 or No. 2 diesel fuel as fuel.
Use SAE15W-40 as lubricating oil.
Aftercooler outlet temperature must not exceed 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
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.
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
a
a
a
a
This table shows the standard values obtained by using the JIS correction coefficients.
Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.
This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Use ASTM No.1 or No. 2 diesel fuel as fuel.
Use SAE15W-40 as lubricating oil.
Aftercooler outlet temperature must not exceed 50C.
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
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.
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
This table shows the standard values obtained by using the JIS correction coefficients.
Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.
This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Use ASTM No.1 or No. 2 diesel fuel as fuel.
Use SAE15W-40 as lubricating oil.
Aftercooler outlet temperature must not exceed 50C.
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
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.
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
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
This table shows the standard values obtained by using the JIS correction coefficients.
Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.
This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Use ASTM No.1 or No. 2 diesel fuel as fuel.
Use SAE15W-40 as lubricating oil.
Aftercooler outlet temperature must not exceed 50C.
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
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.
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
680(+50/0)rpm
This table shows the standard values obtained by using the JIS correction coefficients.
Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.
This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Use ASTM No.1 or No. 2 diesel fuel as fuel.
Use SAE15W-40 as lubricating oil.
Aftercooler outlet temperature must not exceed 50C.
12V140E-3 Series
11
SEN00311-03
2007 KOMATSU
All Rights Reserved
Printed in Japan 06-07 (02)
12
12V140E-3 Series
SEN00313-00
ENGINE
1SHOP MANUAL
2
3
12V140E-3 Series
12V140E-3 Series
SEN00313-00
12V140E-3 Series
SEN00313-00
Testing/Adjusting item
Symbol
1 - 99.9 1,299C
Commercially
Thickness gauge
available
795-471-1310 Adapter
6261-71-6150 Gasket
1
For 140E-3, 5
1
1
2
799-201-1590 Gauge
799-201-1450 Adapter
3
4
799-201-1511 Nozzle
799-201-1571 Tube
2
1
799-401-2320 Gauge
2
1
G 2
3
(Setting)
Adapter
799-101-5220 Nipple (10 x 1.25 mm)
07002-11023
O-ring
6151-51-8490 Spacer
6141-71-1710 Joint
1 14
1 10
12V140E-3 Series
1
2
Controller sensor
Actuator diagnosis
799-401-2320 Gauge
Intake: 0.35 mm
Exhaust: 0.57 mm
3
Testing leakage through
pressure limiter and
return rate from injector
Remarks
Testing exhaust
temperature
Part name
799-401-2220 Hose
Part No.
Testing compression
pressure
1
Q'ty
Commercially
available
Commercially
available
Commercially
available
Commercially
available
Hose
Hose
Measuring cylinder
Stopwatch
07376-70315 Plug
799-601-4130 T-adapter
1 Size: 03
1 For Ne sensor
799-601-4330 Socket
799-601-4240 Socket
799-601-4250 Socket
799-601-9420 T-adapter
799-601-4150 T-adapter
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
799-601-9310 Plate
795-799-5530 Socket
Remarks
795-799-5540 Socket
Controller sensor
Actuator diagnosis
Q'ty
SEN00313-00
12V140E-3 Series
SEN00313-00
Symbol
A
k
a
1.
Part No.
Part name
799-201-2202
790-401-2220
Hose
2.
Install nipple [1] of boost gauge kit A and connect it to gauge [2].
a Example of (L1) on the left bank
3.
12V140E-3 Series
SEN00313-00
Part No.
799-101-1502
1.
2.
Run the engine and test the exhaust temperature in the whole speed range.
a When testing with the engine mounted on
the machine, test on the condition
described in the shop manual for the
machine.
4.
Part name
Digital thermometer
3.
Symbol
12V140E-3 Series
SEN00313-00
Symbol
Part No.
Commercially
available
Part name
Clearance gauge
5.
2.
3.
4.
12V140E-3 Series
SEN00313-00
6.
12V140E-3 Series
SEN00313-00
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.
5.
6.
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.
12V140E-3 Series
SEN00313-00
7.
8.
4)
10
12V140E-3 Series
SEN00313-00
a
a
a
3.
4.
Symbol
Part No.
Part name
Q'ty
799-201-1590
Gauge
799-201-1450
Adapter
799-201-1511
Nozzle
799-201-1571
Tube
1.
2.
12V140E-3 Series
11
SEN00313-00
12
12V140E-3 Series
SEN00313-00
1
2
Part No.
4.
Part name
799-101-5002
Hydraulic tester
790-261-1204
799-401-2320
Hydraulic tester
1.
2.
3.
Symbol
F
12V140E-3 Series
13
SEN00313-00
14
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.)
12V140E-3 Series
SEN00313-00
1
2
3
4
1.
2.
3.
Symbol
Part No.
Part name
799-101-5002
Hydraulic tester
790-261-1204
(Setting)
Adapter
799-101-5220
Nipple
07002-11023
O-ring
799-401-2320
Gauge
Fuel pressure
High idle
4.
5.
12V140E-3 Series
15
SEN00313-00
1.
2.
3.
16
No-injection cranking
a
12V140E-3 Series
SEN00313-00
Symbol
Part No.
Part name
6151-51-8490
6141-71-1710
Joint
Commercially
available
Commercially
available
Commercially
available
Measuring cylinder
Commercially
available
Stopwatch
07376-70315
Plug
12V140E-3 Series
1.
Spacer
17
SEN00313-00
a
a
3)
4)
2.
5)
18
Engine speed
(rpm)
Leakage
(cc/min)
1,600
Max. 10
12V140E-3 Series
3.
SEN00313-00
3)
4)
5)
4.
5.
960
1,700
1,020
1,800
1,080
1,900
1,140
2,000
1,200
12V140E-3 Series
19
SEN00313-00
a
a
1.
20
2.
12V140E-3 Series
SEN00313-00
3.
4.
5.
12V140E-3 Series
21
SEN00313-00
6.
7.
22
12V140E-3 Series
SEN00313-00
a
a
1.
12V140E-3 Series
2.
23
SEN00313-00
a
3.
4.
5.
6.
24
12V140E-3 Series
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.
2.
3.
4.
5.
6.
7.
8.
12V140E-3 Series
SEN00313-00
9.
25
SEN00313-00
1.
2.
3.
4.
26
Adjusting
a If the deflection is out of the standard range,
adjust it according to the following procedure.
1.
2.
3.
4.
12V140E-3 Series
SEN00313-00
2.
12V140E-3 Series
27
SEN00313-00
2006 KOMATSU
All Rights Reserved
Printed in Japan 02-06 (02)
28
12V140E-3 Series
SEN00315-00
ENGINE
1SHOP MANUAL
12V140E-3 Series
40 Troubleshooting
General information on troubleshooting
General information on troubleshooting.......................................................................................................... 2
Points to remember when troubleshooting ........................................................................................... 2
Error codes and failure codes list ......................................................................................................... 3
12V140E-3 Series
SEN00315-00
40 Troubleshooting
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.
2.
3.
3)
4)
5)
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.
12V140E-3 Series
40 Troubleshooting
SEN00315-00
Machine failure
code
111
CA111
111
CB111
115
CA115
115
CB115
122
CA122
123
CA123
131
CA131
132
CA132
135
CA135
141
CA141
144
CA144
145
CA145
153
CA153
154
CA154
187
CA187
187
CB187
212
CA212
213
CA213
221
CA221
222
CA222
227
CA227
227
CB227
234
CA234
238
CA238
238
CB238
263
CA263
263
CB263
265
CA265
265
CB265
271
CA271
Failure phenomenon
271
CB271
272
CA272
272
CB272
273
CA273
273
CB273
274
CA274
274
CB274
322
CA322
323
CA323
324
CA324
325
CA325
331
CA331
12V140E-3 Series
SEN00315-00
40 Troubleshooting
INSITE
error code
Machine failure
code
332
CA332
342
CA342
342
CB342
351
CA351
351
CB351
352
CA352
352
CB352
386
CA386
386
CB386
441
CA441
441
CB441
442
CA442
Failure phenomenon
442
CB442
449
CA449
449
CB449
451
CA451
451
CB451
452
CA452
452
CB452
553
CA553
553
CB553
554
CA554
554
CB554
559
CA559
559
CB559
689
CA689
689
CB689
691
CA691
692
CA692
731
CA731
731
CB731
757
CA757
757
CB757
778
CA778
778
CB778
781
CA781
781
CB781
1117
CA1117
1117
CB1117
1257
CA1257
1257
CB1257
1548
CB1548
1549
CB1549
1551
CB1551
12V140E-3 Series
40 Troubleshooting
SEN00315-00
a
a
INSITE
error code
Machine failure
code
1552
CB1552
1553
CB1553
1622
CB1622
1633
CA1633
2185
CA2185
2186
CA2186
2249
CA2249
2249
CB2249
Failure phenomenon
--*1
--*2
--*3
12V140E-3 Series
SEN00315-00
40 Troubleshooting
2006 KOMATSU
All Rights Reserved
Printed in Japan 02-06 (02)
12V140E-3 Series
SEN00316-00
ENGINE
1SHOP MANUAL
12V140E-3 Series
40 Troubleshooting
12V140E-3 Series
SEN00316-00
40 Troubleshooting
12V140E-3 Series
40 Troubleshooting
SEN00316-00
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
SEN00316-00
40 Troubleshooting
12V140E-3 Series
40 Troubleshooting
SEN00316-00
If we look for the linkage of these three phenomena to possible causes, we find that they have causal relationship with five causes.
Let us explain here the method of using this causal relationship to pinpoint the most probable cause.
12V140E-3 Series
SEN00316-00
40 Troubleshooting
Q w w
Q Q
Defective injector
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
Correct
Causes
Clean
Troubleshooting
Check items
Questions
12V140E-3 Series
40 Troubleshooting
SEN00316-00
w
w
w
Q
Q
w
w
Q
w
w
Q
q
q
q
q
q
Replace
Replace
Correct
Replace
Replace
Remedy
When specific gravity of electrolyte and voltage of battery are measured, they are low
12V140E-3 Series
E E
Causes
Replace
Check items
Questions
SEN00316-00
40 Troubleshooting
Defective injector
E
w Q w w w
w E
Q Q
Q Q
E E
Q
Q
w Q
w w w w
q
q
q
q q
q
q
q
Replace
Replace
Replace
Correct
Replace
Replace
Replace
Replace
Clean
Replace
Correct
Correct
q q
Add
Remedy
Replace
Troubleshooting
Check items
Questions
Causes
12V140E-3 Series
40 Troubleshooting
SEN00316-00
q
q
q
q
q
q
q
Replace
Replace
Replace
Clean
Replace
Clean
Clean
Correct
Clean
q
Replace
Replace
Remedy
Replace
Troubleshooting
Check items
Questions
Causes
12V140E-3 Series
SEN00316-00
40 Troubleshooting
E
w
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
E E
Correct
Clean
Troubleshooting
Check items
Questions
Causes
10
12V140E-3 Series
40 Troubleshooting
SEN00316-00
Causes
EE
Q w Q w w
w Q
Q
w
w Q
Q Q
Q Q Q
Q Q Q
w w
w
w
w
w Q Q
w w
Q Q
Check items
w w
w w
w
w
q
q
q
q
q
q
q q
Replace
Replace
Replace
Replace
Clean
Clean
Correct
Clean
Add
Replace
q
Replace
Remedy
Replace
Replace
Troubleshooting
Questions
Degree of machine
operation
12V140E-3 Series
11
SEN00316-00
40 Troubleshooting
Q
w
Q
Q Q Q Q Q Q
Q
Q
w
Q
w w
w
w
Q Q
w
w Q Q
Q
Q
Q
Q
q
q
q q
q
Correct
Correct
Correct
Replace
Replace
Replace
Clean
Add
Remedy
E E
Replace
Correct
Troubleshooting
Check items
Questions
Causes
12
12V140E-3 Series
40 Troubleshooting
SEN00316-00
1
Defective fuel temperature sensor and/or wiring harness
Causes
Q Q Q
Q
E
Q
12V140E-3 Series
E E
Q Q
Q Q
Q
Q Q Q
w
w
w
w
w w
w
w
w
w
Q
w w Q
w
Q Q
Q Q Q Q
w
w Q
q
q
q q q
q
q
q
q
q
q
q q
q
q
Replace
Replace
Correct
Replace
Replace
Replace
Clean
Replace
Correct
Clean
Replace
Adjusting
Replace
q
Replace
Remedy
E
Q
Correct
Suddenly
Power was lost
Gradually
Non-specified fuel is being used
Replacement of filters not carried out according to Operation and Maintenance Manual
Engine oil replenished more frequently
Dust indicator is red (if indicator is installed)
Air breather hole of fuel tank cap is clogged
Fuel is leaking from fuel piping
Output becomes insufficient after short stop of operation
Color of exhaust Black
gas
Blue under light load
When exhaust manifold is touched immediately after starting engine,
temperature of some cylinders is low
Clean
Troubleshooting
Check items
Questions
Degree of machine
Operated for long period
operation
13
SEN00316-00
40 Troubleshooting
14
12V140E-3 Series
40 Troubleshooting
SEN00316-00
E
w
w
E
Q Q Q
Q
Q
w
Q Q
w
w
Q
w
Q
Q
Q Q
Q
w
w
Q Q Q
Q w
w
w
Q Q
Q
Q
w
Q Q Q
Q
Q w
w
w
q
q
q
q
q
Replace
Adjusting
Adjusting
Correct
Replace
Replace
Replace
Replace
Correct
Adjusting
Replace
Replace
Replace
Causes
Clean
Troubleshooting
Check items
Questions
15
SEN00316-00
40 Troubleshooting
16
Turbocharger 1
Worn seal at blower end
Q
Q
w
Q Q w
w w w w w
w
w
Q w
w
w
Q
w w
w w
Q
w
q
q
q q
q
q q
q
q q
Correct
Correct
Correct
Correct
Replace
Replace
Correct
Replace
Replace
Clean
q q q q
Replace
Remedy
E
w
Replace
E E E
Correct
Causes
Correct
Troubleshooting
Check items
Questions
12V140E-3 Series
40 Troubleshooting
SEN00316-00
Causes
q q
q
q
q
Clean
Replace
Replace
Clean
Clean
Replace
Replace
q
Remedy
12V140E-3 Series
See S-7
Replace
Troubleshooting
Check items
Questions
17
SEN00316-00
40 Troubleshooting
E
Q
Q Q Q
Q
Q Q
w
w
w
w
w
Q
Q
Q Q
Q Q
q
q
q
q
q
Correct
Correct
Replace
q
Replace
Correct
Replace
Replace
q
Correct
Remedy
E E
Correct
Questions
Check items
Troubleshooting
Causes
18
12V140E-3 Series
40 Troubleshooting
SEN00316-00
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)1
General causes why oil is mixed in coolant
q
Internal leakage in lubrication system
q
Internal leakage in cooling system
Broken hydraulic oil cooler or power train oil cooler on installed machine side
Causes
Degree of machine
operation
Oil level
Suddenly increased
Q
Q
Q Q
w
w
q q
12V140E-3 Series
Replace
Replace
Replace
Remedy
Replace
Check items
Q Q
Gradually increased
Troubleshooting
Replace
Questions
19
SEN00316-00
Q w
Q
w
Q
w w w Q
Q
w
Q
w
Q Q
w
w
w
w
w
w
w
See S-13
q q
q
q
q
q
Replace
Replace
Correct
Clean
Adjusting
Replace
Add
Remedy
Clean
Clean
Troubleshooting
Check items
Questions
Causes
Clean
40 Troubleshooting
20
12V140E-3 Series
40 Troubleshooting
SEN00316-00
w
Q
Q
Clogged water pump drain hole (breather hole) and/or defective seal
E
w
w
Q Q
Q
Q
Q
Q
Q
w
w
w
w
q
q q
q
q
q
q
q
Replace
Replace
Correct
Replace
Replace
Correct
Replace
Replace
Correct
q
Remedy
12V140E-3 Series
E E
Replace
Troubleshooting
Check items
Questions
Causes
21
SEN00316-00
40 Troubleshooting
Lack of coolant
E E
Q w
Q
Q
Q w w
w
w
w
w Q
w
w
w
w
w
w
w
w
w
q
q
q
q
q
q
Replace
Correct
Replace
Correct
Correct
Replace
Replace
Add
Replace
E E
Replace
Replace
Troubleshooting
Check items
Questions
Causes
Remedy
22
12V140E-3 Series
40 Troubleshooting
SEN00316-00
12V140E-3 Series
Q Q
Q
Q
w
w
w
w
w
w
w
w Q
w
Q w
Q
Q
w
Q Q
Q
w
q
q
q
q
q q
q
q q
q
Correct
Correct
Replace
Correct
Replace
Replace
Replace
Replace
Replace
q
Correct
Remedy
Replace
Causes
Replace
Troubleshooting
Check items
Questions
23
SEN00316-00
40 Troubleshooting
Q
Q
w
w
Q
Q
Q
w
w
Q
E
Q
Q
Q
Q Q Q Q
E
Q
q
q
q
q
q
q
q
Replace
Adjusting
Replace
Adjusting
Replace
Replace
Replace
q
Remedy
24
Causes
Replace
Troubleshooting
Check items
Questions
12V140E-3 Series
SEN00316-00
40 Troubleshooting
2006 KOMATSU
All Rights Reserved
Printed in Japan 02-06 (02)
26
12V140E-3 Series
SEN00317-00
ENGINE
1SHOP MANUAL
12V140E-3 Series
40 Troubleshooting
12V140E-3 Series
SEN00317-00
40 Troubleshooting
E-13 Code [153/CA153] Charge Air Temp. Sensor High Error (LH bank only) .................................. 28
E-14 Code [154/CA154] Charge Air Temp. Sensor Low Error (LH bank only)................................... 30
E-15 Code [187/CA187] Sensor Sup. 2 Volt. Low Error (LH bank) .................................................... 31
E-16 Code [187/CB187] Sensor Sup. 2 Volt. Low Error (RH bank) ................................................... 31
E-17 Code [212/CA212] Eng. Oil Temp.Sensor High Error (LH bank only) ....................................... 32
E-18 Code [213/CA213] Eng. Oil Temp.Sensor Low Error (LH bank only) ........................................ 34
E-19 Code [221/CA221] Ambient Air Press. Sensor High Error (LH bank only) ................................ 36
E-20 Code [222/CA222] Ambient Air Press. Sensor Low Error (LH bank only) ................................. 38
E-21 Code [227/CA227] Sensor Sup. 2 Volt. High Error (LH bank) ................................................... 40
E-22 Code [227/CB227] Sensor Sup. 2 Volt. High Error (RH bank)................................................... 42
E-23 Code [234/CA234] Eng. Overspeed (LH bank only).................................................................. 44
E-24 Code [238/CA238] Ne Speed Sensor Sup. Volt. Error (LH bank).............................................. 46
E-25 Code [238/CB238] Ne Speed Sensor Sup. Volt. Error (RH bank) ............................................. 48
E-26 Code [263/CA263] Fuel Temp. Sensor High Error (LH bank).................................................... 50
E-27 Code [263/CB263] Fuel Temp. Sensor High Error (RH bank) ................................................... 52
E-28 Code [265/CA265] Fuel Temp. Sensor Low Error (LH bank)..................................................... 54
E-29 Code [265/CB265] Fuel Temp. Sensor Low Error (RH bank) .................................................... 54
E-30 Code [271/CA271] PCV1 Short Error (LH bank) ....................................................................... 56
E-31 Code [271/CB271] PCV1 Short Error (RH bank)....................................................................... 58
E-32 Code [272/CA272] PCV1 Open Error (LH bank) ....................................................................... 60
E-33 Code [272/CB272] PCV1 Open Error (RH bank)....................................................................... 61
E-34 Code [273/CA273] PCV2 Short Error (LH bank) ....................................................................... 62
E-35 Code [273/CB273] PCV2 Short Error (RH bank)....................................................................... 64
E-36 Code [274/CA274] PCV2 Open Error (LH bank) ....................................................................... 66
E-37 Code [274/CB274] PCV2 Open Error (RH bank)....................................................................... 67
E-38 Code [322/CA322] Injector #1 (L/B #1) System Open/Short Error (LH bank) ........................... 68
E-39 Code [323/CA323] Injector #5 (L/B #5) System Open/Short Error (LH bank) ........................... 70
E-40 Code [324/CA324] Injector #3 (L/B #3) System Open/Short Error (LH bank) ........................... 72
E-41 Code [325/CA325] Injector #6 (L/B #6) System Open/Short Error (LH bank) ........................... 74
E-42 Code [331/CA331] Injector #2 (L/B #2) System Open/Short Error (LH bank) ........................... 76
E-43 Code [332/CA332] Injector #4 (L/B #4) System Open/Short Error (LH bank) ........................... 78
E-44 Code [342/CA342] Caribration Code Incompatibility (LH bank) ................................................ 80
E-45 Code [342/CB342] Caribration Code Incompatibility (RH bank) ................................................ 80
E-46 Code [351/CA351] INJ. Drive Circuit Error (LH bank) ............................................................... 82
E-47 Code [351/CB351] INJ. Drive Circuit Error (RH bank)............................................................... 84
E-48 Code [352/CA352] Sensor Sup. 1 Volt. Low Error (LH bank) .................................................... 86
E-49 Code [352/CB352] Sensor Sup. 1 Volt. Low Error (RH bank) ................................................... 86
E-50 Code [386/CA386] Sensor Sup. 1 Volt. High Error (LH bank) ................................................... 88
E-51 Code [386/CB386] Sensor Sup. 1 Volt. High Error (RH bank)................................................... 90
E-52 Code [441/CA441] Battery Voltage Low Error (LH bank) .......................................................... 92
E-53 Code [441/CB441] Battery Voltage Low Error (RH bank).......................................................... 92
E-54 Code [442/CA442] Battery Voltage High Error (LH bank).......................................................... 93
E-55 Code [442/CB442] Battery Voltage High Error (RH bank) ......................................................... 93
12V140E-3 Series
SEN00317-00
40 Troubleshooting
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
Display on
applicable machine
Contents of
trouble
Trouble
Action of
controller
Action taken by engine controller to protect system or devices when engine controller detects
trouble
Problem that
appears on
machine
Phenomenon that appears on engine as trouble as result of action taken by engine controller
(shown above)
Related
information
Causes
2
Possible causes
and standard
value in normal
state
12V140E-3 Series
40 Troubleshooting
SEN00317-00
12V140E-3 Series
SEN00317-00
40 Troubleshooting
Failure code
111
CA111
Contents of
trouble
Action of
controller
Problem that
appears
on machine
Related
information
Trouble
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.
1 Defective fuse
a Prepare with starting switch OFF, then carry out troubleshootDisconnection in wiring haring without turning starting switch ON.
ness
Wiring harness between PW L (female) (3),
Resis2 (Disconnection in wiring or
Max. 1 z
(4) battery (+)
tance
defective contact in connecWiring harness between PW L (female) (1),
Resistor)
Max. 1 z
(2) chassis ground
tance
Ground fault in wiring harness
3
(Short circuit with GND circuit)
Causes
Possible causes
and standard
value in normal
state
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between PW L(female) (3),
(4) battery (+)
Resistance
Min. 1 Mz
Voltage
20 30 V
12V140E-3 Series
40 Troubleshooting
SEN00317-00
12V140E-3 Series
SEN00317-00
40 Troubleshooting
Failure code
111
CB111
Contents of
trouble
Action of
controller
Trouble
Problem that
appears on
machine
Engine continues operation normally, but it may stop during operation or may not be able to start.
Related information
Causes
1 Defective fuse
Possible causes
and standard
value in normal
state
a Prepare with starting switch OFF, then carry out troubleshootDisconnection in wiring haring without turning starting switch ON.
ness
Wiring harness between PW R (female) (3),
Resis2 (Disconnection in wiring or
Max. 1 z
(4) battery (+)
tance
defective contact in connecWiring harness between PW R (female) (1),
Resistor)
Max. 1 z
(2) chassis ground
tance
Ground fault in wiring harness
3
(Short circuit with GND circuit)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between PW R (female) (3),
(4) battery (+) and chassis ground
Resistance
Min. 1 Mz
Voltage
20 30 V
12V140E-3 Series
40 Troubleshooting
SEN00317-00
12V140E-3 Series
SEN00317-00
40 Troubleshooting
Failure code
115
CA115
Contents of
trouble
Action of
controller
Trouble
Abnormality occurred in Ne speed sensor circuit and G (Bkup) speed sensor circuit simultaneously.
Engine stop
Phenomenon
Engine cannot be started (engine has been stopped).
that appears on
Engine stops (if engine has been running).
machine
Related
information
Causes
Possible causes
and standard
value in normal
state
Defective mount of Ne speed Check mount of Ne speed sensor directly for defect (defective
sensor
installation of sensor, internal defect of flywheel, etc.)
Defective mount of G (Bkup) Check mount of G (Bkup) speed sensor directly for defect (defecspeed sensor
tive installation of sensor, internal defect of supply pump, etc.)
Defective connection of sen- Check Ne speed sensor and G (Bkup) speed sensor directly for
sor (Wrong connection)
defective connection (wrong connection).
10
If causes 1 5 are not detected, engine controller may be defective. (Since trouble is in system, troubleshooting cannot be carried
out.)
12V140E-3 Series
40 Troubleshooting
SEN00317-00
Failure code
115
CB115
Contents of
trouble
Action of
controller
Trouble
Abnormality occurred in Ne speed sensor circuit and G (Bkup) speed sensor circuit simultaneously.
Engine stop
Phenomenon
Engine cannot be started (if engine has been stopped).
that appears on
Engine stops (if engine has been running).
machine
Related
information
Causes
Possible causes
and standard
value in normal
state
Defective mount of Ne speed Check mount of Ne speed sensor directly for defect (defective
sensor
installation of sensor, internal defect of flywheel, etc.)
Defective mount of G (Bkup) Check mount of G (Bkup) speed sensor directly for defect (defecspeed sensor
tive installation of sensor, internal defect of supply pump, etc.)
Defective connection
(Wrong connection)
12V140E-3 Series
11
SEN00317-00
40 Troubleshooting
E-5 Code [122/CA122] Charge Air Press. Sensor High Error (LH bank
only)
1
Error code
Failure code
122
CA122
Contents of
trouble
Action of
controller
Trouble
Phenomenon
that appears on Acceleration performance of engine drops.
machine
Related
information
Causes
1
Defective sensor power sup- If code [187/CA187] or [227/CA227] is indicated, carry out troubleply system
shooting for it first.
a Prepare with starting switch OFF, then turn starting switch ON
or start engine and carry out troubleshooting.
PIM
Between (1) (2)
Voltage
Power supply
4.75 5.25 V
Pressure sensor voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness
and controller, too, for another cause of trouble, and then judge.
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring harness
4
(Short circuit with GND circuit)
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
12
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
12V140E-3 Series
40 Troubleshooting
SEN00317-00
Causes
Possible causes
and standard
value in normal
state
Voltage
Power supply
4.75 5.25 V
12V140E-3 Series
13
SEN00317-00
40 Troubleshooting
E-6 Code [123/CA123] Charge Air Press. Sensor Low Error (LH bank
only)
1
Error code
Failure code
123
CA123
Contents of
trouble
Action of
controller
Trouble
Phenomenon
that appears on Acceleration performance of engine drops.
machine
Related
information
Possible causes
and standard
value in normal
state
14
Causes
12V140E-3 Series
SEN00317-00
40 Troubleshooting
E-7 Code [131/CA131] Throttle Sensor High Error (LH bank only)
Failure code
131
CA131
Contents of
trouble
Action of
controller
Trouble
Phenomenon
that appears on Depends on machine model.
machine
Related information
Causes
1
Defective sensor power sup- If code [2185/CA2185] or [2186/CA2186] is indicated, carry out
ply system
troubleshooting for it first.
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
DEC (male)
Resistance
4.0 6.0 kz
0.25 5.0 kz
0.25 5.0 kz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes
and standard
value in normal
state
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring harness
4
(Short circuit with GND circuit)
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
16
OEM L
Voltage
Power supply
4.75 5.25 V
Signal
0.5 4.5 V
12V140E-3 Series
40 Troubleshooting
SEN00317-00
Circuit diagram related to deceleration pedal type throttle sensor (Case of D4755)
12V140E-3 Series
17
SEN00317-00
40 Troubleshooting
E-8 Code [132/CA132] Throttle Sensor Low Error (LH bank only)
Failure code
132
CA132
Contents of
trouble
Action of
controller
Trouble
Phenomenon
that appears on Varies by installed machine
machine
Related
information
Possible causes
and standard
value in normal
state
18
Causes
12V140E-3 Series
SEN00317-00
40 Troubleshooting
E-9 Code [135/CA135] Oil Press. Sensor High Error (LH bank only)
Error code
Failure code
135
CA135
Contents of
trouble
Action of
controller
Trouble
Phenomenon
that appears on
machine
Related
information
Causes
1
Defective sensor power sup- If code [187/CA187] or [227/CA227] is indicated, carry out troubleply system
shooting for it first.
a Prepare with starting switch OFF, then turn starting switch ON
or start engine and carry out troubleshooting.
POIL
Between (1) (2)
Voltage
Power supply
4.75 5.25 V
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring harness
4
(Short circuit with GND circuit)
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
20
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
12V140E-3 Series
40 Troubleshooting
SEN00317-00
Causes
Possible causes
and standard
value in normal
state
Voltage
Power supply
4.75 5.25 V
12V140E-3 Series
21
SEN00317-00
40 Troubleshooting
E-10 Code [141/CA141] Oil Press. Sensor Low Error (LH bank only)
Error code
Failure code
141
CA141
Contents of
trouble
Action of
controller
Trouble
Phenomenon
that appears on
machine
Related
information
Possible causes
and standard
value in normal
state
22
Causes
12V140E-3 Series
SEN00317-00
40 Troubleshooting
E-11 Code [144/CA144] Coolant Temp. Sensor High Error (LH bank
only)
Error code
Failure code
144
CA144
Contents of
trouble
Action of
controller
Trouble
Coolant temperature sensor detection of abnormally high temperature (LH bank only)
Phenomenon
that appears on
machine
Related
information
Causes
Defective coolant tempera1 ture sensor
(Internal trouble)
Possible causes
and standard
value in normal
state
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
TWTR (male)
Coolant temperature
Resistance
10 100 C
0.6 20 kz
a Prepare with starting switch OFF, then carry out troubleshootDisconnection in wiring haring without turning starting switch ON.
ness
Wiring harness between LH J1 (female) (15)
Resis2 (Disconnection in wiring or
Max. 1 z
TWTR (female) (A)
tance
defective contact in connecWiring harness between LH J1 (female) (38)
Resistor)
Max. 1 z
TWTR (female) (B)
tance
Ground fault in wiring harness
3
(Short circuit with GND circuit)
24
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between LH J1 (female) (15)
TWTR (female) (A) and chassis ground
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
LH J1 (female)
Coolant temperature
Resistance
10 100 C
0.6 20 kz
12V140E-3 Series
40 Troubleshooting
SEN00317-00
12V140E-3 Series
25
SEN00317-00
40 Troubleshooting
E-12 Code [145/CA145] Coolant Temp. Sensor Low Error (LH bank only)1
Error code
Failure code
145
CA145
Contents of
trouble
Action of
controller
Trouble
Coolant temperature sensor detection of abnormally low temperature (LH bank only)
Phenomenon
that appears on
machine
Related
information
Possible causes
and standard
value in normal
state
26
Causes
12V140E-3 Series
SEN00317-00
40 Troubleshooting
E-13 Code [153/CA153] Charge Air Temp. Sensor High Error (LH bank
only)
1
Error code
Failure code
153
CA153
Contents of
trouble
Action of
controller
Trouble
Charge temperature sensor detection of abnormally high temperature (LH bank only)
Phenomenon
that appears on
machine
Related
information
Causes
Possible causes
and standard
value in normal
state
TIM (male)
Intake air
temperature
Resistance
10 100 C
0.5 20 kz
All range
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshootDisconnection in wiring haring without turning starting switch ON.
ness
Wiring harness between LH J1 (female) (23)
Resis2 (Disconnection in wiring or
Max. 1 z
TIM (female) (A)
tance
defective contact in connecWiring harness between LH J1 (female) (47)
Resistor)
Max. 1 z
TIM (female) (B)
tance
Ground fault in wiring harness
3
(Short circuit with GND circuit)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between LH J1 (female) (23)
TIM (female) (A) and chassis ground
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
4 Defective engine controller
28
LH J1 (female)
Intake air
temperature
Resistance
10 100 C
0.5 20 kz
12V140E-3 Series
40 Troubleshooting
SEN00317-00
12V140E-3 Series
29
SEN00317-00
40 Troubleshooting
E-14 Code [154/CA154] Charge Air Temp. Sensor Low Error (LH bank
only)
1
Error code
Failure code
154
CA154
Contents of
trouble
Action of
controller
Trouble
Phenomenon
that appears on
machine
Related
information
Possible causes
and standard
value in normal
state
30
Causes
12V140E-3 Series
40 Troubleshooting
SEN00317-00
E-15 Code [187/CA187] Sensor Sup. 2 Volt. Low Error (LH bank)
Error code
Failure code
187
CA187
Contents of
trouble
Action of
controller
Trouble
Sets atmospheric pressure sensor to default value (52.44 kPa) and continues operation.
Sets oil pressure sensor to default value (250 kPa) and continues operation.
Fixes charge pressure sensor value (400 kPa) and continues operation.
Operates G (Bkup) sensor with signals of Ne speed sensor.
Phenomenon
that appears on Output drops.
machine
Related
information
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
187
CB187
Contents of
trouble
Action of
controller
Trouble
Phenomenon
that appears on Output drops.
machine
Related
information
Possible causes
and standard
value in normal
state
12V140E-3 Series
Causes
31
SEN00317-00
40 Troubleshooting
E-17 Code [212/CA212] Eng. Oil Temp.Sensor High Error (LH bank
only)
Error code
Failure code
212
CA212
Contents of
trouble
Action of
controller
Trouble
Engine oil temperature sensor detection of abnormally high temperature (LH bank only)
Phenomenon
that appears on
machine
Related
information
Causes
Defective oil temperature
1 sensor
(Internal trouble)
Possible causes
and standard
value in normal
state
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
TOIL (male)
Oil temperature
Resistance
0 100 C
0.5 36 kz
a Prepare with starting switch OFF, then carry out troubleshootDisconnection in wiring haring without turning starting switch ON.
ness
Wiring harness between LH J1 (female) (17)
Resis2 (Disconnection in wiring or
Max. 1 z
TOIL (female) (A)
tance
defective contact in connecWiring harness between LH J1 (female) (47)
Resistor)
Max. 1 z
TOIL (female) (B)
tance
Ground fault in wiring harness
3
(Short circuit with GND circuit)
32
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between LH J1 (female) (17)
TOIL (female) (A) and chassis ground
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
LH J1
Oil temperature
Resistance
(17) (47)
0 100 C
0.5 36 kz
12V140E-3 Series
40 Troubleshooting
SEN00317-00
12V140E-3 Series
33
SEN00317-00
40 Troubleshooting
E-18 Code [213/CA213] Eng. Oil Temp.Sensor Low Error (LH bank
only)
Error code
Failure code
213
CA213
Trouble
Engine oil temperature sensor detection of abnormally low temperature (LH bank only)
Contents of
trouble
Action of
controller
Phenomenon
that appears on
machine
Related
information
Possible causes
and standard
value in normal
state
34
Causes
12V140E-3 Series
SEN00317-00
40 Troubleshooting
E-19 Code [221/CA221] Ambient Air Press. Sensor High Error (LH bank
only)
1
Error code
Failure code
221
CA221
Contents of
trouble
Action of
controller
Trouble
Atmospheric pressure sensor detection of abnormally high pressure (LH bank only)
Phenomenon
that appears on Output drops.
machine
Related
information
Causes
1
Defective sensor power sup- If code [352/CA352] or [386/CA386] is indicated, carry out troubleply system
shooting for it first.
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
PAMB
Voltage
Power supply
4.75 5.25 V
Signal
0.5 4.5 V
Possible causes
and standard
value in normal
state
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring harness
4
(Short circuit with GND circuit)
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
36
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
12V140E-3 Series
40 Troubleshooting
SEN00317-00
Causes
Possible causes
and standard
value in normal
state
LH J1
Voltage
4.75 5.25 V
0.5 4.5 V
12V140E-3 Series
37
SEN00317-00
40 Troubleshooting
E-20 Code [222/CA222] Ambient Air Press. Sensor Low Error (LH bank
only)
1
Error code
Failure code
222
CA222
Contents of
trouble
Action of
controller
Trouble
Phenomenon
that appears on Output drops.
machine
Related
information
Possible causes
and standard
value in normal
state
38
Causes
12V140E-3 Series
SEN00317-00
40 Troubleshooting
E-21 Code [227/CA227] Sensor Sup. 2 Volt. High Error (LH bank)
Error code
Failure code
227
CA227
Contents of
trouble
Action of
controller
Trouble
Sets atmospheric pressure sensor to default value (52.44 kPa) and continues operation.
Sets oil pressure sensor to default value (250 kPa) and continues operation.
Fixes charge pressure sensor value (400 kPa) and continues operation.
Operates G (Bkup) sensor with signals of Ne speed sensor.
Phenomenon
that appears on Output drops.
machine
Related
information
Causes
1 Defective related system
Possible causes
and standard
value in normal
state
Defective sensor
(Internal trouble)
Atmospheric
pressure sensor
PAMB connector
POIL connector
Charge pressure
sensor
PIM connector
G (Bkup) sensor
G connector
a Prepare with starting switch OFF, then carry out troubleshootDisconnection in wiring haring without turning starting switch ON.
ness
Wiring harness between LH J1 (female) (37)
Resis3 (Disconnection in wiring or
Max. 1 z
respective sensors (female)
tance
defective contact in connecWiring harness between LH J1 (female) (47)
Resistor)
Max. 1 z
respective sensors (female)
tance
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring harness
4
(Short circuit with GND circuit)
40
Disconnect devices
at right in order. If
error code disappears subsequently,
that device has a
defect in it.
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between LH J1 (female) (37)
respective sensors (female) and LH J1
(female) (47) respective sensors (female)
Resistance
Min. 1 Mz
Voltage
4.75 5.25 V
12V140E-3 Series
40 Troubleshooting
SEN00317-00
12V140E-3 Series
41
SEN00317-00
40 Troubleshooting
E-22 Code [227/CB227] Sensor Sup. 2 Volt. High Error (RH bank)
Error code
Failure code
227
CB227
Contents of
trouble
Action of
controller
Trouble
Phenomenon
that appears on Output drops.
machine
Related
information
Causes
1
Possible causes
and standard
value in normal
state
G (Bkup)speed
sensor
G connector
a Prepare with starting switch OFF, then carry out troubleshootDisconnection in wiring haring without turning starting switch ON.
ness
Wiring harness between RH J1 (female)
Resis3 (Disconnection in wiring or
Max. 1 z
(37) respective sensors (female)
tance
defective contact in connecWiring harness between RH J1 (female)
Resistor)
Max. 1 z
(47) respective sensors (female)
tance
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring harness
4
(Short circuit with GND circuit)
42
Disconnect devices
at right in order. If
error code disappears subsequently,
that device has a
defect in it.
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between RH J1 (female)
(37) respective sensors (female) and RH
J1 (female) (47) respective sensors
(female)
Resistance
Min. 1 Mz
Voltage
4.75 5.25 V
12V140E-3 Series
40 Troubleshooting
SEN00317-00
12V140E-3 Series
43
SEN00317-00
40 Troubleshooting
Failure code
234
CA234
Contents of
trouble
Action of
controller
Trouble
Phenomenon
that appears on Engine speed fluctuates.
machine
Related
information
Causes
Possible causes
and standard
value in normal
state
44
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
SEN00317-00
40 Troubleshooting
E-24 Code [238/CA238] Ne Speed Sensor Sup. Volt. Error (LH bank)
Error code
Failure code
238
CA238
Contents of
trouble
Action of
controller
Trouble
Phenomenon
Running engine stops (when G (Bkup) speed sensor is also abnormal).
that appears on
Stopped engine cannot be started (when G (Bkup) speed sensor is also abnormal).
machine
Related
information
Causes
Possible causes
and standard
value in normal
state
Ne speed sensor
NE connector
a Prepare with starting switch OFF, then carry out troubleshootDisconnection in wiring haring without turning starting switch ON.
ness
Wiring harness between LH J1 (female) (16)
Resis2 (Disconnection in wiring or
Max. 1 z
Ne (female) (1)
tance
defective contact in connecWiring harness between LH J1 (female) (48)
Resistor)
Max. 1 z
Ne (female) (2)
tance
Ground fault in wiring harness
3
(Short circuit with GND circuit)
46
Disconnect devices
at right in order. If
error code disappears subsequently,
that device has a
defect in it.
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between LH J1 (female) (16)
Ne (female) (1) and chassis ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between LH J1 (female) (16)
Ne (female) (1) and LH J1 (female) (48)
Ne (female) (2)
Resistance
Min. 1 Mz
Voltage
4.75 5.25 V
12V140E-3 Series
40 Troubleshooting
SEN00317-00
12V140E-3 Series
47
SEN00317-00
40 Troubleshooting
E-25 Code [238/CB238] Ne Speed Sensor Sup. Volt. Error (RH bank)
Error code
Failure code
238
CB238
Contents of
trouble
Action of
controller
Trouble
Phenomenon
Running engine stops (when G (Bkup) speed sensor is also abnormal).
that appears on
Stopped engine cannot be started (when G (Bkup) speed sensor is also abnormal).
machine
Related
information
Causes
Possible causes
and standard
value in normal
state
Disconnect devices
at right in order. If
error code disappears subsequently,
that device has a
defect in it.
Ne speed sensor
a Prepare with starting switch OFF, then carry out troubleshootDisconnection in wiring haring without turning starting switch ON.
ness
Wiring harness between LH J1 (female) (16)
Resis2 (Disconnection in wiring or
Max. 1 z
Ne (female) (1)
tance
defective contact in connecWiring harness between RH J1 (female)
Resistor)
Max. 1 z
(48) Ne (female) (2)
tance
Ground fault in wiring harness
3
(Short circuit with GND circuit)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between LH J1 (female) (16)
Ne (female) (1) and chassis ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between LH J1 (female) (16)
Ne (female) (1) and RH J1 (female) (48)
Ne (female) (2)
Resistance
Min. 1 Mz
48
NE connector
Voltage
4.75 5.25 V
12V140E-3 Series
40 Troubleshooting
SEN00317-00
12V140E-3 Series
49
SEN00317-00
40 Troubleshooting
E-26 Code [263/CA263] Fuel Temp. Sensor High Error (LH bank)
Error code
Failure code
263
CA263
Contents of
trouble
Action of
controller
Trouble
Phenomenon
that appears on
machine
Related
information
Causes
Defective fuel temperature
1 sensor
(Internal trouble)
Possible causes
and standard
value in normal
state
50
Fuel temperature
Resistance
10 100 C
0.6 20 kz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between LH J1 (female) (30)
LH TFUEL (female) (A)
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between LH J1 (female) (30)
LH TFUEL (female) (A) and chassis
ground
Resistance
Max. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
LH J1 (female)
Fuel temperature
Resistance
10 100 C
0.6 20 kz
12V140E-3 Series
40 Troubleshooting
SEN00317-00
12V140E-3 Series
51
SEN00317-00
40 Troubleshooting
E-27 Code [263/CB263] Fuel Temp. Sensor High Error (RH bank)
Error code
Failure code
263
CB263
Contents of
trouble
Action of
controller
Trouble
Phenomenon
that appears on
machine
Related
information
Causes
Defective fuel temperature
1 sensor
(Internal trouble)
Possible causes
and standard
value in normal
state
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
RH TFUEL (male)
Fuel temperature
Resistance
10 100 C
0.6 20 kz
a Prepare with starting switch OFF, then carry out troubleshootDisconnection in wiring haring without turning starting switch ON.
ness
Wiring harness between RH J1 (female)
Resis2 (Disconnection in wiring or
Max. 1 z
(30) RH TFUEL (female) (A)
tance
defective contact in connecResisWiring harness between RH J1 (female)
tor)
Max. 1 z
(47) RH TFUEL (female) (B)
tance
52
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between RH J1 (female)
(30) RH TFUEL (female) (A) and chassis
ground
Resistance
Max. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
RH J1 (female)
Fuel temperature
Resistance
10 100 C
0.6 20 kz
12V140E-3 Series
40 Troubleshooting
SEN00317-00
12V140E-3 Series
53
SEN00317-00
40 Troubleshooting
E-28 Code [265/CA265] Fuel Temp. Sensor Low Error (LH bank)
Error code
Failure code
265
CA265
Contents of
trouble
Action of
controller
Trouble
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
265
CB265
Contents of
trouble
Action of
controller
Trouble
Phenomenon
that appears on
machine
Related
information
Possible causes
and standard
value in normal
state
54
Causes
12V140E-3 Series
SEN00317-00
40 Troubleshooting
Failure code
271
CA271
Contents of
trouble
Action of
controller
Trouble
Phenomenon
that appears on
machine
Related
information
Causes
Possible causes
and standard
value in normal
state
LH PCV1 (male)
Resistance
2.3 5.3 z
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between LH J1 (female) (4)
LH PCV1 (female) (1) and chassis ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Voltage
Max. 1 V
Voltage
Max. 1 V
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
4 Defective engine controller
56
LH J1 (female)
Resistance
2.3 5.3 z
Min. 1 Mz
12V140E-3 Series
40 Troubleshooting
SEN00317-00
12V140E-3 Series
57
SEN00317-00
40 Troubleshooting
Failure code
271
CB271
Contents of
trouble
Action of
controller
Trouble
Phenomenon
that appears on
machine
Related
information
Causes
Possible causes
and standard
value in normal
state
RH PCV1 (male)
Resistance
2.3 5.3 z
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between RH J1 (female) (4)
RH PCV1 (female) (1) and chassis ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Voltage
Max. 1 V
Voltage
Max. 1 V
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
4 Defective engine controller
58
RH J1 (female)
Resistance
2.3 5.3 z
Min. 1 Mz
12V140E-3 Series
40 Troubleshooting
SEN00317-00
12V140E-3 Series
59
SEN00317-00
40 Troubleshooting
Failure code
272
CA272
Contents of
trouble
Action of
controller
Trouble
Phenomenon
that appears on
machine
Related
information
Causes
Possible causes
and standard
value in normal
state
LH PCV1 (male)
Resistance
2.3 5.3 z
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshootDisconnection in wiring haring without turning starting switch ON.
ness
Wiring harness between LH J1 (female) (4)
Resis2 (Disconnection in wiring or
Max. 1 z
LH PCV1 (female) (1)
tance
defective contact in connecWiring harness between LH J1 (female) (5)
Resistor)
Max. 1 z
LH PCV1 (female) (2)
tance
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
3 Defective engine controller
LH J1 (female)
Resistance
2.3 5.3 z
Min. 1 Mz
60
12V140E-3 Series
40 Troubleshooting
SEN00317-00
Failure code
272
CB272
Contents of
trouble
Action of
controller
Trouble
Phenomenon
that appears on
machine
Related
information
Causes
Possible causes
and standard
value in normal
state
RH PCV1 (male)
Resistance
2.3 5.3 z
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshootDisconnection in wiring haring without turning starting switch ON.
ness
Wiring harness between RH J1 (female) (4)
Resis2 (Disconnection in wiring or
Max. 1 z
RH PCV1 (female) (1)
tance
defective contact in connecWiring harness between RH J1 (female) (5)
Resistor)
Max. 1 z
RH PCV1 (female) (2)
tance
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
3 Defective engine controller
RH J1(female)
Resistance
2.3 5.3 z
Min. 1 Mz
12V140E-3 Series
61
SEN00317-00
40 Troubleshooting
Failure code
273
CA273
Contents of
trouble
Action of
controller
Trouble
Phenomenon
that appears on
machine
Related
information
Causes
Possible causes
and standard
value in normal
state
LH PCV2 (male)
Resistance
2.3 5.3 z
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between LH J1 (female) (9)
LH PCV2 (female) (1) and chassis ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Voltage
Max. 1 V
Voltage
Max. 1 V
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
4 Defective engine controller
62
LH J1 (female)
Resistance
2.3 5.3 z
Min. 1 Mz
12V140E-3 Series
40 Troubleshooting
SEN00317-00
12V140E-3 Series
63
SEN00317-00
40 Troubleshooting
Failure code
273
CB273
Contents of
trouble
Action of
controller
Trouble
Phenomenon
that appears on
machine
Related
information
Causes
Possible causes
and standard
value in normal
state
RH PCV2 (male)
Resistance
2.3 5.3 z
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between RH J1 (female) (9)
RH PCV2 (female) (1) and chassis ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Voltage
Max. 1 V
Voltage
Max. 1 V
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
4 Defective engine controller
64
RH J1 (female)
Resistance
2.3 5.3 z
Min. 1 Mz
12V140E-3 Series
40 Troubleshooting
SEN00317-00
12V140E-3 Series
65
SEN00317-00
40 Troubleshooting
Failure code
274
CA274
Contents of
trouble
Action of
controller
Trouble
Phenomenon
that appears on
machine
Related
information
Causes
Defective supply pump
1 PCV2
(Internal disconnection)
Possible causes
and standard
value in normal
state
Resistance
2.3 5.3 z
a Prepare with starting switch OFF, then carry out troubleshootDisconnection in wiring haring without turning starting switch ON.
ness
Wiring harness between LH J1 (female) (9)
Resis2 (Disconnection in wiring or
Max. 1 z
LH PCV2 (female) (1)
tance
defective contact in connecWiring harness between LH J1 (female) (10)
Resistor)
Max. 1 z
LH PCV2 (female) (2)
tance
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
3 Defective engine controller
LH J1 (female)
Resistance
2.3 5.3 z
Min. 1 Mz
66
12V140E-3 Series
40 Troubleshooting
SEN00317-00
Failure code
274
CB274
Contents of
trouble
Action of
controller
Trouble
Phenomenon
that appears on
machine
Related
information
Causes
Defective supply pump
1 PCV2
(Internal disconnection)
Possible causes
and standard
value in normal
state
Resistance
2.3 5.3 z
a Prepare with starting switch OFF, then carry out troubleshootDisconnection in wiring haring without turning starting switch ON.
ness
Wiring harness between RH J1 (female) (9)
Resis2 (Disconnection in wiring or
Max. 1 z
RH PCV2 (female) (1)
tance
defective contact in connecWiring harness between RH J1 (female)
Resistor)
Max. 1 z
(10) RH PCV2 (female) (2)
tance
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
3 Defective engine controller
RH J1 (female)
Resistance
2.3 5.3 z
Min. 1 Mz
12V140E-3 Series
67
SEN00317-00
40 Troubleshooting
Failure code
322
CA322
Contents of
trouble
Action of
controller
Trouble
Phenomenon
Output drops.
that appears on
Idle speed is unstable.
machine
Related
information
Causes
Possible causes
and standard
value in normal
state
Defective injector #1
(Internal trouble)
LH CN1 (male)
Resistance
0.4 1.1 z
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshootDisconnection in wiring haring without turning starting switch ON.
ness
Wiring harness between LH J1 (female) (45)
Resis2 (Disconnection in wiring or
Max. 1 z
LH CN1 (female) (1)
tance
defective contact in connecWiring harness between LH J1 (female) (53)
Resistor)
Max. 1 z
LH CN1 (female) (2)
tance
Ground fault in wiring harness
3
(Short circuit with GND circuit)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between LH J1 (female) (45)
LH CN1 (female) (1) and chassis ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
4 Defective engine controller
68
LH J1 (female)
Resistance
0.4 1.1 z
Min. 1 Mz
12V140E-3 Series
40 Troubleshooting
SEN00317-00
12V140E-3 Series
69
SEN00317-00
40 Troubleshooting
Failure code
323
CA323
Contents of
trouble
Action of
controller
Trouble
Phenomenon
Output drops.
that appears on
Idle speed is unstable.
machine
Related
information
Causes
Possible causes
and standard
value in normal
state
Defective injector #5
(Internal trouble)
LH CN5 (male)
Resistance
0.4 1.1 z
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshootDisconnection in wiring haring without turning starting switch ON.
ness
Wiring harness between LH J1 (female) (46)
Resis2 (Disconnection in wiring or
Max. 1 z
LH CN5 (female) (1)
tance
defective contact in connecWiring harness between LH J1 (female) (60)
Resistor)
Max. 1 z
LH CN5 (female) (2)
tance
Ground fault in wiring harness
3
(Short circuit with GND circuit)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between LH J1 (female) (46)
LH CN5 (female) (1) and chassis ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
4 Defective engine controller
70
LH J1 (female)
Resistance
0.4 1.1 z
Min. 1 Mz
12V140E-3 Series
40 Troubleshooting
SEN00317-00
12V140E-3 Series
71
SEN00317-00
40 Troubleshooting
Failure code
324
CA324
Contents of
trouble
Action of
controller
Trouble
Phenomenon
Output drops.
that appears on
Idle speed is unstable.
machine
Related
information
Causes
Possible causes
and standard
value in normal
state
Defective injector #3
(Internal trouble)
LH CN3 (male)
Resistance
0.4 1.1 z
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshootDisconnection in wiring haring without turning starting switch ON.
ness
Wiring harness between LH J1 (female) (55)
Resis2 (Disconnection in wiring or
Max. 1 z
LH CN3 (female) (1)
tance
defective contact in connecWiring harness between LH J1 (female) (52)
Resistor)
Max. 1 z
LH CN3 (female) (2)
tance
Ground fault in wiring harness
3
(Short circuit with GND circuit)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between LH J1 (female) (55)
LH CN3 (female) (1) and chassis ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
4 Defective engine controller
72
LH J1 (female)
Resistance
0.4 1.1 z
Min. 1 Mz
12V140E-3 Series
40 Troubleshooting
SEN00317-00
12V140E-3 Series
73
SEN00317-00
40 Troubleshooting
Failure code
325
CA325
Contents of
trouble
Action of
controller
Trouble
Phenomenon
Output drops.
that appears on
Idle speed is unstable.
machine
Related
information
Causes
Possible causes
and standard
value in normal
state
Defective injector #6
(Internal trouble)
LH CN6 (male)
Resistance
0.4 1.1 z
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshootDisconnection in wiring haring without turning starting switch ON.
ness
Wiring harness between LH J1 (female) (57)
Resis2 (Disconnection in wiring or
Max. 1 z
LH CN6 (female) (1)
tance
defective contact in connecWiring harness between LH J1 (female) (59)
Resistor)
Max. 1 z
LH CN6 (female) (2)
tance
Ground fault in wiring harness
3
(Short circuit with GND circuit)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between LH J1 (female) (57)
LH CN6 (female) (1) and chassis ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
4 Defective engine controller
74
LH J1 (female)
Resistance
0.4 1.1 z
Min. 1 Mz
12V140E-3 Series
40 Troubleshooting
SEN00317-00
12V140E-3 Series
75
SEN00317-00
40 Troubleshooting
Failure code
331
CA331
Contents of
trouble
Action of
controller
Trouble
Phenomenon
Output drops.
that appears on
Idle speed is unstable.
machine
Related
information
Causes
Possible causes
and standard
value in normal
state
Defective injector #2
(Internal trouble)
LH CN2 (male)
Resistance
0.4 1.1 z
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshootDisconnection in wiring haring without turning starting switch ON.
ness
Wiring harness between LH J1 (female) (54)
Resis2 (Disconnection in wiring or
Max. 1 z
LH CN2 (female) (1)
tance
defective contact in connecWiring harness between LH J1 (female) (51)
Resistor)
Max. 1 z
LH CN2 (female) (2)
tance
Ground fault in wiring harness
3
(Short circuit with GND circuit)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between LH J1 (female) (54)
LH CN2 (female) (1) and chassis ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
4 Defective engine controller
76
LH J1 (female)
Resistance
0.4 1.1 z
Min. 1 Mz
12V140E-3 Series
40 Troubleshooting
SEN00317-00
12V140E-3 Series
77
SEN00317-00
40 Troubleshooting
Failure code
332
CA332
Contents of
trouble
Action of
controller
Trouble
Phenomenon
Output drops.
that appears on
Idle speed is unstable.
machine
Related
information
Causes
Possible causes
and standard
value in normal
state
Defective injector #4
(Internal trouble)
LH CN4 (male)
Resistance
0.4 1.1 z
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshootDisconnection in wiring haring without turning starting switch ON.
ness
Wiring harness between LH J1 (female) (56)
Resis2 (Disconnection in wiring or
Max. 1 z
LH CN4 (female) (1)
tance
defective contact in connecWiring harness between LH J1 (female) (58)
Resistor)
Max. 1 z
LH CN4 (female) (2)
tance
Ground fault in wiring harness
3
(Short circuit with GND circuit)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between LH J1 (female) (56)
LH CN4 (female) (1) and chassis ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
4 Defective engine controller
78
LH J1 (female)
Resistance
0.4 1.1 z
Min. 1 Mz
12V140E-3 Series
40 Troubleshooting
SEN00317-00
12V140E-3 Series
79
SEN00317-00
40 Troubleshooting
Failure code
342
CA342
Contents of
trouble
Action of
controller
Trouble
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
Failure code
342
CB342
Contents of
trouble
Action of
controller
Trouble
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
80
Causes
12V140E-3 Series
SEN00317-00
40 Troubleshooting
Failure code
351
CA351
Contents of
trouble
Action of
controller
Trouble
Phenomenon
that appears on Output drops.
machine
Related
information
Causes
Possible causes
and standard
value in normal
state
2 Defective fuse
a Prepare with starting switch OFF, then carry out troubleshootDisconnection in wiring haring without turning starting switch ON.
ness
Wiring harness between PW L (female) (3),
Resis3 (Disconnection in wiring or
Max. 1 z
(4) battery (+)
tance
defective contact in connecWiring harness between PW L (female) (1),
Resistor)
Max. 1 z
(2) chassis ground
tance
Ground fault in wiring harness
4
(Short circuit with GND circuit)
82
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between PW L (female) (3),
(4) battery (+) and chassis ground
Resistance
Min. 1 Mz
Voltage
20 30 V
12V140E-3 Series
40 Troubleshooting
SEN00317-00
12V140E-3 Series
83
SEN00317-00
40 Troubleshooting
Failure code
351
CB351
Contents of
trouble
Action of
controller
Trouble
Phenomenon
that appears on Output drops.
machine
Related
information
Causes
Possible causes
and standard
value in normal
state
2 Defective fuse
a Prepare with starting switch OFF, then carry out troubleshootDisconnection in wiring haring without turning starting switch ON.
ness
Wiring harness between PW R (female) (3),
Resis3 (Disconnection in wiring or
Max. 1 z
(4) battery (+)
tance
defective contact in connecWiring harness between PW R (female) (1),
Resistor)
Max. 1 z
(2) chassis ground
tance
Ground fault in wiring harness
4
(Short circuit with GND circuit)
84
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between PW R (female) (3),
(4) battery (+) and chassis ground
Resistance
Min. 1 Mz
Voltage
20 30 V
12V140E-3 Series
40 Troubleshooting
SEN00317-00
12V140E-3 Series
85
SEN00317-00
40 Troubleshooting
E-48 Code [352/CA352] Sensor Sup. 1 Volt. Low Error (LH bank)
Error code
Failure code
352
CA352
Contents of
trouble
Action of
controller
Trouble
Phenomenon
that appears on Output drops.
machine
Related
information
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
352
CB352
Contents of
trouble
Action of
controller
Trouble
Phenomenon
that appears on Output drops.
machine
Related
information
Possible causes
and standard
value in normal
state
86
Causes
12V140E-3 Series
SEN00317-00
40 Troubleshooting
E-50 Code [386/CA386] Sensor Sup. 1 Volt. High Error (LH bank)
Error code
Failure code
386
CA386
Contents of
trouble
Action of
controller
Trouble
Phenomenon
that appears on Output drops.
machine
Related
information
Causes
1 Defective related system
Disconnect devices
at right in order. If
error code disappears subsequently,
that device has a
defect in it.
LH common rail
pressure sensor
LH PFUEL connector
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness
3 (Disconnection in wiring or
defective contact in connector)
Possible causes
and standard
value in normal
state
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
88
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
12V140E-3 Series
40 Troubleshooting
SEN00317-00
Causes
Possible causes
and standard
value in normal
state
Voltage
4.75 5.25 V
12V140E-3 Series
89
SEN00317-00
40 Troubleshooting
E-51 Code [386/CB386] Sensor Sup. 1 Volt. High Error (RH bank)
Error code
Failure code
386
CB386
Contents of
trouble
Action of
controller
Trouble
Phenomenon
that appears on Output drops.
machine
Related
information
Causes
1
Defective sensor
(Internal trouble)
Disconnect devices
at right in order. If
error code disappears subsequently,
that device has a
defect in it.
RH common rail
pressure sensor
RH PFUEL
connector
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness
3 (Disconnection in wiring or
defective contact in connector)
Possible causes
and standard
value in normal
state
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
90
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
12V140E-3 Series
40 Troubleshooting
SEN00317-00
Causes
Possible causes
and standard
value in normal
state
Voltage
4.75 5.25 V
12V140E-3 Series
91
SEN00317-00
40 Troubleshooting
Failure code
441
CA441
Contents of
trouble
Action of
controller
Trouble
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
Failure code
441
CB441
Contents of
trouble
Action of
controller
Trouble
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
92
Causes
12V140E-3 Series
40 Troubleshooting
SEN00317-00
Failure code
442
CA442
Contents of
trouble
Action of
controller
Trouble
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
Failure code
442
CB442
Contents of
trouble
Action of
controller
Trouble
Phenomenon
that appears on Engine continues operation normally, but it may stop during operation or may not be able to start.
machine
Related
nformation
Possible causes
and standard
value in normal
state
12V140E-3 Series
Causes
93
SEN00317-00
40 Troubleshooting
2006 KOMATSU
All Rights Reserved
Printed in Japan 02-06 (02)
94
12V140E-3 Series
SEN00318-00
ENGINE
1SHOP MANUAL
12V140E-3 Series
40 Troubleshooting
12V140E-3 Series
SEN00318-00
40 Troubleshooting
E-69 Code [689/CB689] Eng. Ne Speed Sensor Error (RH bank) ..................................................... 22
E-70 Code [691/CA691] Intake Air Temp Sensor High Error (LH bank only) ..................................... 24
E-71 Code [692/CA692] Intake Air Temp Sensor Low Error (LH bank only) ...................................... 26
E-72 Code [731/CA731] Eng. G (Bkup) Speed Sensor Phase Error (LH bank)................................. 27
E-73 Code [731/CB731] Eng. G (Bkup) Speed Sensor Phase Error (RH bank) ................................ 27
E-74 Code [757/CA757] All Continuous Data Lost Error (LH bank)................................................... 28
E-75 Code [757/CB757] All Continuous Data Lost Error (RH bank) .................................................. 28
E-76 Code [778/CA778] Eng. G (Bkup) Speed Sensor Error (LH bank) ............................................ 30
E-77 Code [778/CB778] Eng. G (Bkup) Speed Sensor Error (RH bank) ........................................... 32
E-78 Code [781/CA781] Inter Multi-controller Communication Error (LH bank)................................. 34
E-79 Code [781/CB781] Inter Multi-controller Communication Error (RH bank) ................................ 36
E-80 Code [1117/CA1117] Persistent Data Lost Error (LH bank) ....................................................... 37
E-81 Code [1117/CB1117] Persistent Data Lost Error (RH bank)....................................................... 37
E-82 Code [1257/CA1257] Harness Key error (LH bank) .................................................................. 38
E-83 Code [1257/CB1257] Harness Key error (RH bank).................................................................. 39
E-84 Code [1548/CB1548] Injector #7 (R/B #1) System Open/Short Error (RH bank) ...................... 40
E-85 Code [1549/CB1549] Injector #8 (R/B #2) System Open/Short Error (RH bank) ...................... 42
E-86 Code [1551/CB1551] Injector #10 (R/B #4) System Open/Short Error (RH bank) .................... 44
E-87 Code [1552/CB1552] Injector #11 (R/B #5) System Open/Short Error (RH bank) .................... 46
E-88 Code [1553/CB1553] Injector #12 (R/B #6) System Open/Short Error (RH bank) .................... 48
E-89 Code [1622/CB1622] Injector #9 (R/B #3) System Open/Short Error (RH bank) ...................... 50
E-90 Code [1633/CA1633] KOMNET Datalink Timeout Error (LH bank) ........................................... 52
E-91 Code [2185/CA2185] Throttle Sens. Sup. Volt. High Error (LH bank only)................................ 54
E-92 Code [2186/CA2186] Throttle Sens. Sup. Volt. Low Error (LH bank only) ................................ 56
E-93 Code [2249/CA2249] Rail Press. Very Low Error (LH bank) ..................................................... 57
E-94 Code [2249/CB2249] Rail Press. Very Low Error (RH bank)..................................................... 57
E-95 Code [ *1/] Eng. Overheat (LH bank only) ........................................................................... 58
E-96 Code [ *2/] Eng. Oil Press. Low Speed Derate (LH bank only)............................................ 58
E-97 Code [ *3/] Press. Low Torque Derate (LH bank only)......................................................... 59
12V140E-3 Series
40 Troubleshooting
SEN00318-00
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 sensor circuit detected abnormally high pressure (level 2).
Limits output and continues operation (Limits common rail pressure).
Phenomenon
that appears on Output drops.
machine
Related
information
Possible causes
and standard
value in normal
state
Causes
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 sensor circuit detected abnormally high pressure (level 2).
Limits output and continues operation (Limits common rail pressure).
Phenomenon
that appears on Output drops.
machine
Related
information
Possible causes
and standard
value in normal
state
12V140E-3 Series
Causes
SEN00318-00
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
Phenomenon
that appears on Output drops.
machine
Related
information
Causes
1
Defective sensor power sup- If code [187/CA187] or [227/CA227] is indicated, carry out troubleply system
shooting for it first.
a Prepare with starting switch OFF, then turn starting switch ON
or start engine and carry out troubleshooting.
LH PFUEL
Voltage
Power supply
4.75 5.25 V
Signal
0.25 4.6 V
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
12V140E-3 Series
40 Troubleshooting
SEN00318-00
Causes
Possible causes
and standard
value in normal
state
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
LH J1
Voltage
4.75 5.25 V
0.25 4.6 V
12V140E-3 Series
SEN00318-00
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
Phenomenon
that appears on Output drops.
machine
Related
information
Causes
1
Defective sensor power sup- If code [187/CB187] or [227/CB227] is indicated, carry out troubleply system
shooting for it first.
a Prepare with starting switch OFF, then turn starting switch ON
or start engine and carry out troubleshooting.
RH PFUEL
Voltage
Power supply
4.75 5.25 V
Signal
0.25 4.6 V
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
12V140E-3 Series
40 Troubleshooting
SEN00318-00
Causes
Possible causes
and standard
value in normal
state
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
RH J1
Voltage
4.75 5.25 V
0.25 4.6 V
12V140E-3 Series
SEN00318-00
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
Phenomenon
that appears on Output drops.
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
Phenomenon
that appears on Output drops.
machine
Related
information
Possible causes
and standard
value in normal
state
Causes
12V140E-3 Series
40 Troubleshooting
SEN00318-00
Failure code
553
CA553
Contents of
trouble
Action of
controller
Trouble
Common rail pressure sensor circuit detected abnormally high pressure (level 1).
None in particular.
Phenomenon
that appears on Output drops.
machine
Related
information
Causes
Possible causes
and standard
value in normal
state
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).
Check overflow valve directly for broken spring, worn seat, and
stuck ball.
12V140E-3 Series
SEN00318-00
40 Troubleshooting
Failure code
553
CB553
Contents of
trouble
Action of
controller
Trouble
Common rail pressure sensor circuit detected abnormally high pressure (level 1).
None in particular.
Phenomenon
that appears on Output drops.
machine
Related
information
Causes
Possible causes
and standard
value in normal
state
10
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).
Check overflow valve directly for broken spring, worn seat, and
stuck ball.
12V140E-3 Series
40 Troubleshooting
SEN00318-00
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
Phenomenon
that appears on Output drops.
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
Phenomenon
that appears on Output drops.
machine
Related
information
Possible causes
and standard
value in normal
state
12V140E-3 Series
Causes
11
SEN00318-00
40 Troubleshooting
Failure code
559
CA559
Contents of
trouble
Action of
controller
Trouble
Phenomenon
that appears on Output drops.
machine
Related
information
Causes
1 Defective related system
4 Clogging of filter/strainer
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 common rail pres- Common rail pressure sensor may be defective. Check wiring harsure sensor
ness for damage.
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
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
12
12V140E-3 Series
40 Troubleshooting
SEN00318-00
Fuel level
Clogged fuel tank breather
Stuck or worn feed pump, clogged filter
Leaked or clogged low-pressure fuel pipe
Bypass valve malfunction, defective assembly of other parts (See Fig.1.)
Clogged fuel filter
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
q
q
Note 2: Check, clean, and replace the filters and strainers according to the following procedure.
1)
2)
3)
12V140E-3 Series
13
SEN00318-00
40 Troubleshooting
Work No.
#
Date of check
Engine
Engine serial No.
Service meter
#
Worker's name
A. Visual check
1
Good NG
Good NG
/
*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
MPa
Low idle
Fuel injection timing comHigh idle
mand
Equivalent to rating <By models>
CA
*6
CA
CA
*7
Boost pressure
kPa
*8
Low idle
*9
Low idle
*10
Fuel temperature
Low idle
Unit
Standard value
(Reference
value)
*2
Throttle opening
*3
*4
5
*11
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
SEN00318-00
Checking condition
High idle
Unit
Standard value
(Reference
value)
MPa
{kg/cm2}
Min. 0.15
{Min. 1.5}
Measured
Good NG
value
Good NG
Unit
Standard value
(Reference
value)
cc/min
Max. 10
Equivalent to rating
<By models> 1,600 rpm
cc/min
960
Equivalent to rating
<By models> 1,700 rpm
cc/min
1,020
Equivalent to rating
<By models> 1,800 rpm
cc/min
1,080
Equivalent to rating
<By models> 1,900 rpm
cc/min
1,140
Equivalent to rating
<By models> 2,000 rpm
cc/min
1,200
Checking condition
Measured
Good NG
value
Speed:
Return
rate:
*1 *11:
When inspecting with INSITE (bench test tool), see Operation and Maintenance Manual (Testing
method).
When inspecting with the monitoring function of the machine, use the codes specified for each machine
model.
Equivalent to rating <By models>:
When inspecting the engine unit on the bench, operate it under a load equivalent to the rating. When
the engine is installed to the machine, however, the operation load equivalent to the rating depends on
the machine model.
12V140E-3 Series
15
SEN00318-00
40 Troubleshooting
Failure code
559
CB559
Contents of
trouble
Action of
controller
Trouble
Phenomenon
that appears on Output drops.
machine
Related
information
Causes
1 Defective related system
4 Clogging of filter/strainer
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 common rail pres- Common rail pressure sensor may be defective. Check wiring harsure sensor
ness for damage.
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
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
16
12V140E-3 Series
40 Troubleshooting
SEN00318-00
Fuel level
Clogged fuel tank breather
Stuck or worn feed pump, clogged filter
Leaked or clogged low-pressure fuel pipe
Bypass valve malfunction, defective assembly of other parts (See Fig.1.)
Clogged fuel filter
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
q
q
Note 2: Check, clean, and replace the filters and strainers according to the following procedure.
1)
2)
3)
12V140E-3 Series
17
SEN00318-00
40 Troubleshooting
Work No.
#
Date of check
Engine
Engine serial No.
Service meter
#
Worker's name
A. Visual check
1
Good NG
Good NG
/
*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
MPa
Low idle
Fuel injection timing comHigh idle
mand
Equivalent to rating <By models>
CA
*6
CA
CA
*7
Boost pressure
kPa
*8
Low idle
*9
Low idle
*10
Fuel temperature
Low idle
Unit
Standard value
(Reference
value)
*2
Throttle opening
*3
*4
5
*11
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
SEN00318-00
Checking condition
High idle
Unit
Standard value
(Reference
value)
MPa
{kg/cm2}
Min. 0.15
{Min. 1.5}
Measured
Good NG
value
Good NG
Unit
Standard value
(Reference
value)
cc/min
Max. 10
Equivalent to rating
<By models> 1,600 rpm
cc/min
960
Equivalent to rating
<By models> 1,700 rpm
cc/min
1,020
Equivalent to rating
<By models> 1,800 rpm
cc/min
1,080
Equivalent to rating
<By models> 1,900 rpm
cc/min
1,140
Equivalent to rating
<By models> 2,000 rpm
cc/min
1,200
Checking condition
Measured
Good NG
value
Speed:
Return
rate:
*1 *11:
When inspecting with INSITE (bench test tool), see Operation and Maintenance Manual (Testing
method).
When inspecting with the monitoring function of the machine, use the codes specified for each machine
model.
Equivalent to rating <By models>:
When inspecting the engine unit on the bench, operate it under a load equivalent to the rating. When
the engine is installed to the machine, however, the operation load equivalent to the rating depends on
the machine model.
12V140E-3 Series
19
SEN00318-00
40 Troubleshooting
Failure code
689
CA689
Contents of
trouble
Action of
controller
Trouble
Phenomenon
Running engine stops (when G (Bkup) speed sensor is also abnormal).
that appears on
Stopped engine cannot be started (when G (Bkup) speed sensor is also abnormal).
machine
Related
information
Causes
1
Defective sensor power sup- If code [238/CA238] is indicated, carry out troubleshooting for it
ply system
first.
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring harness
3
(Short circuit with GND circuit)
Possible causes
and standard
value in normal
state
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
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 controller may be defective. (Since trouble is in system, troubleshooting cannot be carried
out.)
20
12V140E-3 Series
40 Troubleshooting
SEN00318-00
12V140E-3 Series
21
SEN00318-00
40 Troubleshooting
Failure code
689
CB689
Contents of
trouble
Action of
controller
Trouble
Phenomenon
Running engine stops (when G (Bkup) speed sensor is also abnormal).
that appears on
Stopped engine cannot be started (when G (Bkup) speed sensor is also abnormal).
machine
Related
information
Causes
1
Defective sensor power sup- If code [238/CB238] is indicated, carry out troubleshooting for it
ply system
first.
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring harness
3
(Short circuit with GND circuit)
Possible causes
and standard
value in normal
state
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
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 controller may be defective. (Since trouble is in system, troubleshooting cannot be carried
out.)
22
12V140E-3 Series
40 Troubleshooting
SEN00318-00
12V140E-3 Series
23
SEN00318-00
40 Troubleshooting
E-70 Code [691/CA691] Intake Air Temp Sensor High Error (LH bank
only)
Error code
Failure code
691
CA691
Contents of
trouble
Action of
controller
Trouble
Intake air temperature sensor detected abnormally high temperature (LH bank)
Phenomenon
that appears on
machine
Related
information
Causes
Possible causes
and standard
value in normal
state
TAM1
Intake air
temperature
Resistance
10 100 C
0.5 20 kz
Between (A)
chassis ground
All range
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshootDisconnection in wiring haring without turning starting switch ON.
ness
Wiring harness between LH J1 (female) (43)
Resis2 (Disconnection in wiring or
Max. 1 z
TAM1 (female) (A)
tance
defective contact in connecWiring harness between LH J1 (female) (47)
Resistor)
Max. 1 z
TAM1 (female) (B)
tance
Ground fault in wiring harness
3
(Short circuit with GND circuit)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between LH J1 (female) (43)
TAM1 (female) (A) and chassis ground
Resistance
Max. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
4 Defective engine controller
24
TAM1 (male)
Intake air
temperature
Resistance
10 100 C
0.5 20 kz
12V140E-3 Series
40 Troubleshooting
SEN00318-00
12V140E-3 Series
25
SEN00318-00
40 Troubleshooting
E-71 Code [692/CA692] Intake Air Temp Sensor Low Error (LH bank
only)
Error code
Failure code
692
CA692
Contents of
trouble
Action of
controller
Trouble
Intake air temperature sensor detected abnormally low temperature (LH bank only)
Phenomenon
that appears on
machine
Related
information
Possible causes
and standard
value in normal
state
26
Causes
12V140E-3 Series
40 Troubleshooting
SEN00318-00
E-72 Code [731/CA731] Eng. G (Bkup) Speed Sensor Phase Error (LH
bank)
1
Error code
Failure code
731
CA731
Contents of
trouble
Action of
controller
Trouble
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
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
Phenomenon
Running engine stops (when Ne speed sensor is also abnormal).
that appears on
Stopped engine cannot be started (when Ne speed sensor is also abnormal).
machine
Related
information
Possible causes
and standard
value in normal
state
Causes
Defective engine Ne speed
1
sensor system
2
12V140E-3 Series
27
SEN00318-00
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
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
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
SEN00318-00
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
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
Causes
1
Defective sensor power sup- If code [187/CA187] or [227/CA227] is indicated, carry out troubleply system
shooting for it first.
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring harness
3
(Short circuit with GND circuit)
Possible causes
and standard
value in normal
state
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
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
30
12V140E-3 Series
40 Troubleshooting
SEN00318-00
12V140E-3 Series
31
SEN00318-00
40 Troubleshooting
E-77 Code [778/CB778] Eng. G (Bkup) Speed Sensor Error (RH bank) 1
Error code
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
12V140E-3 Series
40 Troubleshooting
SEN00318-00
12V140E-3 Series
33
SEN00318-00
40 Troubleshooting
Failure code
781
CA781
Contents of
trouble
Action of
controller
Trouble
Phenomenon
Single-bank operation
that appears on
Engine cannot be started with the key ON
machine
Related
information
Causes
a Prepare with starting switch OFF, then carry out troubleshootDisconnection in wiring haring without turning starting switch ON.
ness
Wiring harness between LH J1 (female) (8)
Resis1 (Disconnection in wiring or
Max. 1 z
RH J1 (female) (8)
tance
defective contact in connecWiring harness between LH J1 (female) (6)
Resistor)
Max. 1 z
RH J1 (female) (6)
tance
Possible causes
and standard
value in normal
state
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between LH J1 (female) (8)
RH J1 (female) (8) and chassis ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
3 Defective engine controller
34
LH J1 (female)
Resistance
108 132 z
Min. 1 Mz
12V140E-3 Series
40 Troubleshooting
SEN00318-00
12V140E-3 Series
35
SEN00318-00
40 Troubleshooting
Failure code
781
CB781
Contents of
trouble
Action of
controller
Trouble
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
SEN00318-00
Failure code
1117
CA1117
Contents of
trouble
Action of
controller
Trouble
Phenomenon
that appears on
machine
Related
information
Possible causes
and standard
value in normal
state
Causes
Failure code
1117
CB1117
Contents of
trouble
Action of
controller
Trouble
Phenomenon
that appears on
machine
Related
information
Possible causes
and standard
value in normal
state
12V140E-3 Series
Causes
37
SEN00318-00
40 Troubleshooting
Failure code
1257
CA1257
Contents of
trouble
Action of
controller
Trouble
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
1 (Disconnection in wiring or
Resisdefective contact in connec- Wiring harness between OEM L (female) (7)
Max. 1 z
OEM
L
(female)
(34)
tance
tor)
Possible causes
and standard
value in normal
state
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Between wiring harness OEM L (female) (8)
and chassis ground
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
3 Defective engine controller
Resistance
Max. 1 z
Resistance
Min. 1 Mz
38
12V140E-3 Series
40 Troubleshooting
SEN00318-00
Failure code
1257
CB1257
Contents of
trouble
Action of
controller
Trouble
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
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wrong connection of harness
1
Connector connection error Between OEM R (female) (7) OEM R
ResisMin. 1 Mz
(female) (34) terminals
tance
Possible causes
and standard
value in normal
state
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Between wiring harness OEM R (female) (8)
and chassis ground
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
3 Defective engine controller
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
12V140E-3 Series
39
SEN00318-00
40 Troubleshooting
Failure code
1548
CB1548
Contents of
trouble
Action of
controller
Trouble
Phenomenon
Output drops.
that appears on
Idle speed is unstable.
machine
Related
information
Causes
Possible causes
and standard
value in normal
state
Defective injector #7
(Internal trouble)
RH CN1 (male)
Resistance
0.4 1.1 z
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshootDisconnection in wiring haring without turning starting switch ON.
ness
Wiring harness between RH J1 (female)
Resis2 (Disconnection in wiring or
Max. 1 z
(45) RH CN1 (female) (1)
tance
defective contact in connecWiring harness between RH J1 (female)
Resistor)
Max. 1 z
(53) RH CN1 (female) (2)
tance
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring harness
3
(Short circuit with GND circuit)
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
4 Defective engine controller
40
RH J1 (female)
Resistance
0.4 1.1 z
Min. 1 Mz
12V140E-3 Series
40 Troubleshooting
SEN00318-00
12V140E-3 Series
41
SEN00318-00
40 Troubleshooting
Failure code
1549
CB1549
Contents of
trouble
Action of
controller
Trouble
Phenomenon
Output drops.
that appears on
Idle speed is unstable.
machine
Related
information
Causes
Possible causes
and standard
value in normal
state
Defective injector #8
(Internal trouble)
RH CN2 (male)
Resistance
0.4 1.1 z
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshootDisconnection in wiring haring without turning starting switch ON.
ness
Wiring harness between RH J1 (female)
Resis2 (Disconnection in wiring or
Max. 1 z
(54) RH CN2 (female) (1)
tance
defective contact in connecWiring harness between RH J1 (female)
Resistor)
Max. 1 z
(51) RH CN2 (female) (2)
tance
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring harness
3
(Short circuit with GND circuit)
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
4 Defective engine controller
42
RH J1 (female)
Resistance
0.4 1.1 z
Min. 1 Mz
12V140E-3 Series
40 Troubleshooting
SEN00318-00
12V140E-3 Series
43
SEN00318-00
40 Troubleshooting
Failure code
1551
CB1551
Contents of
trouble
Action of
controller
Trouble
Phenomenon
Output drops.
that appears on
Idle speed is unstable.
machine
Related
information
Causes
Possible causes
and standard
value in normal
state
RH CN4 (male)
Resistance
0.4 1.1 z
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshootDisconnection in wiring haring without turning starting switch ON.
ness
Wiring harness between RH J1 (female)
Resis2 (Disconnection in wiring or
Max. 1 z
(56) RH CN4 (female) (1)
tance
defective contact in connecWiring harness between RH J1 (female)
Resistor)
Max. 1 z
(58) RH CN4 (female) (2)
tance
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring harness
3
(Short circuit with GND circuit)
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
4 Defective engine controller
44
RH J1 (female)
Resistance
0.4 1.1 z
Min. 1 Mz
12V140E-3 Series
40 Troubleshooting
SEN00318-00
12V140E-3 Series
45
SEN00318-00
40 Troubleshooting
Failure code
1552
CB1552
Contents of
trouble
Action of
controller
Trouble
Phenomenon
Output drops.
that appears on
Idle speed is unstable.
machine
Related
information
Causes
Possible causes
and standard
value in normal
state
RH CN5 (male)
Resistance
0.4 1.1 z
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshootDisconnection in wiring haring without turning starting switch ON.
ness
Wiring harness between RH J1 (female)
Resis2 (Disconnection in wiring or
Max. 1 z
(46) RH CN5 (female) (1)
tance
defective contact in connecWiring harness between RH J1 (female)
Resistor)
Max. 1 z
(60) RH CN5 (female) (2)
tance
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring harness
3
(Short circuit with GND circuit)
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
4 Defective engine controller
46
RH J1 (female)
Resistance
0.4 1.1 z
Min. 1 Mz
12V140E-3 Series
40 Troubleshooting
SEN00318-00
12V140E-3 Series
47
SEN00318-00
40 Troubleshooting
Failure code
1553
CB1553
Contents of
trouble
Action of
controller
Trouble
Phenomenon
Output drops.
that appears on
Idle speed is unstable.
machine
Related
information
Causes
Possible causes
and standard
value in normal
state
RH CN6 (male)
Resistance
0.4 1.1 z
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshootDisconnection in wiring haring without turning starting switch ON.
ness
Wiring harness between RH J1 (female)
Resis2 (Disconnection in wiring or
Max. 1 z
(57) RH CN6 (female) (1)
tance
defective contact in connecWiring harness between RH J1 (female)
Resistor)
Max. 1 z
(59) RH CN6 (female) (2)
tance
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring harness
3
(Short circuit with GND circuit)
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
4 Defective engine controller
48
RH J1 (female)
Resistance
0.4 1.1 z
Min. 1 Mz
12V140E-3 Series
40 Troubleshooting
SEN00318-00
12V140E-3 Series
49
SEN00318-00
40 Troubleshooting
Failure code
1622
CB1622
Contents of
trouble
Action of
controller
Trouble
Phenomenon
Output drops.
that appears on
Idle speed is unstable.
machine
Related
information
Causes
Possible causes
and standard
value in normal
state
Defective injector #9
(Internal trouble)
RH CN3 (male)
Resistance
0.4 1.1 z
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshootDisconnection in wiring haring without turning starting switch ON.
ness
Wiring harness between RH J1 (female)
Resis2 (Disconnection in wiring or
Max. 1 z
(55) RH CN3 (female) (1)
tance
defective contact in connecWiring harness between RH J1 (female)
Resistor)
Max. 1 z
(52) RH CN3 (female) (2)
tance
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring harness
3
(Short circuit with GND circuit)
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
4 Defective engine controller
50
RH J1 (female)
Resistance
0.4 1.1 z
Min. 1 Mz
12V140E-3 Series
40 Troubleshooting
SEN00318-00
12V140E-3 Series
51
SEN00318-00
40 Troubleshooting
Failure code
1633
CA1633
Contents of
trouble
Action of
controller
Trouble
Phenomenon
that appears on Different problems occur on different machine models.
machine
Related
information
Causes
Possible causes
and standard
value in normal
state
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
108
132 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring harness
2
(Short circuit with GND circuit)
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
3 Defective engine controller
52
Resistance
108
132z
Resistance
108
132 z
12V140E-3 Series
40 Troubleshooting
SEN00318-00
12V140E-3 Series
53
SEN00318-00
40 Troubleshooting
E-91 Code [2185/CA2185] Throttle Sens. Sup. Volt. High Error (LH bank
only)
1
Throttle sensor of decelerator pedal type (Case of D475-5)
Error code
Failure code
2185
CA2185
Contents of
trouble
Action of
controller
Trouble
Phenomenon
that appears on Depends on machine model.
machine
Related
information
Causes
Possible causes
and standard
value in normal
state
Decelerator sensor
DEC connector
a Prepare with starting switch OFF, then carry out troubleshootDisconnection in wiring haring without turning starting switch ON.
ness
Wiring harness between OEM L (female)
Resis2 (Disconnection in wiring or
Max. 1 z
(22) DEC (female) (A)
tance
defective contact in connecWiring harness between OEM L (female)
Resistor)
Max. 1 z
(23) DEC (female) (C)
tance
Ground fault in wiring harness
3
(Short circuit with GND circuit)
54
Disconnect devices
at right in order. If
error code disappears subsequently,
that device has a
defect in it.
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between OEM L (female)
(22) DEC (female) (A) and chassis ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between OEM L (female)
(22) DEC (female) (A) and OEM L
(female) (23) DEC (female) (C)
Resistance
Min. 1 Mz
Voltage
4.75 5.25 V
12V140E-3 Series
40 Troubleshooting
SEN00318-00
Circuit diagram related to deceleration pedal type throttle sensor (Case of D475-5)
12V140E-3 Series
55
SEN00318-00
40 Troubleshooting
E-92 Code [2186/CA2186] Throttle Sens. Sup. Volt. Low Error (LH bank
only)
1
Error code
Failure code
2186
CA2186
Contents of
trouble
Action of
controller
Trouble
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
SEN00318-00
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
Phenomenon
that appears on Output drops.
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
12V140E-3 Series
Causes
57
SEN00318-00
40 Troubleshooting
Failure code
*1
Contents of
trouble
Action of
controller
Trouble
Phenomenon
that appears on Output drops.
machine
Related
information
Possible causes
and standard
value in normal
state
Causes
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)
Phenomenon
that appears on Output drops.
machine
Related
information
Possible causes
and standard
value in normal
state
58
Causes
12V140E-3 Series
40 Troubleshooting
SEN00318-00
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)
Phenomenon
that appears on Output drops.
machine
Related
information
Possible causes
and standard
value in normal
state
Causes
12V140E-3 Series
59
SEN00318-00
40 Troubleshooting
2006 KOMATSU
All Rights Reserved
Printed in Japan 02-06 (02)
60
12V140E-3 Series
SEN00320-00
ENGINE
1SHOP MANUAL
12V140E-3 Series
12V140E-3 Series
SEN00320-00
Disassembly
q
In Disassembly section, the work procedures,
precautions and know-how for carrying out
those procedures, and quantity of the oil and
coolant drained are described.
q
The meanings of the symbols used in Disassembly section are as follows.
k Precautions related to safety in execution
of work
a : Know-how or precautions for work
6 : Quantity of oil or coolant drained
4
Assembly
q
In Assembly section, the work procedures, precautions and know-how for carrying out those
procedures, and quantity of the oil and coolant
added are described.
q
The meanings of the symbols used in Assembly section are as follows.
k : Precautions related to safety in execution
of work
a : Know-how or precautions for work
2 : Type of coating material
3 : Tightening torque
5
12V140E-3 Series
SEN00320-00
The recommended coating materials such as adhesives, gasket sealants, and greases used for disassembly and assembly are listed below.
For coating materials not listed below, use the equivalent of products shown in this list.
Adhesive
Category
Komatsu
code
Part No.
Q'ty
Container
LT-1A
790-129-9030
150 g
Tube
LT-1B
790-129-9050
20 g
(2 pcs.)
Polyethylene
container
LT-2
09940-00030
50 g
LT-3
790-129-9060 Adhesive:
Set of
1 kg
adhesive and Hardener:
hardener
500 g
LT-4
790-129-9040
250 g
Holtz
MH 705
790-129-9120
75 g
Three Bond
790-129-9140
1735
Aron-alpha
790-129-9130
201
Polyethylene
Used to seal plugs for drilled holes.
container
Tube
50 g
2g
Quick-setting adhesive.
Polyethylene Quick-hardening type. (max. strength is obtained after
container
30 minutes of application)
Used mainly to stick rubbers, plastics, and metals.
79A-129-9110
50 cc
LG-1
790-129-9010
200 g
790-129-9080
Quick-setting adhesive.
Polyethylene Setting time: Within 5 sec. to 3 min.
container
Used mainly to stick metals, rubbers, plastics, and
woods.
Loctite
648-50
LG-5
Gasket sealant
1 kg
LG-6
790-129-9020
200 g
Tube
LG-7
790-129-9070
1 kg
Tube
Three Bond
790-129-9090
1211
100 g
Tube
Three Bond
419-15-18131
1207B
100 g
Tube
12V140E-3 Series
SEN00320-00
Komatsu
code
Part No.
Q'ty
Container
LM-G
09940-00051
60 g
Can
LM-P
09940-00040
200 g
Tube
G2-LI
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
SYG2-160LI
SYGA-160CNLI
Various
Various
G2-CA
SYG2-400CA
SYG2-350CA
SYG2-400CA-A
Various
SYG2-160CA
SYGA-160CNCA
Various
Molybdenum
SYG2-400M
disulfide grease SYG2-400M-A
LM-G (G2-M)
SYGA-16CNM
SYG2-400T-A
SYG2-16CNT
SYG0-400T-A
(*)
SYG0-16CNT
(*)
400 g
16 kg
SYG2-400B
SYGA-16CNB
SYG2-400BT
(*)
SYGA-16CNBT
(*)
400 g
16 kg
SUNSTAR
GLASS
PRIMER 580
SUPER
Primer
Hyper White
Grease G2-T,
G0-T (*)
*: For cold district
SUNSTAR
PAINT PRIMER
580 SUPER
SUNSTAR
PAINT PRIMER
435-95
20 ml
Glass
container
20 ml
Glass
container
20 ml
Glass
container
417-926-3910
22M-54-27230
SUNSTAR
GLASS
PRIMER
435-41
22M-54-27240
150 ml
Can
SUNSTAR
SASH PRIMER
GP-402
22M-54-27250
20 ml
Glass
container
Grease
Molybdenum disulfide
lubricant
Category
12V140E-3 Series
Komatsu
code
Part No.
Q'ty
Container
SUNSTAR
PENGUINE
SEAL 580
SUPER "S" or
"W"
417-926-3910
320 ml
Polyethylene container
Sika Japan,
Sikaflex 256HV
20Y-54-39850
310 ml
Polyethylene container
SUNSTAR
PENGUINE
SUPER 560
22M-54-27210
320 ml
Ecocart
(Special
container)
SUNSTAR
PENGUINE
SEAL No. 2505
417-926-3920
320 ml
Polyethylene container
20Y-54-55130
333 ml
Polyethylene container
Cartridge
GE TOSHIBA
SILICONES
TOSSEAL 381
12V140E-3 Series
22M-54-27220
333 ml
Caulking material
Adhesive
Category
SEN00320-00
SEN00320-00
Work item
Disassembly and
assembly of engine
assembly
Disassembly and
assembly of cylinder
head
Symbol
Part No.
Part name
790-501-4000
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
Removal and
installation of piston ring
795-100-1191
t 1
Measurement of
cylinder liner projection
795-502-1121
Holder
t 1
795-236-1000
Liner puller
t 1
Installation of cylinder
liner
795-230-5472
Liner driver
t 1
795-331-1110
Wrench
t 1
Installation of piston
795-236-1500
Piston holder
t 1
795-602-2200
Installer
t 1
795-602-2300
Installer
t 1
New/Remodel
Sketches
Q'ty
Tools with part number 79QT-QQQ-QQQQ cannot be supplied (they must be locally manufactured).
Necessity : t . . . . . . Cannot be substituted, should always be installed (used)
: q . . . . . . Extremely useful if available, can be substituted with commercially available part
New/Remodel
: N . . . . . . Tools newly developed for this model and given new part Nos.
: R . . . . . . Tools remodeled from tools already available for other models and given upgraded
part Nos.
: Blank. . . Tools already available for other models, usable without any modification
Tools marked with Q in the sketch column are tools introduced in the sketches of the special tools
(See Sketches of special tools)
Necessity
a
a
Remarks
12V140E-3 Series
Adjusting valve
clearance
12V140E-3 Series
Part No.
795-130-1720
Commercially
available
795-931-1100
Part name
Q'ty
Symbol
Push tool
t 1
Thickness gauge
q 1
Seal puller
q 1
New/Remodel
Sketches
Work item
SEN00320-00
Necessity
Remarks
SEN00320-00
2006 KOMATSU
All Rights Reserved
Printed in Japan 03-06 (02)
12V140E-3 Series
SEN00321-00
ENGINE
1SHOP MANUAL
12V140E-3 Series
12V140E-3 Series
SEN00321-00
1.
2.
5.
Alternator
1) Remove auxiliary equipment belt (1).
2) Remove alternator (2).
2)
3.
4.
12V140E-3 Series
6.
SEN00321-00
9.
7.
8.
12V140E-3 Series
SEN00321-00
2)
Apply a marking to every installation positions of clamps (2) and (3) using paint.
3)
4)
5)
2)
3)
Remove bracket.
Remove all clamps (2) and (3).
Remove 6 high-pressure pipes (4).
12V140E-3 Series
SEN00321-00
2)
3)
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
SEN00321-00
3)
4)
12V140E-3 Series
SEN00321-00
3)
12V140E-3 Series
SEN00321-00
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).
12V140E-3 Series
3)
4)
3]
4]
SEN00321-00
12V140E-3 Series
SEN00321-00
3)
4)
2)
36. Breather
Remove breather (1), blowby pipe (2) and
plate (3).
a Remove the plate on the left bank alone.
3)
10
12V140E-3 Series
SEN00321-00
2]
3]
4]
3)
12V140E-3 Series
11
SEN00321-00
2)
3)
4)
12
12V140E-3 Series
SEN00321-00
3)
12V140E-3 Series
13
SEN00321-00
2)
3)
14
12V140E-3 Series
SEN00321-00
a
a
2)
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.
2)
3)
12V140E-3 Series
15
SEN00321-00
4)
5)
6)
7)
8)
16
9)
4]
5]
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)
SEN00321-00
4)
5)
6)
12V140E-3 Series
17
SEN00321-00
2)
18
12V140E-3 Series
SEN00321-00
2006 KOMATSU
All Rights Reserved
Printed in Japan 03-06 (02)
20
12V140E-3 Series
SEN00322-00
ENGINE
1SHOP MANUAL
12V140E-3 Series
12V140E-3 Series
SEN00322-00
5]
Cylinder block
1) Lift the cylinder block and then set it on
tool A.
4 Cylinder block: 850 kg
2) Before inserting the cylinder liners, prepare the cylinder block according to the
following procedure.
1] Remove the rust and scales from
faces A and B with sandpaper, etc.
until the machined surfaces are
exposed.
2] Polish parts B, R and r with sandpap e r o f a b o u t No . 2 0 0 un t i l t h e y
become smooth.
If part R is sharpened or burrs are
present there, finish it with a scraper
or sandpaper.
F i n i s h t h i s s u r f a c e pa r t i c u l a r l y
smoothly so that it will not damage
the O-ring.
3] If face R is so pitted that it cannot be
repaired, replace the cylinder block.
4] If faces A and parts R and r are pitted, finish them smoothly.
2.
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)
SEN00322-00
4)
12V140E-3 Series
SEN00322-00
1]
2]
5)
6)
7)
8)
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 tempo r a r i l y wi t h th e u s e d h ea d g a s k e t
inserted.
a At this time, observe the following
tightening torque and tightening
order.
3 Temporary tightening torque:
137 157 Nm {14 16 kgm}
a Installation of No. 7 bolt is not necessary.
12V140E-3 Series
SEN00322-00
a
a
a
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
4)
SEN00322-00
5)
6)
7)
8)
a
a
a
9)
SEN00322-00
4.
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
SEN00322-00
3]
4]
5]
6]
7]
8]
12V140E-3 Series
2)
3)
4)
12V140E-3 Series
SEN00322-00
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.
SEN00322-00
7)
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)
12) Tighten connecting rod bolts (1) alternately until the connecting rod cap is
closely contacted.
10
12V140E-3 Series
SEN00322-00
a
5.
12V140E-3 Series
11
SEN00322-00
a
2)
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)
2)
6.
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}
12V140E-3 Series
9.
2)
3)
SEN00322-00
12V140E-3 Series
13
SEN00322-00
3)
2)
14
12V140E-3 Series
4)
SEN00322-00
2)
3)
12V140E-3 Series
15
SEN00322-00
1]
Position
AA
B1B1
B2B2
CC
DD
EE
FF
GG
HH
LL
RR
Note):
5
6
7
(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
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
12V140E-3 Series
2)
Dimension b
Bolt hole
6-12 x 1.75
109 mm
114 mm
Absent
Present
SEN00322-00
Oil seal
press-fitting
depth a
13 14 mm
18 19 mm
12V140E-3 Series
3)
4)
3]
17
SEN00322-00
1]
4]
5)
18
2]
When installing oil seal (1) after modifying its originally intended installation
position.
q
Install oil seal (1) as is using tool
J.
3]
12V140E-3 Series
12V140E-3 Series
SEN00322-00
2)
19
SEN00322-00
2)
3)
20
12V140E-3 Series
2)
3)
4)
SEN00322-00
3]
4]
12V140E-3 Series
21
SEN00322-00
5)
22
2]
When installing the oil seal after modifying its originally intended installation position.
q
Don't use a washer [1] between
tool K and crankshaft.
3]
12V140E-3 Series
SEN00322-00
2)
3)
12V140E-3 Series
23
SEN00322-00
2)
3)
2)
3)
24
12V140E-3 Series
SEN00322-00
27. Breather
Install breather (1), blow-by pipe (2) and plate
(3).
3 Breather mounting bolt:
24.5 29.4 Nm {2.5 3.0 kgm}
a Install plate (3) to the left side bank alone.
30. Suction pie and under plate
1) Using jack [1], install under plate (1) and
then fix it temporarily using the oil pan
mounting bolt.
4 Under plate: 25 kg
2)
12V140E-3 Series
25
SEN00322-00
2)
3]
4]
26
12V140E-3 Series
5]
2)
3)
4)
12V140E-3 Series
SEN00322-00
3
3]
4]
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.
27
SEN00322-00
3)
4)
5)
5)
2)
28
12V140E-3 Series
SEN00322-00
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.
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)
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}
a After the tightening, make sure the Oring is not projecting from the sleeve
nut.
4)
5)
6)
7)
8)
12V140E-3 Series
29
SEN00322-00
9)
2)
37. Crosshead
1) Install crosshead (1).
2 Crosshead sliding portion:
Engine oil (EO30)
30
12V140E-3 Series
SEN00322-00
2)
3)
12V140E-3 Series
31
SEN00322-00
3)
4)
2)
32
SEN00322-00
2)
12V140E-3 Series
33
SEN00322-00
3)
4)
3)
34
12V140E-3 Series
SEN00322-00
2)
12V140E-3 Series
35
SEN00322-00
3)
36
12V140E-3 Series
SEN00322-00
6)
7)
2)
3)
4)
5)
12V140E-3 Series
37
SEN00322-00
2)
38
12V140E-3 Series
SEN00322-00
60. Alternator
1) Install alternator (2).
2) Install auxiliary equipment belt (1).
3) Adjust tension of the auxiliary equipment
belt.
a Adjust its deflection to 20 mm when
the pushing force of 58.8 Nm {6 kgm}
is applied to the belt center through a
finger.
3 Adjuster lock bolt:
53.9 122.6 Nm {5.5 12.5 kgm}
1)
2)
62. Engine wiring harness
Install engine wiring harness (1) on the engine
assembly and then connect the connector and
terminal.
3)
4)
12V140E-3 Series
39
SEN00322-00
5)
6)
7)
8)
9)
40
12V140E-3 Series
SEN00322-00
2006 KOMATSU
All Rights Reserved
Printed in Japan 03-06 (02)
42
12V140E-3 Series
SEN00876-00
ENGINE
1SHOP MANUAL
12V140E-3 Series
12V140E-3 Series
SEN00876-00
Removal
1.
2.
6.
7.
3.
4.
5.
8.
12V140E-3 Series
9.
SEN00876-00
a
2)
Installation
q
Carry out installation in the reverse order to
removal.
3)
[*1]
[*2]
[*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.
4)
[*4]
[*5]
[*6]
12V140E-3 Series
SEN00876-00
Installation
a Check the Teflon seal (Laydown lip seal) by
checking the wear of the shaft and replace it
with the "Standard seal "or " Sleeved seal".
a If the shaft is worn to the degree of luster (If
wear which you feel with your finger is less
than 10 m) and does not have any flaw,
install the standard seal.In other cases, install
the sleeved seal.
a The left one in the following figure is the standard seal and the right one is the sleeved seal.
12V140E-3 Series
SEN00876-00
Installation
Following remedial actions are needed when wear
is recognized on the contact face of the oil seal on
the crankshaft.
1) When a new crankshaft is used or when wear
is not recognized on the contact surface of oil
seal.
q
Install the rear oil seal in such that the dimension from the flywheel housing end face may
conform to the standard dimension indicated in
the figure.
4)
2)
When wear is recognized on the oil seal contact face of crankshaft (2) and oil seal (1)
installation position is movable.
Move the oil seal installation position backward
up to the location shown in the figure where
the lip of a new oil seal won't be in touch with
the wear groove on the crankshaft.
3]
3)
q
12V140E-3 Series
SEN00876-00
4]
a
a
2]
q
5)
a
a
3]
q
12V140E-3 Series
2.
SEN00876-00
Removal
a For the work up to removal of the damper, see
the shop manual for the applicable machine.
1) Remove front oil seal (1).
2)
3)
Installation
Install front seal (1) according to the following procedure.
Following remedial actions are needed depending
on presence and absence wear on the contact face
of the oil seal on the crankshaft.
1) When a new crankshaft is used or when
wear is not recognized on the contact surface of oil seal.
q
Either of the dimensions listed in the
following table shall apply to oil seal
press-fitting depth a depending on
front cover size b and presence/
absence of bolt hole in the cover end
face.
Dimension b
Bolt hole
6-12 x 1.75
109 mm
114 mm
Absent
Present
12V140E-3 Series
Oil seal
press-fitting
depth a
13 14 mm
18 19 mm
SEN00876-00
4)
5)
3]
4]
12V140E-3 Series
2]
When installing oil seal (1) after modifying its originally intended installation
position.
q
Install oil seal (1) as is using tool
J.
3]
12V140E-3 Series
SEN00876-00
SEN00876-00
2006 KOMATSU
All Rights Reserved
Printed in Japan 03-06 (02)
10
12V140E-3 Series